GRAVITY LIFEBOAT

DRAWING : FOR FINAL

SHIPYARD : SSME
HULL NO. : S3078
MODEL : HDL71CFA
PERSONS : 30PERSONS

2015. 05. 22

272-12, Dangwol-ro, Onsan-eup, Ulju-gun, Ulsan, Korea. Tel (82)(52)240-3543 Fax (82)(52)237-4010
 YARD SSME HULL NOS. S3078
PROJECT NAME 109,999
115,000 DWT CLASS PRODUCT OIL TANKER

COMMENTS.

2015. 05. 22 FOR FINAL DRAWING

2014. 11. 17 FOR WORKING DRAWING

2014. 06. 20 APPROVED

2014. 01. 02 FOR APPROVAL DRAWING

DATE DESCRIPTION REMARK

PLAN HISTORY

TOTAL ( 29 ) SHEETS INCL.COVER

APPROVED I. C. YUN MODEL. HDL71CFA

CHECKED I. T. HWANG

DRAWN BY H. J. RYU

DATE 2015. 05. 22 DESIGN TEAM / TEL (82) (52) 240 3543 FAX (82) (52) 237 4010
HLB CO., LTD. Index

I N D E X

1. Characteristic. 4
2. External Arrangement. 5
3. Internal Arrangement. 6
4. Hull Section for Davit. 7
5. Specification of Lifeboat. 8
6. Lifting Hook Release System. 13
6.1 Recommended Davit Falls Master Link. 14
7. Electric Wiring Diagram. 15
8. Position of Receptacle & Plug. 16
9. Equipment List. 17
10. Loosed Inventories List. 19
11. Specification of Engine. 20
.1 Lubrication Oil Chart. 21
.2 Spare Parts and Tool list. 22
12. Detail of Skate. 23
13. Position of Davit Remote Control Wire. 24
14. Fresh Water Flushing Hose. 25
15. Air Support System. 26
16. Shop Test. 27
17. Test Report 28
HN.S3078 LIFEBOAT 1. CHARACTERISTIC

1. Characteristic
1. SHIP

.1 Shipyard ………………………………………………………………………… SSME

.2 Hull No ……………………………………………………………………………S3078

.3 Type of Ship ……………………………………………………………………115,000 DWT CLASS PRODUCT OIL TANKER

.4 Flag ……………………………………………………………………………………MARSHALL ISLAND

.5 Owner ………………………………………………………………………………SCORPIO
2. LIFEBOAT

.1 Number of Boat …………………………………………………………… Two(2)

.2 Type of Boat : Totally Enclosed Lifeboat.

.1 First Type ………………………………………………………………………Only Lifeboat.

.2 Second Type ………………………………………………………………… Life & Rescue Combined Boat.

.3 Launching ……………………………………………………………………… Davit-Launched Type by two falls.

.4 Model ……………………………………………………………………………… HDL71CFA

.5 Dimension (LxBxDxH) ……………………………………………………7.1 x 2.40 x 1.125 x 2.7m

.6 Material ……………………………………………………………………………FRP (Fiberglass Reinforced Plastic).

.7 Boarding ………………………………………………………………………… 30 Persons

.8 Weight :

.1 Light Load with fuel, all equipments and inventories …………………………………… 2879 kg.

.2
2 Boarding Person (82
(82.5Kg
5Kg × 30 ………………………………………………………………………… 2475 kg
kg.

.3 Total Davit Load (.1 + .2) ……………………………………………………………………………… 5354 kg.

.4 Rescue Mode (Hanging Off Condition) with 6 Boarding Persons …………………… 3374 kg.
( .1 + 82.5 kg x 6 Persons )

.9 Installation :

.1 No.1 Boat …………… Starboard Side ………………………… Lifeboat.

.2 No.2 Boat …………… Port Side …………………………………… Life & Rescue Combined Boat.

.10 Certificates of Boats

.1 Classification ………………………………………………KR

.2 Certificates of Boats ……………………………………MED("B+D")

.11 Marking
Before Delivery of Lifeboat : Maker Supply
After Delivery of Lifeboat : Yard Supply
.1 Ship Name …………………………………………………STI SAVILE ROW
.2 Register of Port Name ………………………………MAJURO
.3 Call Sign …………………………………………………… V7JN2

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 4
HN.S3078 LIFEBOAT 2. EXTERNAL ARRANGEMENT
2. External Arrangement
HLB CO., LTD.
TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 5
 LENGTH OVERALL 7100

400 LIFTING HOOKS DISTANCE 6300 400

HLB CO., LTD.

1120
CONNECTION PIECE FOR DAVIT CONTROL WIRE

CANOPY LIGHT
HN.S3078 LIFEBOAT

WATER SPRAY TUBE

4- FIXED POLYCARBONATE WINDOW

WATER SPRAY TUBE

450
AIR PRESS. CONTROL VALVE AIR VENT GRILL

WATER SPRAY TUBE

RADAR REFLECTOR BED
ENGINE 4-OAR
CONTROL LEVER

INT. LIGHT
SEARCH HANDRAIL
AFT TEMPERED LIGHT
GLASS WINDOW
WATER SPRAY FWD TEMPERED
WITH PROTECTION ON-OFF VALVE
GLASS WINDOW
LIFTING HOOKS
WITH PROTECTI
PROTECTION
RELEASE LEVER

2700
ROWLOCK POSITION FOR BOLLARD
2-BATTERY BOX RAINWATER COLLECTOR
2250

PAINTER RELEASE
600 600 600 600 UNIT
448

TEL : +82 52 240 3548 FAX : +82 52 237 4010

HATCH HATCH HATCH HATCH FRP CENTER FRP SIDE
BENCH BENCH
HYDROSTATIC AIR EXHAUST
UNIT FOR INVENTORY NOZZLE
1125

LIFTING HOOKS STEEL PAINTED

F.O. TANK
2 AIR BOTTLES, 67.5 L, 140 Kg/cm2 FLOOR LINE

SIDE BUOYANCY TANK FILLED

WITH P.U.FOAM
AUTOMATIC DRAIN PLUG

1100

CENTER OF SKATE CENTER OF SKATE

SEAT ARRANGEMENT NOTE

1. FRP HULL CONSTRUCTION AND FILLED WITH P.U.FOAM

6 7 8 9 10 11 IN FRP SIDE CASE.
4 5 12
3 1
13
3. Internal Arrangement

2 14 2. L x B x D x H (MOULDED) ; 7.1 x 2.4 x 1.125 x 2.7 m.

3. FOR TANKER VERSION.

30 29 28 4. SELF-RIGHTING TYPE.

5
5
1

27
15
226
16
17 18 24 25 TITLE; HDL 71CF Lifeboat
19 20 21 22
INTERNAL GENERAL ARRANGEMENT
DWG. No. 71C-F-201-01-R0

INJURED PERSON LAY-DOWN AREA FOR RESCUE BOAT

APPROVED BY SCALE NON
CHECKED BY HDL71CFA
DATE 05.06.17
CHECKED BY
DESIGNED BY IN CHANG YUN

PAGE 6
3. INTERNAL ARRANGEMENT
HN.S3078 LIFEBOAT 4. HULL LINES FOR DAVIT

4. Hull Section for Davit

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 7
HN.S3078 LIFEBOAT 5. SPECIFICATION OF LIFEBOAT

5. Specification of Lifeboat

5.1 GENERAL
This totally enclosed lifeboat and as a Rescue Combined Boat has been designed and approved in

accordance with :

A. SOLAS 74 with protocol 1978/1988 and amendments up to 2012 including LSA code

amendments and Maritime regulation of vessel’s registry.

B. IMO Res. MSC.81(70), Part 1 “Revised Recommendation on Testing of Life-Saving

Appliances.”

C. Applied the IMO Res. MSC.272(85).

D. RRS(Release and Retrieval System) in accordance with MSC.317(89), 320(89), and

321(89) is applied.

This boat has been constructed and been of such form and proportions that it has ample stability

in a seaway and sufficient freeboard when loaded with its full complement of persons and

equipments.

This boat is capable of maintaining positive stability when in an upright position in calm sea and

loaded with its full complement of persons and equipment and holed in any one location below

the waterline, assuming no loss of buoyancy material and no other damage.

5.2 CONSTRUCTION

This boat is constructed of FRP by the hand-lay-up method. The hull with cover is moulded in
longitudinally separated port and starboard mold, laminated together after bonding of the side
buoyancy tank. All mats, rovings and resins for laminates are approved by classification society and
the resins are of self-extinguishing quality as usual.
FRP longitudinal side tanks are provided in the hull, filled with P.U.Foam. The floor and center bench
are made of FRP. The metal parts inside as well as outside are of a quality, that corrosion is limited
to a minimum. As far as steel parts are galvanized.

5.3 PROPULSION

The engine is powered by a compression ignition engine and its fuel has a flashpoint of 43˚C
43˚C

more.

The speed of a boat when proceeding ahead in calm sea, when loaded with its full complement of

persons and equipment and with engine-powered auxiliary equipment in operation, is at least 6

knots and at least 2 knots when towing the largest life raft carried on the ship loaded with its full

complement of persons and equipment or its equivalent.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 8
HN.S3078 LIFEBOAT 5. SPECIFICATION OF LIFEBOAT

The capacity of fuel is provided to run the fully loaded boat at 6 knots for a period of not less than

24 hours. The engine is operated near the helmsman position. The detail specification of engine is

able to be seen at the engine manual.

5.4 STEERING

This boat is so arranged that an adequate view forward, after and both sides is provided form
the control and steering position for safe launching and manoeuvring. This boat is provided with

push-pull cable, removable rudder tiller, rudder stock and rudder for remote steering mechanism.

Also, in case against failed the remote control steering mechanism fails, the emergency rudder
tiller is installed near the rudder tiller.

5.5 LIFTING HOOKS RELEASE & RECOVERY

This boat is able to be launched by two falls is fitted with a release mechanism complying

with the following;

1) Have been so arranged that two hooks (forward and aft) are able to release

simultaneously.

2) Have two release capabilities as follows ;

A NORMAL RELEASE

capability which will release the lifeboat when it is waterborne or when there is no load on

the hook.

AN ON-LOAD RELEASE

capability shall release the lifeboat with a load on the hooks. This release mechanism shall
be provided with a hydrostatic interlock unless other means are provided to ensure that
the boat is waterborne before the release mechanism can be activated. In case of failure
or when the boat is not waterborne, there shall be a means to override the hydrostatic
interlock or similar device to allow emergency release. This interlock override capability
shall be adequately protected against accidental or premature use. Adequate protection
shall include special mechanical protection not normally required for off-load release, in
addition to a danger sign. The protection shall be deliberately destroyed by applying a
suitable minimum force, for instance by breaking a protection glass or translucent cover. A
label or thin wire seal is not considered sufficiently robust. To prevent a premature on-load
release, on-load operation of the release mechanism shall require multiple, deliberate and
sustained action or actions by the operator.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 9
HN.S3078 LIFEBOAT 5. SPECIFICATION OF LIFEBOAT

The release mechanism have been so designed that crew members in the lifeboat can clearly

observe when the release mechanism is properly and completely reset and ready for lifting.

Clear operating instructions have provided with a suitably worded warning notice;

The release control by a simple release handle near the helmsman position have clearly

marked in a color that contrasts with its surroundings;

The detail specification of lifting hooks release is able to be seen at the Hook Manual.

5.6 ELECTRIC

The electric of boat is provided for recharging boat’s battery from the ship’s power supply at a supply

voltage not exceeding 50V which can be disconnected at the lifeboat embarkation station by receptacle &

plug. For engine starting and lighting the battery is installed boat inside.

To avoid the damage of electric, the boat have two non fuse breaker. The one(1) non fuse breaker is

connected the external canopy light, the other non fuse breaker is connected the two interior lights and
search light. Also the battery switch is provided for discharging electric of battery.

The detail specification of electric is able to be seen at the Ch.7

5.7 PAINTING and MARKING

FRP inside painted bright gray gelcoat and FRP outside painted orange color gelcoat. The dimension and

number of persons of boat are marked on each side of boat’s stern in block capitals of Roman Alphabet.

The ship name and port of registry are marked on each side of boat’s bow in block capitals of Roman

Alphabet.

Also, the number of boat and call sign are marked on top of boat in block capitals of Roman alphabet. Call

sign to be marked, it should be informed by shipyard before lifeboat delivery.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 10
HN.S3078 LIFEBOAT 5. SPECIFICATION OF LIFEBOAT

5.8 FITTINGS

a. Port and Stb’d FRP side entrance hatches with SUS304 hatch handles.
b. Port and Stb’d Galv. Steel Side Handrail with bed of radar reflector.
c. Fwd & Aft hatches, tempered glass with protection bar for boat Recovery.
d. Port and Stb’d SUS304 lifeline with buoyant handgrips.
e. Port and Stb’d SUS304 Ventilation Grill for natural vent.
f. Four polycarbonate transparent windows on the Helmsman tower.
g. Retro-Reflecting tapes on the boat outside according to IMO Res. A.658(16)
h. One Brass & Rubber Automatic drain plug with keeping chain.

i. One Connection Piece for davit remote control wire.

j. Two Galv. steel lashing guiders for Davit lashing.
k. Fwd/Aft Galv. Steel Bollards.
l. SUS304 painter Release Unit at forward of boat.
m. IMO Symbols related to lifeboat & rescue boat according to IMO Res. A. 760(18)
n. FRP Food tank for keeping foods.
o. Vinyl Rainwater collector in boat inside.
p. SUS304 bolt & nuts of weather part.

Note;
Radar transponder and its bracket to be supplied by ship yard, not supplied by boat maker.

5.9 WATER SPRAY SYSTEM

This fire-protected boat when waterborne is capable of protecting the number of persons it is permitted to
accommodate when subjected to a continuous oil fire that envelops the boat for a period of not less than 8

minutes.
The seawater for this system is drawn from the sea by a self-priming pump connected the engine. It is

possible to turn 'ON' and turn 'OFF' the flow of water over the exterior of boat.
The seawater intake is so arranged as to prevent the intake of flammable liquid from the sea surface.

Also, this system is arranged for flushing with fresh water and allowing complete drainage.
Seawater is delivered to a waterspray tube all around the cover for covering the waterfilm with sprinklers

and flat nozzles.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 11
HN.S3078 LIFEBOAT 5. SPECIFICATION OF LIFEBOAT

5.10 AIR SUPPLY SYSTEM

The boat with self-contained air support system is so arranged that, when proceeding with all entrances
and openings closed, the air in the boat remains safe and breathable and the engine runs normally for a
period of not less than 10 min.
During this period the atmospheric pressure in the boat should neither fall below the outside atmospheric
pressure nor exceed it by more than 20 hPa.

5.11 TEST

Shop test are carried out with authorized surveyor at the boat yard.

HLB CO., LTD.

TEL : +82 52 240 3544 FAX : +82 52 237 4010 PAGE 12
 HN.S3078 LIFEBOAT
TEL : +82 52 240 3548 FAX : +82 52 237 4010
HLB CO., LTD.

6. Lifting Hook Release System

6. LIFTING HOOK RELEASE SYSTEM

TITLE;
RRS ARRANGEMENT
DWG. No. HDL71-1000 REV. 0
PAGE 13

APPROVED BY S. P. ANN SCALE NON

CHECKED BY I. C. YUN 12.08.29 HDL71CTA/FA
DATE Y/M/D
CHECKED BY I. T. HWANG
DESIGNED BY S. J. KWON
HN.S3078 LIFEBOAT 6.1 RECOMMENDED DAVIT FALLS MASTER LINK.

6.1 Recommended Davit Falls Master Link

1. Ring Type Master Link

TALON II 4.0

SWL 4 ton

A Ø 28~29 mm

B 85 mm

B C 79 mm
C

D 230 mm
B/

E 0~43 mm
2

A
A

2. Plate Type Master Link

B

TALON II 4.0

SWL 4 ton

A 28 mm

B 28 mm

C R 42.5 mm

D 80 mm

E 0~28 mm
C

A
Section
A-A
E

A
A

* Operational tests with the master link used by the manufcturers of the launching
appliances should be crried out also before the particular combination of lifeboat/release
hook and launching appliance can be accepted.
HLB CO., LTD.
TEL : +82 52 240 3548 FAX : +82 52 237 4010
PAGE 14
HN.S3078 LIFEBOAT 7. ELECTRIC WIRING DIAGRAM

7. Electric Wiring Diagram

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 15
HN.S3078 LIFEBOAT 8. POSITION OF REC. PLUG

8. Position of REC. & PLUG

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 16
HN.S3078 LIFEBOAT 9. EQUIPMENT LIST

9. Equipment List

Q'ty Wei. Storage

No. Items Sketch Specification Cert
/ Boat (Kg) Position

1 Buoyant Oars Apiton 4 22.0 Boat inside

Stainless
2 Crutch(Rowlock) with lanyard 4 1.2 Boat inside
steel
Aluminium +
3 Boat-hook 2 1.0 Boat inside
Plastic

4 Buoyant bailer Plastic 1 0.3 Inventory box

5 Bucket Plastic 2 1.2 Inventory box

6 Survival manual Book 1 0.2 Inventory box

7 Compass Approved type 1 0.6 MED Boat inside

Sea anchor with hawser

8 Conical type 1 4.0 Boat inside
and tripping line
P.P rope
9 Painter 2 12.8 Boat outside
(φ16 x 50 m)

10 Hatchet with vinyl bag Hardened steel 2 1.0 Boat inside

3 Liter / Person
11 Fresh Water 180 90.0 CLASS Boat inside
(500ml pack)
Stainless +
12 Rustproof dipper with lanyard 1 0.1 Inventory box
Plastic

13 Rustproof graduated drinking vessel Plastic 1 0.1 Inventory box

14 Food Ration 10,000KJ / Packag 30 15.0 CLASS Inventory box

15 Rocket parachute flare in container 4 Inventory box

16 Hand flare in container Approved type 6 3.7 MED Inventory box

17 Buoyant smoke signal in container 2 Inventory box

Waterproof electric torch with

18 Plastic 1 0.3 Inventory box
1 spare set battery & 1 spare bulb
Daylight signalling mirror Stainless +
19 1 0.1 Inventory box
with instruction waterproof card
Waterproof
20 Life-saving signal table 1 0.1 Inventory box
card

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 17
HN.S3078 LIFEBOAT 9. EQUIPMENT LIST

Q'ty Wei. Storage

No. Items Sketch Specification Cert
/ Boat (Kg) Position

21 Whistle with lanyard Plastic 1 0.1 Inventory box

22 First-aid outfit in waterproof pack Approved type 1 0.8 CLASS Inventory box

48h for each person

23 Anti-seasickness tablets in container 180 0.1 Inventory box
(Six-does)

24 Seasickness bag for each person Vinyl 30 0.1 Inventory box

25 Jack-knife with lanyard Hardened steel 1 0.1 Inventory box

26 Tin-opener with lanyard Hardened steel 3 0.1 Inventory box

Buoyant rescue quoit attached 30m Buoyant rubber

27 2 1.2 Inventory box
of buoyant line + Nylon rope

28 Manual pump with bilge line Plastic 1 1.5 Boat inside

29 Set of fishing tackle 1 0.1 Inventory box

Engine maker
30 Tool set 1 1.5 Inventory box
standard
Portable fire-extinguisher
31 Approved type 1 3.8 MED Boat inside
( Dry Powder : 2.0 Kg)

32 Search light Approved type 1 0.8 MED Boat inside

33 Radar reflector(Mental Type) Approved type 1 1.6 MED Inventory box

34 Thermal protective aid Approved type 3 1.2 Inventory box

35 Rainwater collector Vinyl 1 0.5 Boat inside

36 Fall Preventing Device(FPD) - PIN TYPE 2set/ship - Hook Assembly

Only Lifeboat & Rescue Combined Boat Item.

P.P rope
37 Buoyant line for Rescue boat 1/ Ship 6.0 Boat inside
(φ16 x 50m )

Total Equipment Weight (Include Fresh Water)

1 LifeBoat (Item NO.1 ~ Item NO.36) 167.2 Kg

2 Lifeboat & Rescue Combined Boat (Addition Item NO.37) 173.2 Kg

* For items that have expiry date(Item no. 11, 14~17, 22, 23), we supply those valid for at least 24
months from the date of boat delivery.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010
PAGE 18
HN.S3078 LIFEBOAT 10. LOOSED INVENTORIES LIST

10. Loosed Inventories List

Q'ty Wei Storage

No. Items Specification Sketch
/ Boat (Kg) Position

1 Boarding ladder Wood + P.P rope 1 4.0 Boat inside

Maintenance and Training

2 Manual, Engine and Hook maker standard 1 0.4 Inventory box
Manual
3 Electric cable for bat.charger DPNP 2.5 x 5m standard 1 2.4 Boat inside

Fresh water flusing

4 40A(Ship's conn.) x 15m 1/ship 3.3 Boat inside
hose(Flexible Rubber)

5 Air charging hose Maker standard x 50m 1/ship 46.5 Boat inside

Total Weight for Loosed Inventories & Fuel Oil Weight

1 Loosed Inventories Equipment Weight 56.6 Kg

Fuel Oil Capacity is 150 liter for 24hours
2
Fuel Oil Weight ( Gravity is 0.86 ) 129 Kg

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 19
HN.S3078 LIFEBOAT 11. DETAIL SPECIFICATION OF ENGINE

11. Detail Specification of Engine

1. Engine Maker ……………………… HLB CO., LTD.

2. Model …………………………………… HB29D1

3. General Specification.

- Engine Type …………………………………………Marine Diesel, Vertical, 4 - cycle

- Cylinder Bore x Stroke x No. …………… 80mm x 92.4mm x 3

- Engine Horse power …………………………… 29 Hp at 2,800 rpm

- Dimension (LxBxH) …………………………… 822 x 500 x 744mm

- Electric System ……………………………………12V x 1.7KW Start motor, 14V x 50A Alternator

- Cooling System ………………………………… Fresh water cooling with keel cooler

- Exhaust Type ……………………………………… Dry exhaust type

- Propeller Reduction Gear …………………… 2.54 : 1 Fwd Ratio, controled Fwd, Neutral and Aft.

- Fuel Oil Consumption ………………………… 5.7 Liter / H ( at 2,800 rpm )

- Dry Weight ………………………………………… abt. 185 Kg

- Starting Method ………………………………… 2 (two) independent rechargeable batteries

- Fuel Oil Line …………………………………………Oil resistance rubber hose

- Fuel Oil Valve ……………………………………… One(1) valve at fuel oil tank

- Propeller ……………………………………………… 3 - blade (Diameter:18", Pitch:13")

- Propeller Shaft …………………………………… Stainless steel

- Cooling of Stern Gear ………………………… Sea water cooling

- Engine Dashboard ……………………………… Alarm & Warning lamp for Eng.Oil Press & Water temp.,

Engine start/stop key.

- Engine Control …………………………………… Side mounting engine control lever with mechanical

cables for propeller reduction gear and engine governor

at helmsman position.

4. Fuel Oil Tank ………………………………………… 150 Liter for 24 hours full speed running.
Steel Painted.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010
PAGE 20
HN.S3078 LIFEBOAT 11.1 LUB. OIL CHART

11.1 Lub. Oil Chart

Lubricating oil

Marine gear
for engine :
temp. range

Below - 15˚C

Below 5˚C

Above 5˚C
OIL COMPANY OIL TYPE HD OIL GRADE & QUALITY
●
VISCO 5000 SAE 5W-40 API SJ/CF
● ●
BP OIL Vanellus C3 Diesel Turbo SAE 10W-30
● ●
Vanellus C6 Multi SAE 15W-40 API CI-4
www.bp.com
●
Vanellus C3 Diesel Turbo SAE 15W-40
●
Automatic Transmission Fluid

EXXON/MOBIL ●
Mobil Delvac 1 SAE 5W-40 API CI-4 PLUS/CF/SJ
● ●
www.exxonmobil.com Mobil Delvac MX SAE 15W-40 API CI-4/CF/SJ
www.mobil.com
●
Automatic Transmission Fluid
●
SHELL OIL Helix Ultra SAE 5W-40
●
Gadinia Multigrade SAE 10W-30
www.shell.com
www.shell- ● ●
Rimula R3x SAE 15W-40
lubricants.com
●
Automatic Transmission Fluid
SK ENERGY ● ● ●
ZIC 5000 POWER SAE 15W-40 API CI-4
www.skenergy.com ●
Automatic Transmission Fluid

TOTAL MARINE / ELF ●

ELF SYNTHESE 5W50 SAE 5W-40
● ●
www.lubmarine.com DISOLA W 15W40 SAE 15W-40
www.elf.com
●
Automatic Transmission Fluid
CHEVRON TEXACO / ● ●
Ursa Marine 15W-40 SAE 15W-40
FAMM
www.fammllc.com ●
Automatic Transmission Fluid

CASTROL ● ●
TECTION GLOBAL SAE 15W-40
www.castrol.com
●
Automatic Transmission Fluid

GULF-MARINE ● ●
GULFSEA POWER MX 15W-40 SAE 15W-40
www.gulf-marine.com
●
Automatic Transmission Fluid

LUK OIL ● ●
Titan Truck SAE 15W-40
lukoil.com/
●
Automatic Transmission Fluid

Engine Oil Change the oil after the first 50h and every 100h of operation or once a year. 5.8 Liter

Marine Gear Change the oil after the first 25h and every 150h of operation or once a year. 0.6 Liter

Oil Filter Replace oil filter with at least every 2 times oil change.

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 21
HN.S3078 LIFEBOAT 11.2 SPARE PARTS AND TOOL LIST

11.2 Spare Parts and Tool List

11.2.1 Spare Parts List

No. Part Name Sketch Description Weight(Kg) Working Spare

1 Belt Fitted in front of Engine 0.1 1 1

2 Filter - fuel for Engine 0.3 1 1

3 Filter - oil for Engine 0.5 1 1

4 Relay - glow Boat inside 0.4 1 1

11.2.2 Tool List

No. Part Name Sketch Description Weight(Kg) Q'ty/Boat

Hand p
pump p for
1 500mm/ Flex
Flex. Tube 0
0.3
3 1
Lube oil Draining

2 Adjustable Spanner 8"x200mm 0.3 1

3 Polygrip Toge 150mm 0.2 1

4 Open Spanner N/V 8/10 0.1 1

5 Open Spanner N/V 12/14 0.1 1

6 Screw Driver Maker Standard 0.1 1

Total : 2.4

* Tools are depended on Engine maker standard at Boat's delivery.

HLB CO., LTD.

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HN.S3078 LIFEBOAT 12. DETAIL OF SKATE

12. Detail of Skate

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 23
HN.S3078 LIFEBOAT 13. POSITION OF DAVIT REMOTE CONTROL WIRE

13. Position of Davit Remote Control Wire

H HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 24
HN.S3078 LIFEBOAT 14. FRESH WATER FLUSHING HOSE

14. Fresh Water Flushing Hose

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 25
HN.S3078 LIFEBOAT 15. AIR SUPPORT SYSTEM

15. Air Support System

CONNECT SHIP

HLB CO.,, LTD.

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HN.S3078 LIFEBOATS 16. SHOP TEST

16. SHOP TEST

16.1 GENERAL
The Lifeboats shop test should be carried out for first vessel in this series vessel as follow IMO Resolution
MSC.81(70) part 2, 5.3.1 for release mechanism and 5.3.3 for 2hours operation including speed test at the
sea and factory.

For other vessels should be carried out inspection at the factory same with first vessel as follow IMO Resolution
MSC.81(70) part 2, 5.3.1 and 5.3.3 without speed test that had approved by classfication when prototype test
in accordance with IMO Resolution MSC.81(70) part 1. Prototype test for life-saving appliances 6.10 Lifeboat
operational test.

Providing product of lifeboat had approved by classfication in accordance with IMO Resolution MSC.81(70) part 1
Prototype test therefore the shop test shall be carried out as follow IMO Resolution MSC.81(70) part 2 5.3.1 and
5.3.3 as below our provided test procedure including service function test.

16.2 INSPECTION PROCEDURE WITH LOCATION

INSPECTION
NO. INSPECTION ITEMS PROCEDURE LOCATION REMARKS
S F
Each lifeboat with its engine fitted is loaded with IMO Res.MSC.
1 2 hours Operation Test the compensated weights is afloat in the water 81(70)
Part 2, 5.3.3
and carried out the 2 hours operation test.
2 Engine Start Test Engine is started with Battery No.1 and No.2.
Check lights with turn on & off for Interior
3 Electric Light Test
lights,
g ts, Canopy
Ca opy light,
g t, Search
Sea c light.
g t
Pressure of Air Bottle Check the pressure of each air bottle and
4
(Tanker Version Only) regulated pressure.
All hatchs, windows, external fittings are
5 Hose Test watertightness test with waterjet nozzle
(12.5mm diameter, 1.0kg/cm2, 2.0m distance)
After opened the waterspray valve and full speed
Water Spray Test
6 of engine, check the water spray film of external
(Tanker Version Only)
surface.
After boat was loaded to 1.1 times its related
7 Release Mechanism Test load and suspended from its release mechanism
above water, the boat is released with the lever
IMO
1.1 Times of the release mechanism at boat inside. Res.MSC.
Waterborne Check the release mechanism is simultaneously 81(70)
Part 2, 5.3.1
released from each fall and Also,
the the release mechanism is simultaneously
released in the fully waterborne.
After connected the painter to the painter
8 Painter Release Test
release unit of boat, release it at boat inside.
Check ship name, port name, Boat no.
9 Marking
Boarding Persons, etc.
10 Visual Inspection As per specification.
Note : S - Sea , F - Factory

HLB CO., LTD.

TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 27
HN.S3078 LIFEBOATS 17. Test Report

17. Test Report

HLB CO.,LTD.
TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 28
HN.S3078 LIFEBOATS 17.1 Test Report

17.1 Test Report

HLB CO.,LTD.
TEL : +82 52 240 3548 FAX : +82 52 237 4010 PAGE 29
 MAINTENANCE
and TRAINING MANUAL,
ENGINE and HOOK MANUAL
TOTALLY ENCLOSED LIFEBOAT AND RESCUE COMBINED BOAT

HYUNDAI LIFEBOATS CO., LTD.

772, Daejung-ri, Onsan-eup, Ulju-gun, Ulsan, KOREA

Tel ; (052) 240-3551~3 , Fax ; (052) 237-4010
 Document No. : HDL-MAINTENANCE-01-R2

Last Updated : Nov. 2011

INSTRUCTIONS FOR ON-BOARD MAINTENANCE

TOTALLY ENCLOSED LIFEBOAT AND LIFE/RESCUE COMBINED BOAT

HYUNDAI LIFEBOATS CO., LTD.

186-4, Daejung-ri, Onsan-eup, Ulju-gun, Ulsan, KOREA

Tel ; (052) 240-3500, Fax ; (052) 237-4855
 PLAN HISTORY

DATE REV. DESCRIPTION REMARK

Instructions for ON-BOARD Maintenance Intruction (1/1)

Intruction

Maintenance of this Lifeboat and all it's systems is of critical importance to your own safety.
The Engine and Hook Release Systems are fully explained and detailed as to their Operations and
Maintenance in their own Manuals which mush be consulted and their content be included with the
Maintenance requirements for the boats hull and other equipment detailed herein.

SECTION 1: FOR YOUR OWN SAFETY . . .

SECTION 2: MAINTENANCE PRECAUTIONS.

SECTION 3: ORGANIZING MAINTENANCE.

SECTION 4: GENERAL MAINTENANCE INFORMATION.

SECTION 5: MAINTENANCE ROUTINES

PART 1. HOOK RELEASE SYSTEM

PART 2. ENGINE, PROPULSION, & SHAFTING SYSTEM.

PART 3. STEERING SYSTEM

PART 4. BILGE PUMPING SYSTEM

PART 5. FRP HULL & CANOPY

PART 6. ELECTRICS

PART 7. LOOSE GEARS

PART 8. FITTINGS

PART 9. AIR SUPPLY SYSTEM (TANKER VERSION ONLY)

PART 10. WATER SPRAY SYSTEM (TANKER VERSION ONLY)

APPENDIX
1. MANUFACTURER'S MANUAL OF ENGINE
2. MANUFACTURER'S MANUAL OF LIFTING HOOK
Instructions for ON-BOARD Maintenance SECTION 1: FOR YOUR OWN SAFETY(1/1)

SECTION 1: FOR YOUR OWN SAFETY . . .

BEFORE attempting to carry out any major maintenance adjustments or

replacement of parts (NEVER repairs) on this boat and it's Systems.
YOU MUST:

1. Have read and fully understood the accompanying system's Operations Manuals.

2. Have practised thoroughly and become proficient and experienced in the use of each System
and be able to recognised when it is operating correctly-and even more importantly, when it is not.

3. Have the boat already Hanging Off or ashore (supported in a cradle) if working on even near to
the Hooks and their Release Mechanism.

4. NOT attempt any adjustments, dismantling or replacement of load bearing parts, when the boat
is suspended from he Hooks.

5. NOT attempt any major technical maintenance with the boat afloat, parts may fall overboard
and you may not be able to be sufficiently accurate.

6. Check spare parts on board. Whenever you are about to carry out a maintenance Job which
may possibly require a spare part, make sure you have a replacement part available before
dismantling.

7. Stock Control: Keep your Stock Control system up to date.

Instructions for ON-BOARD Maintenance SECTION 2: Maintenance Precautions(1/1)

SECTION 2: Maintenance Precautions

This section is intended only to contain guidance as to the safety precautions that must be taken
before carrying out any maintenance task, as indicated below.

1. General Safety Precautions.

Before carrying out any maintenance operations on a lifeboat and its equipment, as minimum
the precautions below should be followed.

(a) If working on a boat at sea inform the bridge, or if in port inform the officer(s) on duty.
Report to them also when the job is completed and the boat is again ready for emergency use.

(b) Ensure that the means of access to the boat is safe and that the boat is secure in its davit
before boarding.

(c) Never smoke inside lifeboat.

(d) Open doors and hatches to ventilate it well.

(e) Do not touch any part of the release gear unless special precautions have been taken.
See 2. below.

(f) Do not run the engine for more than 5 minutes unless it is afloat.

(g) Do not engage gear when running the engine out of the water, except for a few seconds only,
the stern-bearing may be damaged.

(h) Take all necessary electrical safety precautions if working on that type of equipment.

(I) Never attempt major hull or canopy glassfibre repairs, special facilities and skills are required.
Seek the manufacturers advice for any repair which is more than cosmetic.

2. Special Safety Precaution.

Whenever any work is to be performed on, or even near, the boat's davits, winches, hooks,
central release mechanism, interlock device or any connecting cables, and the boat is not afloat
and moored, or ashore, then the winches, falls, hooks, and release system must be isolated by
by 'hanging-off' the boat on special pendants.

The procedures for Hanging-Off: Refer to Manufacturer's manual of Davit.

Instructions for ON-BOARD Maintenance SECTION 3: Organizing Maintenance(1/1)

SECTION 3: Organizing Maintenance.

Any large project can be a daunting prospect, but when it is broken down into smaller sections,
it becomes a series of small projects which can then be easily and quickly carried out.
This Manual has been created that way to make it easy to follow and to make it simple to enter into
a computerized Planned Maintenance system for your ship if you have one.

Maintenance of any Lifeboat or System within it is an on-going Prevention project to keep it

functioning well. It's purpose is to find problems in advance and prevent them causing trouble
later and is therefore time based but checks on measurements can also be used to predict when
replacement of parts will be needed.

Jobs are grouped together by System and under the headings of weekly, monthly, 6 monthly,
annual and 5 yearly.

Jobs are also related to the main elements of each System so that work can be organised into further
small tasks.

Some Jobs require only the eyes of a person who is familiar and experienced in the boat and
a system's operation, others require tools and / or materials, some require a special jig to be used,
and in time, some may require spare parts.
All these requirements, plus people power, are or can be given on each of the Job Sheets which
comprise this Maintenance Manual.
Instructions for ON-BOARD Maintenance SECTION 4: General Maintenance Information(1/1)

SECTION 4: General Maintenance Information

In the Job Sheets which follow will be found references to various actions and necessary materials,
details are given below.

Lubricants.

Grease : Use only a multi grade marine type water resistant type suitable for both high and low
temperatures, Shell EP2 or equivalent.

Oil : Use only a thin acid free clear oil of marine type, Shell Wire Oil or equivalent.

Cleaning : A clean lint-free cloth with paraffin (kerosene) is recommended for the removal of most
dirt and excess grease.

Protectio : For most rust inhabitant purposes a thin layer of grease is adequate after cleaning.

Spare : Requests for spare parts may be sent direct to us or preferably to the System's
Parts manufacturer, accompanied by a Serial NO., type, model and SWL if applicable.
In cases where no manufacturer of a part is known to you we may be able to supply
direct or give advice as to from where it may be obtained.
In many cases the supply of the parts will be accompanied by our fitting advice.

FOR ENGINE AND HOOK RELEASE SYSTEMS REFER DIRECT TO THE

MANUFACTURERS AS PER THEIR OWN MANUALS, DO NOT USE PARTS FROM ANY
OTHER SOURCE, the risk to your safety is too great.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance General information(1/1)

SECTION 5: MAINTENANCE ROUTINES

General information

PART CODE SYSTEM

PART 1 H : HOOK RELEASE SYSTEM

PART 2 P : ENGINE, PROPULSION & SHAFTING SYSTEM

PART 3 S : STEERING SYSTEM

PART 4 B : BILGE PUMPING SYSTEM

PART 5 G : GRP HULL & CANOPY

PART 6 E : ELECTRICS

PART 7 L : LOOSE GEARS

PART 8 F : FITTINGS

PART 9 A : AIR SUPPLY SYSTEM

PART 10 W : WATER SPRAY SYSTEM

Job numbers.
These are coded according to the System to be maintained above and their timing and also as to
whether they are necessary to bo done during or following a regular inspection.

Schedule
W = Weekly F = Five Yearly
M = Monthly E = Emergency situation
H = Half Yearly (6 months) U = Urgent situation
Y = Yearly C = Corrective Action, not urgent

Example : Job No: H W 001

Schedule
Code
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 1: HOOKS RELEASE SYSTEM (1/1)

PART 1: HOOKS RELEASE SYSTEM

Job No: H 001 Job Title: HOOKS RELEASE SYSTEM

Frequency: Weekly, Monthly, Annual
Refer to: See MANUFACTURER'S MANU Tools: Torch and see MANUFACTURER'S
MANUAL
Materials: See MANUFACTURER'S MANUAL
Parts: See MANUFACTURER'S MANUAL

Special Precautions:

The boat will normally be in the davits.

If possible carry out 1) and 2) below BEFORE boarding, use binoculars.
If okay, then board and inspect close-up.

1) Check Hook Locking Position .

If not correctly aligned move away from the boat immediately and report it.
Hook is either strained or not locked properly.
Boat is in danger and UNSAFE.
Emergency action required, See MANUFACTURER'S MANUAL immediately.

2) Check that fall links are correctly engaged in both the Hooks and that the Musing/Keeper
Plate is in place.
Check both Release Cam Position Indicators are correctly aligned.
If not do Job urgently, See MANUFACTURER'S MANUAL immediately.

Instructions for:

HOOK MANUFACTURERS MANUAL & CREATE JOB ROUTINES AS RECOMMENDED.

The maintenance instruction and schedule of HOOKS RELEASE SYSTEM is fully described in
MANUFACTURER'S MANUAL.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM(1/3)

PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM.

Job No: P 001 Job Title: Engine

Frequency: Weekly, Monthly, Annual
Refer to: See MANUFACTURER'S MANU Tools: Torch and see MANUFACTURER'S
MANUAL
Materials: See MANUFACTURER'S MANUAL
Parts: See MANUFACTURER'S MANUAL

Special Precautions:

Instructions for:

ENGINE MANUFACTURERS MANUAL & CREATE JOB ROUTINES AS RECOMMENDED

The maintenance and repair of engine is fully described in MANUFACTURER'S MANUAL.

Also, a maintenance schedule is given in Engine manual, to this manual a spare parts catalogue
is added to give all the information about spares in case of an overhaul.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM(2/3)

PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM.

Job No: PW010 Job Title: Stuffing box & Bearing Checks
Frequency: Weekly
Refer to: Tools:

Materials: Grease, Oil seal

Parts: None

Special Precautions:

Security of boat if NOT afloat.

Instructions for:

Stuffing box & Bearing Checks

a) If boat is afloat ;
Check the bilges and examine the stuffing box for leakage.
If found leakage, screw tight slightly by driver.
If this is not fully successful then it may be necessary to replace the oil seal.

b) If boat is out of the water:

1) Check play between the prop. shaft and stern tube bearing, it should be minimum.

2) With the engine in neutral, rotate the propeller by hand inspecting for ease of turning and true
rotation looking also for signs of mis alignment, bending, or looseness of any hardware
connection into the FRP hull.

c) Check the propeller blades for damage or loosens from the shaft.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM(3/3)

PART 2: ENGINE, PROPULSION & SHAFTING SYSTEM.

Job No: PW011 Job Title: REPlACE STUFFING BOX

Frequency: As required by Job PW010
Refer to: Tools:

Materials: Oil seal 30mm Diameter.

Sea water resistant Grease
Parts: None

Special Precautions:
See Job PW010.
Note: This Job can only be carried out when the boat is not afloat.

Instructions for:

REPLACE STUFFING BOX

a) Note how close the cover is to it's limit. Unscrew it from the gland and slide it clear.

b) Remove the worn oil seal and check damage of worn oil seal.
If oil seal was damaged, it should be replaced.

c) Replace the cover but do not overtighten, grease the oil seal and rotate the shaft by hand to
distribute it evenly. Test and check when the boat is next afloat.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 3 : THE STEERING SYSTEM(1/2)

PART 3 : THE STEERING SYSTEM

Job No: SW001 Job Title: Steering Gear Check

Frequency: Weekly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Standard Precautions

Instructions for:

Steering Gear Inspection.

a) When boat is not afloat check lower & upper rudder bearings for excessive wear.
Check the play in the upper bearing/gland and if re- packing necessary carry out Job SW002.

b) Check connection of steering cable to the tiller arm, check it's ease of disconnection also for
fitting disconnection also for fitting.

c) Fit and operate the emergency tiller, give persons training in this if possible.
Replace it after use.

d) Examine carefully the mounting of the fixed outer sheath of the steering cable, if loose then
rectify immediately.
While turning the wheel apply lubricant to the exposed part of the inner moving cable as
necessary.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 3 : THE STEERING SYSTEM(2/2)

PART 3 : THE STEERING SYSTEM

Job No: SW002 Job Title: REPACK RUDDER GLAND

Frequency: As required by Job SW001
Refer to: Tools:

Materials: 6mm square packing x500mm.

Sea water resistant Grease
Parts:

Special Precautions:
See Job SW001
Note: This Job can only be carried out when the boat is not afloat.

Instructions for:

Repacking Stern & Other Glands

a) Note how close the cover is to it's limit. Unscrew it from the gland and slide it clear.

b) Remove the worn packing and check the width it has compressed to, count the number of pieces
and confirm that the new material is of greater width.

c) Measure the shaft circumference. Cut new packing material to this length but angle the cut
so that when wrapped around the shaft a close fit is achieved.

d) Wrap the first length around the shaft and insert into the gland noting the position where the
ends meet. Wrap each following length around the shaft in succession with the ends at least
40 degrees offset from the ends of that previously inserted.

e) Replace the cover but do not overtighten, grease the gland and rotate the rudder by hand to
distribute it evenly. Test and check when the boat is next afloat.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 4: THE BILGE PUMPING SYSTEM(1/2)

PART 4: THE BILGE PUMPING SYSTEM

Job No: BW001 Job Title: Bilge pumping system check

Frequency: Weekly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

Bilge pumping system checks

a) Check that suction points in bilge is clear and free from debris.

b) Ensure that the bilge is kept clean, dry and free from debris.

c) Drain bilge, clean bottom valve and close after use.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 4: THE BILGE PUMPING SYSTEM(2/2)

PART 4: THE BILGE PUMPING SYSTEM

Job No: BW001 Job Title: Bilge pumping system

Frequency: Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

Bilge pump inspection.

Explanation ;
The bilge pump system consists of a self priming pump which suck water from bilge.
The bilge pump is of the diaphragm type and is not susceptible to blockage, but should a blockage
occurities a simple matter to clear it.

a) Check that pump is operating correctly. If in doubt, remove pump cover and inspect, removing
any material which may be blocking or obstructing the flow of water.

b) Check all hoses and clamps for damage and tightness.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 5: THE FRP HULL & CANOPY(1/3)

PART 5: THE FRP HULL & CANOPY

Job No: GM001 Job Title: Visual Inspection,FRP Hull & Canopy
Frequency: Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

Visual inspection.

a) Check condition of external F.R.P.

b) Check condition of internal F.R.P.

c) Check condition of internal F.R.P. unit.

d) Clean boat in-and outside with mild soap and fresh water.
Waxing and polishing for outside surface recommended.

e) If gelcoat repairing necessary carry out Job No. GC001

f) If laminate repairing necessary carry out Job No. GC002

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 5: THE FRP HULL & CANOPY(2/3)

PART 5: THE FRP HULL & CANOPY

Job No: GC001 Job Title: Gelcoat repair

Frequency: As Required by Job GM001
Refer to: Tools:

Materials: Gelcoat.
Parts:

Special Precautions:

Instructions for:

Repairing gelcoat.

Explanation ;
Small gelcoat damages or hair cracks can't be avoided during handling of lifeboat and do not
influence the strength of it.

a) However to avoid water penetration such areas should be sand papered and covered with
new gelcoat or paint.

b) Deeper scratches to be filled with filler before.

The gelcoat colours are ;

Outside - International orange.
Inside - Light gray.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 5: THE FRP HULL & CANOPY(3/3)

PART 5: THE FRP HULL & CANOPY

Job No: GC002 Job Title: Laminate Repair

Frequency: As Required by Job GM001
Refer to: Tools:

Materials:
Parts:

Special Precautions:

Laminate damages must be repaired by an authorized workshop.

Instructions for:

Repairing laminate.

Contact an authorized workshop or HYUNDAI LIFEBOATS. Co., Ltd Guidance.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 6: ELECTRICS(1/2)

PART 6: ELECTRICS

Job No: EW001 Job Title: Electrical system

Frequency: Weekly
Refer to: Tools:

Materials:
Parts:

Special Precautions:
Never discharge batteries below 11.4V, otherwise it can be damaged.
Switch off all consumers and battery on-off switch before leaving the boat to prevent
discharging and destroying of batteries.
When the lifeboat engine is running, the engine driven alternator charges the batteries

Instructions for:

Explanation ;
The 24 volt ship supply is connected to the lifeboat by a weatherproof plug and socket situated on
the boat side shell. The plug will pull out of the socket automatically in an emergency launch,
but generally the disconnection should be carried out manually by crew member.

The batteries fitted by the lifeboat manufacturer are of a maintenance free type provided that the
charging system is properly maintained. A 12 volt DC electric system is installed.
When the lifeboat engine is running, the engine driven alternator charges the batteries.
Do not switch off the battery switch when engine runs.

When the lifeboat is stowed in davits, the batteries are charged from ship supply through a battery
charger provided in the boat.

a) Ensure that the ship to lifeboat 24 volt supply plug and socket is properly sealed and undamaged.

b) Ensure that the battery charger is working correctly and that the light operates.

c) Check all bulbs and non-fuse breaker to ensure they are operational. Clean or replace as necessary.

d) Check that all wiring is properly clipped into place and that all joints are clean and protected.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 6: ELECTRICS(2/2)

PART 6: ELECTRICS

Job No: EW001 Job Title: Electrical system

Frequency: Weekly
Refer to: Tools:

Materials:
Parts:

Special Precautions:
Never discharge batteries below 11.4V, otherwise it can be damaged.
Switch off all consumers and battery on-off switch before leaving the boat to prevent
discharging and destroying of batteries.
When the lifeboat engine is running, the engine driven alternator charges the batteries

Instructions for:

e) Check tightness of terminal connections ensuring that both the positive and negative terminals
are absolutely tight. Clean battery poles and coat with grease.

f) Ensure that internal and external light operate.

g) Ensure that search light operate.

See next page for Electric Wiring diagram.

Electric Wiring diagram.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 7: LOOSE GEARS (1/2)

PART 7 : LOOSE GEARS

Job No: LM001 Job Title: Visual Inspection, Loose gear.

Frequency: Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

Explanation ;
The maintenance of many of the items of loose equipment is either self-evident or is described in the
operation manual and specific instructions with the equipment.
The following recommended maintenance instructions apply to those items not included in these
categories.

a) Ensure that all equipment, is stowed in correct location.

Stowage location showing General Arrangement Drawing in Training manual.

b) Check water tanks for leakage and replenish.

c) Check all oars and wooden equipment for rot, shakes, splits, etc.. Replace if necessary.

d) Check all rope, cordage, etc. for damage, fraying or rot. Replace if necessary.

e) Check all galvanized steel equipment for rust. Wire brush and repaint. Replace if necessary.

f) Grease other equipment liable to rust e. g. hatchet, knife, etc..

g) Check electric torch operates satisfactorily. If in doubt, dismantle and clean battery and contacts.
Replace battery or bulb if necessary and obtain fresh spares.

h) Check pressure of fire extinguisher. Recharging if necessary.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 7: LOOSE GEARS (2/2)

PART 7 : LOOSE GEARS

Job No: LM001 Job Title: Visual Inspection, Loose gear.

Frequency: Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

Note ;

Equipment should be kept dry and it should be checked periodically to ensure that it is not affected
by dampness or mildew.
All items of loose equipment with a limited life e. g. polytechnics, should be replaced at the intervals
required by the certificating authority.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 8: FITTINGS (1/3)

PART 8 : FITTINGS

Job No: FW001 Job Title: Visual Inspection Fittings

Frequency: Weekly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

a) Check drain plug and clean area.

b) Check that hatches and doors operate freely.

c) Open door and hatches for ventilation for about 2 hours under dry conditions.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 8: FITTINGS (2/3)

PART 8 : FITTINGS

Job No: FM001 Job Title: Visual Inspection Fittings

Frequency: Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

a) Check safety belt are not tangled and are free to fasten.

b) Inspect head protection for damage.

c) Check painter release is operational.

d) Check hatch and door seals for damage.

e) Check compass fastening and function.

f) Clean windows with mild soap and fresh water, NO solvents !

g) Check all fittings, equipment etc. clean, grease or oil as applicable.

h) Check/Grease doors and hatch sealing, hinges and tightness.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 8: FITTINGS (3/3)

PART 8 : FITTINGS

Job No: FH001 Job Title: Visual Inspection Fittings

Frequency: 6 Monthly
Refer to: Tools: Torch

Materials:
Parts:

Special Precautions:

Instructions for:

a) Check condition of skate.

b) Check condition of lifeline.

c) Check bottom valve floater. Replace if necessary.

d) Check visibility through polycarbonate window. Replace if necessary.

e) Check retroreflective material. Replace if necessary.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 9: THE AIR SUPPLY SYSTEM(1/3)

PART 9 : THE AIR SUPPLY SYSTEM (TANKER VERSION ONLY)

Job No: AW001 Job Title: Air support system check

Frequency: Weekly
Refer to: See Air Support System diagram Tools: Torch

Materials:
Parts:

Special Precautions:
1) A high pressure air system is fitted into this boat and care must be exercised when
handling this type of equipment.
2) This system includes a connecting hoses from the air cylinders to the control valve
which is under constant pressure.
Therefore no attempt must be made to disconnect the hoses or fittings BEFORE
shutting off the air supply at the bottle valves.

Instructions for:

Air support system check.

Explanation ;
This system provides air to enable the engine to run at maximum load r. p. m and for the occupants
to breathe when the lifeboat is closed down and running through fire and/or toxic gases.

a) Check over/under pressure valve is free to operate.

b) Check air cylinder pressure. Minimum permitted pressure ; 128Kg/Cm^2.

Air pressure is usually 140Kg/Cm^2 at atmospheric.

c) Check condition of air system including valve and pressure gauges.

d) Re-charging if air bottle pressure falls below 128 Kg/Cm^2 at 20 C.

Carry out Job No. AC001.

Note ;
1. Effective service life of each air reservoir is 5 years.
2. Air bottles have to re-certified after 5 years.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 9: THE AIR SUPPLY SYSTEM(2/3)

PART 9 : THE AIR SUPPLY SYSTEM (TANKER VERSION ONLY)

Job No: AC001 Job Title: Recharging Air support system

Frequency: As required by Job. AW001,
Refer to: See Air Support System diagram but at least every 5 years.
Tools: Air compressor, Recharging hose kits
Materials:
Parts:

Special Precautions:
1) A high pressure air system is fitted into this boat and care must be exercised when
handling this type of equipment.
2) This system includes a connecting hoses from the air cylinders to the control valve
which is under constant pressure.
Therefore no attempt must be made to disconnect the hoses or fittings BEFORE
shutting off the air supply at the bottle valves.

Instructions for:
Re-charging air cylinder.

a) The main acting valve on the manifold and regulator must be in closed.

b) The valves of cylinder must be fully open.

c) Remove cap from the inward side of the air re-filling connector.

d) Attach connection from recharging unit to the re-filling connector.

e) Recharging the cylinders until the gauge registers 145Kg/cm^2 at 20 C.

(it will be necessary to allow the cylinders to cool in order to measure the correct pressure)
Having cool, top-up as necessary.

f) Remove recharging unit from connection.

g) Replace cap on re-filling connection.

 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 9: THE AIR SUPPLY SYSTEM(3/3)

PART 9 : THE AIR SUPPLY SYSTEM (TANKER VERSION ONLY)

Job No: AC001 Job Title: Recharging Air support system

Frequency: As required by Job. AW001,
Refer to: See Air Support System diagram but at least every 5 years.
Tools: Air compressor, Recharging hose kits
Materials:
Parts:

Special Precautions:
1) A high pressure air system is fitted into this boat and care must be exercised when
handling this type of equipment.
2) This system includes a connecting hoses from the air cylinders to the control valve
which is under constant pressure.
Therefore no attempt must be made to disconnect the hoses or fittings BEFORE
shutting off the air supply at the bottle valves.

Instructions for:
Re-charging air cylinder.

Note ;
a) The air supplied for bottle recharging must be of breathing quality.
It must be dry, oil-free, clean, and with a water contained of not more than 3-4 P.P.M.
Excessive moisture will cause misting of the inner surface of the air cylinders and also can result
in severe icing around the pressure controller and orifices when in the process of discharging.

b) If it is necessary to test the air system, facilities must be available for the immediate recharging
of the bottles after the test.

c) If and when these components are removed from the system, care must be taken upon
subsequent assembly to ensure that they are completely free internally from oil, grease and water.

See next page for Air Support System diagram.

Air Support System diagram.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 10: THE WATER SPRAY SYSTEM(1/3)

PART 10 : THE WATER SPRAY SYSTEM (TANKER VERSION ONLY)

Job No: WW001 Job Title: Water spray system check

Frequency: Weekly
Refer to: See Water Spray System diagram Tools: Torch

Materials:
Parts:

Special Precautions:
This Job can only be carried out when the boat is not afloat.

Instructions for:
Water spray system Check

a) Check that the main water supply valve operates freely, from fully closed to fully open positions.
Dismantle and investigate if it does not.

b) Check spray sea inlet valve lever is free to operate, lubricate if necessary.

c) Check that the hose clamps on the hose to the pipe are tight but not seized.

d) Ensure that the spray pump drain line fixings are secure and that the drain valve is operational.

e) Ensure that all spray nozzles are clear and that the spray deflectors are not damaged.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 10: THE WATER SPRAY SYSTEM(2/3)

PART 10 : THE WATER SPRAY SYSTEM (TANKER VERSION ONLY)

Job No: WM001 Job Title: Water spray system check

Frequency: Monthly
Refer to: See Water Spray System diagram Tools: Torch

Materials:
Parts:

Special Precautions:
This Job can only be carried out when the boat is afloat.
The spray system must be clean by flushing through with fresh water after every drill.

Instructions for:
Water spray system Check

a) Launch the boat.

b) Close all doors and hatches.

c) Run engine.

d) Open water spray main valve.

e) Check the bilge and examine the all systems for leakage. Tight hose clamps if necessary,

f) Check lubricating oil in spray pump bearing housing. Lubricate if necessary.

g) Insure that the pump mounting bolts are secure and that the pump is aligned correctly.

h) Check that the water spray film covers the whole of the boat.

i) Clean by flushing through with fresh water. See Job No. CW001.
 SECTION 5: Maintenance Routines

Instructions for ON-BOARD Maintenance PART 10: THE WATER SPRAY SYSTEM(3/3)

PART 10 : THE WATER SPRAY SYSTEM (TANKER VERSION ONLY)

Job No: WC001 Job Title: Flushing Spray system

Frequency: As required by Job WM001
Refer to: See Water Spray System diagram Tools:

Materials: Fresh water

Parts: Flexible hose.

Special Precautions:
This Job can only be carried out when the boat is not afloat.

Instructions for:
Prevention of blocked with salt.

Explanation ;
This process is essential to prevent blockages and an accumulation of salt in the system.
It should be carried out immediately after the spray system has been used or tested.

a) Arrange for suitable flexible hose supplying fresh water from the platform.

b) Connect hose to flushing devise above the side entrance door.

c) Close sea water inlet valve.

d) Leave boat after shutting all hatches. Shut all doors securely.

e) Turn on fresh water supply and leave on for about 15 to 20 minutes.

f) Observe all sprinkler and nozzles and ensure that water is flowing freely.

g) When flushing is finished, turn off water supply, enter the boat and disconnect the flexible hose
from the flushing devise, replace the drain plug of spray pump and tighten, and open fully the sea
suction valve.

The system will now be ready for emergency use.

See next page for Water Spray System diagram

Water Spray System diagram
 Document No. : HDL-TRAINING-01-R2

Last Updated : Nov. 2011

TRAINING MANUAL
TOTALLY ENCLOSED LIFEBOAT AND LFE/RESCUE COMBINED BOAT

HYUNDAI LIFEBOATS. CO., LTD.

186-4, Daejung-Ri, Onsan-eup, Ulju-gun, Ulsan, KOREA.

Tel ; (052)240-3500, Fax ; (052)237-4855
 PLAN HISTORY

DATE REV. DESCRIPTION REMARK

Training Manual INDEX (1/2)

INDEX

SECTION 1. INTRODUCTION

SECTION 2. ABANDONING SHIP & LAUNCHING

2.1 Stage 1. Sistuation.

2.2 Stage 2. Master orders "Prepare Boats".

2.3 Stage 3. Embarkation & Boarding.

2.4 Stage 4. Launching the boat.

2.5 Stage 5. Releasing the falls.

2.6 Stage 6. Clearing the ship.

2.7 Stage 7. Rescuing others.

2.8 Stage 8. Assembling Liferafts and other Lifeboats.

SECTION 3. INSTALLED SAFETY SYSTEM

3.1 Safety on board.

3.2 Centrally Operated Simultaneous Hook Release System.

3.3 Propulsion Engine.

3.4 Fuel System.

3.5 Steering System.

3.6 Bilge Pumping System & Drain Plug.

3.7 Rowing the Boat.

3.8 Detection of Boat.

3.9 Lifeline.

3.10 Sea Anchor.

3.11 Rain Water Collection.

3.12 Equipment.

3.13 Air Supply System. (Tanker Version Only)

3.14 Water Spray System. (Tanker Version Only)

Training Manual INDEX (2/2)

SECTION 4. COMMUNICATIONS

4.1 VHF radio telephone.

4.2 SART (Search and Rescue Radar Transponder).
4.3 Distress Flares & Signals.
4.4 Radar Reflector.

SECTION 5. OTHER SITUATION

5.1 Launching from a vessel moving ahead.

5.2 Launching into a seaway.
5.3 Emergency Release Out of Water.

SECTION 6. PREPARATIONS FOR RECOVERY

6.1 Davit Safe Working Loads.

6.2 Advance Preparations for Recovery.
6.3 Operation checklist for Re-setting Hooks.

SECTION 7. RECOVERING THE BOAT

7.1 Return to Parent Ship.

7.2 Connecting Fall Rings/Links.
7.3 Hoisting.
7.4 Recovering the Boat in bad weather.
7.5 Foul Weather Strop Recovery.
7.6 Stowing the boat after a Drill.

ANNEX
1. EMERGENCY ESCAPING PROCEDURE OF LIFEBOAT
2. GENERAL ARRANGEMENT DRAWING
3. OPERATING PROCEDURE OF ENGINE
4. EQUIPMENT LIST
5. OPERATING PROCEDURE OF AIR SUPPLY & WATER SPRAY SYSTEM (Tanker Version Only)
6. OPERATING PROCEDURE OF RELEASE GEAR.
※ PROCEDURE AND ARRANGEMENT FOR "HANGING-OFF": Refer to Manufacturer's Manual of Davit.

APPENDIX
1. MANUFACTURER'S MANUAL OF ENGINE
2. MANUFACTURER'S MANUAL OF LIFTING HOOK
Training Manual SECTION 1. INTRODUCTION (1/1)

SECTION 1. INTRODUCTION

The purpose of this "Operations Manual" is to enable the crews of the ship fitted with this Lifeboat
to understand what facilities have been built into it and how they function.

It is very important for every person on board to read and understand this Manual for their own
safety as well as for the safety of their colleagues.

A Lifeboat is the final escape route to safety, it can only be useful to the people inside when each
person knows exactly what has to be done in an emergency - in case the person who would
normally do it has been injured.

When the parent ship has met with disaster a Lifeboat can only preserve life when everybody on
board knows what to do to board it, launch it, and clear away from the stricken ship, safely, in all
conditions and through all the hazards that it has been designed to cope with.
Once away, each person must then know what they must then do to save both themselves an others
who may be in may be in the water or in non-propelled rafts so that they are presented in the best
manner possible to be rescued.

The lifeboat is constructed to meet the performance requirements laid down by SOLAS Regulations
and has been tested to confirm that it does do so.

SOLAS also requires ship's crews to be trained to specific standards of knowledge and expertise,
but the expertise only comes with practice and the experience gained through realistic Drills.

Read this Manual, ask questions, find out what things are for and how to use them.
Your ship is your best Lifeboat, we hope it is never necessary to have to use this boat for it's real
purpose, but be prepared-you only have one life, know how to save it.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (1/8)

SECTION 2. ABANDONING SHIP & LAUNCHING - FULL DETAILS

2.1 Stage 1. Sistuation.

2.2 Stage 2. Master orders "Prepare Boats".

2.3 Stage 3. Embarkation & Boarding.

2.4 Stage 4. Launching the boat.

2.5 Stage 5. Releasing the falls.

2.6 Stage 6. Clearing the ship.

2.7 Stage 7. Rescuing others.

2.8 Stage 8. Assembling Liferafts and other Lifeboats:

2.1 Stage 1. Sistuation.

This section is intended to act as a Checklist, and for copying and use during drills.
It is organised in the chronological sequence of a major emergency, the example being a tanker
surrounded by burning oil on the sea surface.
The Master has not given authority to launch.

(Items marked *S below would be simulated during drills).

The scene:
A terrible misfortune has occurred and people have not yet had time to assess the situation.
A call has been made over the Public Address system for the emergency Working Party to assemble.

Initial actions:
The Master instructs that the situation be assessed and Officers and crew go to the scene and
inspect the damage and it's consequences.

The Master decides on a course of action intended to save the ship. He is kept advised at all times
by those at the scene and at other areas which are affected - Engine Room for example.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (2/8)

Problems:
Efforts to control the situation are not meeting with success; they may be being hampered by people
realising that there is a problem, they may be getting in the way, or perhaps it is not known if people
have been injured or how many are missing.

The Master decides to sound the General Emergency Signal.

This is the signal for all persons not engaged in trying to control the problem to go immediately to
their Muster of Assembly station. This is NOT the signal to abandon ship.

Following a count of those at the Muster / Assembly station(s) he will probably explain the nature of
the problem and if people are missing, injured, etc., he will give orders for a search to be organised
with stretcher and 1st. Aid parties, or whatever can usefully be done at that time.

Situation worsens:
The Master may decide that it will be a wise precaution to make preparations in case it does become
necessary to leave the ship.
He may order one or more of the stages below to be carried out and lifejackets be worn.

The Emergency Escaping Procedure of lifeboat is displayed at boat inside such as

ANNEX 1.

2.2 Stage 2. Master orders "Prepare Boats".

Each person designated as a member of a boats' crew should have instructions to do one or more
of the following:-

1. Overside lighting switched on and swung out.

2. Take one or more SARTs (Search and Rescue Radar Transponder) to the Muster area, the
Embarkation area, or into Survival Craft (boats or liferafts). *S

3. Helmsman or other designated person brings portable VHF radio telephone(s) to the Muster /
Assembly area or the Embarkation area or Survival Craft, having checked their operation.
He should also bring spare charged batteries.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (3/8)

4. Designated persons collect additional fuel, water, clothing / blankets, and any other extra
equipment.

5a) The helmsman and designated launching crew enter boat(s) and carry out the following tasks:-

1) Confirm davit winch control wire is revved through to boat's interior.

2) Check bottom plug closed.
3) Batteries to be switched to operating position(if necessary).
4) Disconnect charging cable.
5) Fuel & coolant levels to be checked, stop cocks checked to be in 'on' position.
6) Water spray system valve opened.
7) Air supply system checked & made ready but not switched on.
8) Hook Release Interlock checked to be 'on', in the green safety position.
Make sure that the tool for breaking the cover of the interlock is stowed nearby - you never
know if it will be needed.

5b) Designated persons on the ships deck carry out the following tasks and checks also at this time:-

1) Painter is rigged leading well ahead of boat and made fast to a strong point on the ship.
2) No maintenance / training "hanging-off" pendants are connected to the boat.
3) Additional equipment of 4. above is passed to crewmen in the boat to be stowed. *S
4) The embarkation ladder(s) should be deployed in case it becomes necessary or possible to
but people on board again if not other ladder or route is available
5) Launching area checked for obstructions.

When complete and if all clear and ready, contact the bridge and report to the Master " Ready for
boarding".

According to the danger threatening the ship the Master will decide if and when people should move
from the Muster / Assembly areas and go th the Embarkation station.
He may give this order just to get people outside if the danger is inside.
This is NOT the order to board the boats.

When the Master finally decides it is in the best interests of the people on board will he give the order
to board boats.
He may instruct boarding only or he may instruct to board and launch.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (4/8)

2.3 Stage 3. Embarkation & Boarding.

1. Persons board the lifeboat to the orders of the helmsman or officer in charge.
They sit down and wait for further instructions.

2. Any casualties on stretchers are taken inboard and stowed across seats and secured in place
using the seatbelts.

3. All other persons put on seat belts.

4. Last person to board reconfirms launching area is clear and that lashings (gripes) have been
released and cleared away.

2.4 Stage 4. Launching the boat.

Although the boat can be launched by a person standing on deck, in a real Abandon Ship emergency
it can only be done from within the boat by the helmsman.
It must always be practiced this way during drills.

Only when the Master has given the order to launch will the following actions be taken.

1. Close all doors & ventilators. *S

2. Helmsman starts engine.

3. In a fire situation, switch air supply system on *S

4. The Helmsman then pulls down and holds down the davit brake control wire.

During Drills this launching control must be practiced frequently and it must be understood and
realised that the result of this pull down and holding down action has the following effects:-

1) Pulling down on the control wire lifts the brake & starts descent, releasing it applies the brake
releasing it applies the brake and stops the descent.

2) The brake has an automatic speed control, it is not possible to slow descent by means of the
control wire, attempts to do so cause wear on the brake and shock loads on hooks, davits etc.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (5/8)

3) The boat should be allowed to descend to the water at the automatically controlled speed and
splash down, this overruns the falls to enable easy release.

7. As soon as the boat plunges into the water, if there is burning oil on the surface or near the boat
the helmsman turns on the water spray system to keep the boat cool.

2.5 Stage 5. Releasing the falls.

The helmsman checks that the Hook Release Interlock is now in the "off", cleared (red-for danger
when lifting) position.
Having removed the manual locking devices he operates the lever to release both hooks
simultaneously.

If the Hook Release Interlock did not disengage automatically he must now override it to enable the
boat to be released.

a). Using the tool provided or any other metal object available, break open the glass (perspex)
cover over the Hook Release Interlock and lift it, holding it in the raised position to clear the
operating lever.

b). Operate the lever in the normal was and the hooks will be released simultaneously.

2.6 Stage 6. Clearing the ship.

Remember that the boat is a totally enclosed type; it has been launched into a burning sea and that
the falls which are hanging loose, now become a danger to the boat.

If the skates are of the type which must be released in order to achieve speed, they should be
released now.

All helmsmen need to acquire skill by practising the necessary manoeuvres to

get away from the ship safely, every boat behaves differently. As guidance only
we offer the following suggestions to be practiced.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (6/8)

In principle, getting away from a ship's side without using boathooks to push the bow out (remember,
it man be a raging inferno outside ) and without crashing into the davit fall blocks entails twisting the
boat by kicking the stern out with rudder hard over, using short bursts of ahead engine power
(making use of the propeller's transverse thrust).

With very little movement ahead the bow should swing in towards the ships side, the stern out.
Release the painter at this stage and with engine full astern, rudder amidships, the boat will pull clear.

Once away, the boats should be run on a compass course through the smoke into clear water as
quickly as possible, the air supply system having only a 10 minute capacity.

2.7 Stage 7. Rescuing others.

Lifeboats are reasonably maneuverable but are not perfect Rescue Boats but with skill learnt through
practice and with a well trained crew, can be used efficiently to save persons in the water.

The helmsman appoints crewmen as lookouts, one with his head through the forward
hatch looking ahead, one at the side door looking abreast the boat on that side, and
one aft with an all round unobstructed view - the helmsman has a more restricted
all-round view.

Crewmen have to be instructed to point clearly towards a survivor, and keep pointing
the whole time; it is no good shouting as the helmsman is inside and will not hear
above the engine and wind / sea noises.

Approaching a Survivor in the sea:

Head unwind of the survivor and swing the boat abreast of him a short distance away and stop.
The boat will lie with the wind abeam and will drift downwind towards the survivor at a faster rate
than he will drift away. The boat also makes a lee.
As soon as possible get hole of the person and bring them alongside. Be careful when using the
engine.

Survivors in the water may be injured but if not and they are still able to, encourage them
to hold on to the boat, s lifelines along the sides and to work their way along to the door
where the boarding ladder has been rigged.
Help them to climb up and into the boat.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (7/8)

Injured people:
If they cannot cling on due to cold or injury, use the boathook to drag them to the door,
try not to worsen their injuries.
To lift an unconscious or severely injured person up and into the boat is not easy and
needs to be practiced. If they are wearing lifejackets this can both help and interfere with
their rescue but the points which follow should help.

Remember:

- A wet person will weigh twice as much as a dry person

- An unconscious or very cold person cannot help themselves
- It is impossible for one person to life another clear of the water.

Unconscious people:
In this boat there is a side door and to recover an unconscious or helpless person needs two
rescuers in the doorway and who need to hang out as far as they can while holding on to a rail
or other point with one hand.

With the survivor below the doorway, his back to the boat, the rescuers then have to use the
buoyancy of the survivor and his lifejacket in then have to use the buoyancy of the survivor and
his lifejacket in combination with the roll of the boat to get him as far out of the water as possible
momentum.
Other people in the boat can be directed to heel the boat and make it roll to help the rescuers.

The rescuers life the survivor as far as they can, then push him down as far and as fast as possible
dragging him higher and higher out of the water each time until it is possible to finally get him clear
and into the boat, hopefully without injuring him further.
Consult the survival Manual and the First Aid kit itself for guidance as to medical care and
protection of injured persons.

2.8 Stage 8. Assembling Liferafts and other Lifeboats:

Liferafts which have not streamed a drogue (sea-anchor) can drift very quickly indeed in even light
indeed in even light winds, more quickly than the boat possibly, therefore the approach to them
them should take this into account.
When passing a line to a raft remember that the boat has the advantage of height, can position
itself upwind, and if the line does miss the raft, the boat can then tow it into a position from
where it can be reached.
Training Manual SECTION 2. ABANDONING SHIP & LAUNCHING (8/8)

Bring all rafts and boats together and lash them to make the largest possible mass, stream drogues
and set up radar reflectors and transponders.
Initiate any EPIRB and radio distress transmissions available on board.

Be prepared for a considerable wait, consult the Survival at Sea Manual in the boats / rafts and
organics accordingly.
At least you will be safe, if not comfortable.
Training Manual SECTION 3. Installed Safety Systems (1/6)

SECTION 3. INSTALLED SAFETY SYSTEMS

3.1 Safety on board.

Personal safety on board is provided in the form of seat belts which should be used at all times
during launch and escape from the ship and in rough sea conditions.
They should only be removed when the helmsman (or other person in charge) considers it to be
safe as they are designed to hold the body in relation to the protection against impact forces
and during a complete capsize.

The boat is fitted with Skates on one side to further cushion the effects of heavy impacts against
the ship's side during launch in poor conditions.
It should be necessary they can be released and recovered inboard by letting go the rope securing
on one side of the boat if they are to be re-used, or jettisoned completely by letting go from both
sides.

3.2 Centrally Operated Simultaneous Hook Release System.

The Hook Release System of this boat is fully detailed and explained in it's own Operated and
Maintenance Manuals to which you must refer.
Two hooks have sufficient Safe Working Load.

It has to be stressed here though that your lives are at great risk if you do not understand how
this system works and how to recognize when it is not working properly.

When kept in good order this system is extremely safe and efficient, but it is a machinery system
which, if neglected or not used correctly, can have result in injuries- which may be FATAL.

LOOK AFTER THIS SYSTEM AND IT WILL LOOK AFTER YOU.

3.3 Propulsion Engine.

The Engine is housed in it's own enclosed casing which is sound insulated to reduce the noise level
so that shouted order from the helmsman can be heard inside the boat. The casing is made to be
fire retardant (not fire proof) and top and sides are detached for maintenance of engine and it's also
used to inject extinguishing foam or powder without admitting extra air and spreading a fire further.
Training Manual SECTION 3. Installed Safety Systems (2/6)

The diesel engine, the keel cooler at boat outside bottom with mixed anti-freezed fresh water, is
specifically designed for use as a Lifeboat propulsion engine having been separatedly tested to
confirm that it meets SOLAS performance requirements, particularly with regard to inversion during
a capsize of the boat.

It is capable of being run out of the water for on more than 5 minutes when out of gear, the
propeller must not be turning or the sea water lubricated stern gland will be damaged.

The Operating Procedure of Engine is displayed at the helmsman's position such as

ANNEX 3.

For fully detailed operation and maintenance instructions plus spares and tools information for the
Engine refer to it's own separate Manuals.

3.4 Fuel System.

The capacity of Diesel Fuel tank is 24 hours with full speed of engine.
In the fuel supply line accessible to people in the boat by means of an extended spindle is a fuel
shut-off valve for use in case of engine fire or tank maintenance / cleaning.
A dipstick for gauging the tank's contents is fitted near the tank.

3.5 Steering System.

The steering of this boat have two, with steering wheel for normal operation and with emergency
tiller for failed normal operation.

The steering wheel in front of helmsman was connected to rudder tiller with mechanical push-pull
cable.

Note: When normal steering has failed it will probably be necessary to disconnect it from the tiller
to be able to use the emergency steering.

The person using the emergency tiller has no compass and cannot see out of the boat sufficiently
for complete control, the helmsman must therefore give steering orders in a clear loud voice.

It is recommended that use of emergency steering is practiced at regular intervals.

Steering System diagram
Training Manual SECTION 3. Installed Safety Systems (3/6)

3.6 Bilge Pumping System & Drain Plug.

A manual bilge is fitted at the aft end of the boat which can drain the boat when afloat.

When the boat is in stow however it does not normally trim to the stern and therefore an automatic
drain valve is fitted near amidships.
Although automatic in the sense that, if it has not been closed manually, a float will rise in the tube
to prevent a large volume of water flooding into the boat.
When afloat this drain valve may not be completely watertight, especially in bad weather.

When preparing to launch the boat the drain valve should always be closed and when back in it's
davits, re-opened to drain the boat.

3.7 Rowing the Boat.

If the engine was failed, it is possible to row this boat, 4 rowlocks are provided together with the
the same number of oars at boat inside.

The side door have to be clipped open and the rowlocks inserted into their mounting points.
Rowing with oars, standing persons, will be able to propel the boat with the helmsman steering as
normal.
This facility is provided only to be able to clear the vessel without the use of an engine.

3.8 Detection of Boat.

For detection at rescue ship or helecopter, the retro-reflective tapes were fitted at boat outside and
ship's name and port name were marked at boat outside.

3.9 Lifeline.

To board from water, the buoyant lifeline was fitted around boat to grip it and climb to boat inside.
Training Manual SECTION 3. Installed Safety Systems (4/6)

3.10 Sea Anchor.

This will be stowed forward ready for deployment and consists of a conical bag which is porous
and stays open when tension is applied to the bridle via the hawser line which is attached to it.
It gives a grip on the water thus keeping the boats head to wind and slows down the rate of drift.

To deploy the drogue firstly make the hawser fast to a strong point on the boats bow, protect it
from chafe if necessary. The second longer but lighter rope is the tripping line which must also be
made fast; this is used to spill (trip) the water from the drogue when bringing it inboard again.

3.11 Rain Water Collection.

Not shown opposite due to it's simplicity the Rain Water Collector is fitted to the forward hatch.

Rain water will run down the hatch and can be collected by opening the valve inside the boat just
below the hatch. A short pipe enables water to be directed into storage containers.

Care must be taken to ensure that containers are clean and that the water collected is not
contaminated by salt, before storing any water check that it is sweet.

3.12 Equipment.

For safe in the sea, the equipment required by SOLAS, such as food, signal, first-aid outfit, fresh
water, etc. stored boat inside. The detail list has appendix 4.
Training Manual SECTION 3. Installed Safety Systems (5/6)

3.13 Air Supply System. (Tanker Version Only)

Beneath the centre bench at the forward end of the boat are stowed the high pressure 67.5 liter
capacity 140 kg/cm2 compressed air bottles connected to a manifold and pipework leading to
a Regulator positioned near the helmsman.

If the boat is to be launched into a hazardous area, either fire or noxious fumes, the system should
be prepared for use before launching in the following steps:-

1) Check all valves on air bottles themselves are open.

2) Open Main valve on manifold.
3) Check that high pressure gauges on manifold and regulator are similar.
4) Open regulator, Check two air outlets are functioning properly.
5) Turn off regulator until needed.

The Operating Procedure for Air Supply System is located nearby helmsman such as
ANNEX 5.

The Air System is designed to provide sufficient air for boarding persons and run the engine at full
speed for at least 10 minutes.
The air flow needs to be adjusted to maintain just a slight over pressure.

The boat is fitted with an automatic pressure valve which will control the pressure internally such that
it will never fall to below that outside (before allowing outside air to enter the boat), nor allow it to
rise to more than 20 hPa(before venting the excess).

Whenever the system has been tested and air used, check the contents of air bottles and
re-charge as necessary following the re-charging procedure given in the Maintenance Manual.

3.14 Water Spray System. (Tanker Version Only)

The other protection system aboard this type of boat is the Water Spray designed to cover the
whole of the boats' exterior in a film of running water for as long as necessary.

The system consists of an engine-driven pump is set into operation by the helmsman opening the
butterfly valve located near him (with an instruction plate), he also turns it off from here when not
needed.

The Operating Procedure for Water Spray System is located nearby helmsman such as
ANNEX 5.
Training Manual SECTION 3. Installed Safety Systems (6/6)

The pump is self-priming and runs continuously whenever the boat is afloat and the engine is
running; it can also run dry for no more than 5 minutes when the boat is out of the water.

Below the pump and exiting through the boat's hull is the water by-pass/pump drain valve which
must be left open at all times.

The main inlet valve, located ahead of the by-pass/pump drain valve, also incorporates a butterfly
valve and this too must be left open at all times, it's closing arrangement being provided for
emergency use only.

The spray pipework outside the boat has special nozzles designed to ensure complete coverage
lf the above water surfaces lf the boat's exterior and after use, the whole pipework system must
be cleaned by flushing through with fresh water using a hose connected to the flushing fitting
above the side door.

This routine of flushing is essential after every drill when the boat is in stow to ensure that spray
heads do not become blocked with salt, during drills each head should be checked for correct and
effective operation.
Training Manual SECTION 4. Communications (1/1)

SECTION 4. COMMUNICATIONS

4.1 VHF radio telephone:

Hand-held battery operated portable Radio Telephones are also kept on charge on the ship's
bridge ready for transfer to Survival craft;
they are provided for communication purposes to other survival or rescue craft rather than a
means of sending a distress signal.

A sing fully charged battery in good condition should, with reasonable economy of use, last a
minimum of 6 hours.
Remember, you have no means of re- charging radio batteries on board, take fully charged
spares with you.

4.2 SART (Search and Rescue Radar Transponder):

A SART is an electronic beacon which when switched on emits a signal which shows up as a' stripe'
on a ship's radar screen.
Most ships have to carry two SARTS, one either side of the bridge, ready for carrying to any Survival
Craft.
Lifeboats will have a special mounting bracket fitted, usually near the stern access door.
Do not forget to switch it on.

4.3 Distress Flares & Signals:

Stowed in a separate watertight cannister with full instructions for use are 4 rocket parachute
flares, 6 hand flares, and 2 smoke floats.
A signalling torch (with spare batteries and bulbs), a daylight signalling mirror, and a whistle are
other means of signalling.

4.4 Radar Reflector:

This is a passive means of making a small target show up more clearly on a ships radar screen and
consists of a foldable diamond shape fitted to a telescopic pole which has to be assembled and
then erected outside to clips provided for the purpose.
Training Manual SECTION 5. OTHER SITUATION (1/2)

SECTION 5. OTHER SITUATION

This Manual has so far detailed how to launch and control the boat in the "calm sea"
straightforward abandon ship situation.
In practice however and particularly in emergencies, the situation may well be opposite to that.
This section will give some practical guidance for the following:-

5.1 Launching from a vessel moving ahead.

Launching from a vessel moving ahead. All lifeboats are designed to be launching from a moving
vessel and the practices required also apply to launches from a vessel moored in a tideway or
current, or when there is a strong wind.
The main factors for special attention which are less necessary in "calm sea" launches, consist of
at least following:-

(a) The correct rigging of the painter to keep the boat as near vertically below the falls
as possible in order to take load off the hooks.

(b) The flow of water past the boat's hull can cause cavitation and affect the disengaging
of the Hook Release Gear Interlock thereby necessitating use of the emergency Interlock
override.

(c) The boat should be launched with only those persons being necessary on board,
all wearing lifejackets as usual.

(d) Having released the hooks, the boat should have it's engine running ahead to stem
the current before releasing the painter.

(e) Using a boathook forward to push off from the ship's side will allow the current to swing
the bow out clear of the forward fall, an increase in engine power will clear the stem fall.

5.2 Launching into a seaway.

It may be necessary to launch into rougher seas or when a swell is running past the ship, the rise
and fall lf water level will cause violent motion and possibly cause damage to the boat and impose
considerable shock loads onto boat and davits. Once waterborne the boat will pitch and heave and
the objective must be to keep control and get clear immediately.
Training Manual SECTION 5. OTHER SITUATION (2/2)

To achieve this objective is difficult and it cannot really be practised but two factors can make
a major difference if performed immediately:-

(a) Keep the davit winch control wire under tension the whole time until the boat is released,
this will prevent the hooks snatching and shock loading the davits and falls.

(b) As soon as the boat touches the water, put the engine slow ahead and rudder hard over
to point the bow in towards the ship's side, the stern out.
As the hooks are released they will swing away from the boat.

If possible, a crewmen with boathook aft can assist this process and the helmsman then uses
engine full astern to get clear.

5.3 Emergency Release Out of Water.

The Emergency Release of a life boat before it is waterborne is fraught with danger and demands
serious and concentrated consideration before it is used.

In fact there are only two scenarios when an Emergency Release should ever need to be considered,
both should only ever occur during a real emergency Abandon Ship situation.

(a) When the sea condition is considered to be too severe but the emergency is that great that
the risk of an "on-load" launch to drop the boat into the water is determined to be less of a
danger to the lives of those in the boat than attempting to carry out the normal waterborne
"off-load" release.

(b) When during an otherwise normal descent the davit winch brake fails and stops the boat
reaching the water and there is no one left on board the ship to rig an embarkation ladder to
let the boat's occupants return aboard;
furthermore the situation is such that remaining suspended from the falls and waiting for the
parent ship to sink lower in the water is also considered tp be too dangerous.

This Lifeboat's Release Gear System has been designed such that three separate actions are
necessary to override the Release Interlock which, whitest the boat is not afloat, will be engaged
and will prevent the normal "off-load" release being used.

See this system's Operations Manual for full details of the methods of using the emergency
"On-Load" release facility.

This Section of this Manual has emphasized the risks to life of using it.
Training Manual SECTION 6. Preparations for Recovery (1/3)

SECTION 6. PREPARATIONS FOR RECOVERY

6.1 Davit Safe Working Loads.

Davits are designed to lower fully laden boats but are not designed to recover them at that same
weight.
Unless the davit serves a Rescue Boat and has a Safe Working Load stated as being adequate will
be the same and only hoist the boat with crew of 3 persons aboard.

Masters of some ships may insist that all persons leave the boat before hoisting more than a few
centimeters above the water.
Always have a means of landing excess persons to shore or direct to ship in place before launching
a boat.

6.2 Advance Preparations for Recovery.

Having released the boat from the falls upon launching, the first action after clearance from the ship
upon launching, the first action after clearance from the ship must always be to re-set the hooks.
This is a task which needs special care and time to check and double-check that it has been done
properdifficulty, and should be repeated for training those on board who arely, without problems or
difficulty, and should be repeated for training those on board who are unfamiliar with this
arrangement and hook type.

The Hook Release System contains a number of safety features which include:

An automatic Interlock which will engage and block operation of the Hook Release Handle
whenever the boat is out of water, and disengage from it when afloat.
An Override facility to this Interlock is available to permit release should there be a mechanical
failure of the device.

Means to prevent the Release Handle from being in advertently operated.

A red Release Handle locking pin requiring two actions to remove it.

The Central Release mechanism cannot be returned to it's operating position unless both hooks
have been returned to their correct position and the locking devices are also correctly engaged.

Maladjustment indicators to inform boat crews that the system requires attention
even if successfully locked.
Training Manual SECTION 6. Preparations for Recovery (2/3)

6.3 Operation checklist for Re-setting Hooks:

1) Crew return both hooks to their working position and, having checked the Hook Position
indicators report to the helmsman "hooks returned".
The hooks have to held in this position.

2) The helmsman moves the Release Handle to it's vertical position.

If the system on this boat is of a 're-cocking' type the handle will not return to it's fully locked
position (with the lugs on it's side relocated between the Mechanism's side plates).
The helmsman then orders "Re-cock Hooks" and waits.

3) The crewmen lift the re-cocking levers which re-sets the Release Cam to the locking position
so that they can let go of the hooks moves parts inside the Central Release Mechanism itself.

4) When both hooks are fully re-set the Release Handle will drop down with it's lugs between
the side plates to the locked position, the red Safety Pin can then be inserted and this should
now be done.

5) Once the Release Handle is locked at it's correct position, the order "Check Locking
Cam Position" is given.
The crewmen then has to sight that the Indicator on the Locking Cam is pointing to it's 'safe'
mark on the hook side plate and report "Aft (Forward) Hook-Cam Position checked and okay".

6) Once both hooks have been reported, i. e. they both appear to be locked, (it can be very
difficult to see clearly), the helmsman orders "Check Hooks" and the crewmen then inspect
both the Hook Position and the Cam Position Indicators once more
before physically trying to re-open the hooks by hand, reporting back "Forward (Aft) Hook
checked and locked".

If a hook has slipped out of it's correct locking position without being noticed by the crewmen
it's tail may be lying above the Locking Cam, and in this position Re-Cocking will still
operate but the hook will not be locked.

The re-check of the Hook Position Indicator at (5) above should reveal this but for added
security in view of the danger of an unlocked hook, this second physical check must always
be made.
Training Manual SECTION 6. Preparations for Recovery (3/3)

7) Both crewmen should move along the boat to helmsman and discuss the re-setting operation
to confirm that:-

a) Both hooks swivelled easily back to their correct working positions smoothly and
without catching or jamming and that their Hook Position Indicators could be clearly
seen and were not damaged or oblitered.

b) That the re-cocking action was also smooth and easily operated.

c) That the Release Lever operated as expected and was also performed smoothly
when releasing and re-setting, no performed smoothly when releasing and re-setting,
no undue force was required or roughness/jerkiness was felt.

d) That the Cam Position Indicator was clearly seen to be aligned correctly, not off centre
or damaged.

( If any aspect of the whole operation was not completely satisfactory,

it must be investigated and be attended to as a matter of urgency )
Training Manual SECTION 7. Recovering the Boat (1/4)

SECTION 7. RECOVERING THE BOAT - IN FAIR CONDITIONS

7.1 Return to Parent Ship.

With excess persons disembarked the skates should be re-fitted (if it was necessary to remove them)
and the boat return to beneath it's falls.
The boat's painter should have been left hanging vertically down the side of the ship and the first
step is to approach and retrieve it.

Wind/tide/current conditions will determine the best approach angle and direction but once the eye
of the painter is re-attached to it's own release hook on the bow, it will assist in positioning the boat
at or near it's falls.
Running the boat astern drawing the painter out towards the ships stern will result in movements
the stern can be controlled in most conditions but it may be sometimes necessary to run a line down
from the ship to the stern of the boat to assist.

Another aid is to have a tail rope attached to the falls above the connection link or ring;
this lets crewmen gain control of the boats position while the blocks are well above the boat.

7.2 Connecting Fall Rings/Links.

The boat is brought under the falls taking care that the blocks/rings/links do not make heavy contact
with the boat.
The rings/links are attached to the hooks and checked to confirm that the mousing plate now
prevents their dislodging again.

7.3 Hoisting.

The order is given to the winch controller on deck to begin to lift the boat just clear of the water and
then stop.

During this initial lift the two crewmen should watch their hooks carefully, checking for any sign
of movement as the weight is taken.
The checks of both the Hook Position and the Cam Position should be made continuously,
any problem being reported to the helmsman immediately.
Training Manual SECTION 7. Recovering the Boat (2/4)

As soon as the boat is clear of the water and hoisting is stopped the Hook Release Interlock should
be checked to confirm that it has re-engaged itself automatically, if not put the boat back in the
water immediately.

Even if everything is found to be in good order it may be prudent to disembark the remaining
crewmen, otherwise the crewmen should be seated wearing lifejackets and with seat belts secure
before the order to continue hoisting is given.
The engine may now be stopped, but not before now.

7.4 Recovering the Boat in bad weather.

Bad Weather Recovery Problems. It may be necessary to recover the boat in conditions very different
to the fair weather conditions upon which the foregoing has been based.
The following risks and dangers require consideration and thought for the safety of persons in the
boat for the boat itself:

Attempting to attach the heavy links of falls to a boat's hooks when it is pitching heavily is
is virtually impossible to do safely, accidents happen all too easily in such conditions resulting
in crushed hands or skull fractures, plus a boat out of control.

Even if the links could be successfully attached, as the winch takes the strain the pitching of the
boat will impose shock loads into the lifting gear, loads which for safety should be avoided.

7.5 Foul Weather Strop Recovery.

Essential and to be mandatory from July 1998 for Rescue Boats but equally useful for other boats,
one lower risk method of achieving recovery in such conditions is to use a more resilient lifting
medium, one which is lightweight and through elasticity, is shock absorbent - a pair of Foul Weather
Strops.

A pair of webbings sling of appropriate size/strength and of length less than the hanging-off
pendants (see Manufacturer's manual of Davit maker) are attached by shackles to one point of a
"monkey face" (or triangle plate) on each of the falls; the other ends have a soft eye (no shackle)
which hangs lower than the normally used link of the falls.
This soft eye attaches direct to the boat's release hooks, NOT to the Auxiliarly Lifting Points.
Training Manual SECTION 7. Recovering the Boat (3/4)

Taking the same hoisting precautions as in Section 7 above, the boat can be lifted clear
of the water, followed by hoisting until the fall blocks are near the davit head and the previously
rigged "hanging off" pendants are within reach of the Auxiliarly Lifting Point on each of the boat's
two hook assemblies.

Once the pendants are attached, the boat can be gently lowered and the weight transferred to
them thus relieving both the falls and the hooks themselves.
The webbing slings are then detached manually, the falls lowered and the fall links connected into
the hooks in the normal way.

As the weight is transferred back to the falls all the checks of hooks and their position indicators
must again be made.

The boat can then be hoisted into it's davits and stowed and secured properly, ready for emergency
use.
The "hanging-off" pendants must be removed and stowed away from the boat.

7.6 Stowing the boat after a Drill.

The Davit Manufacturer's Operations Manual should be referred to for full details of the davit system
operation and the stowing and securing of the boat.

7.7 Preparing the boat after a Drill for use in an emergency.

Once re-stowed and secured in the davits, the crewmen aboard must then carry out the following:-

(1) All loose equipment to be re-stowed.

(2) Radios to be returned to the bridge for recharging.

(3) Fuel tank to be refilled, oil levels checked & replenished, fresh water coolant to be
topped up if needed.

(4) Water spray system to be flushed through with fresh water.

(5) Electrical charging line to be reconnected,

(6) Bottom drain plug re-opened.

(7) The davit winch control wire to be re-threaded through into the helmsman's cockpit.
Training Manual SECTION 7. Recovering the Boat (4/4)

(8) If the Air System has been used this must be recharged.

If any problems were found, minor repairs or scheduled maintenance is required,

these must be attended to immediately.

Finally, the ventilators should be left open, doors closed, and the boat be left ready in
all respects for emergency use.
 1 2 3 4

11

11 5

8
6

7
9 1 2 4 5 LOWER TO WATER
10 FULL SPEED ESCAPE

6 8

9 8 6
7
ANNEX 1. EMERGENCY ESCAPING PROCEDURE OF LIFEBOAT
 ANNEX 2. GENERAL ARRANGEMENT DRAWING (FOR CT/CNT/CF/CNF TYPE)
16 41 17
17
35 36
25 25
35 24 29
36
40
26 25
42 15 26 24
11 11 39 14

23 11
27 27 15
7 28 37 38 34

33

4
30 34

3 5 31 NO. DESCRIPTION REMARK

1 ENGINE
2 STERN TUBE
3 PROPELLER
17 16 4 RUDDER
5 RUDDER SHORE PIECE
46 6 FUEL OIL TANK
8 29 7 EXHAUST PIPE OULET
18 8 STEERING WHEEL
9 ENGINE CONTROL LEVER
9 10 LIFTING HOOK RELEASE LEVER
26
11 LIFTING HOOK
11 14 19 26 11
18 12 HOOK SHORE PIECE
44 13 HYDROSTATIC UNIT
14
10 22
14 WINDOWS FOR HOOK RECOVERY
32 15 SIDE HATCH
27 20 27 16 TOP HATCH
7 21 28 17 CANOPY LIGHT
12 43 18 INTERIOR LIGHT
19 SEARCH LIGHT
20 BATTERY BOX
6 21 INVENTORY BOX
22 CRUTCH (ROWLOCK)
12 23 HATCH HANDLE
24 SIDE HANDRAIL
25 WATER SPRAY TUBE TANKER VERSION ONLY
45 26 LASHING GUIDE
2 1 13 31 27 BOLLARD
28 PAINTER RELEASE UNIT
29 AIR VENT GRILL
30 LIFELINE
33 33 31 DRAIN PLUG
32 EMERGENCY TILLER
33 SKATE
34 SKATE FIXING ROPE
35 SCUTTLE (FIXED WINDOW)
36 RADAR REFLECTOR BED
37
37 SIDE BENCH

SHIP CENTER
38 CENTER BENCH
1 6 21 39 BOAT HOOK
40 OAR
41 DAVIT CONTROL WIRE PIECE
38 42 RETRO REFLECTIVE TAPE
43 WATER PUMP TANKER VERSION ONLY
11 24 25 11 44 WATER SPRAY ON-OFF VALVE TANKER VERSION ONLY
14 45 AIR BOTTLES TANKER VERSION ONLY
46 AIR PRESSURE CONTROL VALVE TANKER VERSION ONLY
26 41 26
15
SCALE NONE
DATE
STANDARD
GENERAL ARRANGEMENT
DWG. No.
ANNEX 3. OPERATING PROCEDURE OF ENGINE (FOR HB29D1, HB36D1 HDLB ENGINE)
START STOP

NORMAL NORMAL
① Switch "ON" No.1 Battery switch. ① Put the engine control lever into the neutral position.

② Put the engine control lever into the neutral position. ② Turn starter key to "OFF" button until the engine stops
on engine operation panel.
③ Turn automatic fuses switch "ON". Turn starter switch to
"GLOW" position and hold in this position for 10-20 sec, ③ Switch "OFF" No.1 & No.2 Battery switch.
depending on ambinient temperature on engine operation panel.
EMERGENCY
④ Turn starter switch to "START" until the engine start. Move the eingine stop lever into the neutral position.

WARNING !!
EMERGENCY DO NOT RUN THE ENGINE OVER 5 MIN. WHEN THE LIFE-BOAT IS
① Switch "ON" No.2 Battery Switch. OUT OF WATER.

② Same step ②③④ of normal.

Eng. operation
panel
Control
※ WARNING !!
lever
Only engage "AHEAD" or
Neutral "ASTERN" when engine is idling.
Battery
switch
No. 1 No. 2 Ahead Astern
Glow lamp OIL lamp Charge lamp Water lamp

OFF
OFF Gear release
GLOW OFF
ON button(push; off)
Automatic START
ON
O ON
O Fuses Put control lever into ahead & astern
warning alarm Starter Key suitable power as soon as possible.
ANNEX 4. EQUIPMENT LIST (1/2)

Q'TY STORAGE
NO. ITEM SPECIFICATION
PER BOAT POSITION

1 Buoyant oar Apiton 4 Boat inside

Galvanized
2 Crutch(Rowlock) with lanyard 4 Boat inside
steel
Aluminium +
3 Boat-hook 2 Boat inside
Plastic

4 Buoyant bailer Plastic 1 Inventory box

5 Bucket Plastic 2 Inventory box

6 Survival manual Book 1 Inventory box

Boat inside
7 Compass Approved type 1
(near steering stand)

Sea anchor with hawser and

8 Conical type 1 Inventory box
tripping line
Boat outside
9 Painter P.P. rope 2
(near bow of boat)
Each end of
10 Hatchet with vinyl bag Hardened steel 2
boat inside
Refer to
11 Fresh water 3 Liter / Person Lifeboat Inventory box
Drawing
Stainless +
12 Rustproof dipper with lanyard 1 Inventory box
Plastic

13 Rustproof graduated drinking vessel Plastic 1 Inventory box

Refer to
Food tank or
14 Food ration 10,000KJ / Package Lifeboat
Drawing
Inventory box

15 Rocket parachute flare in container Approved type 4 Inventory box

16 Hand flare in container Approved type 6 Inventory box

17 Buoyant smoke signal in container Approved type 2 Inventory box

Waterproof electric torch with Morse signalling,

18 1 Inventory box
1 spare set battery and 1 spare bulb Plastic
Daylight signalling mirror with Stainless +
19 1 Inventory box
instruction Waterproof card
Waterproof
20 Life-saving signal table 1 Inventory box
card
 (2/2)

Q'TY STORAGE
NO. ITEM SPECIFICATION
PER BOAT POSITION

21 Whistle with lanyard Plastic 1 Inventory box

22 First-aid outfit in waterproof case Approved type 1 Inventory box

Refer to
23 Anti-seasickness medicine 48h for each person Lifeboat Inventory box
Drawing
Refer to
24 Seasickness bag for each person Vinyl Lifeboat Inventory box
Drawing

25 Jack-knife with lanyard Hardened steel 1 Inventory box

26 Tin-opener with lanyard Hardened steel 3 Inventory box

Buoyant rescue quoit attached Buoyant rubber

27 2 Inventory box
30m of buoyant line with Nylon rope

Stern end of
28 Manual pump with bilge line Plastic 1
boat inside

29 Set of fishing tackle Maker standard 1 Inventory box

Engine maker
30 Tool set 1 Inventory box
standard

31 Portable fire-extingusher Approved type 1 Boat inside

Boat inside
32 Search light Approved type 1
(near steering stand)

33 Radar reflector Diamond shape 1 Inventory box

Refer to
34 Thermal protective aid Approved type Lifeboat Inventory box
Drawing

35 Rainwater collector Wooden + P.P. rope 1 Inventory box

P.P. rope 1
36 Buoyant line for rescue (combined) boat Boat inside
with thimble per Ship

-The end of List-

ANNEX 5. OPERATING PROCEDURE OF AIR SUPPLY & WATER SPRAY SYSTEM
(TANKER VERSION ONLY)

① Close all openning hatchs and natural ventilator if exist.

② Open all air bottle valves slowly.
③ Open main valve.
④ Open regulator valve slowly and keep low pressure 4.2 ∼ 4.5 kg/cm2.
⑤ Start engine and full speed up.
⑥ Open water spray main valve.
⑦ After use of the system, decrease engine rpm and close all the valves.

② R
③
④
< AIR SUPPLY SYSTEM >

water spray at boat outside.

Pump < WATER SPRAY SYSTEM >

WARNING :
① Air support system is for a period of abt. 10 minutes.
② Don't touch overpressure valve on air duct to prevent ears damage.
③ Water spray system is for use when waterborne.
④ Water spray system is able to be used max. 5 minutes with engine idle rpm
out of water.

⑤ Do not operate the water spray system without air supply system. Boarding
person can be injured due to sudden change of pressure.
 MARINE DIESEL ENGINE
(HB29D1, HB36D1)

OWNER`S MANUAL

Revision 1 / January 23, 2015

(Document No. : E0901-00002)
HLB C o . , L t d .

272-12, Dangwol-ro, Onsan-Eup, Ulju-Gun, Ulsan, Korea 689-892

Tel: +82 52 240 3500 / Fax: +82 52 237 4010 / Web Site: www.hdboat.com
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.
Warning

Second highest level of risk.

Incorrect or incomplete operation may result in equipment damage.
Caution

Less critical mandatory instructions.

Mandatory

Important note that should be emphasized.

Note

A prohibited action.
Incorrect action may result in death of occupants.
Never

1
INDEX

1. General arrangement plan --- 3 page

2. Operation the engine --- 6 page

3. Maintenace --- 10 page

4. Technical data --- 23 page

5. Engine part list--- 28 page

6. Transmission manual --- 58 page

2
1. GENERAL ARRANGEMENT PLAN
1) NAMES OF PARTS
(1) Intake manifold
(2) Speed control lever
(3) Engine stop lever
(4) Fuel injection pump
(5) Fuel feed pump
(6) Water pump
(7) Oil filter
(8) Exhaust manifold
(9) Alternator
(10) Starter motor
(11) Oil level dipstick
(12) Oil pressure switch
(13) Oil pan
(14) Engine oil drain plug
(15) Engine oil filler cap
(16) Marine gear
(17) Coupling flange
(18) Control lever – marine gear
(19) Marine gear control cable bracket
(20) Marin gear oil drain plug
(21) Engine mounting bracket
(22) Coolant outlet plug
(23) Coolant tank cap
(24) Air cleaner
(25) Coolant water temperature sensor assy
(26) Stop solenoid valve
(27) Belt

3
2) DIMENSIONS

4
2) DIMENSIONS

ENGINE TYPE HB29D1, HB36D1

MARINE GEAR TYPE HBG200

L (mm) 859.3

W (mm) 500

H (mm) 650

X1 (mm) 220

X2 (mm) 104

X3 (mm) 615

X4 (mm) 251.3

M1 (mm) 470

M2 (mm) 331.9

5
2. OPERATING THE ENGINE

Operating manual
This Owner’s Manual is intended to help you get the maximum return on your investment and to ensure your safety.
We recommend that you thoroughly read and understand this Owner’s Manual before handling, storing, installing, operating or
servicing the engine. Should your engine require parts or service, please contact HLB CO., LTD.
We will need the following information in order to assist you.
1. Engine make, model number and serial number.
2. Names and code numbers of parts to be ordered.
3. Make and model number of the machine in which engine is installed.

Preparation before first start

1. Check that oil level is between the marks on the dipstick, placed at the side of the engine.
2. Check the lubricating oil of reverse and reduction gear
3. We always recommend checking of oil level before start.
4. Fill the fuel tank. Use only diesel fuel.

# Diesel fuel standards

- Diesel oil ISO 8217 DMA
- BS 2869 A1 or A2
- Diesel oil fuel No.2-D(ASTM D975)

After the engine has been taken into use

Always check the engine and make sure it is ready for safe operation before installing the engine, be sure that the equipment is on firm,
level Ground. Do not run the engine on gradients. Never use starting fluid or gasoline in the air intake. Engine damage will result and
an explosion may occur.

Before start
1. The oil level of the engine should be checked every 14 days or every 25 hours of running. It is not necessary to refill oil of the level
is between the two marks on the dipstick.
2. The oil level of the reduction gear should be checked every 14 days or every 25 hours of running.
3. Check the quantity of fuel in the tank.

6
STARTING ENGINE (BUTTON TYPE-SMART KEY)
1. Put the marine gear into “neutral position” by means of gear separation button.
2. Press 1 time the "START" button on engine operation panel
(Automatically all lamps are light on for 1 second)
3. Automatically fuel solenoid valve is operated and operate pre-heating system for 9 seconds and then starter motor
rotate the engine. (Do not operate glow plugs continuously for more than 180 seconds and the starter should not
work for more than 20 seconds continuously.)
4. Automatically operate the after-heating system for 8 seconds to reduce exhaust gas.
5. Run at a idle speed until the engine reaches a normal operating temperature before doing work

- If you do not want to engine pre-heating, push the start button three times continuously within 1 second
and then engine will be starting without pre-heating.
- Verify that the oil lamp, water lamp and charge lamp lights are off after run the engine. If either light is
on, stop the engine immediately.
- To secure long life and maximum power it is recommended to run the engine for the first 25 hours at
not more than 80% of the maximum output.
- Do not run the engine over idle speed (about 1000 rpm) and 5 minutes without supplying it with
cooling water or seawater. Either the engine seawater pump will be damaged or the engine will be
damaged from overeating. Before starting the engine, be sure to supply seawater or cooling water
with provided auxiliary device to the seawater pump.

ALARM SYSTEM
INSTRUMENT PANEL ALARM POINT
GLOW LAMP GLOW SWITCH ON
OIL LAMP BELOW 0.5 kg/cm2
CHARGE LAMP ALTERNATOR CONDITION CHECK

WATER LAMP ABOVE 110℃

Automatically engine stop when the oil lamp or water lamp light is on.

7
COLD START
If you want to cold start the lifeboat engine at minus 30℃, please check the list as below.

CONTENT SPECIFICATION
Model HB29D1 or HB36D1
Fuel type Diesel 50% + Kerosene 50%
Battery capacity 80 AH
Heater-cooling water 230W-AC42V
Lubrication oil SAE 5W-30
Cable-battery 50sq•mm
Antifreezing solution ratio Antifreezing solution 50% and Water 50%

8
MANEUVERING

1. With the control lever in neutral position the engine is idling, and the
marine gear is in neutral. When the lever is moved forward in range 1,
the marine gear is engaged to “Ahead” first by means of working clutch-
forward, and then in range 2 the engine R.P.M is increased.
When the lever is moved from the neutral position to range 3, the marine
Gear is engaged to “Astern” first by means of working clutch-backward,
And then in range 4 the engine R.P.M is increased.

DO NOT STOP CONTROL LEVER IN CLUTCH RANGE(0~1 or 0~3)

2. Only engage “Ahead” or “Astern” when the engine is idling.

3. To accelerate engine without engaging gear operate gear release button 5 and move control handle in either direction.

For tests or maintenance the engine can idle for about 5 minutes with the boat out of the water.

Never turn the main battery switch OFF whist the engine is running. This can destroy the alternator.

STOPPING THE ENGINE

(2)
1. Move the engine control lever into the neutral position.
2. Turn the starter switch to “OFF” and remove the key.
(TURN KEY TYPE)
D C
Press the "STOP" button on engine operation panel.
(BUTTON TYPE-SMART KEY)
3. Turn the all of battery switch to “OFF”

If engine do not be stopped in spite of doing the preceding 1~3, move the engine stop lever (2) to the
“STOP” position(D).

9
3. MAINTENANCE

BLEEDING THE FUEL SYSTEM

Bleeding air from the fuel system may be required.
1. After the fuel filter has been removed or any fuel lines have been disconnected.
2. If the fuel tank has been allowed to run dry.
3. After long-term storage.

Bleed air from the fuel system. Check for leaks.

1. Loosen an air plug.
2. Check fuel leakage of air plug.
3. Operate manual pump up and down. Bleed air from the fuel system.
4. Start the engine after screw air plug.

Replacing the fuel filter periodically will significantly reduce injection pump and fuel injector wear.

ENGINE OIL & OIL FILTER

Stop the engine when you change engine oil, fuel oil cartridge or check engine oil level.

Checking and adding engine oil

1. Always check oil level before starting.
2. Wait at least 5 minutes after shutdown to get an accurate oil level reading.
3. Wipe the dipstick clean, insert it all the way in and remove to get the correct oil level reading.
4. If the oil level is below the lower mark on the dipstick, add oil through the fill port on top of the engine.
5. For the best results, it is recommended that the oil level be kept at the upper mark.
6. Use SAE 15W-40 oil or equivalent.
7. Always drain the oil completely when changing. Never mix different oils or engine damage may result.

Changing engine oil

1. Change the oil after the first 50 hours of operation.
2. Remove the hose plug from the flywheel cover using oil drain pump and allow all of the oil to
drain. Draining the oil will be easier when the engine is slightly warm.
3. Reinstall the plug and fill with the correct amount of oil Ensure that the oil
level on the dipstick is at the upper mark.

4. Change the oil after every 150 hours of operation thereafter.

10
 Replacing the oil filter
Oil gauge
1. Replace oil filter with at least every 2 times oil change.
2. Remove the filter using a filter wrench.
3. Apply a thin layer of clean oil to the gasket on the new filter.
4. Screw the new filter on. Hand tighten only.
5. Ensuring that oil level is correct and run the engine.
6. Check for leaks. Recheck that the filter is hand-tight.

7. Clean up and properly dispose of any spilled oil. Wipe any spilled oil from the engine.

FAN BELT
MEASUREMENT AND ADJUSTMENT
Measure the deflection by depressing the center of the belt between the fan
drive pulley and the alternator pulley at 98N (10kgf, 22lbs) of force. If the
deflection is out of the specified value, loosen the bolts and nuts and adjust the
location of the alternator. If the belt is damaged or worn, replace the belt.
Fan belt deflection : 7~9mm

Low belt tension can result in engine overheating and insufficient battery charging. A belt that is too
tight may cause bearing failures and belt life may be shortened.

BELT TENSION ADJUSTMENT

1. Loosen both bolts that attach the alternator.
2. Move the alternator to adjust belt tension.
3. Retighten the bolts after adjustment.

11
COOLING SYSTEM.
Cooling water pump : impeller type.
Cooling water : fresh water
Cooling system capacity (with keel cooler)
HB29D1 ------ 6.3 ℓ HB36D1 ------ 6.3 ℓ
TEMP. COOLING WATER----- 75~100°C
An anti-freeze concentration of 40% should be used as an all year round coolant. This concentration will give low temperature
protection down to -25℃.

In addition to, a 40% concentration will protect the cooling system from corrosion.

- The coolant mixture should not exceed 50% anti-freeze by volume.

Anti-freeze Vol% Freezing point (°C)

40 -24
50 -37

- This data is the industry standard for a typical ethylene glycol based antifreeze.

- Do not use dirty water or seawater for coolant.

- Check pressure cap condition tighten securely after service.
- When coolant is added, start the engine and check again before it gets hot. It may require
additional coolant.
- To avoid injury, always stop the engine and allow it to cool before changing the coolant or
performing any other cooling system service.
- Do not remove the pressure cap while the engine is hot. Escaping steam or coolant will cause
serious injury to you or any bystanders.

12
ELECTRIC SYSTEM
ELECTRIC SYSTEM
The engine is equipped with a 12 volt electrical system consisting of a starter motor and an alternator, the max charging current of
which is 50 Amp.

- It is not allowed to connect additional equipment to the wiring system of the engine.
- Possible additional equipment has to be connected directly to the terminals of the battery.

BATTERY
The level of the electrolyte in the battery should be checked every 14 days or every 25 operating hours.
The battery must never be isolated from the alternator, when the engine is running.

LONG-TERM STORAGE (BATTERY)

1. Before long-term engine storage remove the battery. fully charge the battery, store the battery in a dry, dark place.
Do not store on the ground or a concrete surface.
2. Batteries will discharge even when not in use.
During long periods of inactivity, recharge regularly to maintain readiness and battery life.

13
CONNECTOR CONFIGURATION.

Connector View and Numbering Order

Connector view

Illustration in the Shop

Actual Illustration Remarks
Manual

Male Male It is not the shape of the connector housing, but the
connector pin that distinguishes between male and
female connector.
For individual detailed numbering refer to the Connector
Configuration.

Numbering Order

Female Connector Male Connector Remarks

Female Connector’s pins are numbering in order from

upper right to lower left.
Male Connector’s pins are numbered in order from upper
left to lower right.

14
ENGINE CIRCUIT DIAGRAM (BUTTON TYPE – SMART KEY)

※ NOTE
When check of engine circuit diagram, use the multimeter – Do not use the checkclamp

15
Electric wiring (BUTTON TYPE – SMART KEY)

SMART KEY

CONNECTOR PIN
1 BATT(+) 11 FUEL/HOL

2 12 FUEL/PUL

3 BATT(-) 13

4 WTS 14 “N” SW

5 WTS 15

6 RPM INPUT 16 START

BUZZ GLOW
7 17
OUTPUT OUTPUT
8 OIL PRESS 18 ALT(R)

9 ALT 19 FUEL/HOL
GLOW
10
INPUT

16
WIRING ASSY-ENGINE CONTR

CONNECTOR PIN
1 BATT(+) 12 FUEL/PUL
Extension references 2 13
L = 2.2 meters E9120-21002
L = 5.9 meters E9120-29002 3 BATT(-) 14 “N” SW
“A” applies only to the tachometer 4 WTS 15
5 WTS 16 START
RPM GLOW
6 17
INPUT OUTPUT
BUZZ
7 18 ALT(R)
OUTPUT
8 OIL PRESS 19 FUEL/HOL
PULL IN
9 ALT A
COIL
GLOW GLOW
10 B
INPUT PLUG
11 FUEL/HOL C START/MAG

17
WIRING ASSY-ENGINE SUB

CONNECTOR PIN
1 BATT(+) 12 FUEL/PUL
2 13
3 BATT(-) 14 “N” SW
4 WTS 15
5 WTS 16 START
RPM GLOW
6 17
INPUT OUTPUT
BUZZ
7 18 ALT(R)
OUTPUT
8 OIL PRESS 19 FUEL/HOL
PULL IN
9 ALT A
COIL
GLOW GLOW
10 B
INPUT PLUG
11 FUEL/HOL C START/MAG

18
SPARE PARTS LIST
Q’TY
REF. No. PART. No. DESCRIPTION REMARKS
HB29D1 HB36D1

E5640-72531 FAN BELT 1 1 TOOL BOX

1
FAN BELT Installed water
E5640-72531 1 1
(Only water pump type lifeboat) pump

2 E0980-M1050 FILTER – FUEL 1 1 TOOL BOX

3 E6201-32443 FILTER – OIL 1 1 TOOL BOX

4 T4180-69951 RELAY – GLOW 1 1 TOOL BOX

PERIODIC CHECKS
WEEKLY MONTHLY YEARLY 5-YEARLY REMARKS

Engine idle operation 5 minutes 0

Checks : Engine oil level 0

Marine gear oil level 0

Cooling liquid level 0

Renew every
Anti-freeze content 0
2 years
Control cables engine/gearbox 0

Battery 0

Shaft Mechanical seal bolt 0

Electric starter drive 0 Protect for rust

Change : Lubrication oil 0

Gear oil 0

Lubricating engine oil filter 0 0

Fuel filter 0 0

Clean : Air filter 0

Adjust : (If necessary) V-belt 0

※ Required replacement at 5-Yearly inspection : Oil filter, Fuel filter

19
TROUBLESHOOTING

PROBLEM: ENGINE WILL NOT START OR IS DIFFICULT TO START

Possible Cause Corrective Action

Engine doesn’t crank • Change oil level by whether (temperature).
Or crank slowly. • Check battery and cables

• Ensure that there is fuel in the tank.

• Clean the fuel system and replace fuel if water, dirt or other impurities are present.
• Check the fuel filter. Clean or replace as required.
Insufficient fuel flow
• Check and bleed air from fuel filter, injection pump and fuel lines.
• Check and clean injection nozzles, being careful not to damage the orifice.
• Replace injection nozzle(s) if not working properly after cleaning.

• Check and adjust valve clearance when the engine is cold.

Improper valve clearance
HB29D1, HB36D1 : intake 0.25mm, exhaust 0.30mm
• Check valves for leakage – grind valves to correct.
Low compression • Check for bad valves, piston wear, ring damage or wear, or liner wear.
Have parts replaced.
Incorrect fuel injection timing • Proper injection timing (crank angle before top dead center) : 18°

PROBLEM: ENGINE SUDDENLY STOPS RUNNING

Possible Cause Corrective Action

• Check fuel level and refill.
Lack of fuel
• Check the fuel system. Repair leaks and bleed air from the system.
Clogged or faulty fuel
• Clean or replace as needed.
injector(s)
• Check for and repair leaks. Fill to correct oil level.
Seizure due to lack of • Check for clogged oil filter and replace.
lubrication • Check oil pump and lubrication system.
• Check to see if engine bearing clearance is within specifications.
• Follow oil and filter service instructions to prevent future occurrences.

20
PROBLEM: LOW ENGINE POWER OUTPUT

Possible Cause Corrective Action

Clogged or faulty fuel • Check and clean injection nozzles, being careful not to damage the orifice.
injector • Replace injection nozzle(s) if not working properly after cleaning.

• Check valves for leakage – grind valves to correct.

Low compression
• Check for bad valves, piston wear, ring damage or wear, or liner wear. Have parts replaced.

Insufficient fuel flow • Check and service fuel system

• Check for and repair leaks. Fill to correct oil level.

• Check for clogged oil filter and replace.
Seizure of Moving parts • Check oil pump and lubrication system.
• Check to see if engine bearing clearance is within specifications.
• Follow oil and filter service instructions to prevent future occurrences.

Incorrect fuel injection timing • Proper injection timing (crank angle before top dead center) : 18°

• Check and adjust valve clearance when the engine is cold.

Improper valve clearance
HB29D1, HB36D1 : intake 0.25mm, exhaust 0.30mm

• Check the injection pump and valve assembly. Replace as required.

• Poor quality fuel or improper fuels will accelerate injection pump wear.
Fuel injection Pump wear
• Adjust to proper injection pressure
HB29D1, HB36D1 : 150~160 kgf/cm2

PROBLEM: EXHAUST SMOKE OR DARK EMISSIONS

Possible Cause Corrective Action

Fuel governor malfunction • Contact HLB CO., LTD. for repairs.

Poor quality fuel • Drain and replace with proper fuel. DIESEL ONLY

Faulty fuel injector • Clean or replace as required.

• Check injection timing, injection pump, valve adjustment and typical causes of low compression.
Incomplete fuel combustion
Make adjustment or repairs as needed.

THE ENGINE MUST BE STOPPED IMMEDIATELY IF:

Possible Cause Corrective Action

Engine speed suddenly
• Check the fuel system and injection timing.
changes
Unusual sound occurs • Check all moving parts
Exhaust smoke or dark
• Check for loose or damaged parts
emissions appear
Bearing overheated • Check for lubricating system leaks

• Check for lubricating system leaks

Oil pressure warning light • Check for proper oil level
comes on • Check the oil pressure relief valve
• Check the oil pressure switch

21
PROBLEM: ENGINE OVERHEATS

Possible Cause Corrective Action

Low coolant level • Check for and repair leaks. Add coolant.

Loose or broken fan belt • Adjust or replace belt as required.

Anti-freeze concentration too high • Add water or replace coolant to achieve proper mix.

Cooling system dirty • Flush and clean system.

Defective coolant tank cap • Replace defective cap.

Faulty thermostat • Check and replace thermostat

Defective temperature
• Calibrate using thermometer and replace, if necessary.
gauge or sending unit
Engine overload • Reduce load. If overheating persists, check other causes.

Low oil level • Check for oil system leaks. Check and adjust oil level.

Leaking head gasket • Replace head gasket.

Fuel injection timing • Check and adjust timing.

Unsuitable fuel • Replace fuel with the clean fuel of the proper type and grade.

22
4. TECHNICAL DATA

ENGINE SYSTEM
HB29D1 HB36D1
TYPE Vertical, water-cooled 4cycle diesel engine
Working principle 4 stroke
Number of Cylinder Cylinder 3
Cylinder volume cc 1393 1647
Bore and Stroke ¢ X mm 80 X 92.4 87 X 92.4
Combustion Chamber Spherical type
Compression ratio 22:1
output 2800rpm 29 36
Idling speed 950
Fuel Injection Pump Type Bosch K type pump
Rate of fuel Combustion g/psh Under 200
Starting system ℓ Electric starting with starting motor
Rotation direction From the side of F/W C.C.W (Counter clockwise)
weight kgf 193 199

VALVE TIMING AND INJECTION POINT

HB29D1 / HB36D1

Inlet valve opens Before TDC 8°

Inlet valve closes After BDC 35°

Exhaust valve opens Before BDC 45°

Exhaust valve closes After TDC 8°

INLET 0.25mm
Valve clearances
(cold engine)
EXHAUST 0.30mm

FUEL SYSTEM
HB29D1 / HB36D1
Injection pressure Kgf/㎠ 150~160
Injection timing BTDC 18°

23
LUBRICATING SYSTEM
HB29D1 / HB36D1
Type of lubrication oil pump Gear pump
Lubrication oil pressure :
Kg/㎠ 0.5
warm engine, minimum
Lubrication oil viscosity SAE 15W-40
Lubrication oil content ℓ 5.8

MARINE GEAR
HBG200
Lubrication oil viscosity ATF
Lubrication oil temperature 120℃ (248℉)
Lubrication oil content 0.6 ℓ

COOLING WATER SYSTEM

HB29D1 / HB36D1

Cooling water temperature ℃ 70~95

Cooling water capacity ℓ 6.3

ELECTRICAL SYSTEM
HB29D1 / HB36D1

Battery voltage VOLT 12

Battery output AH 60

Starting output KW 1.7

Alternator A 50

Water Temp Sensor ℃ 110

Oil press SW Kg/㎠ 0.5

Glow plug W 163 X 3

24
TORQUES
HB29D1 / HB36D1

Cylinder head bolts Kgf.m 10.5 ~ 11

Connecting rod bolts Kgf.m 4.5 ~ 5.0

Flywheel / counterweights Kgf.m 10 ~ 11

Gearbox Kgf.m 3 ~ 3.5

Flexible coupling between

Kgf.m 9 ~ 9.5
engine and gear

Head cover Kgf.m 0.9 ~ 1.2

Glow plug Kgf.m 2.0 ~ 2.5

Crankshaft nut Kgf.m 14 ~ 16

Nozzle holder Kgf.m 5.0 ~ 7.0

Injection pipe nut Kgf.m 2.5 ~ 3.5

Oil pressure SW Kgf.m 1.5 ~ 2.0

25
LUBRICATION OIL CHART FOR HB29D1, HB36D1
Lubricating oil
for engine :
temp. range

Marine gear
Below - 15˚C

Above 5˚C
Below 5˚C
OIL
OIL TYPE HD OIL GRADE & QUALITY
COMPANY

` SAE 5W-40 API SJ/CF ●

Vanellus C3 Diesel Turbo SAE 10W-30 ● ●

BP OIL
Vanellus C6 Multi SAE 15W-40 ● ●
www.bp.com
Vanellus C3 Diesel Turbo SAE 15W-40 ●

ATF Transmission Fluid ATF Oil ●

EXXON/MOBIL Mobil Delvac 1 SAE 5W-40 API CI-4 PLUS/CF/SJ ●

www.exxonmobil.co Mobil Delvac MX SAE 15W-40 API CI-4/CF/SJ ● ●

m
www.mobil.com Mobil Multipurpose ATF ATF Oil ●

Helix Ultra SAE 5W-40 ●

SHELL OIL
Gadinia Multigrade SAE 10W-30 ●
www.shell.com
www.shell- Rimula R4x SAE 15W-40 ● ●
lubricants.com
SPIRAX S4 ATF X ATF Oil ●

SK ENERGY ZIC 5000 POWER SAE 15W-40 API CI-4 ● ● ●

www.skenergy.com ZIC ATF XPIII ATF Oil ●

TOTAL MARINE / ELF SYNTHESE 5W50 SAE 5W-40 ●

ELF
DISOLA W 15W40 SAE 15W-40 ● ●
www.lubmarine.com
www.elf.com ELFMATIC G3 ATF Oil ●

CHEVRON Ursa Marine 15W-40 SAE 15W-40 ● ●

TEXACO / FAMM
www.fammllc.com TEXAMARIC 7045E ATF Oil ●

TECTION GLOBAL SAE 15W-40 ● ●

CASTROL
www.castrol.com Transmax Dex III
ATF Oil ●
Multivehicle

GULF-MARINE GULFSEA POWER MX 15W-40 SAE 15W-40 ● ●

www.gulf-
marine.com GULFSEA ATF III ATF Oil ●

Titan Truck SAE 15W-40 ● ●

LUK OIL
lukoil.com/
Titan AFT 4000 ATF Oil ●

26
 Engine Oil Change the oil after the first 50h and every 100h of operation or once a year. 5.8 Liter

Marine Gear Change first time after 25h and every 150h or once a year. 0.6 Liter

Oil Filter Replace oil filter with at least every 2 times oil change.

RECOMMENDATIONS
OIL TYPE SAE Grade Quality level Lubricants

ENGINE OIL 15W-40 Diesel engine

TRANSMISSION OIL
ATF Cone clutch type transmission
(HBG200)

27
 MARINE DIESEL ENGINE

(TYPE HB29D1, HB36D1)

PART`S CATALOG

Revision 1 / January 23, 2015

HLB C o . , L t d .

272-12, Dangwol-ro, Onsan-Eup, Ulju-Gun, Ulsan, Korea 689-892

Tel: +82 52 240 3500 / Fax: +82 52 237 4010 / Web Site: www.hdboat.com

28
 TABLE OF CONTENTS

E010 CYLINDER BLOCK ……………………………………………… 2

E 0 2 0 O I L PA N … … … … … … … … … … … … … … … … … … … … … … . . 4
E030 CYLINDER HEAD ………………………………………………… 5
E040 GEAR CASE ………..…..……………………………………….. 6
E050 CRANKSHAFT BEARING CASE ……………………………… 8
E 0 6 0 VA LV E , R O C K E R A R M … … … … … … … … … … … … … … … . . 9
E070 CYLINDER HEAD COVER …………………………………… 10
E080 CAMSHAFT …………………………………………………….. 11
E090 PISTON, CRANKSHAFT ……….……………………….. 12
E100 F LY W H E E L … … … … … … … … … … … … … … … … … … . . 14
E110 NOZZEL HOLDER ………….………………………….. 16
E120 FUEL CAMSHAFT ……….……….………………….. 17
E130 SPEED CONTROL P L AT E …….……………………. 19
E140 ENGINE STOP LEVER ……………………………… 20
E150 GOVERNOR …………………………………………….. 22
E160 WAT E R PUMP ………………………………………….. 23
E170 WAT E R PIPE …………………………………………….. 24
E180 A LT E R N AT O R ………………………………………….. 25
E190 MANIFOLD ……………………………………………….. 26
E200 COOLANT R E S E RV E TA N K ………………………… 27
E210 INSTRUMENT P L AT E ……………………………….. 28
E220 R E L AY BOX …………………………………………….. 29
E230 WIRING …………………..…………………………….. 30
E240 SWITCH, I S O L AT O R ………………………………….. 31

29
E010 CYLINDER BLOCK

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5803-01011 CYLINDER BLOCK ASS’Y 1
01 E5647-01011 CYLINDER BLOCK ASS’Y 1
02 E5803-01113 CYLINDER BLOCK 1
02 E5640-01113 CYLINDER BLOCK 1
03 E5900-96031 PLUG 5 5
04 E5900-96021 PLUG 2 2
05 06311-75018 PLUG 3 3
06 06311-75045 PLUG 1 1
07 15221-0338-3 CAP, SEALING 5 5
08 15221-0339-2 CAP, SEALING 2 2
09 05012-00408 PIN, STRAIGHT 2 2
10 05012-00609 PIN, STRAIGHT 2 2
11 05012-00612 PIN, STRAIGHT 2 2
12 05012-01018 PIN, STRAIGHT 1 1
13 15221-3365-1 PIN, PIPE 1 1
14 06312-10020 PLUG 1 1
15 15221-3361-1 PLUG 1 1

30
E010 CYLINDER BLOCK

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
16 15021-3366-1 GASKET 1 1

17 E6301-33812 PIN, PIPE 1 1

18 E6200-35013 OIL PUMP ASS’Y 1 1

19 E5500-35154 GASKET, OIL PUMP 1 1

20 01023-50650 BOLT WITH WASHER 4 4

21 19202-3566-1 GEAR, OIL PUMP DRIVING 1 1

22 05712-00410 KEY 1 1

23 E6300-35681 NUT, FLANGE 1 1

24 E5500-39013 SWITCH, OIL 1 1

25 E6300-35692 GUIDE, OIL GAUGE 1 1

26 21604-M1011 BRACKET-LH 1 1

27 21604-M1021 BRACKET-RH 1 1

28 01133-51230 BOLT 7 7

29 01133-51030 BOLT 1 1

31
E020 OIL PAN

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5608-01613 OIL PAN 1 1
02 E5500-01623 GASKET, OIL PAN 1 1
03 E6314-02033 FLANGE BOLT WITH PIN 20 20
04 E6313-32111 FILTER 1, OIL 1 1
05 01654-50820 FLANGE BOLT WITH PIN 1 1
06 04811-00160 O RING 1 1
07 E6313-36414 OIL GAUGE 1 1
08 E6303-33661 WASHER, SEAL 1 1
09 E6303-33751 PLUG 1 1

32
E030 CYLINDER HEAD

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5803-03042 CYLINDER HEAD ASS’Y 1
01 E5603-03042 CYLINDER HEAD ASS’Y 1
02 E5803-03112 CYLINDER HEAD 1
02 E5603-03112 CYLINDER HEAD 1
03 15221-0337-3 SEALING CAP 9 9
04 15221-0349-3 SEALING CAP 1 1
05 E5900-96021 PLUG 3 3
06 E6850-13581 GUIDE, INLET VALVE 3 3
07 E6850-13561 GUIDE, EXHAUST VALVE 3 3
08 E6301-03148 HOT PLUG 3 3
09 01513-50822 STUD 1 1
10 15221-0175-1 ENGINE HOOK 2 2
11 02763-50080 NUT, FLANGE 1 1
12 01123-50816 BOLT WITH WASHER 1 1
13 E5800-03315 GASKET, HEAD 1 1
14 E6850-03451 BOLT HEAD 14 14

33
E040 GEAR CASE

Q'TY
REF.NO. PART NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5627-04107 ASSY CASE, GEAR 1 1
02 E5627-04117 CASE, GEAR 1 1 ORDER BY 1
03 E5800-96031 PLUG 3 3
04 04811-00150 O RING 1 1
05 04811-00220 O RING 2 2
06 04811-00360 O RING 1 1
07 05012-00612 STRAIGHT PIN 2 2
08 E5627-32302 OIL FILTER SUPPORT 1 1
09 E5800-96031 PLUG 1 1
10 04811-00180 O RING 1 1
11 E5627-32323 OIL FILTER SUPPORT GASKET 1 1
12 E5627-91131 BOLT, HEXAGON SOCKET 3 3
13 E5627-91141 BOLT, HEXAGON SOCKET 1 1
14 15521-3229-1 JOINT PIPE 1 1
15 04011-50180 PLAIN WASHER 1 1
16 15241-3695-2 SPRING 1 1
17 E5500-36932 VALVE SEAT 1 1
18 07715-03213 STEEL BALL 1 1

34
E040 GEAR CASE

Q'TY
REF.NO. PART NO. DESCRIPTION REMARKS
HB29D1 HB36D1
19 E5627-04132 GASKET, GEARCASE 1 1
20 01123-50802 BOLT 2 2
21 01123-50835 BOLT WITH WASHER 1 1
22 01123-50860 BOLT WITH WASHER 2 2
23 01123-50870 BOLT WITH WASHER 5 5
24 01123-50875 BOLT WITH WASHER 2 2
25 01123-50885 BOLT WITH WASHER 3 3
26 15521-7332-1 WATER RETURN FLANGE 1 1
27 E5500-73332 WATER RETURN FLANGE GASKET 1 1
28 01023-50620 BOLT WITH WASHER 2 2
29 01513-50616 STUD 1 1
30 02056-50060 NUT 1 1
31 04512-50060 SPRING WASHER 1 1
32 E6201-32443 OIL FILTER 1 1
33 04811-00160 O RING 1 1
34 E5806-04151 COVER 1 1
35 01754-50610 FLANGE BOLT 1 1

35
E050 MAIN BEARING CASE GROUP

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6300-04044 MAIN BEARING CASE ASS’Y 1 1
02 E6300-04542 BOLT 1, BEARING CASE 6 6
03 E6300-04363 GASKET 1 1
04 E6300-04813 COVER BEARING 1 1
05 E6300-04822 GASKET, BEARING COVER 1 1
06 01654-50830 BOLT, FLANGE 16 16
07 E5500-04464 SEAL, OIL 1 1
08 E6300-04054 MAIN BEARING CASE ASS’Y 1 1 1
09 E6300-04064 MAIN BEARING CASE ASS’Y 2 1 1
10 04014-50100 WASHER, PLAIN 2 2
11 15291-0456-2 BEARING CASE BOLT 2 2 2
12 05012-00408 PIN, STRAIGHT 6 6

36
E060 VALVE, ROCKER ARM

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6301-13111 VALVE, INLET 3 3
02 E6301-13121 VALVE, EXHAUST 3 3
03 15221-1324-2 SPRING, VALVE 6 6
04 E5500-13332 RETAINER, VALVE SPRING 6 6
05 E6403-13361 COLLET, VALVE SPRING 12 12
06 E6301-13151 SEAL, VALVE STEM 6 6
07 E5800-14001 ROCKER ARM SHAFT ASS’Y 1 1
08 E5800-14501 ROCKER ARM SHAFT 1 1 ORDER BY 7
09 E6301-14331 CAP, SEALING 2 2 ORDER BY 7
10 E6301-14351 BRACKET ROCKER ARM 3 3
11 E6301-14431 WASHER, PLAIN 2 2
12 E6301-14311 SPRING, ROCKER ARM 2 2
13 04612-00190 SNAP RING 2 2
14 E6301-14111 ROCKER ARM 6 6
15 15021-1424-1 NUT 6 6
16 E5500-14232 SCREW, ADJUSTING 6 6
17 E6510-91502 BOLT, ROCKER ARM SUPPORT 3 3

37
E070 CYLINDER HEAD COVER

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5608-14502 CYLINDER HEAD COVER ASS’Y 1 1
02 E5608-14511 CYLINDER HEAD COVER 1 1
03 E6510-14671 O RING 1 1
04 07712-01607 STEEL BALL 1 1
05 E5608-14031 ASSY, VALVE COVER 1 1
06 E2020-29000 COVER-VALVE 1 1
07 03024-50510 SCREW 4 4
08 E5850-14561 OIL PROTECTOR 1 1
09 E5850-14521 GASKET, CYLINDER HEAD COVER 1 1
10 E5608-05512 AIR BREATHER 1 1
11 09318-88180 CLAMP, HOSE 2 2
12 E6510-33661 BOLT, HEAD COVER 8 8

38
E080 CAMSHAFT

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5500-15553 TAPPET 6 6
02 E6300-15113 ROD, PUSH 6 6
03 E5603-16011 CAMSHAFT ASS’Y 1 1
04 E5603-16151 CAMSHAFT 1 1 ORDER BY 3
05 06350-00607 PLUG, SET 2 2
06 15521-1651-1 GEAR, CAMSHAFT 1 1
07 05712-00720 KEY 1 1
08 E5500-16272 STOPPER, CAMSHAFT 1 1
09 01123-50818 BOLT 2 2
10 E6300-24012 IDLE GEAR ASS’Y 1 1
11 E6300-24212 GEAR, IDLE 1 1 ORDER BY 10
12 E6300-24281 BUSH, IDLE GEAR 1 1
13 E6300-24371 COLLAR 2 1 1
14 E6300-24321 CIR – CLIP 1 1
15 E6300-24253 SHAFT, IDLE GEAR 1 1
16 01754-50820 BOLT, FLANGE 3 3

39
E090 PISTON, CRANKSHAFT

Q’TY REMARKS
REF.NO. PART.NO. DESCRIPTION
HB29D1 HB36D1
01 E5803-21011 PISTON ASS’Y 3
01 E6301-21017 PISTON ASS’Y 3
02 E5803-21111 PISTON 3
02 E6301-21114 PISTON 3
03 E6300-21313 PIN, PISTON 3
03 E6720-21312 PIN, PISTON 3
04 E5800-21052 PISTON RING ASS’Y 3
04 E6301-21053 PISTON RING ASS’Y 3
05 E5800-21152 RING 1 PISTON 3
05 E6301-21152 RING 1 PISTON 3
06 E5800-21162 RING 2 PISTON 3
06 E6300-21162 RING 2 PISTON 3
07 E5800-21202 RING, OIL 3
07 E6301-21202 RING, OIL 3
08 E6300-21332 SNAP RING 6 6
09 E6300-22018 ROD, CONNECTION ASS’Y 3 3
10 E6300-22114 ROD, CONNECTING 3 3 ORDER BY 9

40
E090 PISTON, CRANKSHAFT

Q’TY
REF.NO PART.NO DESCRIPTION REMARKS
HB29D1 HB36D1
11 E6300-21353 BUSHING 3 3
12 E5800-22141 BOLT, CONNECTING ROD 6 6
13 E6300-22312 BEARING, CONNECTING ROD 6 6
14 E5616-23014 CRANK SHAFT ASS’Y 1 1
15 E5800-23115 CRANK SHAFT 1 1 ORDER BY 14
16 06350-00708 PLUG, SET 3 3
17 08121-06002 BEARING, BALL 1 1
18 E6200-23472 CRANKSHAFT METAL 1 1 1
19 E6200-23482 CRANKSHAFT METAL 2 6 6
20 E6300-23531 SIDE METAL 1 2 2
21 E6300-23541 SIDE METAL 2 2 2
22 05712-00720 KEY 1 1
23 E6200-24112 GEAR, CRANKSHAFT 1 1
24 15471-2331-1 SLINGER, OIL 1 1
25 04811-10300 O-RING 1 1
26 E6510-23251 COLLAR, CRANKSHAFT 1 1
27 E5500-11302 SEAL, OIL 1 1
28 15221-2336-1 CRANK SHAFT NUT 1 1

41
E100 FLYWHEEL

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5806-25011 FLYWHEEL ASS’Y 1 1
02 E5806-25111 FLYWHEEL 1 1 ORDER BY 1

03 15221-6382-4 GEAR, RING 1 1 ORDER BY 1

04 E5500-25164 BOLT, FLYWHEEL 6 6

05 E5608-04611 HOUSING, FLYWHEEL 1 1
06 15521-0479-2 GASKET 1 1
07 15521-0468-2 COVER, TIMING MARK 1 1
08 01123-50816 BOLT 2 2
09 01674-51032 BOLT, FLANGE 11 11
10 01133-51240 BOLT 2 2
11 E5500-63016 STARTER 1 1
12 E6200-04623 GASKET 1 1
13 02114-50080 NUT 1 1
14 04512-50080 WASHER, SPRING 1 1
15 01133-51030 BOLT 1 1

42
E100 FLYWHEEL

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
16 01517-51028 STUD 1 1
17 02176-50100 NUT 1 1
18 04512-50100 WASHER, SPRING 1 1
19 06331-35016 PLUG 1 1
20 E4410-31011 COUPLING, TRANSMISSION 1 1
21 BOLT 4 4 ORDER BY 20
22 43504-M1020 COVER, MISSION HOUSING 1 1
23 11403-08253 BOLT 10 10
24 21604-M1031 BRKT-REAR 2 2
25 01133-51230 BOLT 8 8

43
E110 NOZZLE, HOLDER

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6300-53005 NOZZLE HOLDER ASS’Y 3 3
02 E6300-53651 SEAL, HEAT 3 3
03 E6300-53021 GASKET 3 3
04 E5610-53714 PIPE 1, INJECTION 1 1
05 E5610-53723 PIPE 2, INJECTION 1 1
06 E5610-53734 PIPE 3, INJECTION 1 1
07 15121-5385-2 CLAMP 1, PIPE 2 2
08 T4815-67371 CLAMP 2, PIPE 2 2
09 03024-50520 SCREW 2 2
10 E6301-65512 PLUG, GLOW 3 3
11 E5800-65562 CORD, GLOW PLUG 1 1
12 E5800-42501 OVERFLOW PIPE ASS’Y 1 1
13 09661-40300 TUBE, FUEL 1 1
14 09318-88080 CLAMP, HOSE 2 2

44
E120 FUEL, CAMSHAFT

Q’TY
REF.NO PART.NO DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5640-16021 CAMSHAFT, FUEL ASS’Y 1 1
02 E5640-16171 CAMSHAFT, FUEL 1 1
03 08240-00001 BEARING, BALL 1 1
04 08153-06205 BEARING, BALL 1 1
05 05712-00525 KEY 1 1
06 E6300-51053 INJECTION PUMP GEAR ASS’Y 1 1
07 E6300-51153 GEAR, INJECTION PUMP 1 1 Order by 6
08 07715-00403 BALL 7 7 Order by 6
09 E6300-55453 SLEEVE GOVERNOR 1 1 Order by 6
10 07715-03205 STEEL BALL 39 39 Order by 6
11 15221-5569-2 CASE, GOVERNOR BALL 1 1 Order by 6
12 15221-5574-1 CIR-CLIP, BALL CASE 1 1 Order by 6
13 15221-5547-1 CIR-CLIP 1 1 Order by 6
14 04612-00240 SNAP RING 1 1
15 15221-1632-1 STOPPER FUEL CAMSHAFT 1 1
16 01123-50814 BOLT 2 2
17 01513-50822 STUD 2 2

45
E120 FUEL, CAMSHAFT

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
18 E5603-52111 INJECTION PUMP SHIM 1(0.38t) 2 2
19 E8103-52111 INJECTION PUMP SHIM 1(0.28t) 2 2
E5500-52111 INJECTION PUMP SHIM 2(0.15t) 1 1
E5500-52111 INJECTION PUMP SHIM 3(0.1t) 1 1
20 E5800-51015 INJECTION PUMP ASSEMBLY 1 1
21 04512-50080 SPRING WASHER 2 2
22 02156-50080 NUT 2 2
23 01123-50822 BOLT WITH WASHER 2 2
24 E6500-42412 FUEL PIPE JOINT 1 1
25 E5629-24401 EYE BOLT 1 1
26 01513-50618 STUD 2 2
27 15241-5214-1 FUEL PUMP GASKET 1 1
28 E5775-52031 FUEL PUMP ASSEMBLY 1 1
29 04512-50060 SPRING WASHER 2 2
30 02056-50060 NUT 2 2
31 15371-4217-0 HOSE 1, FUEL 1 1
32 14911-4275-1 CLIP,PIPE 2 2
33 T4240-36332 PACKING 1 1
34 E6200-16213 COVER,CAMSHAFT 1 1
35 01123-50818 BOLT WITH WASHER 4 4

46
E130 SPEED CONTROL PLATE

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6301-54122 ADJUSTING BOLT 1 1
02 E6305-92021 NUT 1 1
03 E6305-96652 GASKET 2 2
04 E6305-54221 NUT, GAP 1 1
05 E6305-54281 SNAP RING 1 1
06 E6305-54421 CAP 1 1
07 E6858-57151 LEVER, SPEED CONTROL 1 1
08 E5850-57112 SPEED CONTROL PLATE 1 1
09 E5850-57212 GASKET, SPEED CONTROL 1 1
10 E5850-57921 SPRING 1 1
11 05411-00420 PIN, SRPING 1 1
12 15471-5798-1 OIL SEAL 1 1
13 01754-50620 BOLT, FLANGE 3 3
14 15221-8821-1 STUD 1 1
15 02751-50060 FLANGE NUT 1 1
16 15108-5728-4 STOPPER 2 2
17 02056-50060 NUT 2 2
18 07811-10820 WIRE 1 1
19 07918-00001 SEALING LEAD 1 1

47
E140 ENGINE STOP LEVER

Q'TY
REF.NO. PART NO. DESCRIPTION REMARKS.
HB29D1 HB36D1
01 E5850-54093 IDLE APPARATUS ASSEMBLY 1 1
02 04724-00140 PACKING 1 1
03 E5850-54282 BUSH 1 1
04 E5850-54272 SHAFT 1 1
05 E5850-54261 SPRING 1 1
06 E5850-54291 IDLE ADJUSTMENT BODY 1 1
07 04811-00060 O RING 1 1
08 15521-5426-1 SPRING 1 1
09 E5850-54252 IDLE ADJUSTING BOLT 1 1
10 E5850-92011 NUT 1 1
11 E5205-54271 CAP 1 1
12 E5500-51662 GASKET 1 1
13 E5627-33112 OIL FILLER COVER 1 1
14 E5608-57481 CABLE BRACKET 1 1
15 01754-50620 BOLT WITH WASHER 2 2
16 01754-50616 BOLT WITH WASHER 2 2
17 E5800-33144 OIL FILLER PLUG 1 1
18 15221-8821-1 STUD 2 2

48
E140 ENGINE STOP LEVER

Q'TY
REF.NO. PART NO. DESCRIPTION REMARKS.
HB29D1 HB36D1
19 E5850-57212 SPEED CONTROL PLATE GASKET 1 1
20 E5850-57712 STOP LEVER 2 ASSEMBLY 1 1
21 E5850-57921 SPRING 1 1
22 E5850-57112 SPEED CONTROL PLATE 1 1
23 15471-5798-1 OIL SEAL 1
24 02761-50060 FLANGE NUT 2 2
25 01754-50620 BOLT, FLANGE 2 2
26 E5850-57731 ENGINE STOP LEVER 1 1 1
27 05411-00420 SPRING PIN 1 1
28 01513-50614 STUD 2 2
29 04814-06310 O RING 1 1
30 E5850-56605 STOP SOLENOID GUIDE 1 1
31 E6850-60012 STOP SOLENOID ASSEMBLY 1 1
32 02761-50060 FLANGE NUT 2 2

49
E150 GOVERNOR

Q'TY
REF.NO. PART NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5608-56021 GOVERNOR LEVER ASSEMBLY 1 1
02 E5627-56051 FORK LEVER ASSEMBLY 1 1
03 E5627-56041 ASSY FORK LEVER 1 1 1
04 15021-5616-4 FORK LEVER PIN 1 2 2
05 E6200-54172 PIN 1 1
06 E6300-54231 SPRING 1 1
07 15601-5443-1 SET SCREW 1 1
08 15221-5615-1 FORK LEVER SHAFT 1 1
09 E6300-56131 FORK LEVER 2 1 1
10 15021-5624-3 LEVER SHAFT BOLT 1 1
11 04512-50060 SPRING WASHER 2 2
12 15221-5623-5 FORK LEVER HOLDER 1 1
13 15221-6641-1 BOLT 1 1
14 01754-50830 BOLT WITH WASHER 2 2
15 01023-50628 BOLT WITH WASHER 1 1
16 04012-50060 PLAIN WASHER 1 1
17 E6300-56414 GOVERNOR SPRING 1 1 1
18 E6313-56421 GOVERNOR SPRING 2 1 1

50
E160 WATER PUMP

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6308-73031 WATER PUMP ASS’Y 1 1
02 E5627-73471 BODY, WATER PUMP 1 1
03 E5800-73551 BEARING WATER PUMP 1 1
04 E5800-73513 IMPELLER 1 1
05 E5800-73052 MECHANICAL SEAL ASS’Y 1 1
06 E5800-73522 FLANGE 1 1
07 E5616-74252 PULLEY, FAN 1 1
08 E5627-73432 GASKET, WATER PUMP 1 1
09 01123-50828 BOLT 4 4
10 01023-50618 BOLT 8 8
11 01518-50822 STUD 1 1
12 02156-50080 NUT 1 1
13 04512-50080 WASHER, SPRING 1 1
14 15221-8821-1 STUD 1 1
15 04512-50060 WASHER, SPRING 1 1
16 02056-50060 NUT 1 1

51
E170 WATER PIPE

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E6304-72911 FLANGE THEMO WATER 1 1
02 E5500-72922 GASKET WATER FLANGE 1 1
03 01754-50820 BOLT, FLANGE 2 2
04 01513-50822 STUD 1 1
05 01123-50870 BOLT 1 1
06 02763-50080 NUT 1 1
07 E5500-73342 PIPE, WATER RETURN 1 1
08 15521-7334-1 TUBE 1 1
09 09318-88180 CLAMP, HOSE 2 2
10 E5800-73011 THERMOSTAT ASS’Y 1 1
11 E5500-73272 GASKET THERMOSTAT COVER 1 1
12 E2010-29000 COVER-THERMOSTAT 1 1
13 01123-50835 BOLT WITH WASHER 2 2
14 E7240-32731 TEMPERATURE SENSOR ASSY 1 1
15 E2010-29200 THERMOSTAT-SPRING 1 1
16 E2010-29100 THERMOSTAT-WASHER 1 1
17 E6303-33661 WASHER, SEAL 1 1
18 E6303-33751 PLUG 1 1

52
180 ALTERNATOR

Q’TY REMARKS
REF.NO. PART NO. DESCRIPTION
HB29D1 HB36D1

01 E7230-64012 ALTERNATOR ASSY 1 1

02 E5800-64102 COLLAR, AC BATTERY 1 1

03 01173-51005 BOLT 1 1

04 04013-50100 PLAIN WASHER 1 1

05 04512-50100 SPRING WASHER 1 1

06 02176-50100 NUT 1 1

07 E5800-64423 SUPPORT, ALTERNATOR 1 1

08 04015-50080 PLAIN WASHER 1 1

09 01127-50825 BOLT WITH WASHER 1 1

10 01754-50612 FLANGE BOLT 4 4

11 05712-00720 KEY 1 1

12 E5620-74285 FAN DRIVE PULLEY 1 1

13 E5640-72531 FAN BELT 1 1

14 04012-50050 PLAIN WASHER 1 1

15 04512-50050 SPRING WASHER 1 1

16 02054-50050 NUT 1 1

53
E190 MANIFOLD

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E5800-11822 GASKET INTAKE MANIFOLD 1 1
02 E5800-11766 MANIFOLD, INTAKE 1 1
03 01123-50822 BOLT 5 5
04 01513-50828 STUD 3 3
05 01513-50870 STUD 3 3
06 E5806-12351 GASKET, EXHAUST MANIFOLD 1 1
07 E2030-29010 EXHAUST MANIFOLD ASS’Y 1 1
08 02751-50080 NUT, FLANGE 6 6
09 E5608-12371 GASKET 1 1
10 28504-M1032 FLANGE, EXHAUST MANIFOLD 1 1
11 01123-50825 BOLT 4 4
12 28101-M1012 AIR CLEANER 1 1
13 14000-05700 CLAMP, AIR CLEANER 1 1
14 E6510-05552 BREATHER PIPE CONNECTOR 1 1

54
E200 COOLANT RESERVE TANK

Q’TY REMARKS
REF.NO. PART.NO. DESCRIPTION
HB29D1 HB36D1
01 E6308-73270 COVER-THERMOSTAT 1 1
02 14000-02500 CLAMP 4 4
03 E5205-72863 HOSE, COOLANT FITTING 1 1
04 28511-M1040 NIPPLE 2 2
05 28504-M1022 WATER COOLDED EXHAUST MANIFOLD 1 1
06 25115-M2010 NECK-RADIATOR 1 1
07 25330-33101 CAP ASSY 1 1
08 84035-00000 HOSE, WATER 1 1
09 25300-B0000 KEEL COOLER 1 1

55
E210 INSTRUMENT PANEL
1

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
07 94114-M1020 SMART START KEY 1 1 SMART KEY TYPE

E220 RELAY

3 2 1

Q’TY
REF.NO. PART.NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 T4180-69951 RELAY-GLOW, F/CUT, S 3 3
02 E2110-29002 RELAY BRACKET-SIDE 1 1
03 53214-B1123 COVER-RELAY 3 3
SMART KEY TYPE
04 11404-08123 BOLT 3 3
05 E2120-29002 RELAY BRACKET-UPPER 1 1
06 01133-51020 BOLT WITH WASHER 2 2

56
E230 WIRING

1 2

Q’TY
REF.NO. PART NO. DESCRIPTION REMARKS
HB29D1 HB36D1
01 E9110-29002 WIRING ASS’Y –ENG SUB 1 1
02 E9120-21003 WIRING ASS’Y –ENG CONTR(2.2 m) 1 1
SMART KEY TYPE
02 E9120-29003 WIRING ASS’Y –ENG CONTR(5.9 m ) 1 1
03 E3990-21000 HORIZONTAL SWITCH ASSY 1 1

E240 SWITCH, ISOLATOR

1 2

Q’TY
REF.NO PART.NO DESCRIPTION REMARKS
HB29D1 HB36D1
01 37201-M1011 ISOLATOR 1 1 2P/OUT
01 37201-M1030 ISOLATOR 1 1 3P/OUT
02 95101-M1070 SWITCH,BATTERY CHOICE 2 2

57
TRANSMISSION MANUAL
(TYPE HBG200)

58
INTRODUCTION

The present manual is part of the product’s scope of supply and reading and understanding are essential.
This manual contains guidelines and recommendations to let the owner use and safely operate the marine
transmission.
This manual should always accompany the transmission and should be carefully stored in a safe and easily
accessible.

GENERAL SAFETY RULES

- Do not operate or service this equipment before reading the instructions and guidelines included in this
manual.
- Check, before and during the use of the equipment, against hazardous situations.
- Do not perform any equipment modifications or removal of the transmission or its parts.
- NEVER perform any servicing, adjusting, repairing or unplugging on running equipment (first stop the
engine, place all controls in neutral and wait for all moving parts to stop)

The manufacturer is not liable for any damage or loss caused by wrong installation, abuse,

misuse, negligent or careless maintenance of the transmission.

The customer/operator has to make sure that no external forces affect the transmission as

well as vibrations or symptoms caused by torsion and bending because of the interaction

between engine propeller shaft and propeller.

59
DIMENSION

SPECIFICATION

Ratios (forward/backward) 2.54:1 / 2.43:1

Fluid grade ATF oil

Weight (kgf) 11.2

Oil capacity (L) 0.6

60
MAINTENANCE
Frequent and systematic inspection will assure to
your transmission many years of trouble-free service.

Oil level checks

Weekly check oil level, using oil gauge.
With engine in OFF position, weekly check against oil leaks
from the output flange.
Correct oil level : index mark on dipstick.
Always use the same oil grade when refill the oil. Don’t overfill
the transmission oil. This will create higher operation temperatures.

Oil change
First oil change : after 25 operating hours
Oil change : every 500 operating hours or yearly (whichever occurs first)

PROCEDURE
1. Remove the drain plug from cover of marine gear
2. Drain the oil
3. Reinstall the drain plug
4. Remove the oil gauge
5. Fill with the correct amount of oil.
Check and top up the oil level to the (“MAX”) mark of the oil dipstick
6. Check the oil gauge breather (2 hole)
7. Reinstall the oil gauge

Shifting and reversing the transmission : During normal operation, the transmission should be
shifted with the engine at idle speed only.
Engine start : Start engine with gearbox in neutral only. Starting the engine with the
transmission engaged may be harmful for people aboard or hazardous for the boat and people
and boats in the vicinity
Inspections : Control and inspections have to be performed with engine OFF and once the
transmission has cooled only.

61
IDELTIFICATION
A name plate is fixed on each transmission housing : information printed on are essential
for warranty and spare part ordering :

62
TROUBLESHOOTING

SYMPTOM CAUSE REMEDY

High oil temperature - Improper oil level (high or low) - Check and fill or drain with proper
oil to the correct level.

Excessive noise - Bearing failure - Overhaul marine transmission

- Improper alignment - Check alignment of engine and
transmission and transmission
output flange to propeller shaft.
Correct as necessary.

Oil escaping from breather - Oil level too high - Adjust oil level
- Wrong type of oil - Drain and refill with
recommended oil
- Clogging the breather holes - Remove the foreign substance in
the oil gauge

63
TRANSMISSION PART LIST

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS.

1 E4250-31004 COVER-CASE 1
2 E4240-31004 CASE 1
3 E4190-31003 COVER-OIL SEAL INPUT 1
4 E4210-31002 COVER-OUTPUT 2
5 E4510-31000 GASKET-COVER BEARING 1
6 E4460-31002 WASHER-FLAT HEADED BOLT 1
7 E4290-31002 GAUGE-TM OIL 1
8 E0216-03000 SEAL WASHER 1
9 E0210-03000 SEAL WASHER 1
10 E4310-31050 NUT ROCKING 1
11 E4162-32000 FLANGE 1
12 E1100-12510 DRAIN PLUG 1
13 E4280-31002 FORK 1
14 E4520-31000 SPRING 1
15 E4350-31000 GASKET-HOUSING 1
16 E4270-31005 SHAFT-CONTROL 1
17 E4340-31002 PIN-LEVER CONTROL 1
18 E4260-32000 HOSING-CONTROL 1
64
REF.NO. PART NO. DESCRIPTION Q'TY REMARKS.

19 E4450-31003 BRKT-CONTROL 1
20 E4360-31003 LEVER-CONTROL 1
21 AB146 PIVOT 1
22 ST9565 CLAMP 1
23 1321-02016 SPLIT PINS 1
24 1339-03015 SPRING PIN 1
25 1021-05010 SLOTTED HEAD SCREWS 2
26 1021-06020 SLOTTED HEAD SCREWS 1
27 1012-05001 NYLON NUT 2
28 1042-08018 HEXAGON BOLTS WITH FLANGE 4
29 1042-08030 HEXAGON BOLTS WITH FLANGE 6
30 1042-06025 HEXAGON BOLTS WITH FLANGE 8
31 1003-08020 HEXAGON SOCKET HEAD CAP SCREWS 1
32 1326-08000 PLAIN WASHERS 1
33 1324-08000 SPRING LOCK WASHERS 1
34 2804-30042 OIL SEAL 1
35 2804-25042 OIL SEAL 1
36 2804-25035 OIL SEAL 1
65
REF.NO. PART NO. DESCRIPTION Q'TY REMARKS.

1 E4180-32000 SHAFT-IDLE 1
2 E4370-31000 NEEDLE ROLLER BEARING 1
3 E4380-31000 NEEDLE ROLLER BEARING 1
4 E4150-32000 GEAR-IDLE 1
5 E4220-31003 SPACE(IDLE SHAFT) 1
6 2805-14000 O - RING 1
7 E4320-31000 TAPER ROLLER BEARING 3
8 E4380-31000 SPACE-GEAR 4
9 E4370-31002 SLEEVE BEARING-GEAR 2
10 E4112-32000 GEAR FORWARD 1
11 E4390-31000 NEEDLE ROLLER BEARING 2
12 E4140-32000 CONE CLUTCH 1
13 E4171-32000 SHAFT-OUTPUT 1
14 E4122-32000 GEAR BACKWARD 1
15 E4330-31000 TAPER ROLLER BEARING 1
16 E4400-31050 SPACE (END PLAY) 2
17 E4310-31002 NUT-LOCKING 1
18 E4131-32050 SHAFT-INPUT 1 21, 23HP
18 E4131-32000 SHAFT-INPUT 1 29, 36HP
66
To order spare parts for the engine and transmission, please contact HLB CO., LTD

Korea / Head Office

#772, Daejung-Ri, Onsan-Eup, Ulju-Gun, Ulsan, Korea

Tel: +82 52 240 3530~2

Fax: +82 52 237 4854

www.hdboat.com

www.hlbnetworks.com

E-mail: service@hdboat.com

Singapore / Branch Office

10, HoechiangRoad, #14-02 Keppel Tower, Singapore 089315

Tel: +65 6493 6923~4

Fax: +65 6493 6925

www.hdbsingapore.com

E-mail: info@hlbsingapore.com

67
OPERATION AND MAINTENANCE MANUAL
FOR RELEASE MECHANISM

(MODEL : TALONⅡ 4.0, TALONⅡ 6.0, TALON 9.0 )

Revision 10 / September 23, 2014

(Document No. : H1000-90000)
HLB C o . , L t d .

272-12, Dangwol-ro, Onsan-Eup, Ulju-Gun, Ulsan, Korea 689-892

Tel: +82 52 240 3500 / Fax: +82 52 237 4010 / Web Site: www.hdboat.com

1
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.
Warning

Second highest level of risk.

Incorrect or incomplete operation may result in equipment damage.
Caution

Less critical mandatory instructions.

Mandatory

Important note that should be emphasized.

Note

A prohibited action.
Incorrect action may result in death of occupants.
Never

2
 TABLE OF CONTENTS

1. General

2. Release gear operation for launching and recovery

2.1 Method of checking proper closure of release hooks

2.2 Launching operation
2.3 Recovery operation

3. On-load/off-load release gear system

3.1 General
3.2 Fore and aft hook units
3.3 Release handle unit
3.4 Hydrostatic interlock unit

4. Assembly and spare parts

4.1 Hook assembly

4.2 Release handle unit
4.3 Hydrostatic interlock unit
4.4 Cable specification
4.5 Torque specifications

5. Inspection & maintenance

5.1 Guideline for periodic inspection and maintenance by crew members

5.2 Guideline for servicing, periodic inspection by certified service engineer
5.3 Preparing release gear for inspection and maintenance
5.4 Inspection and maintenance plan

3
1. General
The lifeboats are stored on the boat davits on both sides of the ship. In case of emergency, the crew
can board the lifeboat and escaped with the lifeboat directly from its stowage position.

The launching appliance consists of a boat davit (davit arm, frame, platform, falls, suspension block,
and gripes/lashing device) and a boat winch (reduction gears, hand brake and centrifugal brake).

Swinging out and lowering of the lifeboat can be controlled both from the inside of the lifeboat and
at the ship’s deck. The lowering speed of the lifeboat can be controlled by operating the remote
control wire inside the lifeboat or by operating the remote control lever on the ship’s deck. Moreo-
ver, it is possible to suspend the lowering operation of the lifeboat at any height.

Recovery of the lifeboat is performed by operating the boat winch with the push-button switch box.
When the davit arm reaches a prescribed position, the boat winch is automatically stopped by the
limit switch. After the activation of the limit switch, the boat winch is operated manually to wind
up the lifeboat to its stowage position. The boat winch is provided with a safety device to prevent
the reverse operation of the manual handle.

The lifeboat is equipped with on-load/off-load release gear which complies with the requirements
of the IMO Life-Saving Appliance (LSA) Code. The release gear system is equipped with a hy-
drostatic interlock system so that it will normally not release the hooks until the boat is waterborne.

To avoid possible injury or death, read this manual carefully before using the boat davit, the boat
winch, and the on-load/off-load release gear.

Operational tests with the master link used by the manufacturers of the launching
appliances should be carried out also before the particular combination of lifeboat/
Note release hook and launching appliance can be accepted.

4
1.1 General specification

SWL (safe working load)

Model
Hanging off pendents Operating force of Release
Hook
(same as pendent lug) handle

TALONⅡ 4.0 4TON 2.5TON Max. 40kgf

TALONⅡ 6.0 6TON 3TON Max. 40kgf

TALON 9.0 9TON 4.8TON Max. 70kgf

Some sketches in the manual may not correspond exactly to the lifeboat-type de-
scribed in the manual. The principles and procedures are, however, correct.
Note

5
1.2 Recommended Davit Falls Master Link (Ring Type)

Figure Ring Type Master Link

TALONⅡ 4.0 TALONⅡ 6.0 TALON 9.0

SWL Min. 4 TON Min. 6 TON Min. 9 TON

A 28~29 mm 32 ~ 34 mm

B 85 mm 115 mm

C 79 mm 155 mm Use the only our supplies.

D 230 mm 263 mm

E 0~43 mm 0~32 mm

6
1.3 Recommended Davit Falls Master Link (Plate Type)

Figure Plate Type Master Link

TALONⅡ 4.0 TALONⅡ 6.0 TALON 9.0

SWL Min. 4 TON Min. 6 TON Min. 9 TON

A 28 mm 32 mm

B 28 mm 32 mm

C R 42.5 mm R 57.5 mm Use the only our supplies.

D 80 mm 85 mm

E 0~28 mm 0~32 mm

Section A-A

7
 1. Check points during the operation of Lifeboat & Davit

A) Check the hook indicator

B) Check the condition of connection parts between lifeboat
hook and davit
C) During davit test, do not onboard of the lifeboat.
D) Do not carry out tests under the windy & heavy sea.

2. Do not lower the lifeboat on the water during the davit test.
(The lifeboat should be in on-load condition)

3. If the davit link is in abnormal position when the lifeboat

is lifted up, release the load on hooks, make the davit link
to be in normal position and lift the lifeboat.

4. Even if the davit link is detached from the hook, do not lift the
lifeboat with only one release hook.
.

Caution

Normal position ex) Abnormal position

8
2. Release gear operation for launching and recovery
2.1 Method of checking proper closure of release hooks

2.1.1 Safe use and operation of lifeboats during drills and inspection and maintenance is dependent
on knowing that the release gear is properly reset.

Never enter lifeboat without ensuring complete closure of release hooks.

Incomplete resetting of the release hooks can cause the lifeboat to drop

Never resulting in death.

2.1.2 Purpose of on-load release. The IMO LSA Code requires, among other things, that the lifeboat
be fitted with “on-load release capability which will release the lifeboat with a load on the
hooks. The release mechanism shall be so designed that crew members in the lifeboat can
clearly observe when the release mechanism is properly and completely reset and ready for
lifting. . . .” On-load release is needed for launching when there is a current, when the ship is mak-
ing way, or potentially if there are waves which cause the hydrostatic interlock to only release in-
termittently. On-load release also allows an empty or fully loaded boat to drop from any height,
which can kill or seriously injure the occupants. Therefore it is critical to know that the release gear
is properly reset and the release handle secured.

9
2.1.3 Ensuring release hook closure. The first thing to check whenever entering the lifeboat when it
is (or will be) supported by the falls is properly reset as follows:

No. Operation Guide Schematic Diagram

Check that the indicators are in

the green zone (locked position) <One side-indicator1>
1 on each hook side plate

<Activity on the ship>

<The opposite side-indicator2>

Check that the hook safety pin

not inserted into side plate.
2

<Activity on the ship>

10
 Check that the release handle is
Release
in the closed (locked) position handle reset Indicator in Green zone

3 and safety pin is installed.

<Activity in the lifeboat>

Safety pin inserted

Ensure the hydrostatic indicator

4 is in the Green zone.

<Activity in the lifeboat>

11
2.2 Launching operation

2.2.1 Releasing procedure

A flow chart of the off-load and on-load releasing procedure is shown in the following figure.

Release procedure

OFF –LOAD RELEASE ON –LOAD RELEASE

(See paragraph 2.2.2) (See paragraph 2.2.3)

(1) Pull out the safety pin on the release

(1) Confirm that lifeboat is waterborne.
handle.

(2 ) Pull out the safety pin on the release

(2) Remove the hydrostatic interlock
handle.
cover.

WARNING!
Operate the release handle
only upon confirmation of
safety by the officer in (3) Lift up hydrostatic interlock lever
charge! and hold it.
Release of the lifeboat
from a height can cause
injury or death

(3) Lift up the release handle and pull (4) Lift up the release handle and pull
down by one action. down by one action.

Release operation completed.

12
2.2.2 Off-load release

This operation is the normal method of launch and

release is conducted when the lifeboat is fully waterborne.

Confirm the following before the operation :

• The lifeboat is fully waterborne
• The engine is started.
Caution • All crew are in their seats with their seatbelts fastened.

No Operation Guide Schematic Diagram

Confirm that the lifeboat is wa-

terborne.
1

<Activity in the lifeboat>

safety pin
Pull out the safety pin on the re-
lease handle.
2
<Activity in the lifeboat>

Lift up the release handle and Pull

to the fully open position by one
3
action.
<Activity in the lifeboat>

In a case where the hook is not released by the above operations,

confirm condition of each hook and whether the boat is waterborne or
not. Even though the hooks cannot be released by the off-load release

Note operation described above, on-load release procedure, described in the

following pages, is possible.

13
2.2.3 On-load release operation procedure.
Emergency Release (include hydrostatic interlock
unit override procedure)
This procedure must only be used under extreme
emergency conditions with the lifeboat 1 meter
(maximum) within of water.

• Pay due precautions and conduct the on-load release operation in

accordance with orders of the officer in charge.
• Operation of the release handle upon insufficient confirmation of
safety may result in death or injury due to dropping the lifeboat in the
Warning
water from a height.

Confirm the following before the operation :

• The lifeboat is not fully waterborne
• The engine is started.
Caution • All crew are in their seats with their seatbelts fastened.

• Before this on-load release operation, prior action below

should be done.

Caution

14
No. Operation Guide Schematic Diagram

Confirm that the lifeboat is as

close as possible to the water sur-
face, but that the hydrostatic in-
1
terlock is not triggered.

<Activity in the lifeboat>

Pull out the safety

pin
Pull out the safety pin on the re-
lease handle.
2
<Activity in the lifeboat>

Remove the hydrostatic interlock

3 cover.

<Activity in the lifeboat>

Lift up hydrostatic interlock lever

4 and hold it.

<Activity in the lifeboat>

Pull the release handle to the fully

5 open position by one action.
<Activity in the lifeboat>

15
2.2.4 Training/drill/maintenance release operation

This operation is conducted when the lifeboat can be used only during training /drill/
maintenance operation.

 Before operation the davit, insert safety pin to fore and aft hooks.
Caution
A flow chart of the off-load and on-load releasing procedure is shown in the following figure.

Release procedure

OFF –LOAD RELEASE ON –LOAD RELEASE

(See paragraph 2.2.4) (See paragraph 2.2.5)

(1) Before operation the davit, insert safety pin

(1) Before operation the davit, insert safety pin
to fore and aft hooks.
to fore and aft hooks.

(2) Confirm that the lifeboat is as close as pos-

(2) Confirm that lifeboat is waterborne.
sible to the water surface, but that the hydro-
static interlock is not triggered.

(3) Pull out the fore and aft hook safety pins.
(3) Pull out the fore and aft hook safety pins.

(4) Pull out the safety pin on the release handle. (4) Pull out the safety pin on the release handle.

(5) Open the release handle cover-side plate.

WARNING!
Operate the release handle only
upon confirmation of safety by
the officer in charge! (6) Lift up hydrostatic interlock lever and hold
Release of the lifeboat from a it.
height can cause injury or death

(5) Lift up the release handle and pull (7) Lift up the release handle and pull down by
down by one action. one action.

Release operation completed.

16
2.2.4.1 Off- load release (Training/drill/maintenance release operation)

Confirm the following before the operation :

• The lifeboat is fully waterborne
• The engine is started.
Caution • All crew are in their seats with their seatbelts fastened.

No. Operation Guide Schematic Diagram

hook safety pin

Before operation the davit, insert
safety pin to fore and aft hooks.

1 <Activity on the ship >,

<Activity in the lifeboat>

Confirm that the lifeboat is water-

borne.
2

<Activity in the lifeboat>

hook safety pin

Pull out the fore and aft hook safety
pins.
3

<Activity in the lifeboat>

Pull out the safety pin on the release

handle.
4
<Activity in the lifeboat>

Lift up the release handle and pull

to the fully open position by one ac-
5 tion.

<Activity in the lifeboat>

17
2.2.4.2 On- load release (Training/drill/maintenance release operation)

This procedure must only be used under extreme emergency conditions with the lifeboat 1
meter (maximum) within of water.

• Pay due precautions and conduct the on-load release operation in

accordance with orders of the officer in charge.
• Operation of the release handle upon insufficient confirmation of
safety may result in death or injury due to dropping the lifeboat in the
Warning
water from a height.

Confirm the following before the operation :

• The lifeboat is not fully waterborne
• The engine is started.
Caution • All crew are in their seats with their seatbelts fastened.

• Before this on-load release operation, prior action below

should be done.

Caution

Latch of the interlock cover should be un-

locked using tools.

- Customer can use the spanner in the engine

tool box stored in the inventory box of life
boat to unlock the latch.
- Spanner : 10mm

18
No. Operation Guide Schematic Diagram

hook safety pin

Before operation the davit, insert
safety pin to fore and aft hooks.

1 <Activity on the ship >,

<Activity in the lifeboat>

Confirm that the lifeboat is as close

as possible to the water surface, but
that the hydrostatic interlock is not
2
triggered.

<Activity in the lifeboat>

hook safety pin

Pull out the fore and aft hook safety

pins.
3

<Activity in the lifeboat>

Pull out the safety

Pull out the safety pin on the release pin
lever.
4
<Activity in the lifeboat>

Open the release handle cover-side

plate.
5
<Activity in the lifeboat>

19
 Lift up hydrostatic interlock lever
6 and hold it.

<Activity in the lifeboat>

Lift up the release handle and Pull

to the fully open position by one ac-
7 tion.

<Activity in the lifeboat>

20
2.3 Recovery operation
Outline of the resetting procedures is shown in the following figure.
• Incomplete resetting may result in death or serious injury due to
dropping of the lifeboat in the water from a height.
Warning

Resetting Procedure

Hook Release handle

One person each to be stationed One person to be arranged.

for the fore and aft hooks.

(1) Ensure fore and aft hooks are

rotated into reset position.

(2) Insert the fore and aft hooks safety (3) Push release handle back in
pin. locked position.

(5) Confirm the fore and aft hooks are in (4) Insert the release handle safe-
the locking position (green zone). ty pin.

(6) Hook the master links onto the forward

and aft release hooks by pushing the link
past the Self locker on the release hooks,
observe the Self locker are closed.

(8) Hoist the lifeboat just clear of the

water and stop hoisting.

(9) Check to ensure the hook locking

device(safety pin) can be rotated.

(10) Stow lifeboat.

(11) Once all checks are complete, crew

persons are instructed to remove the
hook safety pins and place them in their
stored location.

21
2.3.1 Resetting procedure of release hook

The resetting procedure is to be in accordance with the following steps.

• At least three people are required for the resetting of the hooks.

NOTE

No. Operation Guide Schematic Diagram

hook

Ensure fore and aft hooks are rotated

into reset position.

Ensure the movement is

freely.
1
Check whether the
hook hole and side plate
hole for safety pin are Hook hole
exactly aligned.

<Activity in the lifeboat>

Side plate hole

hook safety pin

Insert the safety pin in the side

plate hole on each hook assembly.
2

<Activity in the lifeboat>

Push release handle back in locked

3 position.

22
 Make sure that the release handle
is in the closed (locked) position
and insert the safety pin. If the re-
4
lease handle is not in its closed
(locked) position, it is not possible
to insert the safety pin.

Confirm the fore and aft hooks

are in the locking position (green

5 zone).

Cam position check. <One side-indicator1> <The opposite side-indicator2>

Hook the master links onto the

Master link
forward and aft release hooks by
pushing the link past the Self
locker on the release hooks, ob-
6
serve the Self locker are closed.
Self locker
closed position

Check the Self locker

closed position.

Hoist the lifeboat just clear of the

water and stop hoisting.

Confirm that the fore Maximum

7 and aft hooks are 1 meter
properly connected.

<Activity on the ship> and <Activity

in the lifeboat> Sea level

The hydrostatic interlock indica-

tor went all the way to the Green Indicator in Green zone
zone in the locked position.
8

Check the indicator.

<Activity in the lifeboat>

23
 Check to ensure the hook locking
device(safety pin) can be rotated.

Check the hook Hook safety pin

9
safety pin

<Activity in the lifeboat>

Stow lifeboat.

10 <Activity on the ship>

<Activity in the lifeboat>

Once all checks are complete,

crew persons are instructed to
Stored location
11 remove the hook safety pins and
place them in their stored location.

• If the hook safety pin cannot be rotated, then the lifeboat must be
lowered to the water. Once the load is off the hooks, the release control
unit must be open and reset again. Hoist the lifeboat just clear of the
water and repeat step 9. If the hook safety pin still cannot be rotated,
NOTE
leave the hook safety pin in and hoist all the way home. Service is
required immediately!

24
3. On-load/off-load release gear system “TALON”

3.1 General
This section describes the details of the release gear system. Read this section carefully for safe
operation. This release gear system consists of fore and aft hooks, a release handle near the steering
console, a hydrostatic unit and the associated cables (see Fig. 3.1.1).

The releasing operation of the hooks is conducted at the release handle near the steering console
through the control cables terminating at the fore and aft hooks. The interlock system including
the hydrostatic interlock unit is provided to prevent the release of the hooks when the boat is not
waterborne.

The system also has an on-load release function which makes it possible to over-ride the interlock
by the hydrostatic unit. Incorrect on-load release operation may cause fatalities and due precautions
should be taken for this operation.

Fig.3.1.1 Schematic of release gear system

25
3.2 Fore and aft hook units

3.2.1 Structure and parts names

The structure and parts names of the fore and aft hooks are shown in Figures 3.2.1.1 and 3.2.1.2.
The fore and aft hooks are generally identical except for the direction of installation.

Fig. 3.2.1.1 Perspective of the hook assembly

Fig. 3.2.1.2 Internal view of the hook assembly

26
3.2.2 Releasing

When the release handle near the steering console is pulled, the cam is turned by the control cable.
And stopper is turned automatically by the weight. And the hook is turned and released. (see figure
3.2.2.1)

Fig. 3.2.2.1 Release principle of the hook unit

3.2.3 Resetting

To ensure the proper resetting of the fore and aft hooks, the procedures described in paragraph 3.2.3.1
should be followed. First return the fore and aft hooks to the close position and rotate the handle to han-
dle close position. Automatically the fore and aft cams, stopper also return to the closed position.

Fig. 3.2.3.1 Reset principle of the hook unit

27
3.3 Release handle unit

3.3.1 Structure and parts names

The structure and parts names of the release handle are shown in figures 3.3.1.1 and 3.3.1.2.

Fig. 3.3.1.1 Perspective of the release handle unit

Fig. 3.3.1.2 Internal view of the release handle unit

28
3.3.2 Operation

When the lifeboat is fully waterborne, the lifeboat can be released by removing the safety pin and
then pulling the release handle fully and quickly to the open position (off-load release). The lifeboat
can also be released by the same operation of the release handle even though the lifeboat is not fully
waterborne, by opening the interlock cover and lifting up the interlock lever. This over-rides the
interlock function of the hydrostatic interlock unit (on-load release) are shown in figures 3.3.2.1

Fig. 3.3.2.1 Operation procedure of the release handle

29
3.4 Hydrostatic interlock unit

3.4.1 Structure and parts name

Structure and parts names of the hydrostatic interlock unit are shown in figures 3.4.1.1

Interlock cable (to the hydrostatic inter-

lock lever of the release handle
unit)

Pressure of seawater
Fig. 3.4.1.1 Perspective and Internal view of the hydrostatic interlock unit

3.4.2 Operation

When the lifeboat is fully waterborne, the hydrostatic interlock unit pushes up the interlock lever
through the interlock cable by the water lifting the float and thus allowing the release handle to be
operated. Contrary to this, operation of the release handle is not allowed by the hydrostatic inter-
lock unit when the lifeboat is not fully waterborne and the interlock is shown in figures 3.4.2.1

Fig. 3.4.2.1 Schematic diagram of the interlock

30
4. Assembly and spare parts

The components of the release system will be delivered completely assembled. However, it is im-
portant to know the assembly procedure for all components. This section provides instructions for
the hook assembly, release handle unit, and hydrostatic interlock unit.

To order spare parts for the release system, please contact HLB Co., Ltd.

Korea / Head Office

#772, Daejung-Ri, Onsan-Eup, Ulju-Gun, Ulsan, Korea

Tel: +82 52 240 3530~2

Fax: +82 52 237 4854

www.hdboat.com

www.hlbnetworks.com

E-mail: service@hdboat.com

Singapore Office

HLB Singapore Pte. Ltd.

Tel: +65 6493 6923~4

Fax: +65 6493 6925

E-mail: info@hlbsingapore.com

Web: www.hdbsingapore.com

Shanghai Branch Office.

Room1107, No.2277, Zuchongzhi Road, Zhangjiang Hi-Tech park,
Pudong New District, Shanghai 201210, China

Tel: +86-21-5079-3528

Fax: +86-21-5079-3520

www.hlbshanghai.com

E-mail: info@hlbshanghai.com

31
4.1 Hook assembly

Figure 4.1.1 Exploded view of hook assembly

32
- Hook assembly spare parts index

<TALONⅡ 4.0>
NO PART NO PART NAME Q’TY REMARKS

1 H2010-40101 SIDE PLATE-LH 1

2 H2010-40201 SIDE PLATE-RH 1

3 H2010-40300 SUPPORT-PIN HOOK LH 1

4 H2010-40400 SUPPORT-PIN HOOK RH 1

5 H2010-40500 SUPPORT-CAM 1

6 H2010-40600 BACK PLATE-OUTSIDE 1

H2020-40000 1 Alternative
7 HOOK
H2020-40100 1

8 H2030-40000 PIN-HOOK 1

9 H2040-40000 BUSH-HOOK PIN 1

10 H2050-40000 WASHER-HOOK 2

11 H2060-40000 STOPPER 1

12 H2070-40000 PIN-STOPPER 1

13 H2080-40000 BUSH-STOPPER 1

14

15 H2100-40001 CAM 1

16 H2110-40000 BUSH-CAM LH 1

17 H2120-40000 BUSH-CAM RH 1

18 H2130-40000 INDICATOR-CAM 1

19 H2140-40000 LEVER-CAM 1

20 H2150-40000 SPACER-CAM 1

21 H2160-40000 COVER-CAM ASSY 1

22 H2170-40000 CLEVIS-HOOK 1

23 H2180-40000 PENDENT LUG 1

24 H2190-40001 PIN-PENDENT LUG 1

25 H2200-40000 BUSH-PENDENT LUG 1

26

27 H2220-40000 BLOCK 1

28 H2230-40003 SELF LOCKER 1

29 H2240-40000 SUPPORT-SELF LOCKER 2

30 H2250-40002 BOLT-SELF LOCKER 4

31 H2260-40000 SIGN-INDICATOR-LH 1

32 H2270-40000 SIGN-INDICATOR-RH 1

33 H2280-40000 SAFETY-PIN ASSY 1

34 H2290-40000 CLAM-HOOK CABLE 1

35 H2300-40000 BACK PLATE-INSIDE 1

36 H2310-40000 WARNING PLATE 2

33
37 H2320-40000 NAME PLATE 1

38

39 1002-12065 HEXAGON HEAD BOLTS 1 M12X1.75X65

40 1002-12075 HEXAGON HEAD BOLTS 1 M12X1.75X75

41 1002-08020 HEXAGON HEAD BOLTS 1 M8X1.25X20

42 1002-10055 HEXAGON HEAD BOLTS 2 M10X1.5X55

43 1003-05012 HEXAGON SOCKET HEAD CAP SCREWS 3 M5X0.8X12

44 1061-05008 HEXAGON SOCKET BUTTON HEAD SCREWS 4 M5X0.8X08

45 1003-08012 HEXAGON SOCKET HEAD CAP SCREWS 4 M8X1.25X12

1012-20001 NYLON NUT (HOOK) 1 M20X2.5

46
1012-16001 NYLON NUT (PENDENT-LUG) 1 M16X2.0

1012-12001 NYLON NUT (BLOCK) 2 M12x1.75

1012-16001 NYLON NUT (STOPPER) 1 M16X2.0

47
1012-20001 NYLON NUT (CAM) 1 M20X2.5

1012-24001 NYLON NUT (CAM) 1 M24X3.0

48 1012-10001 NYLON NUT 2 M10X1.5

49 1325-08000 TOOTHED LOCK WASHERS 1 Ø8

50 2805-26000 O-RING 1 P25.5

51 2801-00000 GREASE NIPPLES 4 A-PT 1/8

34
<TALONⅡ 6.0>

NO PART NO PART NAME Q’TY REMARKS

1 H2010-60101 SIDE PLATE-LH 1

2 H2010-60201 SIDE PLATE-RH 1

3 H2010-60300 SUPPORT-PIN HOOK LH 1

4 H2010-60400 SUPPORT-PIN HOOK RH 1

5 H2010-60500 SUPPORT-CAM 1

6 H2010-60600 BACK PLATE-OUTSIDE 1

H2020-60000 1 Alternative
7 HOOK
H2020-60100 1

8 H2030-60000 PIN-HOOK 1

9 H2040-60000 BUSH-HOOK PIN 1

10 H2050-60000 WASHER-HOOK 2

11 H2060-60000 STOPPER 1

12 H2070-60000 PIN-STOPPER 1

13 H2080-60000 BUSH-STOPPER 1

14 H2090-60000 WASHER-STOPPER 2

15 H2100-60001 CAM 1

16 H2110-60000 BUSH-CAM LH 1

17 H2120-60000 BUSH-CAM RH 1

18 H2130-60000 INDICATOR-CAM 1

19 H2140-60000 LEVER-CAM 1

20 H2150-60000 SPACER-CAM 1

21 H2160-60001 COVER-CAM 1

22 H2170-60000 CLEVIS-HOOK 1

23 H2180-60000 PENDENT LUG 1

24 H2190-60000 PIN-PENDENT LUG 1

25 H2200-60000 BUSH-PENDENT LUG 1

26

27 H2220-60000 BLOCK 1

28 H2230-60003 SELF LOCKER 1

29 H2240-60000 SUPPORT-SELF LOCKER 2

30 H2250-60002 BOLT-SELF LOCKER 4

31 H2260-60000 SIGN-INDICATOR-LH 1

32 H2270-60000 SIGN-INDICATOR-RH 1

33 H2280-60000 SAFETY-PIN ASSY 1

34 H2290-60000 CLAM-HOOK CABLE 1

35 H2300-60000 BACK PLATE-INSIDE 1

36 H2310-60000 WARNING PLATE 2

37 H2320-60000 NAME PLATE 1

35
38

39 1002-16080 HEXAGON HEAD BOLTS 1 M16X2.0X80

40 1002-16090 HEXAGON HEAD BOLTS 1 M16X2.0X90

41 1002-08020 HEXAGON HEAD BOLTS 1 M8X1.25X20

42 1002-10060 HEXAGON HEAD BOLTS 2 M10X1.5X60

43 1003-06020 HEXAGON SOCKET HEAD CAP SCREWS 3 M6X1.0X20

44 1061-05010 HEXAGON SOCKET BUTTON HEAD SCREWS 4 M5X0.8X10

45 10642-10025 HEXAGON SOCKET COUNTERSUNK HEAD SCREWS 4 M10X1.5X25

1012-24001 NYLON NUT (HOOK) 1 M24X3.0

46
1012-20001 NYLON NUT (PENDENT-LUG) 1 M20X2.5

1012-16001 NYLON NUT (BLOCK) 2 M16X2.0

47 1012-20001 NYLON NUT (STOPPER,CAM) 2 M20X2.5

1012-24001 NYLON NUT (CAM) 1 M24x3.0

48 1012-10001 NYLON NUT 2 M10X1.5

49 1325-08000 TOOTHED LOCK WASHERS 1 Ø8

50 2805-26000 O-RING 1 P25.5

51 2801-00000 GREASE NIPPLES 4 A-PT 1/8

36
<TALON 9.0>

NO PART NO PART NAME Q’TY REMARKS

1 H2010-90102 SIDE PLATE-LH 1

2 H2010-90203 SIDE PLATE-RH 1

3 H2010-90300 SUPPORT-PIN HOOK LH 1 H2010-90002

4 H2010-90400 SUPPORT-PIN HOOK RH 1 SIDE PLATE
ASSY
5 H2010-90500 SUPPORT-CAM 1

6 H2010-90602 BACK PLATE-OUTSIDE 1

7 H2020-90001 HOOK 1

8 H2030-90000 PIN-HOOK 1

9 H2040-90001 BUSH-HOOK PIN 1

10 H2050-90001 WASHER-HOOK 2

11 H2060-90000 STOPPER 1

12 H2070-90000 PIN-STOPPER 1

13 H2080-90001 BUSH-STOPPER 1

14 H2090-90000 WASHER-STOPPER 2

15 H2100-90001 CAM 1

16 H2110-90001 BUSH-CAM LH 1

17 H2120-90001 BUSH-CAM RH 1

18 H2130-90001 INDICATOR-CAM 1

19 H2140-90001 LEVER-CAM 1

20 H2150-90000 SPACER-CAM 1

21 H2160-90000 COVER-CAM ASSY 1

22 H2170-90001 CLEVIS-HOOK 1

23 H2180-90001 PENDENT LUG 1

24 H2190-90001 PIN-PENDENT LUG 1

25 H2200-90002 BUSH-PENDENT LUG 1

26 H2210-90000 WASHER-PENDENT LUG 2

27 H2220-90001 BLOCK 1

28 H2230-90000 SELF LOCKER 1

29 H2240-90000 SUPPORT-SELF LOCKER 2

30 H2250-90000 BOLT-SELF LOCKER 4

31 H2260-90001 SIGN-INDICATOR-LH 1

32 H2270-90001 SIGN-INDICATOR-RH 1

33 H2280-90001 SAFETY-PIN ASSY 1

34 H2290-90001 CLAM-HOOK CABLE 1

35 H2300-90000 BACK PLATE-INSIDE 1

36 H2310-90000 WARNING PLATE 2

37 H2320-90000 NAME PLATE 1

37
38 H2330-90000 SUPPORT-PENDENT LUG 1

39 1002-20100 HEXAGON HEAD BOLTS 1 M20X2.5X100

40 1002-20110 HEXAGON HEAD BOLTS 1 M20X2.5X110

41 1002-08020 HEXAGON HEAD BOLTS 1 M8X1.25X20

42 1002-10070 HEXAGON HEAD BOLTS 2 M10X1.5X70

43 1003-06014 HEXAGON SOCKET HEAD CAP SCREWS 3 M6X1.0X14

44 1061-05010 HEXAGON SOCKET BUTTON HEAD SCREWS 4 M5X0.8X10

45 10642-10025 HEXAGON SOCKET COUNTERSUNK HEAD SCREWS 4 M10X1.5X25

46 1012-24001 NYLON NUT 2 M24x3.0

47 1012-20001 NYLON NUT 5 M20x2.5

48 1012-10001 NYLON NUT 2 M10X1.5

49 1325-08000 TOOTHED LOCK WASHERS 1 Ø8

50 2805-26000 O-RING 1 P25.5

51 2801-00000 GREASE NIPPLES 2 A-PT 1/8

38
- Assembly

Follow the procedure below for the assembly of the release hook.

1. Side plate assembly

Place the side plate assembly as below(Figure 4.1.2). Side plate assembly contain side plate-LH,
side plate-RH, support-pin hook LH, support-pin hook RH, support-cam and back plate-outside
(Figure 4.1.1) and that parts are welded.

Figure 4.1.2 Side plate assembly with position of specified parts

39
2. Hook group

When assemble the hook group, Please see the Figure 4.1.2, 4.1.3 and 4.1.4

- Inner parts of side plates(1, 2) : Washer-hook(10, 2EA), Bush-hook pin(9), Hook(7)

- Outside parts of side plate-RH(2) : Pin-hook(8), Grease nipple(51)
- Outside part of side plate-LH(1) : Nylon nut(46)

Figure 4.1.3 Hook group

Figure 4.1.4 Hook group with side plates

40
3. Stopper group

When assemble the stopper group, Please see the Figure 4.1.2, 4.1.5 and 4.1.6

- Inner parts of side plates(1, 2) : Bush-stopper(13), Washer-stopper(14, 2EA), Stopper(11)

- Outside parts of side plate-RH(2) : Pin-stopper(12), Grease nipple(51)
- Outside part of side plate-LH(1) : Nylon nut(47)

Figure 4.1.5 Stopper group

Figure 4.1.6 Stopper group with side plates

41
4. Cam group
When assemble the cam group, Please see the Figure 4.1.2, 4.1.7 and 4.1.8

- Inner part of side plates(1, 2) : Cam(15)

- Outside parts of side plate-RH(2) : Nylon nut(47), Lever-cam(19), Spacer-cam(20), Bush-cam
RH(17), O-ring(50)
- Connection parts of Lever-cam(19) : Bolt(41), Washer(49), Clevis-hook(22)
- Outside parts of side plate-LH(1) : Bush-cam LH(16), Indicator-cam(18), Nylon nut(47)

Figure 4.1.7 Cam group

Figure 4.1.8 Cam group with side plates

42
5. Clamp-hook cable group
When assemble the clamp-hook cable group, Please see the Figure 4.1.2, 4.1.9 and 4.1.10

- Inner part of side plates(1, 2) : Nylon nut(48, 2EA)

- Outside parts of side plate-RH(2) : Clamp-hook cable(34), Bolt(42, 2EA)

Figure 4.1.9 Clamp-hook cable group

Figure 4.1.10 clamp-hook cable group with side plates

43
6. Pendent lug group
When assemble the pendent lug group, Please see the Figure 4.1.2, 4.1.11 and 4.1.12

- Inner parts of side plates(1, 2) : Washer-pendent lug(26, 2EA), Bush-pendent lug(25), Pendent lug(23)
- Outside part of side plate-RH(2) : Pin-pendent lug(24)
- Outside part of side plate-LH(1) : Support-pendent lug(38), Nylon nut(46)

Figure 4.1.11 Pendent lug group

Figure 4.1.12 pendent lug group with side plates

44
7. Block, safety-pin assy group

When assemble the Block, safety-pin assy group, Please see the Figure 4.1.2, 4.1.13 and 4.1.14

- Inner part of side plates(1, 2) : Block(27)

- Outside parts of side plate-RH(2) : Bolt(39), Bolt(40)
- Outside parts of side plate-LH(1) : Safety-pin assy(33), Nylon nut(47, 2EA)

Figure 4.1.13 Block, safety-pin assy group

Figure 4.1.14 Block, safety pin assy group with side plates

45
8. Cover-cam assy , sign-indicator LH,RH group

When assemble cover-cam assy , sign-indicator LH,RH group, Please see the Figure 4.1.2, 4.1.15
and 4.1.16

- Outside parts of side plate-RH(2) : Sign-indicator-RH(32), M5 screw(44, 2EA), Cover-cam

assy(21), M6 screw(43, 3EA)
- Put the silicon contact surface of side plate-RH(2) and cover-cam assy(21)

 TALON II 4.0, 6.0 : Use silicone for PC. (Polycarbonate)

Caution
- Outside parts of side plate-LH(1) : Sign-indicator-LH(31), Screw(44, 2EA)

Figure 4.1.15 Cover-cam assy , sign-indicator LH,RH group

Figure 4.1.16 Cover-cam assy, sign-indicator-LH,RH group with side plates

46
9. Self-locker , support-self locker group

When assemble the Self-locker , support-self locker group, Please see the Figure 4.1.2, 4.1.17 and
4.1.18

- Outside parts of side plates(1, 2) : Self locker(28), Bolt-self locker(30)

- Outside parts of side plate-RH(2) : Support-self locker(29), Screw(45, 2EA)
- Outside parts of side plate-LH(1) : Support-self locker(29), Screw(45, 2EA)

Figure 4.1.17 Self-locker , support-self locker group

Figure 4.1.18 Self-locker , support-self locker group with side plates

47
4.2 Release handle unit

Figure 4.2.1 Exploded view of Release handle unit

48
- Release handle unit spare parts index

NO PART NO PART NAME Q’TY REMARKS

1 H4010-0000 PLATE-SIDE RH 1

2 H4020-0000 PLATE-SIDE LH 1

3 H4030-0000 GLASS 1

4 H4040-0000 RELEASE HANDLE ASSY 1

5 H4050-0000 LOCKER ASSY 1

6 H4060-0000 COVER-SIDE PLATE 1

7 H4070-0000 SAFETY PIN ASSY 1

8 H4080-0000 SUPPORT-HYDRO CABLE 1

9 H4090-0000 SUPPORT-HOOK CABLE 2

10 H4100-0000 CLAMP-HOOK CABLE 2

11 H4110-0000 PLATE-RELEASE HANDLE 1

12 H4120-0000 SPACER-20 3

13 H4130-0000 SPACER-75 4

14 H4140-0000 SPRING-LOCKER 1

15 1002-06010 BOLT 4 M6X1.0X10

16 1002-08020 BOLT 8 M8X1.25X20

17 1002-12170 BOLT 3 M12X1.75X170

18 1002-08105 BOLT 2 M8X1.25X105

19 1002-16100 BOLT 1 M16X2.0X100

20 1324-08000 SPRING WASHER 10 M8

21 1326-16001 PLAIN WASHER 1 M16

22 1326-12000 PLAIN WASHER 14 M12

23 1012-08001 NUT-NYLON 10 M8

24 1012-12001 NUT-NYLON 5 M12

25 1012-16001 NUT-NYLON 1 M16

26 1002-12100 BOLT 2 M12X1.75X100

27 1326-06000 PLAIN-WASHER 4 M6

49
4.3 Hydrostatic interlock unit

Figure 4.3.1 Exploded view of Hydrostatic interlock unit

50
- Hydrostatic interlock unit spare parts index

NO PART NO PART NAME Q’TY Q’TY REMARKS

H5000-40001 ● Alternative
HYDRO ASS’Y
H5001-40000 ●

H5010-40000 1
1 COVER-HYDRO UPPER
H5010-40100 1

H5020-40000 1
2 COVER-HYDRO LOWER
H5020-40100 1

3 H5030-40000 PLANGE-PLATE 1 1

4 H5040-40000 PLATE-DIAPHRAGM 1 1

5 H5050-40000 DIAPHRAGM 1 1

6 H5060-40000 PLATE-HYDRO 1 1

7 H5070-40000 BRKT-FITTINGS 1

8 H5080-40000 FITTINGS-ONE TOUCH 2 Ø12 , PT1/4

9 H5090-40000 HOSE-AIR 1 1 Ø12X500mm

10 1017-04010 FLAT HEADED BOLT 4 4 M4X0.7X10

8 M8X1.25X20
11 1002-08020 HEXAGON HEAD BOLTS
10 M8X1.25X30

12 1002-08030 HEXAGON HEAD BOLTS 6 6 M8X1.25X30

1324-08000 SPRING WASHER 8

13 Ø8
1326-08000 PLAIN WASHER 10

14 1324-08000 SPRING WASHER 6 6 Ø8

15 1043-08000 HEXAGON NUTS WITH FLANGE 10 M8X1.25

16 H5100-40000 BAND 2 Ø12

51
4.4 Cable specification

Push / Pull cables requirements

Hook cable Hydrostatic interlock unit cable
Type
TALONⅡ4.0 TALONⅡ6.0 TALON 9.0 TALONⅡ4.0, 6.0 and TALON 9.0

Length

Stroke / travel 100mm 25mm

Threaded end type 5/16-24 UNF-2A M10 X 1.25 M5 X 0.8

Series / SWL 64C / 180kgf 64C / 180kgf 84C / 450kgf 31B / 50kgf

- Length = Measured Length + 200mm

- Minimum bending radius of TALON 9.0 hook cable : 150mm
- Minimum bending radius of TALONⅡ 4.0, 6.0 hook cable : 125mm
- Minimum bending radius of Hydrostatic interlock unit cable : 50mm
Cable assembly length : Minimum 15mm

Warning

4.5 Torque specifications

BOLT SIZE TORQUE (N-m )

M4 5

M5 5

M6 10

M8 15

M10 30

M12 45~50

M16 50~60

M20 100

M24 150

52
5. Inspection & Maintenance

Lifeboats, launching appliances and release gear are required by SOLAS regulationⅢ/20 to be in-
spected weekly and monthly according to the instruction for on-board maintenance complying with
the requirements of SOLAS regulation Ⅲ/36.

5.1 Guideline for periodic inspection and maintenance by crew members

Weekly, monthly inspection and routine maintenance may be done by crew members under the di-
rect supervision of a senior ship’s officer

5.1.1 General precautions

During weekly, monthly inspection and routine maintenance by crew members
- Please inform a senior ship’s officer before starting any inspections and maintenances on the
Lifeboat
- Please make sure that the lifeboat is definitely secured to the davit.
- The crew members should be well-acquainted with these guidelines before starting works.
- Please open all hatches, doors and windows for ventilation
- Do not operate the release mechanism and touch any part of release system before checking
the safety precautions.
- Do not operate the engine without permission

5.1.2 Inspection and maintenance plan

Release gear should be inspection and maintained weekly and monthly in accordance with the fol-
lowing tables which list the items to be checked, the method inspection, the procedures to be fol-
lowed and the frequency at which the items are to be attended to.

53
5.2 Guideline for servicing, periodic inspection by certified service engineer
All other inspections, servicing and repair except weekly, monthly inspection and routine mainte-
nances mentioned above should be conducted by appropriately trained and certified service person-
nel of HLB Co., Ltd. Inspections and servicing will be conducted in accordance with the following
tables by a valid HLB certified engineer.

All inspections, servicing and repair works for annual inspection are only allowed to
be carried out by certified service engineers with a valid certificate as authorized
service engineer for lifeboat. HLB Co., Ltd. has no responsibility for unauthorized
works to the lifeboat system and avoid all guarantees.
Defects found through annual inspection have to be solved and damaged parts to be
fixed or replaced by authorized service engineer.
Caution

54
5.3 Preparing Release gear for inspection and maintenance

To prepare the release gear for maintenance, refer to the following procedure:

No. Operation Guide Schematic Diagram

Check that the indicators are

in the green zone (locked po-
sition) on each hook side <One side-indicator1>

1 plate

<Activity on the ship>

<The opposite side-indicator2>

55
 Check that the locking device
is inserted on each hook side
plate
2

<Activity on the ship>

Check that the release handle

is in the closed (locked) posi-
tion and safety pin is in-
3
stalled.

<Activity in the lifeboat>

Connect the maintenance as-

sembly to the forward and
aft pendent lug or it can be
done with the lifeboat in the
warer.
4

The maintenance assembly

contain the wire, link and
shackle
<Activity in the lifeboat>

56
5.4 Inspection and maintenance plan
Release gear system should be inspected and maintained in accordance with the following tables.
The tables list the items to checked, the method of inspection, the procedures to be followed.

Table 5.2.1.1 Inspection and maintenance plan for Lifeboat release and retrieval system.
Maintenance plan
Items Method Inspection procedure
W M 1Y 5Y
- Confirm the release gear is closed position before
any inspection of release gear system.
- Remove any dirt, salts, dust on the release gear.
Release gear
Visual - Check for any damage of release gear system X X X X
(hook assembly)
- Ensure all bolts are secured.
- Check the indicator in the locking position
(locking position : green color)
Moving parts
- Check the operation is smoothly when the lifeboat
(Hook, Stopper,
Visual is fully waterborne condition or supported by the X X
Cam, Pendent
pendent lug.
lug,)
- Check for any damage
Cables - Check all cable end connectors. Replace as neces-
(Hydro, Aft, Visual sary. X X X R
Fwd) - Check the cable end fittings for signs of corrosions.
Clean as needed
- Remove any dirt on the grease nipple of hook pin
- Add marine grease on the grease nipple of pin-hook
Grease nipple Visual X X X X
,pin-stopper, pin-pendent lug and cam if needed
※ A good quality marine grease should be used
- When the lifeboat is in the water or disconnected
from the davit, lift up the hook by hand and measure
the contact surface.
Visual -Measure the contact surface between hook and
Hook and stopper and X X X X
stopper using the D2.6mm round gauge
Gauge
※ Note : If the D2.6 round gauge is inserted in the
contact surface, replace pin-hook, pin-stopper and
stopper (See Figure 5.4.1 as below)
- Check curvature of pin-hook, pin-stopper and
Pin-hook, Visual pin-pendent lug against a flat edge.
Pin-stopper and and X X
※ Note : If there is a curvature offset of 0.5mm
pin-pendent lug Gauge
from the original surface (See Figure 5.4.2 as below)
- Check the contact surface of cam for wear marks
Visual where the stopper impacts the cam
Cam and X X
※ Note : If indentation is greater than 1mm, replace
Gauge
cam (See Figure 5.4.3 as below)
- Check for any damage
- Ensure all components move freely.
Release handle - Check the interlock indicator is closed position
Visual X X X X
unit (closed position : green color)
- Check the hydrostatic interlock unit control cable
- Ensure all bolts are secured.
- Check for any damage
Hydrostatic in-
Visual - Ensure all bolts are secured. X X X X
terlock unit

57
Required replace item
Yearly Diaphragm
5-yearly Diaphragm, Cables(hydrostatic, Fwd, Aft)

Figure 5.4.1. Check the contact surface between hook and stopper using the D2.6mm round gauge

58
Figure 5.4.2 Check the pin-hook, pin-stopper and pin-pendent lug

Figure 5.4.3 Check the cam

59