32 foot transportable u.s. department of port security ... operator's... · 32 foot...

32 FOOT TRANSPORTABLE

PORT SECURITY BOAT (TPSB)

OPERATOR’S HANDBOOK

July 2012

U.S. Department of Homeland Security

United States

Coast Guard

THESE DATA ARE SUBMITTED WITH LIMITED RIGHTS UNDER GOVERNMENT

CONTRACT NO. HSCG23-09-D-MNQ230. THESE DATA MAY BE REPRODUCED AND

USED BY THE GOVERNMENT WITH THE EXPRESS LIMITATION THAT THEY WILL

NOT, WITHOUT WRITTEN PERMISSION OF THE CONTRACTOR, BE USED FOR THE

PURPOSES OF MANUFACTURE NOR DISCLOSED OUTSIDE THE GOVERNMENT;

EXCEPT THAT THE GOVERNMENT MAY DISCLOSE THESE DATA OUTSIDE THE

GOVERNMENT FOR PUBLICATION AND DISTRIBUTION; PROVIDED THAT THE

GOVERNMENT MAKES SUCH A DISCLOSURE SUBJECT TO PROHIBITION AGAINST

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Record of Changes

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RECORD OF CHANGES

CHANGE

NUMBER

DATE OF

CHANGE

DATE

ENTERED ENTERED BY

Transportable Port Security Boat (TPSB) Information Book

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Table of Contents

vi

TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 1-1

SECTION A. SAFETY ..................................................................................................................................... 1-1

SECTION B. WARRANTY INFORMATION ............................................................................................... 1-2

2. CHARACTERISTICS ................................................................................................... 2-1

SECTION A. GENERAL DESCRIPTION ...................................................................................................... 2-1 A.1 Design ...................................................................................................................................................... 2-1 A.2 Performance Data ..................................................................................................................................... 2-2

SECTION B. BOAT HULL DESCRIPTION ................................................................................................... 2-3 B.1 Construction ............................................................................................................................................. 2-3 B.2 Fendering System ..................................................................................................................................... 2-3 B.3 Bilge and Voids ........................................................................................................................................ 2-4 B.4 Engine Compartment ................................................................................................................................ 2-6 B.5 Deckhouse ................................................................................................................................................ 2-8 B.6 Hatches and Deck Storage ....................................................................................................................... 2-12 B.7 Deck Fitting ............................................................................................................................................ 2-13 B.8 Weapons and Ammunition ...................................................................................................................... 2-13

SECTION C. TRAILER ................................................................................................................................. 2-15 C.1 Construction ........................................................................................................................................... 2-15 C.2 Specifications ......................................................................................................................................... 2-15 C.3 Equipment .............................................................................................................................................. 2-15

3. BOAT SYSTEMS........................................................................................................... 3-1

Section A. CONSOLE ....................................................................................................................................... 3-1 A.1 Engine Indicators and Controls ................................................................................................................. 3-3 A.2 Helm ........................................................................................................................................................ 3-4 A.3 Throttle Control ........................................................................................................................................ 3-6 A.4 Fuel Flow ................................................................................................................................................. 3-7 A.5 Navigation Equipment .............................................................................................................................. 3-9 A.6 Communication Equipment ..................................................................................................................... 3-10 A.7 Crew Intercom ........................................................................................................................................ 3-12 A.8 Lighting.................................................................................................................................................. 3-13 A.9 Heater/Defrost ........................................................................................................................................ 3-15 A.10 Wiper / Washer ..................................................................................................................................... 3-16

Section B. DC POWER ................................................................................................................................... 3-17 B.1 Power Distribution, 12VDC .................................................................................................................... 3-17 B.2 Engine Power ......................................................................................................................................... 3-19


v

B.3 Automatic Charge Relays ........................................................................................................................ 3-20 B.4 Power Distribution Breaker Panels .......................................................................................................... 3-20 B.5 Shore Power/ Battery Charger ................................................................................................................. 3-21

SECTION C. PROPULSION .......................................................................................................................... 3-22 C.1 Engine and Outdrive ............................................................................................................................... 3-22 C.2 Engine Cooling System ........................................................................................................................... 3-23 C.3 Exhaust System ...................................................................................................................................... 3-24

SECTION D. SAFETY EQUIPMENT ........................................................................................................... 3-25 D.1 Fire Extinguishers ................................................................................................................................... 3-25 D.2 Throw Bag ............................................................................................................................................. 3-26 D.3 Ignition Cutoff Safety Lanyard................................................................................................................ 3-26 D.4 Life Ring & Boathook. ........................................................................................................................... 3-27 D.5 First Aid Kit ........................................................................................................................................... 3-28

4. OPERATING PROCEDURES ...................................................................................... 4-1

A.1 Lowering/Raising Top .............................................................................................................................. 4-1 A.2 Installing/ Removing Soft Enclosure ......................................................................................................... 4-4 A.3 Lifting Procedure ...................................................................................................................................... 4-7 A.4 Charging Batteries with Shore Power ........................................................................................................ 4-7 A.5 Launching/Recovering .............................................................................................................................. 4-8 A.6 Basic Maneuvering ................................................................................................................................... 4-9 A.7 Emergency Procedures.............................................................................................................................. 4-9

5. MAINTENANCE / TROUBLESHOOTING ................................................................ 5-1

SECTION A. MAINTENANCE INTERVALS................................................................................................. 5-2

SECTION B. TROUBLESHOOTING ............................................................................................................ 5-11

APPENDIX A ....................................................................................................................... A-1

APPENDIX B ........................................................................................................................ B-1

APPENDIX C ....................................................................................................................... C-1

List of Figures

vii

LIST OF FIGURES

Figure 2-1 Fender Cross Section ............................................................................................. 2-3

Figure 2-2 Fendering System Inflation Point ........................................................................... 2-3

Figure 2-3a Bilge Pump .......................................................................................................... 2-4

Figure 2-3b Bilge Plug ............................................................................................................ 2-5

Figure 2-4 Flotation Foam ....................................................................................................... 2-6

Figure 2-5 Engine Compartment ............................................................................................. 2-7

Figure 2-6 TPSB Top, Raised and Lowered ............................................................................ 2-8

Figure 2-7 Antenna Swivel Mount .......................................................................................... 2-8

Figure 2-8 Soft-Sided Enclosure Panels Installed .................................................................... 2-9

Figure 2-9 Crew Seat ............................................................................................................ 2-10

Figure 2-10 Bow Deck Jump Seat ......................................................................................... 2-11

Figure 2-11 Ballistic Armor .................................................................................................. 2-11

Figure 2-12 Deck Openings ................................................................................................... 2-12

Figure 2-13 Lifting Setup ...................................................................................................... 2-13

Figure 2-14 Weapons & Ammunition.................................................................................... 2-14

Figure 3-1 Console .................................................................................................................. 3-1

Figure 3-2a Port Switch Panel ................................................................................................. 3-2

Figure 3-2b STBD Switch Panel ............................................................................................. 3-2

Figure 3-2c Center Console ..................................................................................................... 3-2

Figure 3-3 Engine Controls ..................................................................................................... 3-3

Figure 3-4 Helm ...................................................................................................................... 3-4

Figure 3-5 Steering Cylinders .................................................................................................. 3-4

Figure 3-6 Steering Power Assist Pump .................................................................................. 3-5

Figure 3-7 Throttle Control ..................................................................................................... 3-6

Figure 3-8 Fuel Cutoff Valves ................................................................................................. 3-7

Figure 3-9 Fuel Flow Diagram ................................................................................................ 3-8

Figure 3-10 Navigation System Circuit Diagram ..................................................................... 3-9

Figure 3-11 Radio Equipment ............................................................................................... 3-10

Figure 3-12 Radios Schematic ............................................................................................... 3-11

Figure 3-13 Gentex LVIS ...................................................................................................... 3-12

Figure 3-14a Lighting Schematic........................................................................................... 3-13

Figure 3-14b Lighting Schematic .......................................................................................... 3-14

Figure 3-15 Heater / Defroster and Access ............................................................................ 3-15

Figure 3-16 Windshield Wiper / Washer ............................................................................... 3-16

Figure 3-17 Power Distribution ............................................................................................. 3-17

Figure 3-18 Battery Disconnect Switch Diagram ................................................................... 3-18

Figure 3-19 Power Distribution Box ...................................................................................... 3-18

Figure 3-20 Battery Disconnect Switches .............................................................................. 3-19


viii

Figure 3-21a 12VDC Main DC Panel .................................................................................... 3-20

Figure 3-21b 12VDC Circuit Breaker Panel .......................................................................... 3-20

Figure 3-22a AC Battery Charger .......................................................................................... 3-21

Figure 3-22b Shore Power Plug ............................................................................................. 3-21

Figure 3-23 Bravo 1-XR1 Stern Drive ................................................................................... 3-22

Figure 3-24 Engine Cooling System ...................................................................................... 3-23

Figure 3-25 Engine Exhaust System ...................................................................................... 3-24

Figure 3-26 Fire Extinguishers .............................................................................................. 3-25

Figure 3-28 Ignition Kill Switch ............................................................................................ 3-26

Figure 3-29 Life Ring and Boathook ..................................................................................... 3-27

Figure 3-30 First Aid Kit ....................................................................................................... 3-28

Figure 4-1 Hard Top, Stowed and Raised ................................................................................ 4-1

Figure 4-2a Hard Top Bolts ..................................................................................................... 4-2

Figure 4-2b Hard Top Latches ................................................................................................. 4-2

Figure 4-3 Aft Brace Bar & Pin ............................................................................................... 4-3

Figure 4-4 Aft Brace to Engine Bulkhead ................................................................................ 4-3

Figure 4-5 Forward Brace Arm ............................................................................................... 4-3

Figure 4-6 Soft Side Support Channel ..................................................................................... 4-4

Figure 4-7 Twist Locks ........................................................................................................... 4-4

Figure 4-8a Soft Side Enclosure .............................................................................................. 4-5

Figure 4-8b Soft Side Enclosure .............................................................................................. 4-6

Figure 4-9 Lifting the TPSB Using a Crane ............................................................................. 4-7

List of Tables

ix

LIST OF TABLES

Table 2.1 Vessel Specifications .............................................................................................. 2-1

Table 2.2 Trailer Specifications ................................................................................................ 2-

Table 2.3 Engine Compartment ................................................................................................ 2-

Table 5.1 Engine Maintenance ................................................................................................ 5-

Table 5.2 Engine Inspection and Maintenance of EPA Related Parts ........................................ 5-

Table 5.3 Mercury Bravo Sterndrive ........................................................................................ 5-

Table 5.4 Electrical Maintenance ............................................................................................. 5-

Table 5.5 Engine Troubleshooting ............................................................................................ 5-

Table 5.6 Mercury Bravo Sterndrive Troubleshooting .............................................................. 5-

Table 5.7 Helm Troubleshooting .............................................................................................. 5-

Table 5.8 Power Assist Pump Troubleshooting......................................................................... 5-


x


Chapter 1: Introduction

1-1

1. INTRODUCTION

This handbook outlines safety and operational procedures for the Coast Guard’s 32’ Transportable Port Security Boat (TPSB). It defines physical characteristics, operational capabilities and limitations, normal operation and emergency procedures, boat fittings, and an outfit list.

IN THIS CHAPTER

SECTION TOPIC SEE

PAGE

A Saftey, Warnings, Cautions and Notes. 1-1

B Warranty Information 1-2

SECTION A. SAFETY

This manual has been written to include a number of safety instructions to ensure the safe operation and maintenance of your vessel. The safety information listed in this manual is not all-inclusive. It may be general in nature in some cases and detailed in others. Commercial Off-the-Shelf (COTS) manuals from the manufacturers of the major components such as engines will be used in conjunction with this manual. The information in this manual and the COTS manuals shall be completely read, and personnel shall have a thorough understanding of all component systems and their proper performance before operating the Boat.

WARNINGS, CAUTIONS, AND NOTES

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout the handbook:

WARNING

CAUTION !

NOTE

Operating procedures or techniques that must be carefully followed to avoid

equipment damage.

An operating procedure or technique that must be emphasized.

Operating procedures or techniques that must be carefully followed to

avoid equipment damage.

Operating procedures or techniques that must be carefully followed to

avoid personal injury or loss of life.


1-2

SECTION B. WARRANTY INFORMATION

Boat operators should consult the Equipment Manufacturer’s Manuals for warranty information regarding specific system components. (See Appendix C.)

Chapter 2 – Boat Hull Description

2-1

2. CHARACTERISTICS

INTRODUCTION

This chapter describes the standard 32ft TPSB features and equipment. All illustrations in this handbook are for familiarization purposes only.

SECTION TOPIC SEE

PAGE

A General Description 2-1

B Hull 2-3

C Trailer 2-15

SECTION A. GENERAL DESCRIPTION

A.1 Design

The Kvichak 32 ft Transportable Port Security Boat (TPSB) is designed and capable of effectively operating in shallow water areas as well as safely operating in sea conditions as outlined below. The TPSB is designed to enable the crew to carry out their mission of Port, Waterways, and Coastal Security, Maritime Law Enforcement and Search and Rescue operations while limiting their exposure from the elements, reducing the physically demands placed on their bodies operating in conditions of high impact and immediate protection from hostile fire. The TPSB is a diesel powered twin engine stern drive mono-hull boat with a continuous, watertight and self-bailing, main deck. It has shock mitigation seating for a crew of four and stations to mount two (2).50cal and/or two (2) M240 machine guns. It also has a watertight stowage compartment amidships for anti-swimmer grenades.

WARNING

This boat is not self-righting. Due care in cargo storage and boat

handling should be taken at all times.


2-2

A.2 Performance Data

Table 2.1

Vessel Specifications

Characteristics Specification

Length 32’ 7 1/2”

Length (Boat On Trailer) 38’ 6 17/32”

Beam 7’ 11 3/8 ”

Beam (Boat On Trailer) 8’ 6”

Height (One trailer with mast lowered) 12’ 5 3/8”

Height (On trailer with top lowered) 10’ 6”

Draft 19in, trimmed up, 24” trimmed in nav. Pos.

Max. Speed 45 Knots

Max. Stopping Time < 12 sec

Engines Twin Yanmar 315 6LPA-STZ C3

Outdrives Bravo1 XR1

Fuel Capacity 150 Gallons

Endurance (with 20% reserve) 8 hrs idle speed and 2 hrs full speed

Boat Weight (Light) 8,426 lbs

Boat Weight (Fully Outfitted Condition) w/

trailer

11,306 lbs.

Towing Capacity 5 tons

Normal Operating Crew 4

Operating Parameters 12 ft seas survivable, 8ft fully capable

Seating 4 Shock mitigating seats with semi-active

dampening +1 fwd seat.


2-3

SECTION B. BOAT HULL DESCRIPTION

B.1 Construction

The TPSB is constructed with a marine grade aluminum hull with multiple strakes to maximize all aspects of performance. The TPSB main decks are watertight and self bailing. The TPSB uses scupper socks on the transom to help prevent water intrusion during backing operations. All fittings on the main deck are flush so as to prevent tripping.

B.2 Fendering System

The fendering system is a hybrid foam/air structure sheathed with a heavy duty reinforced urethane. The fendering has a bonded rub strake from bow to stern at the proudest outboard fendering surface. (Figure 2-1) An inner air bladder is used to add rigidity and absorb shocks. The air bladder is inflated to 8 psi. Inflation points are located directly under the boarding steps, both port and starboard. (Figure 2-2)

Figure 2-1

Fender Cross Section

Figure 2-2

Fendering System Inflation Point


2-4

B.3 Bilge and Voids

Bilge

The TPSB is constructed with a watertight deck over a continuous bilge. All fluids that collect in the bilge flow aft to the engine compartment. When deployed, an electric bilge pump discharges overboard (Figure 2-3a). The bilge pump is powered directly from the house load battery through a 15 A breaker. The bilge pump control switch is located in the STBD switch panel at the coxswains console and can be set to MANUAL, OFF, or AUTO. When trailering, the bilge can be drained through a bilge plug located on the transom (Figure 2-3b).

Figure 2-3a

Bilge Pump

Transportable Port Security Boat (TPSB) Information BookC

2-5

Figure 2-3b

Bilge Plug

Voids

All voids not being used for equipment or storage are filled with foam. (Figure 2-4)


2-6

Figure 2-4

Flotation Foam

B.4 Engine Compartment

The engine compartment consists of an isolated enclosure holding the two engines and propulsion support equipment. This includes:

Item Qt.

Yanmar 6LPA-STZ C3 marine diesel engines 2

Engine Starter Batteries, 12 VDC 2

House Load Batteries, 12 VDC 2

DC Distribution and Breaker Box 1

115 VAC Breaker and Battery Charger 1

Salt Water Strainers 2

Drive Tilt/Trim Pumps (Electric-Hydraulic) 2

Gear Lube Monitor Bottles 2

Hydraulic Steering Rams 2

Steering Boost Pump 1

Fuel Flow Sensors (2 supply & 2 return) 4

Fuel Filter / Water Separators – Racor 460 MAM 10 2


2-7

Figure 2-5

Engine Compartment


2-8

B.5 Deckhouse

The crew compartment consists of a full width center console control station surrounded by ballistic armor and an articulated hard top roof, providing shelter in inclement weather conditions.

B.5.a Hard Top

The roof consists of an aluminum hard top that mounts lights, signal devices, plus the communication and navigation antennas. It is articulated such that it may be lowered for trailering, (Figure 2-6)) In addition, the radio antenna are swivel mounted (Figure 2-7) and can be lowered independently for stowage, low bridge situations, and trailering. See Operations Procedure A1 (page 4-1) for details on lowering the Hard Top.

Figure 2-6

TPSB Top, Raised and Lowered

Figure 2-7

Antenna Swivel Mount


2-9

B.5.b Soft Side Panels

The crew is also protected from the elements by vinyl and canvas side panels that zip and snap into place (Figure 2-8). The soft enclosure is easily removed for storage off vessel in appropriate weather or when trailering the boat.

Figure 2-8

Soft-Sided Enclosure Panels Installed

B.5.c Seating

The TPSB features shock-mitigating seating for four crew members within the deckhouse. The coxswain and navigator’s seats fold down for comfortable operation of the TPSB while standing (Figures 2-9). When powered (20A breaker, breaker panel, radio locker), each shock mitigation seat has an individual semi-active shock dampener which is adjustable to both the weight of the occupant (95 to 300 lbs) and the sea state of the boat. (See Coast Dynamics Shoxsdual2 Semi-Active Mitigation System manual for details, listed in Appendix C.)


2-10

Figure 2-9

Crew Seat


2-11

A fifth, jump seat is provided on the bow deck. The seat folds up and out of the way when not in use. (Figure 2-10)

Figure 2-10

Bow Deck Jump Seat

B.5.b Armor

The crew/passenger area is protected with replaceable composite ballistic armor (Figures 2-11). The armor is bolted to the boat and utilizes designed hard-points to interface with predetermined mounting features incorporated in the armor’s design.

Figure 2-11

Ballistic Armor


2-12

B.6 Hatches and Deck Storage

The TPSB has deck access to three below deck storage areas, the engine compartment, the fuel tank, and a forward flotation void. (Figure 2-12)

Figure 2-12

Deck Openings


2-13

B.7 Deck Fitting

Deck Cleats and Chocks: Six deck cleats are located along the gunwales (three to port, three to starboard). One chock for the anchor line is located at the bow. Tow Posts: Two posts, one forward and one aft, can be used for towing and anchoring. Each is rated for 10,000 lbs static load. The tow posts also double as Heavy Weapons Mounts. Lifting Fittings: Four fittings, two (port & stbd) on the forward deck, and two (port & stbd) on the transom are provided for lifting the TPSB, with or without the trailer attached. (Figure 2-13)

Figure 2-13

Lifting Setup

B.8 Weapons and Ammunition

Heavy weapons mounts are located on the bow and aft decks. Light Machine Gun mounts are located Port and Starboard behind the deckhouse. Personal weapons storage mounts are attached to the sides of the Shock Mitigation seats. Hot barrel brackets are mounted port and starboard behind the deckhouse, and forward of the deck house console. (Figure 2-14)


2-14

Figure 2-14

Weapons & Ammunition


2-15

SECTION C. TRAILER

C.1 Construction

The TPSB trailer is constructed of heavy duty aluminum I-beam. The trailer is a heavy duty commercial built trailer fully capable of making continuous cross country movements with only preventive maintenance requirements. The trailer is designed to be fully capable for submersion during launch without hazards and features fully sealed electrical system and pressurized wheel bearings.

C.2 Specifications

Table 2.3

Trailer Specifications

Characteristic Specification

GVW Rating 13,800 lbs

Max Net Capacity 12,650 lbs

Trailer Net Weight 1800 lbs

C.3 Equipment

The TPSB trailer is equipped with the following:

a. 3500 pound retrieval winch

b. Tie-down points

c. 16 inch spare tire and carrier

d. 8000 pound side wind drop leg jack

e. Submersible LED lights

f. Fresh water flushing system and connections

g. Stainless Steel/Cadmium surge disc braking system


2-16


Chapter 3 Boat Systems

3-1

3. BOAT SYSTEMS

Section A. CONSOLE

The TPSB console is outfitted with the controls and gauges and instruments needed to operate the vessel (Figure 3-1). This includes the following:

1. Propulsion a. Steering b. Throttle and Drive Tilt c. Engine Control & Fuel Monitoring d. Electric Trim Tabs

2. Navigation a. Radar (DSF-4D) b. GPS (GPS-37) c. NavNet Multi Display Integrator / Digital Chart (MFD-12) d. AIS (Automatic Identification System) Radio (L-3 Protec) e. Digital Electronic Heading Sensor / Magnetic Compass f. Network Depth Sounder (DFF1)

3. Communication a. VHF Marine Band Radio b. VHF Tactical Radio c. UHF Tactical Radio d. Secure Radio (USCG supplied)

Figure 3-1

Console

Electrical Switch Panels are located Center and STBD on the console, along with a remote control for the mast mounted search light, and a light dimmer / wiper control panel. (Figures 3.2a, 3.2b, & 3.2c)


3-2

Figure 3-2a

Port Switch Panel

Figure 3-2b

STBD Switch Panel

Figure 3-2c

Center Console


3-3

A.1 Engine Indicators and Controls

Analog and digital gauges for the Yanmar 6LPA-STZ C3 engines are located within easy view of the coxswain (Figure 3- 3 below. See Yanmar Operation Manual for details.) In addition, there are indicators for Fuel Level, Fuel Flow, Drive Unit Trim Angle, Salt Water Pump Pressure, Alternator Voltage, and controls for the Electric Trim Tabs,

Figure 3-3

Engine Controls

INDICATOR LIGHT

PANEL

STB

INDICATOR LIGHT

PANEL

PORT

FUEL

LEVEL

TACH

PORT

TRIM GAUGES

OIL

PRESSURE

OIL

PRESSURE

IGNITION IGNITION


3-4

A.2 Helm

The TPSB uses a SeaStar tilt wheel hydraulic helm (Figure 3-4), with power hydraulic assist. The helm controls both stern drive units; each stern drive is equipped with an individual steering cylinder (Figure 3-5). The electrically powered Hydraulic Steering Assist Unit is located in the Engine Compartment, aft on the STBD side. (Figure 3-6)

Figure 3-4

Helm

Figure 3-5

Steering Cylinders


3-5

Figure 3-6

Steering Power Assist Pump


3-6

A.3 Throttle Control

Engines RPM, drive direction (Fwd / Aft) and drive angle (trim angle) are controlled with a Teleflex CH7800 dual throttle control with integrated trim/tilt functions (Figure 3-7).

Figure 3-7

Throttle Control

The handle mounted rocker switches control the hydraulic Trim / Tilt pumps that adjusts the trim of the outboard stern drives. The housing mounted rocker switches are used to tilt the drive units all the way up for trailering / storage. (See the Telexfex CH788 manual for details.)

CAUTION: Only use housing mounted tilt switches for trailering

operations.


3-7

A.4 Fuel Flow

Each engine uses a closed loop, constant flow fuel supply system. Fuel is continuously pumped from the fuel tank, filtered, and sent to each engine, and the excess fuel is then cooled and re-circulated back to the fuel tank. (Figure 3-8) Fuel flow to and from each engine is metered and the difference is displayed on flow meters to the left and right of the Helm, indicating fuel consumption and rate of consumption (Figure 3-9). (See section 3-A.1, Engine Indicators and Controls for meter locations.)

NOTE

Figure 3-8

Fuel Cutoff Valves

Fuel cutoff valves for each engine are located beneath the mid deck

access hatch (between the shock mitigation seats).


3-8

Figure 3-9

Fuel Flow Diagram


3-9

A.5 Navigation Equipment

The TPSB is equipped with the Coast Guard’s standard Scalable Integrated Navigation System (SINS) built around a Furuno NavNet radar/char plotter system. (Figure 3-10) The system features an MFD-12 Radar/Video Plotter, DRS4D Raydome, Furuno RD-30 Multi-Display Unit, PG500R heading sensor, GP-37 GPS/DGPS with GPA-019 antenna, DFF1 Network Sounder with transducer, and Richie magnetic compass. The digital navigation displays are located on the console and the compass is directly above the helm. (See the manufactures’ manuals for detailed equipment operation, listed in Appendix C.)

Figure 3-10

Navigation System Circuit Diagram


3-10

A.6 Communication Equipment

The TPSB is equipped with a Motorola XTL-5000 Tactical VHF radio system, XTL-5000 Tactical UHF radio system, and Standard Horizon GX5500S secondary VHF with Digital Selective Calling features. Space is also provided for a Harris PRC-117 secure VHS.

Figure 3-11

Radio Equipment


3-11

Figure 3-12

Radios Schematic


3-12

A.7 Crew Intercom

A Gentex Light Vehicle Intercom System (LVIS) provides wired communication between crew members and access to the boat’s radios. Hard-wired connection points are located at each of the four crew seats in the enclosure, at two points on the bow deck, port and stbd, and at the port and stbd aft gunner positions. (Figure 3-13). (See Gentex manuals for detailed information.)

Figure 3-13

Gentex LVIS


3-13

A.8 Lighting

The TPSB lighting consists of navigation lights, flood lights (port & stbd), law enforcement lights (port & stbd), a remotely controlled spotlight, night vision (NVIS) lights (fwd & aft floods & an overhead light), overhead lights in the deckhouse, and courtesy lights illuminating the fwd and aft decks. (Figures 3.14a & 3.14b) Dimmers for the NVIS lights are located on the control console

Figure 3-14a

Lighting Schematic


3-14

Figure 3-14b

Lighting Schematic


3-15

A.9 Heater/Defrost

To provide for crew comfort in all conditions, a Sure Marine REALHEAT heater/defroster (Figure 3-15) is integrated into the coolant system on the starboard engine. Controls for the fan are located on the console under the radar display. The heating unit is located in the starboard side of the console.

Figure 3-15

Heater / Defroster and Access


3-16

A.10 Wiper / Washer

The TPSB uses a two blade, single motor, wiper / washer to remove spay and dirt from the windscreen. (Figure 3-16) The control switch is mounted to the left of the helm in the middle switch panel). The wipers have a low and a high speed setting. Press the control switch to activate the washer fluid pump.

Figure 3-16

Windshield Wiper / Washer


3-17

Section B. DC POWER

B.1 Power Distribution, 12VDC

Two battery switches are located on the forward engine compartment bulkhead and turn on power to the engines and household loads (Figure 3-17). Each engine has a dedicated ignition/starter battery while the household loads are powered by a pair of batteries in parallel. Each engine battery and/or the household batteries can be cross connected to provide extra power to start the engines. (Figure 3-18)

Figure 3-17

Power Distribution


3-18

Figure 3-18

Battery Disconnect Switch Diagram

The DC power distribution box (Figure 3-19) is located forward within the engine compartment on the starboard fwd bulkhead. The battery disconnect switches are mounted through the bulkhead to the outside of the engine compartment bulkhead, accessible from the aft deck. (Figure 3-20)

Figure 3-19

Power Distribution Box


3-19

CAUTION !

Figure 3-20

Battery Disconnect Switches

B.2 Engine Power

Each engine has a 12 VDC alternator which is used to supply engine and house loads when

underway and charge the various batteries. Two voltage meters (port and stbd) display the

alternator voltage for each engine. (Optimal alternator voltage is 14.2 ± .3 VDC.)

CAUTION !


equipment damage. Do not disconnect the batteries or leave them combined while the

engines are running.


equipment damage. Only combine batteries as needed to start engines. Do not leave

batteries combined during normal operation or when charging the

batteries with shore power.


3-20

B.3 Automatic Charge Relays

The ships batteries, both engine batteries and the house load batteries, are automatically kept charged when either engine is running. The Automatic Charge Relays (ACR) cross connect the batteries during charging, and isolate the batteries when they are discharging. Port & Stbd ADR lights located on the middle switch panel, next to the lights dimmer switch, indicate which engine (or both) is charging the boat’s batteries.

NOTE

B.4 Power Distribution Breaker Panels

Power is directed to various onboard house loads from a 12VDC switch panel located in the tunnel, (Figure 3-21a) and a circuit breaker panel (Figure 21b) located under the console, stbd, next to the radios.

Figure 3-21a

12VDC Main DC Panel

Figure 3-21b

12VDC Circuit Breaker Panel

The Automatic Charge Relays are open and the batteries are not cross

connected when the batteries are being charged from shore power.


3-21

B.5 Shore Power/ Battery Charger

A 12 volt, 20 A battery charger for the boat batteries is located in the Engine Compartment, aft, on the port bulkhead. (Figure 3-22a). A shore power inlet is located stbd on the outside of engine compartment bulkhead. (Figure 3-22b)

Figure 3-22a

AC Battery Charger

Figure 3-22b

Shore Power Plug


3-22

SECTION C. PROPULSION

C.1 Engine and Outdrive

The TPSB propulsion system consists of twin inboard/outboard Yanmar 6LPA-STZC3 water cooled 4-cycle 6-cylinder 315 horsepower diesel engines with Mercury Bravo 1-XR stern drives (Figures 3.23). See Yanmar STZC Operation Manual for details.

Figure 3-23

Bravo 1-XR1 Stern Drive


3-23

C.2 Engine Cooling System

The Yanmar diesel engines on the TPSB use a two stage water cooling system. During operation, each engine’s sea water pump draws raw water from the sea, using both the seacock and the cooling inlet on the outdrives. The raw water runs through a seawater strainer before it reaches the pump. and is then pumped to the engine’s heat exchangers; first to the fuel return heat exchanger, then the intercooler, then engine oil cooler, and finally to the fresh water coolant heat exchanger. After exiting the fresh water heat exchanger, some of the raw water is diverted to the wet exhaust manifold to cool the exhaust gases. The remainder is discharged through the outdrive. For additional information, refer to the Yanmar STZC Operation Manual.

Figure 3-24

Engine Cooling System


3-24

C.3 Exhaust System

The TPSB’s exhaust system is a wet exhaust with an above water exhaust gas bypass. Raw cooling water is pumped through the engine’s heat exchangers and into the wet exhaust elbow to cool the exhaust gas being discharged from the turbo charger. The cooled gas and water mixture is sent to the exhaust horn attached to the outdrive. An exhaust gas bypass allows some of the gas to be discharged directly overboard to reduce exhaust back pressure. For additional information, refer to the Yanmar STZC Operation Manual.

Figure 3-25

Engine Exhaust System


3-25

SECTION D. SAFETY EQUIPMENT

D.1 Fire Extinguishers

Three fire extinguishers are stowed on board the TPSB; one behind the coxswain’s seat, one behind the navigator’s seat, and one on the forward engine compartment bulkhead, stbd side. (Figure 3-26). Fire Ports into the engine compartment are provided on the forward engine compartment bulkhead (Figure 3-27).

CAUTION !

Figure 3-26

Fire Extinguishers

Figure 3-27 Fire Port

Operating procedures or techniques that must be carefully followed to avoid equipment damage. To use the fire ports, place the discharge horn of the fire extinguisher

against the transparent seal of the fire port. Push in firmly to break the

seal, then discharge the extinguisher into the engine compartment.


3-26

D.2 Throw Bag

A throw bags is stored in the forward storage compartment and can be clipped on to the hot barrel ring for easy access when underway.

D.3 Ignition Cutoff Safety Lanyard

An ignition dead man switch with attached lanyard is installed and located under the helm console. When the lanyard is attached to the coxswain, it will kill the engines if the coxswain is accidently thrown from their station. (Figure 3-28) Engines can be re-started 30 seconds after the ignition cutoff lanyard is pulled out, without having to reset the switch.

Figure 3-28

Ignition Kill Switch


3-27

D.4 Life Ring & Boathook.

A life ring and telescoping boathook are stowed under the hard top. (Figure 3-29).

NOTE: Ensure that the Velcro strips on the life ring align with

the Velcro on the mounting bracket with stowing the ring.

Figure 3-29

Life Ring and Boathook


3-28

D.5 First Aid Kit

A ten-person first aid kit is stowed behind the coxswain’s seat (Figure 3-30)

Figure 3-30

First Aid Kit

Chapter 4: Operating Procedures

4-1

4. OPERATING PROCEDURES

A.1 Lowering/Raising Top

The Hard Top of the TPSB’s enclosure can be lowered to meet height requirements for transportability. (Figure 4-1) Three people can accomplish this task in about five minutes with tools. General steps for lowering the roof are as follow:

1. Ensure that the crew seats are moved all the way forward and that the armrests are all in the lowered position.

2. Remove the hardtop securing bolts in each corner of the console, above the windshield, using proper size wrenches (Figure 4-2a).

3. Release the Hard Top latches (Figure 4-2b) at the top of the windscreen. 4. Remove the quick release pins attaching the two aft brace bars (port & stbd) to the

forward roof support bars (Figure 4-1 & 4-3). 5. With 3 people, one forward center and two aft, lift, pull back, and lower the top to the

stowed position. (Figure 4-1) 6. Secure the two aft brace bars (port & stbd) to the brackets on the engine compartment

bulkhead with the quick release pins. (Figure 4-4) 7. Release the ends of the forward brace arm from the hard top (Figure 4-5) and attach them

to the bracket on each of the forward roof support bars. (Figure 4-1). Secure with quick release pins.

Figure 4-1

Hard Top, Stowed and Raised


4-2

Figure 4-2a

Hard Top Bolts

Figure 4-2b

Hard Top Latches


4-3

Figure 4-3

Aft Brace Bar & Pin

Figure 4-4

Aft Brace to Engine Bulkhead

Figure 4-5

Forward Brace Arm


4-4

A.2 Installing/ Removing Soft Enclosure

The TPSB is equipped with a soft sided enclosure to provide crew comfort. There are 9 individual panels to create this enclosure, three panels port, stbd, and aft. The panels slide into a circular channel along the edge of the roof (Figure 4-6). Adjacent panels can be joined together with zippered seams. The bottoms of the side are secured to the sides with twist lock fasteners Figure 4-7), while the aft panels use tie down straps.

Figure 4-6

Soft Side Support Channel

Figure 4-7

Twist Locks


4-5

Use the following steps to attach the soft side enclosure: 1. Starting with either side, insert panels 1, 2, then 3 into the support channel (Figure 4-8). 2. Zipper the adjoining edges of the panels together. 3. Secure the bottom of the panels to the boat with the installed twist locks. 4. Repeat steps 1 thru 3 for the other side.

Figure 4-8a

Soft Side Enclosure


4-6

5. Along the aft edge of the Hart Top, insert panels P, C, and S (Figure 4-8b). 6. Zipper panels P & S into their respective sides. 7. Zipper panel C to panel P and/or S as necessary to seal the deck enclosure.

Figure 4-8b

Soft Side Enclosure


4-7

A.3 Lifting Procedure

The TPSB has four lift fittings designed and tested for lifting the TPSB, either alone or with its trailer. (Figure 4-9)

Figure 4-9

Lifting the TPSB Using a Crane

A.4 Charging Batteries with Shore Power

1. Make sure that both boat engines are secured. 2. Close the battery switch for each set of batteries to be charged (Engine and/or House

Batteries). 3. Make sure that the Shore Power Breaker is in the open position. 4. Attach the shore power cable to the shore power inlet.

NOTE

5. Close the Shore Power Breaker. The selected batteries should now be charging.

The following breakers on the Main DC Distribution Box

should be closed:

Port & Stbd Charge Input breakers

House Charge Input breaker

Port & Stbd Charge Relay breakers


4-8

A.5 Launching/Recovering

The steps for launching and recovery of the TPSB are as follows.

NOTE

A.5.a Launching

1. Ensure the bilge plug is installed. 2. Check all bilge areas for water or debris. Check that both Salt Water Intake Valves

(seacocks) are open. 3. Turn on House Battery power and ensure bilge pump is on and functioning properly. 4. Remove transportation straps. 5. Back trailer and boat into water about 2/3 of the way. 6. Follow engine start procedure. 7. Check water flow at strainers and allow engines to warm up to operating temp. 8. Disconnect bow strap from bow eye and with drive legs in half trim, back boat into water. 9. Apply power in reverse and back boat away from trailer.

A.5.b Recovery

1. Ensure trailer is properly attached to truck. 2. Inspect trailer. 3. Back trailer into the water and leave the front 6 inches of the trailer bunks out of the

water. 4. Set parking brake on truck. 5. Carefully maneuver TPSB on trailer. 6. If trailer is located correctly in the water the boat will not go all the way to the stop on the

trailer. 7. Once boat is on the trailer connect the bow strap onto the bow eye. 8. Winch boat up to the stop on the trailer. Power may need to be added by the coxswain to

assist in winching. 9. Follow engine shutdown procedure and secure engines. 10. Once boat is at the trailer stop, pull truck forward until the boat is clear of the ramp. 11. Secure the boat to the trailer with the tie downs. 12. Inspect bilge for fuel or oil. 13. If no fuel or oil is present remove bilge plug and drain water. 14. Check that the trailer is properly connected to truck before driving away.

USCG procedures supersede these instructions.


4-9

A.6 Basic Maneuvering

A.6.a Starting procedures.

1. Check fluid levels:

a. Oil b. Coolant c. Gear lube d. Power trim/tilt

2. Open seacocks. 3. Turn master engine battery switch on by turning handle to the ON position. (Each engine

battery will be connected to its own engine.) 4. Ensure that fuel cutoff valves are open. 5. Place controls in “Neutral” position by moving the control levers to the detent so the

levers are upright. 6. Set either port or starboard engine ignition switch to the RUN position. The engine

audible alarm should sound and the alternator warning light and low oil pressure warning lights should illuminate. Voltmeter should read at least 12 VDC.

CAUTION !

7. Push and hold START button until engine starts (approximately 10 seconds). Release start switch.

8. Once running, within a short time the voltmeter should read 14.2 ±.3 VDC. 9. Repeat steps 6 & 7 to start remaining engine.

4.6.b Stopping the engines.

1. Place the control levers in neutral. 2. Allow engines to cool gradually and uniformly by idling for 3 to 5 minutes before

shutting off after a full load operation. 3. When ready to shut down the engine, press and hold the Stop button, or turn the ignition

switch to OFF until the engine stops running. 4. Repeat step 3 for remaining engine. 5. Turn engine battery master switch to OFF position. 6. Check the bilge for evidence of fluid leaks.

A.7 Emergency Procedures

Run away engine.

Close fuel valves on fuel tank located under fuel access cover in crew compartment.

Onboard fire.

Use onboard fire extinguishers to extinguish fires.


equipment damage.

If the audible alarm does not sound, vessel is considered non-

operational; report to unit maintenance for corrective action.


4-10

WARNING

In the case of an engine compartment fire, close the engine hatch

covers, then place the discharge nozzle of a fire extinguisher into one

of the two fire ports. Push the nozzle in to break the seal and then

discharge the full contents of extinguisher. Leave the engine hatch

covers closed to allow the extinguishing agent to smother the fire.

Chapter 5: Maintenance / Troubleshooting

5-1

5. MAINTENANCE / TROUBLESHOOTING

INTRODUCTION

This chapter describes the maintenance and troubleshooting procedure to properly maintain the

TPSB. Please note that this chapter does not cover everything to maintain the vessel. Refer to

the appropriate original equipment manufacturer manual for further information.

IN THIS CHAPTER

SECTION TOPIC SEE

PAGE

A Maintenance Intervals 5-2

B Troubleshooting 5-11

Daily and periodic maintenance is important to keep the engine in good operating condition. The

following is a summary of maintenance items by periodic maintenance intervals. Periodic

maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil

used, and are hard to establish definitively. The following should be treated only as a general

guideline.

CAUTION !

Operating procedures or techniques that must be carefully followed to avoid equipment damage.

Establish a periodic maintenance plan according to the engine

application and make sure you perform the required periodic

maintenance at intervals indicated. Failure to follow these guidelines

will impair the engine’s safety and performance characteristics, shorten

the engine’s life and may affect the warranty coverage on your engine.


5-2

SECTION A. MAINTENANCE INTERVALS

Introduction

The following tables allow for proper maintenance of the TPSB. Please refer to the appropriate

OEM manuals for more detail.

Table 5.1

Engine Maintenance

ITEM

DAILY 50

HOURS

125

HOURS

250

HOUR

S

500

HOURS

1000

HOURS

1250

HOUR

S

Whole Visual

inspection of

engine

exterior

X

Fuel system Check fuel

level X

Drain fuel /

water

separator

X

Replace fuel

filter element X

Initial

X

Check fuel

injection

timing

X

Lubricating

System

Check engine

oil level X

Change

engine oil X

Initial

X

Replace oil

filter element X

Initial X

Wash engine

oil cooler X


5-3

Fresh Water

Cooling

System

Check

coolant level X

Change

coolant X

Clean and

check the

cooling water

passage

X

Clean the

cooling water

system

X

Seawater

Cooling

System

Check

seawater

outlet

discharge

X

During

Operatio

n

Check of

replace

seawater

pump

impeller

X

Check or

replace the

zinc anodes

X

Check and

clean the

seawater

passage

X

Piping Clear or

replace the

exhaust /

water mixing

elbow

X

Check or

replace fuel

line and

rubber hoses

X

Electrical

System

Check the

alarm and

indicators

X


5-4

Check the

electrolyte

level in the

batteries

X

Adjust the

tension of the

alternator V-

belt or

replace V-

belt

X X

Remote

Control

Handle

Check and

lubricate the

remote

control cable

operation

X

Adjust

control

cables

X

Intake and

Exhaust

System

Wash turbo

charger

blower

X

Clean air

cleaner X

Intake and

Exhaust

System

Continued

Adjust the

intake and

exhaust valve

clearance

X Initial

X

Lap the

intake and

exhaust

valves

X

Miscellaneou

s

Replace the

timing belt X


5-5

Table 5.2

Engine Inspection and Maintenance of EPA Related Parts

Parts Interval

Clean fuel injector nozzle 1500 hours

Check fuel injection nozzle (adjustment) 3000 hours

Check injection pump adjustment 3000 hours

Check turbocharger adjustment 3000 hours

Check electronic engine control unit and its associated sensors and

actuators

3000 hours


5-6

Table 5.3

Mercury Bravo Sterndrive

SYSTEM ITEM

DAILY 50

HOURS

100

HOURS

200

HOURS

500

HOURS

1000

HOURS

1250

HOURS

Bravo

Sterndrive

Check propellers

for damage X

Check tie bar

fasteners X

Check gear lube

level X

Check fluid level

in trim pump

reservoir

X

Check steering

system for

binding or loose

components

X

Visually check

all hoses and

fittings

X

Lube propeller

shaft and re-

torque the nut

X

Inspect water

inlets X

Inspect anodes

replace after 50%

eroded

X

Change

sterndrive gear

lube

X

Re-torque gimble

ring U bolts X

Re-torque aft

engine mounts X


5-7

Check steering

and controls for

loose or damaged

parts

X

Inspect sterndrive

U-joints X

Inspect and

lubricate the

splines on the U-

joint shaft

X

Inspect U-joint

Bellows X

Inspect exhaust

tube X

Inspect shift

bellows X

Inspect clamps

on gimbal

housing

X

Check engine

alignment X

Lubricate the

gimbal bearing

and engine

coupler

X


5-8

Table 5.4

Electrical Maintenance

SYSTEM ITEM

DAILY 50

HOURS

100

HOURS

200

HOURS

500

HOURS

1000

HOURS

1250

HOURS

Network

Sounder

Check

transducer

cable for

loose or

damaged

connections

X

Check power

cable for

loose or

damaged

connections

X

Check

ground for

corrosion

X

Check power

supply

voltage

X

Clean unit X

Clean / check

transducer

face

X

NAVNET

3D

Check that

all cables are

fastened.

X

Check cables

for corrosion

X

Clean display X

Clean radar

antenna

X


5-9

RD-30

AND

GP-37

Check

connections

on rear of

unit

X

Check

ground

system.

Ensure it is

free of rust

and corrosion

X

Check

battery

terminals.

Ensure they

are free of

corrosion

X

Check

antenna

X

Clean unit X

Gentex

crew

comm.

Ensure RIIC

and CCP

mounting

hardware is

secure.

X

Ensure RIIC

and CCP

enclosure

covers are

secure.

X

Ensure CCP

headset

connector

protective

caps are

installed and

secure when

not in use.

X


5-10

Ensure all

support

station

connector

protective

caps are

installed and

secure when

not in use.

X

Ensure all

cables are

dressed and

secure.

X

Clean the

outer surface

of the CCP’s

with fresh

water and a

soft bristle

brush.

X

Rinse the

outer surface

of the CCP’s

with fresh

water after

brushing.

X


5-11

SECTION B. TROUBLESHOOTING

Introduction

The following tables list common problems and possible solutions. Please refer to the

appropriate OEM manuals for more detail.

Table 5.5

Engine Troubleshooting

TROUBLE PROBABLE CAUSE MEASURE

No charge lamp

No voltage

(Alarm buzzer does not

sound)

1.Faulty battery

2.V-belt is loose or damaged

3.Alternator is not generating

power

1. Check battery.

2. Adjust V-belt tension or

replace belt.

3. Ask for repairs.

C.W. Temp. Lamp goes

on

1. Insufficient Glycol coolant in

coolant tank.

2. Leakage in fresh water

(Glycol coolant) cooling system.

3. Fresh water cooling pump is

damaged.

4. Inside of C.W. system is dirty.

1. Check and replenish

Glycol coolant.

2. Ask for repairs for coolant

leakage.

3. Ask for repairs.

4. Ask for repairs

Low oil pressure

indicator goes on

Insufficient engine oil. Replenish oil.

C.W. level alarm

indicator goes on

Insufficient Glycol coolant in

coolant tank.

Check and replenish Glycol

coolant.

Gear oil alarm indicator

goes on

Insufficient drive oil. Replenish drive oil.

Boost pressure alarm

indicator goes on.

Boost pressure adjustment

device is damaged.

Ask for repairs.

Fuel filter alarm indicator

goes on

Increased fuel filter drain. Drain water separator.

Low pressure on raw

water gages.

1. Insufficient discharge of

cooling seawater.

2. Damaged cooling seawater

pump.

1. Kingston cock is closed.

2. Kingston cock is clogged.

3. Suction hose is damaged

or joints are loose.

4. Check seawater pump

impeller.

Alarm buzzer does not

sound

Circuit broken or buzzer

damaged.

Ask for repairs.

Some alarm lamps do not

light.

Circuit broken or lamp burnt out. Ask for repairs.

Alarm buzzer does not Short circuit Ask for repairs.


5-12

cut off

Some alarm lamps do not

go out

Damaged sensor or switch Ask for repairs.

Engine doesn’t start 1. No fuel.

2. Air in fuel line.

3. Bad fuel.

4. Clogged fuel filter.

5. Poor fuel injection.

6. Pressure leakage from

intake/exhaust valves.

1. Replenish fuel; bleed.

2. Bleed.

3. Replace fuel.

4. Replace fuel filter.

5. Ask for repairs.

6. Ask for repairs.

Starter does not turn or

turns slowly

1. Insufficient battery charge.

2. Faulty cable connection at

terminal.

3. Faulty starter switch.

4. Faulty starter.

1. Check battery charge.

2. Remove rust from

terminal; retighten.

3. Ask for repairs.

4. Ask for repairs.

Black smoke emitted 1. Overload.

2. Insufficient fuel.

3. Boost pressure low.

4. Faulty spraying of F.O.

injection.

5. Excessive intake / exhaust

valve top clearance.

1. Reduce load.

2. Replace fuel.

3. Wash turbocharger blower.

4. Ask for repairs.

5. Ask for repairs.

White smoke emitted 1. Insufficient fuel.

2. Faulty spraying of F.O.

injection.

3. Fuel injection timing off.

4. Lube oil burns/excessive

consumption.

1. Replace fuel.

2. Ask for repairs.

3. Ask for repairs.

4. Ask for repairs.


5-13

Table 5.6

Mercury Bravo Sterndrive Troubleshooting


Remote control operates

hard, binds, has excessive

free-play, or makes

unusual sounds

Insufficient lubrication on the

shift and throttle linkage

fasteners.

Lubricate.

Obstruction in the shift or

throttle linkages.

Remove obstruction.

Loose or missing the shift and

throttle linkages.

Check all throttle linkages. If

any are loose or missing, ask

for repairs.

The shift or throttle cable is

kinked.

Straighten the cable or ask for

repairs. Replace cable that

cannot be straightened.

Steering wheel turns hard

or jerky

Low power steering pump

fluid.

Check for leak. Refill system.

Insufficient lubrication of the

steering components.

Lubricate.

Loose or missing steering

fasteners or parts.

Check all parts and fasteners.

Replace any missing parts or

fasteners. Tighten any loose

fasteners.

Contaminated power steering

fluid.

Flush system and replace with

new fluid.

Power trim does not

operate. (Electric motor

does not operate)

Blown fuse. Replace fuse.

Loose or dirty electrical

connections or damaged

wiring.

Check all the associated

electrical connections and the

wires (especially the battery

cables). Clean and tighten the

faulty connections. Repair or

replace the wiring.

Power trim does not

operate. (Electric motor

operates but sterndrive unit

does not move.)

The trim pump oil level is

low.

Fill trim pump with oil.

The drive is binding in the

gimbal ring.

Check for obstructions.


5-14

Table 5.7

Helm Troubleshooting


During filling, helm

becomes completely

jammed.

1. Blockage in the line

between the helm and

cylinder.

2. Pro helm with an

unbalanced cylinder.

3. Tilt mechanism to helm

pump wheel shaft nut, NOT

installed properly.

1. Make certain hose/tubing

has not collapsed during

installation.

2. DO NOT use ANY PRO

helm pump with ANY un-

balanced cylinder.

3. Tighten and torque nut.

System is very difficult to

fill.

Air keeps burping out to of

helm, even after system

appears full.

System not being bled

properly/ completely

Consult with your cylinder

installation manual for proper

bleeding.

Cylinder is mounted upside

down, trapping air in the

cylinder body.

Install cylinder with bleed

fittings point UP.

Steering is stiff and hard to

turn, even when the vessel

is not moving.

Mechanical binding of

sterndrives.

Ensure sterndrives move

freely with cylinder

disconnected.

Restriction in hose. See fault 1.

Air in system. See fault 2.

Wrong fluid has been used. Use SeaStar steering fluid, or

fluid that meets MIL-PRF-

5606H

Steering is easy to turn at

the dock, but, becomes

hard to turn when

underway.

Steering wheel is too small. Install larger wheel (28”

MAX)

Cylinder doesn’t provide

enough force to turn drives.

Confirm cylinder installed is

right for the boat.

Incorrectly set, or adjusted

torque tab.

Readjust torque tab.

Mechanical interference. See fault 3.


5-15

Table 5.8

Power Assist Pump Troubleshooting


Power assist unit does not

turn on.

Blown fuse/ breaker. Replace fuse/ breaker.

Wrong electrical connections. Refer to wiring diagram.

Turns the wrong way. Lines reversed. Review the plumbing

diagrams for your system;

confirm that your hoses are

hooked up correctly.

Wheel is bumpy. Air in system. Re-bleed. Concentrate on

remaining air in the P/A unit.

Helm locks up in both

directions.

1. Hoses are installed in the

wrong ports.

2. Kinked or collapsed line.

1. Review the plumbing




2. Check all lines for sign of a

collapsed or kinked line.

Helm only turns in one

direction and free wheels

in the other.

Port or Starboard line is

connected to the reservoir R

port on the P/A unit.

Review the plumbing




Steering is very hard (stiff). 1. P/A unit is not turned on.

2. Partially kinked or

collapsed line.

3. H1, H2 or R port screen

filters are plugged with

contamination.

1. See fault 1.

2. Check all lines for a sign

off a collapsed or kinked line.

3. Remove H1, H2 and R

hoses and fittings. Clean

screens located in the adapter

fittings.

No power assist, Lights are

blinking.

Note sequence of blinking

lights.

See page 22 of OEM manual

for details.

Appendix A: Outfit Items & Stowage Plan

Appendix A. 1

Appendix A Outfit Items and Stowage Plan

Item Quantity Location

National Ensign 1 Bucket, fwd stowage

USCG Ensign 1 Bucket, fwd stowage

Flashlight 2 Bucket, fwd stowage

Binoculars 2 Bag next to fwd seats

Bucket 1 Fwd stowage locker

Portable Signal Horn 1 Bucket, fwd stowage

Spare propellant for signal horn 1 Bucket, fwd stowage

Spare part/tool bag 1 Fwd stowage locker

Spare kill switch lanyard 1 Tool bag, fwd stowage

Portable bilge pump 1 Port engine hatch

Life ring 1 Aft deck

Float free light 1 Aft deck

Snap hook for marker light lanyard 1 On light

Throw bag 2 Fwd stowage

Snap hook for throw bag 2 Tool bag, fwd stowage

Pyrotechnics storage container 1 Fwd stowage locker

10 person First Aid kit 1 Tool bag, fwd stowage

Rescue strop 1 Fwd stowage locker

30ftx6/8in mooring lines 6 Fwd stowage locker

Fenders 2 Fwd stowage locker

Boathook 1 Overhead

1 ¼“ shackle 1 Tool bag , Fwd stowage

Navigation Rules International-Inland 1 In nav bag at nav station

Parallel plotter 1 In nav bag at nav station

Dividers 1 In nav bag at nav station

Nautical slide rule 1 In nav bag at nav station

Search pattern wheel 1 In nav bag at nav station

Pencils 5 In nav bag at nav station

Pencil sharpener 1 In nav bag at nav station

Anemometer 1 In nav bag at nav station

Stop watch 1 In nav bag at nav station

Penlight 1 In nav bag at nav station

Chart 1 In nav bag at nav station

Pump, trailer hubs 1 Bucket, fwd stowage

Skiff hook 1 Tool bag, fwd stowage

Hook snap (304, 4.625 3970 SWL) 1 Tool bag, fwd stowage

Pelican MityLight red lens 1 In nav bag at nav station

Anchor line, with 12” eye 1 Fwd stowage, anchor bag

Gentex headsets, w/ext. cords & switches 4 Fwd stowage locker


Appendix A. 2

Item Quantity Location

Harris battery eliminator 1 Fwd stowage locker

Motorola charger and key loader 1 Fwd stowage locker

Misc. manuals * Fwd stowage locker

Shock cord 35” / 31” Max 54” 1 Fwd stowage locker

Fender inflator 1 Fwd stowage locker

Fender repair kit 1 Fwd stowage locker

Anchor 1 Fwd anchor storage

18” shock cord w/hooks 1 Fwd anchor storage

Bug Screen 1 Fwd stowage locker

Appendix B: Spares List

Appendix B. 1

Appendix B Spares List

DESCRIPTION VENDOR QTY

Engine Spares:

YANMAR 6LPAM-STZC3 ENGINE

IMPELLER, SEAWATER PUMP YANMAR EA 2

FILTER, ELEMENT, AIR YANMAR EA 2

FILTER, FUEL, FOR YANMAR 6LPAM-STZC3 ENGINE

YANMAR EA 2

FILTER, OIL, FOR YANMAR 6LPAM-STZC3 ENGINE

YANMAR EA 2

TIMING BELT YANMAR EA 2

V-BELT YANMAR EA 4

CARTRIDGE, FUEL FILTER/WATER SEPARATOR

RACOR EA 2

ANTIFREEZE, 1 GALLON CONTAINER, 50/50 MIX, ORANGE

CHEVON GL 16

OIL, ENGINE, 15W-40, 1 QT CONTAINER DELO QT 16

FLUID, HYDRAULIC STEERING, 1 QUART SEASTAR QT 4

ANODE, ZINC, FW PS FUEL YANMAR EA 10

ANODE, ZINC, AIR COOLER YANMAR EA 2

Controls Spares:

for: YANMAR 6LPAM-STZC3 ENGINE

30' TELEFLEX CONTROL CABLE TELFLEX EA 2



Sterndrive Spares:

HIGH PERFORMANCE GEAR LUBE MERCURY MARINE

QT 4

POWER TRIM FLUID MERCURY MARINE

EA 1

U-JOINT & GIMBAL BREARING GREASE 14OZ CARTRIDGE

MERCURY MARINE

EA 1


Appendix B. 2

DESCRIPTION VENDOR QTY

ENGINE COUPLER SPLINE GREASE 14OZ CARTRIDGE

MERCURY MARINE

EA 1

SPECIAL LUBRICANT 101 8OZ TUBE MERCURY MARINE

EA 1

ALUMINUM ANODE KIT BRAVO 1 DRIVES MERCURY MARINE

EA 2

Sponson Spares:

comes with fender system

SPONSON REPAIR KIT WING EA 1

Additional Spares:

ANODE, TEARDROP, ZINC, 1.000 THICKNESS x 2.000 WIDTH x 5.250 LENGTH, STREAMLINED

CANADA METALS

EA 2

Strap wrench

EA 1

Hand Pump, Jobsco 34060-0130, engine oil drain dipstick connector

EA 1

Alignment tool

MERCURY MARINE

EA 1

Shift cable alignment tool

MERCURY MARINE

EA 1

Flusher kit QUICK SILVER EA 1

Dual water pickup flush kit QUICK SILVER EA 1

Funnel

EA 1

Tire Change Device, Drive on

EA 1

Lug wrench, 4-way

EA 1

Appendix C: OEM Manual List

Appendix C. 1

Appendix C OEM Manual List

Manual Name VENDOR

6500 Cruise Master Flow Scan

6LP2 Maintenance Yanmar

Forespar Ball Valve, Tech Tips Forespar

Furuno DFF1 Furuno USA

Furuno GP37 Furuno USA

Furuno MFD12 Furuno USA

Furuno RD30 Furuno USA

Globemaster Compass Ritchie Navigation

ISCH7800 Throttle Teleflex Marine

Lenco Trim Tabs Lenco Marine

MerCruiser Bravo Outdrive Operation & Maintenance Mercury Marine

Model 2004B & 2012 Strobe Beacons Whelen

NaviLED Instruction Sheet Hella Marine

Racor Product Sheet (Fuel Filter) Parker / Racor

SeaStar Power Assist Pump TeleFlex Marine

SeaStar Steering (070323-R) Teleflex Marine

SeaStar Tilt Helm Teleflex Marine

6500 Cruise Master Flow Scan

6LP2 Maintenance Yanmar

Forespar Ball Valve, Tech Tips Forespar

Furuno DFF1 Furuno USA

Furuno GP37 Furuno USA

Furuno MFD12 Furuno USA

Furuno RD30 Furuno USA

Globemaster Compass Ritchie Navigation

Kvichak Marine Industries, Inc.

469 NW Bowdoin Place

Seattle, WA 98107

COMDNINST M16114.nn

32 FT Transportable Port Security Boat (TPSB)

Boats 32101 through 32180

32 foot transportable u.s. department of port security ... operator's... · 32 foot...

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