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(I
ERNST
HATECKE
CUra
LIFEBOAT
DMG-39
NANNI
MANUAL FOR OPERATION, MAINTENANCE

AND
TRAINING
FOR
FREEFALL LIFEBOATS
"V"
ERNST
HATECKEr
Survival- & Deck equipment

Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail: email@Hatecke.de
www.hatecke.de
Edition 12/06
Index
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
Operation Manual
In the interest of safety
Yard and yardnumber
Handling and use of freefall-lifeboats
Description of GFF-boats
Stowageplan for equipment
Alarm
Alarm
Stretcher
Instruction for launching
Freefalliaunching
Start the engine
Emergency tiller/radar reflector
Air supply and sprikler system (only for tanker lifeboats)
1.1.14 S p r i n k l e r s y s t e m (only for tanker lifeboats)

1.1.15 Air s u p p l y s y s t e m (only for tanker lifeboats)
1.2
Maintenance Manual
1.2.1 In the interest of safety
1.2.2 Charging the battery by solargenerator
1.2.3 Wiring diagram for battery charging by solargenerator
1.2.4 Charging the battery (from the ship)
1.2.5 Wiring diagram for battery charging from the ship (Standard)
1.2.6 Wiring diagram for battery charging from the ship (with engine heater, optional)
1.2.7.1 Weekly inspection
1.2.7.2 Monthly inspection
1.2.7.3 Annual thorough examination (ace. to IVISC.1/Circ.1206)
1.2.7.4 5-Years overhaul and testing (ace. to MSC.1/Circ.1206)
1.2.7.5 Log Scheme
1.2.7.6 Authorized service station
1.2.8 Maintenance of GRP-boats
1.2.9 Lubricant-and fuelplan
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
Trainings manual:
Trainings instructions
Handling and use of freefall-lifeboats
Launching and recovery instructions
Freefalliaunching
Simulated launching (from MSC.I/Circ. 1206)
Simulated launching
Additional:
Engine manual
Engine certificate
Function description of the charging regulator
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatccke.de, www.hatecke.de
1.1 Operation Manual
ERNST
HATECKEf::
"~N

Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-{0)4143-9152-40
www.hatecke.de
WARNING
1. Before launching close all hatches and the entrance door.

2. Secure all items and fasten seat belts (adjust to your size).
3. Don't wear lifejackets during freefall launching. Failure to observe this procedure may
lead to serious injury or death!
4. Keep out of the way of the propeller.
5. Always keep hands and feet clear when near moving and rotating machinery.
6. Before starting the engine, read it's instruction manual.
7. Pyrotechnics in the inventory case are EXPLOSIVES.
8. During operation of davit be cautious with long links, snap hooks and counter weights.
9. DO NOT open the engines cool water filler cap when hot.
10.Before releasing aft lashing to enter boat for maintenance or training fasten falls of davit
/ crane to the long links of hoisting slings from boat. After maintenance or training
fasten lashing again and afterwards release hoisting slings from falls.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, www.hatecke.de
1.1.2 Yard and yardnumber
The information given in this manual is based on our long experience and "know-how" in
the building of totally enclosed lifeboats.
In case of an emergency it is very important that the occupants know how to handle the
lifeboat and it's equipment.
All personel should study this manual at lifeboat drills, to make themselves thorougly
conversant with the system and to ensure a speedy and safe launching in an emergency.
The technical specifications are not binding and can be altered without prior notice.
In case of enquiries regarding existing boats please quote the details given below:
.>.,p.
Building no.
GFF6,5M
10837
ERNST
HATECKEf:

Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
1.1.3 Handling and use of freefalMifeboats
At launching:
1. The occupants should always use the same seat.
2. In an emergency situation, the boat should be launched with the engine running. Where
lifeboat drills are being carried out, start the engine and run it for a short time and then
switch off before launching the boat. Start the motor again when the boat is afloat.
3. Lifejackets should not be worn during the launching of the boat, but should be taken
on board and put on as soon as the boat is afloat. The wearing of a lifejacket during
launching may lead to injury!
4. Check before launching that the impact area is free from floating objects.
5. During the launching period (release/water-borne) the boat occupants must ensure that
their heads remain close to the head rests provided at each seat.
6. As soon as the boat is afloat, the hydraulic release piston should be brought back to its
housed position.
Lifting the boat back on board:

1. Before leaving the seat, loosen the seat belt.
The boat lifting sling(s) should be put into the crane hook(s) from the aft platform.
Do not stand on the cabin roof.
2. Before setting the boat back into the launching ramp, the securing hook on the ramp
cross-strut should be put in the "open" position.
3. Once the boat is back in the launching ramp and secured in place, open vents, connect
the battery charger cable (if any) and start the charger.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.1.4 Description of GFF-boats

Hull and canopy:
The complete boat is constructed of G.R.P. material using selfextinguishing resins.
The hull is of round frame constructions, with a fine entry for high speed and good freefall
immersion characteristics.
The boat has a transom stern with a rescue platform at waterline level designed to assist in
bringing on board those being rescued.
The canopy is of double skin construction designed to act as buoyancy to make the boat
self-righting even when partly flooded.
The innerbottom has hatches to the storage and engine compartmen.

The external hull and canopy are orange coloured (RAL 2004), the internal surfaces are
light green (RAL 6019)
Engine:
The engine fitted is a water-cooled (closed system) diesel engine and is installed below the
cabin sole and gives a boat speed in exess of 6 knots.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: O49-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatccke.de, www.hatecke.de
1.1.5 Stowageplan for equipment
(JPK)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
(3}
(^
(1,2,4,5.7-11.15,18.22-25,28-34)(19)(J6)
(27) ( 6 ) (17) (25)
1 buoyant bailer
2 buckets
2 hatchets
1 Container with distress signals as:
6 hand flares
4 rocket parachute flares
2 buoyant smoke signales, orange
1 daylight signal mirror
1 jackknife with tin opener and marling spike
1 electr. torch with 1 spare bulb and 2 spare batteries
2 tin opener
1 fire extinguisher
1 fishing tackle
1 whistle
5 Itrs. containers with drink water (3 Itrs. for each person)
lifeboat food ration (one for each person)
2 drink cups
1 sea anchor towing and mooring line
2 painters, 15m long, dia. 14mm
2 buoyant lines, 30m long, dia. 8mm, with buoyant rescue quoits
1 first aid kit for lifeboats with seathlckness rations (6 doses for each person)
1 lifeboat compass
1 manual bilge pump
1 radar reflector
Diesel-fuel
2 boat hooks
1 search light
thermal protective aids (one for 10 persons/min. 2 per boatt)
1 Survival-manual/life-saving signal card
1 embarkation ladder
loose equipment:
25. 1 key for seats/fuel tank
26. 1 set lifting slings
27. 1 emergency tiller
28. 2 straps for stretcher
spare parts for the engine:
29. 1 vee-belt
30. 1 fuel filter
31. 1 pump impeller
32. 1 oil filter
33. 1 set of common tools
34. 1 oil drain pump
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, ww.hatecke.de
1.1.6 ALARM
All personal proceed to boat station.

Warm clothing to be worn.
Lifejackets to be carried but not put
on.
Note: Do not put on lifejacket
before the lifeboat is afloat.
Failure to observe tis procedure
may lead to serious injury or
death during the launching.
1. Disengage the the boat lashings.

2. Disconnect the battery charger
(does not aplly to boats equiped
with solargenerator).
3. Board the freefall lifeboat.
Boatyard Ernst Hateckc GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatccke.de, www.hatecke.de
1.1.7 ALARM
A
3.
DANGER
CAUTION:
Secure all items fasten seat
embarcation hatch
hatch and vent
Close all hatches and openings.
4.
Fasten seat belts as soon as seated!!!
Boatyard Emst Hatcckc GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone; 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: cmail@Hatccke.de, ww.hatake.de
1.1.8 Stretcher
To SOLAS 74(83) chapter III, regulation 41 " The lifeboat shall be so arranged that
helpless people can brought on board either from the sea or on stretchers."
Inside the boat the stretcher has to be secured. Four lashing points are on the floor of the
boat, two lashing belts are in the equipment locker.
All handling and use of the stretcher will be done to the stretcher manufacturers
instructions.
For missuse of stretchers in freefall lifeboats ERNST HATECKE GmbH will not be
responsible.
1.1.9 The system instruction for launching
Freefall
The boat runs down the launching ramp and on hitting the water submerges briefly before
emerging and moving away from the stern of the ship.
Instructions for free-fall launching look at next page.
Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: cmai!@Hatecke.de, ww.hatecke.de
1.1.10 Freefall launching
Close all hatches and vents.

Fasten seat belts.
Close the valve screw (pos.1), operate the hydraulic
pump (pos.2). (After abt. 20 strokes the locking device
will disengage - the boat is now free.)
CAUTION:
Before replacing the boat in the launching ramp, the
hydraulic piston should brought back into its housed
position by opening the valve screw (pos.1)
EMERGENCY RELEASE:
Operate only when mainreiease system is damaged.
Close the valve screw (pos. 3).
Operate the emergency release pump (pos. 4). (After abt. 30 strokes the locking device
CAUTION:
Before replacing the boat in the launching ramp, the hydraulic piston should be brought
back into its housed position by opening the valve screw (pos. 3). After replacing the boat
in the launching ramp the valve (pos. 3) should remain in the open position.
1.1,11 start the engine
searchlight
masthead lantern
V-*Q interior light
charging lamp
oil pressure
engine temperatui
STOP
START
NANNI ENGINE
To start the engine:

1. Switch on main power (main swith). 7 ON
2.
With gear lever in NEUTRAL, press the grey button and move lever into Ahead / Start
position.
3. Press the START-button.

4.
OSTART
Bring the gear lever bacl< into the NEUTRAL position

back automatically).
(the grey gear button springs
* Speed and gear box control lever:

a) With the grey gear button pressed in, the lever controls only the engine speed.
b) With the button in the "out"-position, the lever first operates the gear change (either
ahead or astern) and then by further movement of the lever away from the neutral
position, the engine speed is increased.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: craail@Hatecke.de, www.hateckc.de
1.1.12 Emergency tiller / radar reflector
In case of malfunction of the steering gear it is

possible to steer with an emergency tiller.
1. The emergency tiller is located near the seats
below the steering tower.
2. Fit the emergency tiller through the floor (near
the embarcation hatch) on to the rudder shaft.
The radar reflector is stored in the equipment

locker. Assemble the radar reflector. Mount it in
the socket on the aft end of the superstructure.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone: 0049-{0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, www.hateckc.de
1,1.13 Air supply and sprinkler system

(only for tanker lifeboats)
Befor launching in case of fire:

1. Open the compressed air bottle valves.
2. Close all vents.
3. Open the sea valve at the sprinkler pump.
4. Open the valve of the air supply system.
After testing the sprinkler system with sea water, the system should be flushed
through with fresh water.
Boatyard Ernst Hatecke GmbH, Am Ruenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.1.14 sprinkler system

In case of passage through any fire, it is necessary to engage the sprinkler system.
The sprinkler system is designed to cool the surface of the boat.
The sprinkler system also fulfills the equally important purpose of keeping the temperature
inside of the boat low enough for comfort and safety.
freshwater connection
The sprinkler system consists of sprinkler pump fitted at the fore end of the engine,
operated by the engine via a flexible clutch. The sprinkler pump delivers the water to the
sprinkler tubes and to the spraynozzles.
After testing the sprinkler system with sea water it should be flushed through with
freshwater.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, wwv.hatecke.de
1,1.15 air supply system

Air supply system:
To supply the boat with fresh air in case of passage through fire or a cloud of gas the boat
is equipped with bottles of compressed air.
The quantity of compressed air is sufficient to supply passengers and engine with fresh air
for 10 minutes.
The compressed air bottles (T) (50 Itrs.x200 bar) are connected to a joint pipe system (2).
Through a valve(3) the compressed air passes into the pressure reducer (4).
The pressure reducer is so adjusted, that it will supply the fresh air for 10 minutes into the
inner of the boat.
Refilling of the compressed air bottles
Unscrew the protection cap from the filler piece a n d connect the high pressure hose
from the compressor. Make sure that the valve @ is closed. Charge the bottles (T) until the
pressure gauge (7) shows a pressure of 200 bar (make sure that the bottles valves (6)are
opened. Disconnect the high pressure hose of the compressor and fit the protection cap to
the fillerpiece(5). The air supply system is now ready for use.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: O49-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hateckc.de
1.2 Maitenance Manual
ERNST
HATECK _
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
1,2,1 In the interest of safety
WARNING

1-2,2 Charging the battery by solar generator

Nanni Diesel Engine
solar generator
riCHARGING OF BATTERIES: \
1.
OFF
2.
SWITCH BATTERY
SELECTION WEEKLY
v_
Note:
The solar generator will supply constant charging current if the boat is on board.
If the engine is running the batteries will be supplied by engines dynamo.
Only sealed Battery type should be used!
Caution:
Do not open the batteries I
Do not top up with water!
Fasten batteries after installation!
((I
1,2,3 Wiring diagram for battery charging by solargenerator
n
o Y?
Nanni Diesel Engine
o o o o Q Q
_.
32
v-^86
83
87
14
SGI--/
31
13
15A\
86
87
85
30
MAINS WITCH
RELAY
INBOX
30
STARTING
RELAY
IN SOX
HEATING
RELAY
INBOX
ENGINE
STOP
RELAY
SL
^^-
04
p 2
789
04
p2
pi
Connecting
t)OX
Searching light
rt!
XX
'ôior
aenerotor
8
Alternator
-'--^v Engine starter
6
Overcharge
protecon
/77
r-
\l 6
Switch Battery
(Stop Pos.)
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatccke.de, ww.hatecke.de
1.2,4 Charging the battery (from the ship)

Nanni Diesel Engine
[connect the charger cable]
Connect the charger cable for 42 Volt AC.

CHARGING OF BATTERIES
^
2.
OFF
SWITCH BATTERY
SELECTION WEEKLY
Note:
Check charging current of the battery charger which is fitted under the helmsman's seat.
On board the ship, the charging cable should be kept connected to the lifeboat battery
charging socket and the batteries kept under constant charge.
Caution:
Maximum charging current is 6 amps.
Only sealed Battery type should be used!
Caution:
Do not open the batteries !
Do not top up with water!
Fasten batteries after installation!
^.
1.2.5 Wiring diagram for battery charging from the ship

(Standard)
Nanni Diesel Engine
r:;
^
:J
o Q o o o
ICE
_J
32
21
-V--^---
SPI-22
14
15A\
n}
86
87
I R3 \
I RI I
MAINS WITCH
RELAY
INBOX
R2
8S
STARTING
RELAY
INBOX
30
HEATING
RELAY
INBOX
ENGINE
STOP
RELAY
,4
04
Êngine
0 2
05
789
04
5.
^ X'
14 i
Ix^
01
(g^l
XX
datierie
AltematOf
1 2 V= i1
cnarqer
^^^<h
o'^
|l V
rh
V. A
Switch Battety
(Slop Pos.)
Slop control box
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: eraail@Hatecke.de, www.halecke.de
1.2,6 Wiring diagram for battery charging from the ship

(with engine heater, optional)
r:;
^
Nanni Diesel Engine
o o o o Q o
CE
32
-H-
14
SGI--/
31
13
15A\
86
87
MAINS WITCH
RELAY
INBOX
83
STARTING
RELAY
INBOX
30
HEATING
RELAY
INBOX
ENGINE
STOP
RELAY
"V
789
A 0
XI
,.
i XI
^Â
2
3 txjx
_Epgine
0-1
Searching light
Eng i
<2& ottery
heater
c h a r g e r 1 60X f
17oowi
;55V
Alternator
o>-^
/TV
10A 16A
V
W <>
!
42
Switch Battery
(Stop Pos.)
Stop control box
*-
rî
01
Qualification level.
By supervision of a senior ships officer in accordance with the information provided by the manufacturer
Electrical installation:
done
remark
1. Check battery charging system.

2. Check functioning of external and inside lights.
3. Switch the battery switch
Engine:
4. Test run the engine, demonstrate that the gearbox and gearbox train
are engaging satisfactorily.
Miscellaneous:
5. Visual inspection of the boat to ensure that they are ready for use.
Only for Tanker Lifeboats:

Air supply system:
6. Check the pressure (200 bar) at the gauge.
If necessary fill up the pressure to 200 bar.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0M9-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
lai
Electrical Installation:
done
remark
1. Check battery charging System.

2. Check function of external and internal lights.
3. Switch the battery switch
Engine:
4.
5.
6.
7.
Check fuel level in the tank (Fill up the fuel tank only on launching ramp).
Check lubricating oil level in the engine and gear box.'(Renew oil and oil filter at least once a year)
Check the cooling water level in the compensating tank.
Check functioning of the oil pressure lamp, the water temperature lamp and the
battery charching lamp.
8. Check the tension of the generators drive-belt.
9. Check the antifreeze In the cooling water.
10. Grease the sterntube bearings (5 turns with the grease gun which is fitted in the
engine space).
11. Test run the engine, demonstrate that the gear box is engaging satisfactory.
Hydraulic release gear:

12. Check the oil level in the pumps and the fittings for tightness.
Miscellaneous:
13.
14.
15.
16.
17.
18.
Lubricate all hatch dogs and hinges.

Check inventory.
Lubricate the release and the lashing hook.
Lubricate the lifting sling.
Drain the bilge.
Visual inspection of the boat to ensure that it is ready to use.
* with boat on even keel
Only for tanker lifeboats:

Air supply system:
19. Check the pressure (200bar) at the pressure gauge. If necessary fill
up the pressure to 200 bar.
Caution:
Do not apply oil anywhere to the air supply system !
Oil under pressure explodes !
sprincler system:
20. Check operation of the sea water inlet valve and grease it.
21. Drive the boat and use sprincler system for one minute minimum.
22. After testing the sprincler system should be flushed with fresh water.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.2.7.3 Annual thorough examination
(acc.toMSC.1/Circ.1206)
By manufacturers representative or a person appropriately trained and certified by tine manufacturer.
Lool< at page 1.2.7.6 Authorized service stations.
Items listed in checklists for the weekly/monthly inspections form the first part of the
annual thorough examinatio. When carrying out this examination the inspection of these
items should be performed by the ship's crew in the presence of the manufacturer's
representative or a person appropriately trained and certified by the manufacturer for the
work to be done.
Inspection and maintenance records of inspections and routine maintenance carried out
by the ship's crew and the applicable certificates for the launching appliances and
equipment should be available.
L i f e b o a t : Examination and check for satisfactoiy condition and operation
1. Condition of Lifeboat structure including fixed and loose equipment.

2. Engine and propulsion system.
3. sprincler system, where fitted.
4. Air supply system, where fitted.
5. Manoeuvring system.
6. Power supply.
7. Bailing system.
R e l e a s e G e a r : Examination and check for satisfactory condition and operation *
8. Operation devices for activation of release gear.

9. Hydraulics hoses annd fittings.
10. Holding device fastening.
Test:
11. Operation test of release function
according to manufacturers checklist (Doc.no. 0201)
Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, www.hatecke.de
1.2.7.4 5-Years Overhaul & Testing
By manufacturers representative or a person appropriately trained and certified by the manufacturer.
Look at page 1.2.7.6 Authorized service stations.
Items listed in checklists for the weekly/monthly inspections also form the first part of the
annual through examination, when carrying out this examination the inspection of these
work to be done.
L i f e b o a t : Examination and check for satisfactory condition and operation *
1. Condition of Lifeboat structure including fixed and loose equipment.

2. Engine and propulsion system.
3. Sprincler system, where fitted.
4. Air supply system, where fitted.
5. Manoeuvring system.
6. Power supply.
7. Bailing system.
R e l e a s e G e a r : Examination and check for satisfactory condition and operation *
8. Operate devices for activation of release gear.

9. Hydraulic hoses and fittings.
10. Holding device fasteming.
Test:
11. Operation test of release function
12. Overload test Ace. to SOLAS Chapt.lll, reg. 20.11.2
according to manufacturers checklist (Doc. no 0202)
Boatyard Ernst Hatecke GmbH, Am Ruenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, ww.hatecke.de
1.2.7.5 Principal log scheme

No: Kind of service:
Note:
Date:
Name:
Boatyard Ernst Hatecke GmbH, Am Ruenstrora 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.2.7.6 Authorized service stations

Necessary larger repairs, as well as the "annual thorough
examination" and the "5-years overhaul" should be conducted by the
manufacturer's representative or a person appropriately trained and
certified by the manufacturer.
ERNST
HATECKEr
Please contact:
HATECKE SERVICE GMBH

Am Ruthenstrom 1
21706 Drochtersen / Germany
Telefon: +49-4143-9152-60
Telefax: +49-4143-9152^4
e-mail: service@hatecke.de
Internet www.hatecke.de
1.2.8 Maintenance of GRP-boats
Even GRP-boats are subject to damage to greater or lesser extent. The most common
damages are scratches in the gelcoat which may also penetrate the laminate.
The gelcoat colours are:
Outer surface: orange
RAL 2004
Inner surface: light green RAL 6019
In case of extensive damage contact the builders at the following address.
Sometimes the gelcoat finish looks dull and the colour is faded.
Restore the original finish by sanding the surface with a fine grade water sandpaper of
grade 400 or finer, or using a rubbing compound.
After sanding or rubbing the surface must be waxed. Rubbing should be done by hand or
with a rotary polishing buff. Waxing should always done by hand.
ERNST
^'^'i-^
HATECKEr^Z
1 ^

Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
1.2.9 Lubricant- and fuel plan

OIL LIST FOR FREEFALL-LIFEBOATS, TYPE GFF/GFF M
Ambient temperature for -25 up to +50C
No.
Est. qty. unit: Oil: LTRS.

Grease: KGS.
QTY/SET
SET/SHIP
TOTAUSHIP
APPLICATION POINT
RECOMMENDATION
Engine
Multigrade oil
SAE15W-40
API CD/SF
Look at engine
manual
Gearbox
DEXRON
ATF-oil
API CD/SF
Look at engine
manual
fueltanl<
Marine Diesel
with plogging point
lower -25C
4
4a
4b
4c
Grese points
Sterntube
Rudder-trunk
Others
Grease with
EP additives
NLGI-class 2
2,50
2,50
Hydr. release system
ISOVG15HLP
3,00
3,00
ca. 120
ca.120
Remarks:
The boat has been delivered with oil filled and fuel partially filled.
For further informations look at engine manufacturers instruction manual.
1.3 Trainings iVIanuai
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
1.3.1 Trainings instructions

To SOLAS chapter III,part B, regulation 19,3.3.3 "...each lifeboat shall be launched, and
manoeuvred in the water by its assigned operating crew, at least once every three
month during an abandon ship drill."
To SOLAS chapter III,part B, regulation 19.3.3.4 "Lowering into the water, rather than
launching of a lifeboat arranged for free-fall launching, is acceptable where free-fall
launching is impracticable provided the lifeboat is freefall launched with ist
assigned operating crew aboard and manoeuvred in the water at least once every
six month"....
Furtheron to chapter III,part C, regulation 44, 6.5.1.5
"It should be possible to test the release mechanism without launching the
lifeboat".
ToMSC.1/Circ.1206,Annex2, 2.4.1:
MSC.1/Circ.1206
"The monthly drills with free-fall lifeboats should be carried out according to the
manufacturer's instructions, so that the persons who are to enter the boat in an
emergency are trained to embark the boat, to take their seats in a correct way and to
use the safety belts; and also are instructed on how to act during launching into the
sea."
To MSC.1/Circ.1206, Annex 2, 2.4.2:

MSC.1/Circ.1206
"When the lifeboat is free-fall launched as part of a drill, this should be carried out
with the
minimum personnel required (max. 4 persons) to manoeuvre the boat in the water
and to recover it.
The recovery operation should be carried out with special attention, bearing in mind
the
high risk level of this operation.
Where permitted by SOLAS, simulated launching should be carried out in
accordance with the manufacturer's instructions, taking due note of
MSC.1/Circ.1206 on Guidelines for simulated launching of free-fall lifeboats."
On the following pages you will find:

1.3.3 Handling and use of freefall-lifeboat
1.3.4 Launching instructions
1.3.6 Recovery procedures
1.3.7 Sinnulated launching (from MSC.1/Giro. 1206)
1.3.8 Simulated launching
Boatyard Ernst Hateckc GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
WARNING

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, wwv.hatecke.de
1.3.3 Handling and use of freefall-lifeboats

At launching:
1.
The occupants should always use the same seat.
2.
In an emergency situation, the boat should be launched with the engine running.
Where lifeboat drills are being carried out, start the engine and run it for a short time
and then switch off before launching the boat. Start the motor again when the boat is
afloat.
3.
Lifejackets should not be worn during the launching of the boat, but should be taken
on board and put on as soon as the boat is afloat. The wearing of a lifejacket during
iauncliing may lead to injury!
4.
Check before launching that the impact area is free from floating objects.
5.
During the launching period (release/water-borne) the boat occupants must ensure
that their heads remain close to the head rests provided at each seat.
6.
As soon as the boat is afloat, the hydraulic release piston should be brought back to
ist housed position.
Lifting the boat back on board:

1.
Before leaving the seat, loosen the seat belt.
2.
The boat lifting sling(s) should be put into the crane hook(s) from the aft platform. Do
not stand on the cabin roof.
3.
Before setting the boat back into the launching ramp, the securing hook on the ramp
cross-strut should be put in the "open" position.
4.
Once the boat is back in the launching ramp and secured in place, open vents,
connect the battery charger cable (if any) and start the charger.
Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatccke.dc, ww.hatecke.de
1.3.4 Launching and recovery instructions
Freefall:
The boat runs down the launching ramp and on
hitting the water submerges briefly before
emerging and moving away from the stern of
the ship.
Instructions for launching procedure on the
following page.
Instruction for free-fall look also in the
Operation Manual (in front of this).
Launching by davit:
In some cases (shallow water, ice-drift, drifting
parts of the cargo) it is necessary to launch the
boat with max. number of persons by davit.
Instruction for launching procedure look at the
davit manufacturers instruction.
Recovery by davit:
Freefall lifeboat with crew of max. 4 persons
must be sailed astern under the davit.
Instructions for recovery procedure look at the
davit manufacturers instructions.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: eraail@Hatccke.de, www.hatecke.de

Fasten seat belts.
CAUTION:
HYDRAULIC PISTON
EMERGENCY RELEASE:
LOCKING DEVICE
Operate only when mainrelease system is damaged.

Operate the emergency release pump (pos. 4). (After abt. 30 strokes the locking device
CAUTION:
Before replacing the boat in the launching ramp, the hydraulic piston should be brought
back into its housed position by opening the valve screw (pos. 3). After replacing the boat
in the launching ramp the valve (pos. 3) should remain in the open position.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, www'.hatecke.de

INTERNATIONAL MARITIME ORGANIZATION
4 ALBERT EMBANKMENT
LONDON SEI 7SR
(from MSC.1/Circ.1206, Annex 2)
;li
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IMO
IMO GUIDELINES FOR SIMULATED LAUNCHING OF FREE-FALL LIFEBOATS

1 Definition
Simulated launching is a means of training the crew in the free-fall release procedure of free-fall lifeboats and in verifying the satisfactory
function of the free-fall release system without allowing the lifeboat to fall into the sea.
2 Purpose and scope
The purpose of these Guidelines is to provide a basic outline of essential steps to safely carry out simulated launching. These Guidelines
are general; the lifeboat manufacturers instruction manual should always be consulted before conducting simulated launching.
Simulated launching should only be carried out with lifeboats and launching appliances designed to accommodate it, and for which the
manufacturer has provided instructions. Simulated launching should be carriedout under the supervision of a responsible person who
should be an officer experienced in such
procedures.
3 Typical simulated launching sequence
3.1 Check equipment and documentation to ensure that all components of the lifeboat and launching appliance are in good operational
condition.
3.2 Ensure that the restraining device(s) provided by the manufacturer for simulated launching are installed and secure and that the
free-fall release mechanism is fully and correctly engaged.
3.3 Establish and maintain good communication between the assigned operating crew and the responsible person.
3.4 Disengage lashings, gripes, etc. installed to secure the lifeboat for sea or for maintenance, except those required for simulated
free-fall.
3.5 Participating crew board the lifeboat and fasten their seatbelts under the supervision of the responsible person.
3.6 All crew, except the assigned operating crew, disembark the lifeboat. The assigned operating crew fully prepares the lifeboat for
free-fall launch
and secures themselves in their seats for the release operation.
3.7 The assigned operating crew activates the release mechanism when instructed by the responsible person. Ensure that the release
mechanism operates satisfactorily and the lifeboat travels down the ramp to the distance specified in the manufacturer's
instructions.
3.8 Recover the lifeboat to its stowed position, using the means provided by the manufacturer and ensure that the free-fall release
mechanism is fully and correctly engaged.
3.9 Repeat procedures from 3.7 above, using the back-up release mechanism when applicable.
3.10 The assigned operating crew disembarks the lifeboat.
3.11 Ensure that the lifeboat is returned to its normal stowed condition. Remove any restraining and/or recovery devices used only for
the simulated launch procedure.
The simulated launching operation should be carried out with

special attention, bearing in mind the high risk level of this operation
Simulated launching of free-fall lifeboats without allowing the lifeboat to fall into the sea.
1.
2.
Connect the falls of the davit by their hooks to the long link of the hoisting slings.
Top up the davit until the falls, the counterweight, and the long link of the
hoisting slings are all vertical "in line" (hoisting slings also must be tight).
Maybe you have to" winch up" the falls a little bit.
IMPORTANT:
Do not allow slack on the falls, otherwise the running distance on the sliding ramp
will be to long.
3. Disconnect the aft lashing of the boat.

4. Participating crew board the lifeboat and fasten their seatbelts under the supervision of
the responsible person.
5. All crew, except the assigned operating crew (max. 3 persons), disembark the lifeboat. The
assigned operating crew fully prepares the lifeboat for free-fall launch and secures
themselves in their seats for the release operation.
6. The assigned operating crew activates the release mechanism when instructed by the
responsible person.
7. Operate the release mechanism (instructions inside the boat or on page 1.3.4 of this
manual).
8. Recover the lifeboat to its stowed position, using davit and winch (look at Launching ramp
manual) and ensure that the free-fall release mechanism is fully and correctly engaged.
9. Repeat procedures from 6. above, using the back-up release mechanism when applicable.
IMPORTANT
All information here given on this page depent on ERNST HATECKE GmbH
manufactured davit systein type "FFA" ERNST HATECKE GmbH will not be
responsible on any systems of other manufacturers.
For handling and training look at the manuals of these manufacturers.
Boatyard Ernst Hateckc GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: cmail@Hatecke.de, www.hatecke.de
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KUBOTA BASIC
ENGINES
TABLE OF CONTENTS
1. SAFETY INFORMATION
2. GENERAL INFORMATION
3. ENGINE IDENTIFICATION
Technical Characteristics
4. PREPARATION BEFORE
STARTING
5.
ENGINE OPERATION
Starting the engine
Stopping the engine
Running in/Guarantee visit
List of guarantee verification operations
MAINTENANCE
Engine oil drain
Replacing the oil filter
Reducer reverser gear box
Replacing thefiieloil filter
Replacing the complete injector nozzle fitting
Cleaning the cooling system
Cleaning the thermostat
Electrical/Battery equipment
Cylinder head
Rocker arm adjustment
Recommendations
Periodic maintenance table
-J
Recommended on board repair kit
1 - SAFETY INFORMATION
These directions for use have been provided to help you to use your engine and itsfittings.They include
important instructions which should be observed while operating the engine.
These instructions must be read by the operator.
They should be permanently kept in the place where the engine is used.
SAFETY SYMBOLS
These symbols are used to indicate danger. They are intended to attract your attention to those elements
or operations which can endanger you or other users of this engine. Read the instructions highlighted by
the safety symbols attentively. It is essential that you read the instructions and the safety regulations
before starting the engine.
A
A
A
DANGER
Signifies that a very serious danger exists which may result in the strong possibility of death
or serious injury if the specific suitable safety measures are not observed.
WARNING
Signifies that a danger exists which may cause injuries or death if specific suitable safety
measures are not observed.
ATTENTION
Reminds you of safety measures or directs your attention to dangerous practices which may
cause injuries to persons or damage the boat or its components.
The user should take all necessary precautions as regards operation and protection and should seek the
advice of a professional.
Disregard for these safety instructions may lead to:
Bodily harm, environmental pollution dangers (leaks of dangerous substances), dangers to property with
risks of failure of the essential functions of the engine.
OBSERVING THE SAFETY RECOMMENDATIONS

Follow the warning and attention labels affixed to the engine
Disengage the contact key and turn off the battery main switch before performing any work on
the engine or its fittings
Close the engine cover and replace the protection devices before starting the engine
Always keep the area surrounding the engine clean and free of any debris
Place anyflammableliquids outside and away from the engine compartment
Never use the engine when under the influence of alcohol or medication
WEAR PROTECTIVE CLOTHING
To avoid bodily injury, remain clear of rotating parts and do not wear oversize garments close to a
running engine
Use safety equipment such as glasses, gloves, etc. according to circumstances and needs
FUELS AND LUBRICANTS
Stop the engine before adding fuel or lubricant

Do not smoke and do not draw near with an open flame whilst adding fuel
Wear gloves when checking for any possible leaks
Hot lubricating oil can bum you - allow the engine to cool before checking the motor oil level,
changing the motor oil, or the oil filter cartridge
Always use the fuels and lubricants recommended by NANNI DIESEL
ENGINE EXHAUST WARNING
Run the engine in a well ventilated place, away from persons and animals-the accumulation of engine
exhaust can be toxic
PRESSURE
Do not open the engine coolant and motor oil reservoir caps when the engine is warm. Release all
pressure in the line before loosening the caps
Do not check for possible pressure leaks with bare hands - wear gloves - liquids ejected under
pressure may cause serious injury - in case of contact with a spurt of fluid, immediately consult a
physician
BATTERY
A mixture of highly explosive, inflammable and volatile gas, forms when recharging the battery.
Never smoke and do not draw near to the battery with an openflameor spark
Never short circuit the battery terminals
The battery electrolyte is highly corrosive - Wear protective gloves and glasses.
ELECTRICAL WIRING
Turn off engine electrical contact and battery main switch before any repair to the electrical
equipment.
Check the state of the cables and the electrical wiring - a short circuit may cause fire.
DISPOSAL OF FLUIDS
The different fluids used for the operation of the engine may be toxic and hazardous to your health.
Carefully read the instructions appearing on the labels of these products.
Observe the environmental protection regulations relative to the disposal of motor oil, fuel, engine
coolantfluid,filtersand batteries
2 - GENERAL INFORMATION
Your NANNI DIESEL engine is a product of the research and quality manufacturing of NANNI
fNDUSTRIES. It is constructed from the finest materials available, according to finite specifications, and
in accordance with very strict production methods.
Your NANNI DIESEL engine is a dependable and long-lasting power source for your boat.
Proper installation of the engine on board your boat is of the greatest importance for safe navigation and also for respect of the
environment.
The NANNI INDUSTRIES engineers are among the world's most highly skilled. Their experience, their
knowledge of the seas, their mastering of techniques in association with the skills of the engineers of
MAN and KUBOTA guarantee you the best available combination of performance/reliability/economy.
WARNING: The installation of your engine must be performed by a naval vessel mechanics
professional, in compliance with the NANNI INDUSTRIES installation instructions.
These operating instructions contain information which are necessary for the proper operation of the
engine.
Present in over 50 countries through its network of agents and authorised dealers, NANNI INDUSTRIES
guarantees your safety world-wide.
Whether it be parts, labour, or simply advice, everything has been considered to properly serve your
needs.
Do not hesitate to contact your authorised NANNI DIESEL dealer.
Read this manual attentively before proceeding with the installation of the engine.
Follow the safety measures.
WARNING: The proper operation of a marine engine is linked to use suitable for the engine and its gear
box's specifications (type of boat, hours and RPMofuse).
3 - ENGINE IDENTIFICATION
On all correspondence, requests for information and orders for parts, it is essential to indicate the
references appearing on the engine and reversing gearbox identification plates.
Type
B Serial number
C NANNI Serial number
D Specification
IMPORTANT: Note the serial number and the engine and transmission model designations. Keep a
copy of this information in a safe place.
IDENTIFICATION OF PRINCIPAL PARTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Keel cooling
Engine coolant filler hole A
Not valid
Fresh water pump
Not valid
Alternator
Flexible suspension
Electrical connector
Starter
Engine oil filler hole
Engine oil change pump
Air filter
Dry exhaust
Oil filter
Oil pressure transmitter
Reverse gear box
Injection pump
Fuel pump
Fuel filter
Stop control
Speed-control
Not valid
Not valid
Not valid
4 - PREPARATION BEFORE STARTING

Once the engine has been installed on board, and before removing the protective covers from the various filler holes, clean the
external surfaces of the engine.
GENERAL VERIFICATION
Fill with motor oil and transmission fluid
Fill with coolant fluid
Check tension of belts
Check that the different connectors and oil and water change plugs are properly tightened
Check that the electrical cable terminal, battery terminals, battery switch, extension wiring
connectors are properly tightened
Check the electrolyte level of the batteries
Check the acceleration and stop controls (by moving them several times)
Check for proper synchronisation of the "gas and clutch" lever (essential in the case of a single
lever control). Clutching must terminate when starting to accelerate.
Perform a final check of the clamps as well as a visual check of the marine propulsion assembly.
If necessary, retouch the paint on the assembly and the accessories.
DANGER: Do not do not draw near to the battery with an open flame or spark. A mixture of
extremely explosive gasforms when the battery is being recharged- Do not short circuit
The battery electrolyte is highly corrosive: if the battery acid comes in contact with the skin,
immediately wash with soapy water - in case of contact with the eyes, rinse abundantly with water
and immediately consult a physician.
- Start with the positive terminal when connecting cables to the battery.
- Start with the negative terminal when disconnecting cables from the battery
WARNING:
Do not allow fuel or lubricant to spill on the engine.
The fluids usedfor the operation of the engine may be dangerous to your health.
The motor oil may damage your skin - wear gloves.
NOTE: Modem diesel engines are precision machines which require the use of high quality
lubricants.
ENGINE AND REVERSING GEARBOX LUBRICATION
Engine
Oil pump driven lubrication system, pressure regulated by a discharge valve.
Disposable cartridge oil filter
Transmission
Refer to separate specifications
Adding motor oil
Through the filler hole located on the rocker arm cover, unscrew the cap. check the level with the aid
of the dipstick. Do not exceed the maximum level.
NOTE: Qualities and quantities of oil are described in the table of technical characteristics
FUEL SYSTEM
Composition
Main disposable cartridge filter
Fuel pump (A)
Injection pump (B)
High pressure injector pipe
Injectors
Fuel system purge
Check the fiiel level in the reservoir
Open the fiiel valve. Unscrew the thumbwheel A. Move thefiaelpump hand lever; if necessary, turn
the crankshaft ft)r resistance.
Move the hand pump a certain number of times to expunge any air bubbles in the return system.
Retighten the thumbwheel A
Start
DANGER: - Do not smoke, or draw near with an open flame or spark
- Always mop up any spilledfitel
KEELCOOLING SYSTEM
It consists of one closed liquid coolant system.
Closed liquid coolant system
It consists of a pump controlled by the crankshaft by means of a V-belt, a Keel cooling and a thermostat.
Coolant fluid
Recommendations for the first use
Check that the Keel Cooling block fiuid drain plug and the carter motor are tightened.
Prepare a permanent antifreeze mixture with 50% antifreeze and 50% fresh water. The necessary
quantity is indicated in the technical specifications..
a) Engines with A cap and expansion tank: Fill the mixture into the A filler hole until the maximum fill
level is reached; close cap A. Pour the mixture into the expansion tank filler hole until the maximum fill
level is reached; close cap . Start the engine and verify the level after several minutes.. Subsequent checks
are to be made only with the expension cap; do not again open the A cap.
Allow the engine to run for 2 to 3 minutes whilst gradually accelerating.
Stop the motor and top off the expention tank fluid level.
The additional fills will be only with fresh water when the engine is cold
DANGER: - Fill the engine with coolant liquid only when the engine is turned off and cold - Do not smoke or draw near with
aflame.
-Stay clear of rotating parts while the engine is operating.
ATTENTION: Never add undiluted antifreeze.
ELECTRICAL EQUIPMENT
Engine -
a Battery
Alternator
Starter
Glow plug
Stop solenoid
_ Oil pressure alarm
g Water temperature alarm
h Water temperature gauge (option)
i Connector
j Oil pressure gauge (option)
Instrument panel
a Water temperature alarm indicator
b Oil pressure alarm indicator
c Glow plug indicator
d Battery charge indicator
e Audible alarm buzzer
f Starter button
g Stop button
h Instrument lighting
i Connector
Wire position
1
2
3
4
5
6
7
8
9
10
11
Colour
Red
Black
Brown
Brown 1
White
Function
Positive
Negative
Starter
Glow plug
Stop
Violet
Grey-1
Yellow-green
D + alternator
Oil alarm
Water alarm
5. ENGINE OPERATION
STARTING THE ENGINE
DANGER - Firmly close the engine cover and replace the protective elements before
starting the engine
Check the diesel fuel level
Open the diesel fuel feeder valve
Check the engine and gear box motor oil levels
Check the level of coolant fluid
Close the battery valve
Check that the gear box control lever is in the neutral position
Desynchronise the clutch gas control by using the device on the box
Position the gas control lever in the accelerate position
Switch on the main power, the oil alarm indicator will illuminate and the buzzer will sound
Then preheat by pushing the red botton in first position (for 5 to 10 seconds depending upon the
outside temperature)
Then push completely the same botton until the engine starts. Release it immediately after the motor
has started
Check the indicators and otherfiinctionsafter the engine starts
Immediately stop the engine if the buzzer sounds, if the temperature rises abnormally or if the other
indicators illuminate
ATTENTION: Search for and eliminate the cause before starting the engine
Allow the engine to run at approximately 1000 rpm
If the engine does not start on the first attempt, repeat the steps after waiting 30 to 60 seconds after each
attempt
WARNING: Never cut the electrical circuit by using the battery main switch whilst the engine is
running. This may cause damage to the alternator.
STOPPING THE ENGINE
Return the control lever to the idle/neutral position

Allow the engine to idle for several minutes in order to stabilise the temperature
Push the stop button
ATTENTION - Check the engine and the engine compartment for any possible leaks.
ENGINE RUN IN - GUARANTEE VISIT

Running in
During the first 20 hours of operation, it is recommended that you take precautions to properly Run in
your engine and that you not attain maximum engine performance except during short periods.
Never race your engine immediately after starting, without having allowed it to warm up.
Guarantee visit
This mandatory visit with an authorised NANNI DIESEL representative will take place either after 20
hours of operation or 45 days after your engine is placed in service..
Every new engine is guaranteed against all parts defects according to the terms and conditions specified
9
^m
on the certificate of guarantee which is furnished to the buyer upon delivery of the engine (warranty card
to be returned).
LIST OF GUARANTEE VERIFICATION OPERATIONS - (Customer's Responsibility)
DANGER: To avoid bodily injury, stop the engine and allow it to cool, turn off the battery main
switch before any repair
Follow the safety and environmental protection instructions
Change the lubricant of the:
- Engine
Reverser gear box
Clean:
- The diesel fuel pre-filter
Check:
- The level of the coolant fluid
- Theadjustment of the valves
The tightness of the intake and exhaust manifold
The tightness and the operation of the diesel fuel system
The tightness of the cooling system
The belt tensions
- The tightness of the screws and bolts
- The tightness of the engine mounts
- The alignment of the engine
- The stuffing box
- The lubrication of the stuffing box
Replace:
- The oil filter cartridge
- The diesel fuel filter cartridge.
Electrical equipment
Check:
- The tightness of the contacts and cable terminals
- The level and density of the battery electrolyte
The alternator charge
- The correct operation of the instrument panel
Perform:
- A check of the condition of the battery.
10
6. MAINTENANCE
DANGER: To avoid bodily harm, stop the engine and allow it to cool, turn of the battery main
switch before making any repairs
Follow the safety and environmental protection instructions
The performance level of lubricants necessary for the proper operation of the engine and the
recommended maintenance schedule are described on page X.
IMPORTANT - These recommendations are essential. Following these recommendations will prolong
the life of your engine and will affect the applicability of the guarantee which is provided.
- Do not make any unauthorised modifications to the engine.
Damage caused by the use of parts not bearing a manufacturer's reference number are not covered by
the guarantee
Repairs and maintenance must be performed by an authorised NANNI DIESEL engine repair facility
If the engine is used for a number of hours less than the number specified for maintenance intervals, then maintenance must be
performed at least once per year.
In this case, it is recommended that maintenance be performed before winter storage. The engine will
therefore be protected by new, clean lubricants.
Valve adjustments
- The valves are adjusted according to their injection order
Place the valves in a rocking motion on the cylinder before being adjusted
Turn the crankshaft in the direction in which the engine rotates, so as to place the piston at upper dead
centre
- Adjust the intake and exhaust valves (refer to the values in the table of technical characteristics)
Electrical equipment
- Regularly check the tension of the alternator belt. Tighten the belt between the pulleys. It should have
10 mm give
DANGER -Stop the engine and turn off the battery main switch before making any repairs to the
electrical system
11
Battery
-
Check the battery charge once per season

The density of the electrolyte should be between 1.270 and 1.285
The electrolyte should be check periodically. The level should be maintained at 1 cm above the
accumulator plates. Add distilled water, if necessary.
DANGER - Never draw near with a flame, and never check the battery with "a spark", because the
gases which may be released are inflammable and explosive - The battery electrolyte is highly corrosive.
If battery acid come in contact with your skin, immediately wash with soapy water, eyes, rinse abundantly
with water and immediately consult a physician
Do not short circuit.
RECOMMENDATIONS
In order to ensure proper operation of the alternator and integrated regulator:
Never:
- Turn off the battery main switch whilst the engine is running (risk of damage to the regulator)
Reverse the battery terminals. The terminals are respectively marked + (positive) and - (negative); the
negative is earthen; the cable terminations and the cables must be correctly attached.
Change the charge circuit while the engine is running.
For use of several batteries, install a charge distributor (consult with us).
In case of starting the engine with a spare battery and jumper cables, proceed in the following manner:
Disengage the main battery circuit, connect the spare battery to the main battery by connecting the +
to the + and the - to the -. Once the engine starts, disconnect the jumper cables and do not cut the main
battery circuit.
You must disconnect the 2 battery cables when:
you use a battery charger
- before any repair to the electrical system
before doing any soldering work on a metal hull
Rinsing the cooling system
Fresh water system
- Remove the tank cap
Drain the water from the Keel cooling block and from the engine block
Refill the system with fresh water and let the engine run for several minutes
- Drain the water and again replace it with a mixture of antifreeze and fresh water
Fill the cooling system according to instructions.
NOTE: In the case where a hot water system is connected to the engine, also completely empty the latter and to refill it, note
the quantity of the coolant mixture being added. Check to see that all air is purgedfi-om the system during the refilling
WARNING: Liquid under pressure. Do not open the cap when the engine is warm. Allow the engine to
cool and open the cap with caution.
Cleaning the Keel Cooling Block
Remove the covers

Replace the O-rings and remount the tube and the covers
Do not forget the copper gaskets on the covers assembly screws..
WARNING: Corrosive products may hazardous to your health. Read the instructions on the product
label carefully.
12
Replacement of the diesel fuel filter

The diesel fuel filter is a disposable-type filter.
Close the fuel valve
- Unscrew the cartridge at the head of the filter
Coat the gasket of the new cartridge with engine lubricant
Screw the new cartridge onto the filter head, then tighten it by hand % of a turn (do not use tools)
Open the fuel valve
- Purge the system
Start the engine and check for sealing
ATTENTION: - Always mop up and spilledfuel
- Follow the environmental protection instructions
Replacement of the injectors
Remove:
The injectors piping
- The screw and the diesel fuel return piping
- The complete injector
Dismantle the injector
- Replace the injector gasket and nozzle
Remount the parts and check the injector calibration value
WARNING: Do not allow diesel fuel to spray onto your skin - wear gloves
IMPORTANT: This work must be performed by an authorised NANNI DIESEL engine repair facility.
The injectors should be checked every 400 hours or every 2 years
Motor oil change
The motor oil is removed by the oil change pump, preferably when the engine is slightly warm
Pump until the engine is completely drained
Refill to full level with new motor oil
- Check the level with the use of the dipstick
- Do not exceed the maximum level
WARNING: Hot oil can burn you Avoid all contact with your skin
Respect the environmental protection regulations
13
Replacement of the oil filter

- The cartridge is of the disposable type
Unscrew the cartridge at the head of the filter
- Coat the gasket of the new cartridge with engine lubricant
Screw the new cartridge onto the filter head, then tighten it by hand % of a turn (do not use tools)
- Check that the filter does not leak when the engine is running
Stop the engine and add motor oil to the maximum fill level if necessary
WARNING: Hot oil can bum your - Avoid all contact with your skin
Respect the environmental protection regulations
Reversing gear box

Refer to detailed instructions in the reversing gear box manual attached to the operating manual
Consult with us for specific reversing gear box information
Reversing gear box control system
Verify the remote controls regularly. The cable stroke should be 35 mm on both sides of dead centre (O
A = O - B). The lever must be able to move freely to its stroke limits.
Attention to the lever position
(refer to fig. et )
Turbo
Engines equipped with a Turbo: Turbo compressor should be checked every 400 hour for proper
operation
DANGER: To avoid bodily injury, do not start the motor without the air filter
IMPORTANT: Allow the engine to idle before stopping the engine
14
6 - MAINTENANCE
Periodic Maintenance Table

EVERY
DAY
CHECK
Oil level (engine and gear box)
Battery charge (indicator)
Water temperature and operation
General sealing
Battery electrolyte level (every 15 days)
Operation of the controls
Belt tensioii
Valve adjustment
Starter and alternator mountings
Tightness of screws and assemblies
AT 20
HRS
EVERY
100 HRS
EVERY 200 HRS

OR EVERY YEAR
x
X
x
X
X
X
X
X
X
Engine mounting and alignment

Injector calibration
Thermostat, to be cleaned
Level in the heat exchanger
Keel cooling tube
REPLACE:
Oil filter
Fuel filter
Motor oil
Gear box lubricant
Coolant fluid
EVERY 400 HRS OR

EVERY 2 YEARS
X
X
X
X
X
X
X
X
15
Technical specifications
NANNI DIESEL ENGINE
Number of cylinders
Maximum power
*
Maximum rated load *
Idle speed (on gear)
Maximum no load speed
Cycles
Stroke-Bore ratio
Cubic cylinder capacity
Rate of compression
Rotation direction
Injection order
Injection pump
Injection pressure
Fuel consumption
Advemce injection timing
Weight (including, gear box)
Alternator
Battery capacity (minimum)
Cooling system
4.150 KG
3.100 KG
4 in line
3 in line
27.6 kW (37.5 hp)
21.3kW(29hp)
3 600 rpm
3 000 rpm
850 rpm
950 rpm
3 900 rpm
3 300 rpm
4
4
76 x 73.6 mm
78 x 78.4 mm
I 001cm3
1498 cm3
22/1
23/1
Counter clock-wise
Counter clock-wise
1-3-2
1-3-4-2
Nippon Denso (Bosch type)
Nippon Denso (Bosch type)
140 bar
140 bar
190g/kW/h
190 g/kW/h
2 2 + 1 before UDC
11 (static) 23 to 3 000 rpm
130 kg
145 kg
12V-60A
12 V - 6 0 A
llOA/h
llOA/h
By fresh water /sea water keel cooling
Coolant fluid:
(50% water + 50% antifreeze)
Valve clearance (when cold)
Motor oil
Motor oil capacity
0- 35 forward
HURTH gear box *
HURTH gear box oil capacity
HURTH gear box lubricant
TECHNODRIVE gear box *
TECHNODRIVE gear box oil capacity
TECHNODRIVE gear box oil
Anti-pollution certification
Electromagnetic compatibility
CEM 89/336/CE
41
51
)
0.15 to 0.20 mm (intake and exhaust)

API CD - SAE 15 W 40
4.5 1
4.5 1
ZFIOM
ZF12M
0.55 1
0.35 1
Automatic Transmi ssion Fluid, Type A
TMC40
TMC60
0.21
0.8 1
API C D - S A E 15 W 40
BSO - Level 2
BSO - Level 2
Certificate no. CE P98155T
Certificate no. CE P98155T
ATTENTION: The specifications are defined only for use ofpleasure craft. Consult with us for all other uses.
DESCRIPTION
V-belt
Oil filter
Fuel oil filter
Recommended on board repair kit for motor types 3.100 K and 4.150 KG
Quan
3.100 KG
4.150KG
970 637 399
970 637 399
970 302 742
970 302 742
970 310 302
970 622 350
Rocker arm cover gasket

Complete nozzle fitting
Glow plug
Thermostat
Thermostat gasket
O-ring tube
Injector gasket
2
1
970 302 833

970 302 816
970 302 821
970 301412
970 302 608
970 301 719
970 142 109
970
970
970
970
970
970
970
302 765
302 816
302 821
301412
302 608
301 719
142 109
16
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NAtiONAL blSTMlBUTORS
ALGERIA (-.213)
ENTREPRISE CONSTRUCTIONS NAVALES

Nationale 11 km 15 -16202 AIN BENIAN. , S 2.271.00.26. Fax: 2.271.00.26.
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MARTINIQUE
#
ANTILLES MARINE SERVICE
Montgerald - face au chantier naval - 97290 MARIN
S 74.70.78. Fax: 74.63.71.
E-MAIL: antillesmarineOwanadoo.fr
GUADELOUPE
ASSISTANCE MARINE
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97190 LEGOSIER
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KING HARKEN S.A.
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COLLINS MARINE PTY. LIMITED
UNIT 26 -17-21 Bowden Street
ALEXANDRIA, NSW - 2015 SYDNEY
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E-MAIL: Detericollinsmarine.com.au
INTERNET: www.collinsmarine.com.au
INMACO
P.O. BOX 13383, MUHARRAQ
BAHRAIN
S 17.344.577. Fax: 17.344.577
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Noorderlann 181 - B-2030 ANTWERP
S 3.543.85.51. Fax : 3.544.72.54.
E-MAIL: Dcasteels{5).manrollo.be
Marine Link Machinery Compagny
G/F to 2/F Tung Wong Building
16 C Main Street East - Shaukiwan, Hong Kong
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Calle 25 Esq.. Hospital Centro Habana - LA HABANA - CUBA
S 7.878.95.32. Fax : 7.878.95.33.
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MOLO - JIRI PASLER
PrimaTorska 49 -180 00 PRAHA 8
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E-MAIL: jpaslerOmbox.vol.cz
VM d.o.o.
M. MUZEVICA 43 - 51265 DRAMALJ
S 5178 6118. Fax: 51 78 69 29
INDUSTRIES MARINE SERVICE
SCHFERWEG 12 - D-24941 FLENSBURG
S 461.503.21.33. Fax : 461.503.21.22.
E-MAIL: imsO.nannidiesel.de
TEAN INGENERIA ELECTRICA CI
150 (E6-31) Vicente Cordenas - Y Japon - QUITO
S 22.25.09.42 Fax : 22.25.09.42
E-MAIL: teanO.accessinter.net
MARIN TEC
4, Mohamed Mazhar ST.- ZAMALEK - CAIRO
S 2.737.01.20. Fax : 2.737.01.29.
E-MAIL ::marin tecOvahoo.com
JAKARI
Regatil 1 - Pirita Sadam - EE0019 TALLINN
9 6.398.993. Fax : 6.398.994.
ANDERSENS BEDING
FO-490 STRENDUR
S 22.27.18. Fax: 44.19.32.
E-MAIL : hand.DOSt.olivant.fo- INTERNET www.nummar.fo
TAPIMER OY
Palopellonkatu 1 - 04250 KERAVA
9 9.274.65.30. Fax: 9.274.653.15.
E-MAIL : taoimerOtaDimer.fi - INTERNET : www.tapimer.fi
SOPOM
BP 9167 - PAPEETE - TAHITI
9 42.99.69. Fax: 41.98.70.
E-MAIL: soDomOmail.pf
INDUSTRIE MARINE SERVICE
SCHFERWEG 12 - D-24941 FLENSBURG
S 461.503.21.33. Fax: 461.503.21.22.
E-MAIL: ims@nannidiesel.de
MOTOCRAFT S.A.
48, Alimou avenue -17455 ALIMOS-ATHENS
S 210.988.82.88. Fax: 210.985.01.02.
E-MAIL : motocraflO.hol.qr - INTERNET : www.motocraft.qr
AUTO & MARINE SERVICE NUUK A/S
Industrivej 29 - Postbox 905 - 3905 NUUK
9 32.37.05. Fax: 32.44.05.
E-MAIL : amsnuukOoreennet.ql - INTERNET: www.ams.ql
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H-2131 GOD - JOZSEF ATTILA U.I5
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Riverside Estate - BRUNDALL - NORWICH - NORFOLK NR13 5PU
S 1603.71.40.77. Fax: 1603.71.22.11.
YAMITY.S.B. LTD
P.O. BOX 6158-61061 TEL AVIV
S 3.527.17.78. Fax : 3.527.17.72.
E-MAIL: mil.vamitvsb.co.il
NANNI TRADING SRL
VIA ANTON GUILIO BRAGAGLIA, 31/A - 00123 ROMA
S 06.308.84.251. Fax : 06.308.84.254.
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01 - P.O. BOX452 -ABIDJAN
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SAKAI FIRM Limited.
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Espace Etemad - ANTANANARIVO
S 20.22.300.90. Fax: 20.22.229.23.
E-MAIL:polvma@qaecar.com
GAETANO CARUANA LTD
CCL Buildings, Trig LX-Xghir, C/W,Midina road - ZEBBUG ZBG 05
S 21.460.881. Fax: 21.465.824.
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JET MARINE
Parcelle 23 - AGADIR
614.29.673. Fax: 614.29.673
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S.N.I.M.
Departement Achats - BP 42 - NOUADHIBOU
S 574 1205/1215. Fax : 574 9013/9027
KUBOT BASED ENGINES
CRAMM INGENIEURS-EN
Hadelsburo - Postbus 510 - NL-8901 BH LEEUWARDEN
S 58.28.80.700. Fax : 58.28.80.643.
E-MAIL: salesOcramm.nl
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NEW CALEDONIA (-.687)
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MAN ROLLO B.V.

Koraalrood 17 - P.O. BOX 595P - NL-2700 AN ZOETERMEER
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NEPTUNE ENTRETIEN SARL
Bale de Numbo - 3 bis rue Carnot - 98846 NOUMEA
a 687.28.53.60. Fax : 687.28.01.95.
E-Mail: neptune(aoffratel.nc - INTERNET: www.neptune.nc
LEES DELTA MARINE
P.O. BOX 72 047, Papakura - AUCKLAND
S 9.299.6019. Fax: 9.298.9986.
E-MAIL: lees.deitaOJxtra.CO.nz - INTERNET : www.enqineer.net.nz
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Postbox 55 - N-6280 SOVIK
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STR RACIBORSKIEGO 32 - 80-215 GDANSK
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PORTUGAL r-.351)
Fishina:
SOCIEDADE VICTOR, LDA
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B.C. MASTER GROUP S.R.L.
Str.Bacului NR.39 A SECT.1 - BUCURESTI 78606
S 0740.045.699. & 0745.532.237.
E-MAIL: masterqroup@mvmail.ro
MARINTECHSERVICE
OFF. 512, M.38 Krasnogvardeyskaya - Gelendzhik, Krasnodarsky
353461 RUSSIA
S 86.14.15.42.85. Fax : 86.14.42.85.
E-MAIL: valervOJmts.com.ru
MAN B&W Diesel Singapore
29 Tuas Avenue 2
Singapore 639460
Tel (65) 63 49 1600
Fax (65) 6897 8605
NAVIGATOR
Zgorne Gameljne 35 D - 61211 SMARTNO
S 061.555.409. Fax : 061.555.409.
E-MAIL : ioconaviqatorO.volia.net
STAR MARINE CC
P.O. BOX 3361 - North End - Port Elisabeth 6056
S 41.484.7465/7 Fax : 41.484.37.92.
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PASCH Y CIA. S.A.
Paseo Campo de Volantin, 24 - Aparatdo 244 - 48080 BILBAO
S 94.413.26.60. Fax :94.413.26.62.
E-MAIL : Daschbio@Dasch.es - INTERNET : www.Dasch.es
MALTE MANSON AB
BOX 123 - S-596 23 SKNNINGE
S 142.299.100. Fax : 142.413.50.
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INTERNET: www.maskin-marindelar.se
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Haldenstrasse 26B - CH-8306 BRTTISELLEN
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E-MAIL: infoOihamiiton-aq.ch - INTERNET : www.hamilton-indust.ch
COMPTOIR INDUSTRIEL & NAUTIQUE
7, rue IBNZohn-1002 TUNIS
S 1.794.275. Fax: 1.794.275.
E-MAIL: xavier.ancona(a)libertvsurf.fr
TURKEY (-.90)
KUBOTA BASED ElVGrNES

OTO ORMAN TICARET LTD.
Nobethane CAD. N 11 - 34420 SIRKECI
ISTAMBUL
S 212.528.36.57. Fax : 212.526.77.36.
E-MAIL: orman(a!suDeronline.com
MAN BASED ENGINES
UNITED KINGDOM (-.44)
UNITED states (-.01)
MAN KAMYON VE OTOBUS TIC LTD. STI

Firuzkoy Yolu N 32 - 34840 AUCILAR - ISTAMBUL
S 212.675.04.15. Fax : 212.675.04.33.
E-MAIL: Cetin Onal@mn.man.de
A.R. PEACHMENT MARINE
Riverside Estate - BRUNDALL - NORWICH - NORFOLK NR13 5PU
S 1603.71.40.77. Fax: 1603.71.22.11.
E-MAIL; sales(a)Deachment.co.uk
INTERNET: www.peachment.co.uk
AMERICAN POWER CORP.
BP 787 - BELIZE CITY, CA
S 01.501.225.760. Fax : 01.501.225.759
USA OFFICE
AMERICAN POWER CORP.
14250 SW136 street, Bay 3 - FL 33186 MIAMI
305.251.9771. Fax: 305.251.9776
E-MAIL: miami.americanDower.com
POWER QUEST PRODUCTS, INC.
909 FM 2094 - KEMAH TX 77565 - TEXAS
S 281.334.6720. Fax : 281.334.9554.
E-MAIL: DOweraOwt.net
WATERWAY POWER CENTER
2017 Renard Court - 21401 ANNAPOLIS, MD
S 410.266.0590. Fax ; 410.266.0534
E-MAIL: waterwavmarine(35aol.com
INTERNET: www.watenA/avmarine.com
VENEZUELA (-.58)
EDUARDO CALCANO & CIA, C A .

Casas Bote C - N 248 El Morro Puerto La Cruz - ANZOATEGUI
S / . F a x : 281.281.75.48
E-MAIL: eclplc(a)vahoo.com
maDmm:a_:(]&sce_^
1
Spare parts catalogue

Catalogue de pieces dtacfies
(ErsatzteiC^taCog
CataCogo de piezas de repuesto
CataCogo parti di ricamSio
3.100KC-SOLAS
HATECKE VERSION
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Nos reservamos el derecho de aportar, sin previo aviso ni obligacin de puesta al dia de este catlogo, las
modificaciones necesarias por razones tcnicas o comerciales.
Las reproducciones o traducciones, incluso parciales, estan prohibidas sin autorizacin escrita de nuestra parte.
Ci riserviamo il diritto di apportare, senza preaviso e senza l'obbligo di aggiornare questa pubblicazione, le modifiche
eventualmente necessarie per qualunque necessit tecnica o commerciale.
Riproduzione, anche parziale, vietata senza nostra autorizzazione scritta.
NANNI INDUSTRIES S.A.

Zone industrielle - avenue Mariotte - B.P.107 - 33260 LA TESTE - FRANCE
Tel.: (00.33) 05 56 22 30 60 - Fax. : (00.33) 05 56 22 30 79
1 - PREFACE
1,1 For technical reasons and for simplification, the illustrations in this catalogue are only by way of example.
2 - GUIDE FOR CONSULTATION OF THE CATALOGUE
2.1 Identify in the table 00,00 "table Index" the table to be consulted.
2.2 Every table is composed of two pages.
An enlarged view of the articles is shown on the first page.
The tables giving part number, quantities relating to the engine and eventual obervations are shown on the second page.
3 - RULES FOR ORDERING
3.1 All orders must be written and sent to NANNIDIESEL. Spare Parts Dept. with the following references :
- Quantities requested
- Part no
- Number of order, method of shipment, etc
3.2 for urgent orders or in case of doubt, it is necessary to indicate the serial number and the year of productiion of the engine and as much useful information possible to identify the part.
4-GENERAL
4.1 Any queries concerning your orders of spare parts must bear the number and date ot the order and/or the number of the sales invoice.
4.2 Any complaints regarding shipments must be presented within 8 days from receipt of the goods.
4.3 Any mistakes deriving from the transmission or incorrect interpretation of urgent orders taken by telephone, telegram or telex will be chargeable to the Distributor who passed the order.
1 - PREFACE
1,1 Pour des ralsons techniques et de simpllcit, les illustrations de ce catalogue sont seulement fournies titre indicatif.
2 - METHODE DE CONSULTATION DU CATALOGUE
2.1 Rechercher sur la page 00,00 "index des planches" le numro de la planche consulter.
2.2 Chaque planche est composee de 2 pages. La premiere page montre la vue clate des pieces. La deuxieme page donne les symboles, les quantits pour moteur, ainsi que les observations eventuelles.
3 - INSTRUCTIONS POUR COMMANDES DE PIECES
3.1 Toutes les commandes doivent tre adresses NANNIDIESEL avec les elements suivants :
- Quantit demande
- Code de la piece
- Numro de commande, mode d'expdition, etc
3.2 Pour des commandes urgentes ou en cas de doute, il est necessaire d'indiquer le numro de serie et l'anne de fabrication du moteur ainsi qu'un maximum d'informations permettant d'identifier la piece.
4 - GENERALITES
4.1 Tout renseignement concernant votre commande de pieces dtaches doit comporter le numro et la date de la commande et/ou le numro et la date de la facture de vente.
4.2 Toute reclamation concernant l'expdition doit tre faite sous 8 jours dater de la reception de la commande.
4.3 Toute erreur decoulant de l'expdition ou d'une mauvaise interpretation d'une commande urgente enregistree par telephone, tlgramme ou telex sera la charge du distributeur qui a pass la command
PAGE NUMBER REVISION EDITION
DATE
DESCRIPTION
ENGINE CATALOGUE
3 WOKC-SOLAS-HATECKE
EOJ^DQCoD&i!/
SPHE PARIS CATALOGUE MODIFICATION

GROUP
00-00
PAGE
1
REV
-
ED
1
DATE
02-03-04
DESCRIPTION
GROUP N
CYLINDER HEAD COVER/ OIL BREATHER

FUEL PIPE
FUEL FILTER ASSY
HEAT EXCHANGER EXH MANIFOLD'
05-00
21-00
23-00
46:00 __
ELECTRICS
77-0""80-0' ""'
82-00
91-00
95-00
FLYWHEEL H O U S I N G '
REAVERSING GEAR
ENGINE MOUNT
SPARE PARTS LIST
DESCRIPTION - 3 100KC-SOLAS
GROUP
00-00
PAGE 1 REV
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DATE
02-03-04
DESCRIPTION
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REMARKS
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ENGINE TYPE
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02-03-04
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HOUSING HEAT EXCHANGER

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PAGE
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46.01
02
02-03-04
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77.02
01
02-03-04
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GROUP
PAGE
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82.00
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02-03-04
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95.00
01
REV
ED
DATE
02-03-04
solarnova
Professional-Line
Solar module SOL 12 K

For applications like sport- and
commercial shipping, hobby and small units
For the electrical provision of low power consuming
equipment the solamova offers this heavy load
module. 40 crystalline silicon cells of size 5 x 5 cnf
are connected by a: specific high reliable welding
process. This module has a nominal power of 12
watts and is designed for nominal battery voltages of
12 volts.
The established sandwich-technique protects the
module excellent against environmental influences
as for instance rain, dust, hail and seawater. The
edges of the module are protected by a sealing of
synthetic rubber and a frame made of stainless
steel. The connection cables comply with the
instructions of VDE and are led out UV-protected at
the module rearside. In addition a plastic cap
guarantees the complete sealing of the cable
connections.
The specific regidity of this module is based on the
usage of two chemically hardened glass plates in
combination with the small module size. By this the
module is well suitable for sailing and motor
yachts.This type of module is also designed for a
lifetime of more than 20 years and is proved since
many years in similar construction for following
applications:
Communication Systems:
Data recording and transmission
Emergency highway calling systems
Portable transceivers
Relay stations
Traffic Systems:
Railway communication systems
Warning lights
Obstruction lights
Navigation buoys
Life-boats
Measuring Technique
Remote measuring and data recording of meteorological, climatological and environmental
data
Recreation, Sport and Hobby Systems:

Recreation vehicles
Camping/Caravans
Sailing ships
Motor ships
Handheld radios
Amateur radios
CB-radios
Refrigerators
Lighting
Fans
Circulation pumps for swimming pools
Fountains
Power supply for expeditions
n
Mechanical Data:
Electrical Data:
Solar cell
Base material:
crystalline silicon
Solar cell temperature
Cell size:
5 x 5 cm*
QOC
25 C
60 C
Open circuit voltage
25.3 V
23.1V
20.2 V
Short circuit current
0.70 A
0.72 A
0.73 A
Voltage at power max.
20.5 V
18.4 V
15.6 V
0.64 A
0.65 A
0.66 A
13.1 W
12.0 W
10.3 W
Embedding
Glass/EVA/Glass
The rnaxirnurn deviation of nominal power is less than 10 %.

All values mentioned above are valid for an irradiation of AM
1.5-10mW/cm^.
Frame
Stainless steel
Weight
approx. 1490 g
Energy Output per Module:

Nominal voltage:
Solar cell temperature:
Cable
Length: 150 cm
(FFY11Y-2X 1.5mm*)
(+) = brown; {-) = blue
12 V
25 C
irradiation
(kWh/rhM]
3.0
4.0
5.0
6.0
2.0
2.6
3.3
3.9
Accessories
Teakwood mounting brackets
Qualification:
Dimensions in mm
This module generation conresponds to the
specification no. 503 of the Joint Research Centre
ISPRAoftheCEC.
V*2 I;,. .
'.iS*%-'^' 665^
Operation Conditions:
Temperature
T,|: -50''C; T ^ : +90''C
Humidity
up to 100% rel.humidity at
+90''G
Wind pressure
stable up to wind speeds of

von 160 km/h
CorrosiiDh
corrosion-resistant to sea water

and maritime climate
Hi.
vS?*-r
^^^^:
*" Boundary values for short term exposure only!
Remarks:
Installation of modules has to be perfbnmed such a
way that the rearward connections (leads, junction
box) are located above.
solamova
Produktions- und Vertriebsgesellschafl mbH
Industriestrae 23-33
D-22880 Wedel
Telephone (O 41 03) 60-256 25
Telefax (O 41 03) 60-47 01
The technical data given merely serve for

information purposes and - depending on the
individual application concerned - can vary.
s o t 12K EA)12.96
solarnova
Charge Regulator
CDC 106, CDC 206
Operating Instructions
The charge regulators BCR123 40-150 and BCR 243 80-240 have
been specially designed for use in photovoltaic systems with
smaller outputs. They can be used for 12 V or 24 V batteries. Due
to the high protection class IP 65, they can also be installed
outdoors. Modern circuitry ensiures an extremely low own electric
energy consumption (at 12 V) of PV = 0.1W. The units can be used
for solar generators with a charge output up to 150 W with the 12
V verslonand up to 240 W with the 24 V version. They protect the
battery safely against overcharging and overdischarging, operating conditions which would othenvise drastically reduce the
service life of the batteries. The built-in varistor protects the unit
against voltage peaks which might develop from lightning striking
near the solar generator.
RQ resistor for different electrolyte temperature

Temperature
in kOhm
in-C
-10 ... 0
0 ...+10
-(10 ... +20
-1-20 ... +30
-^30 ... +50
>+50
27.0
18.0
15.0
12.0"
6.8
3.9
End Load Voltage [V] 2 %

12 V Battery 24 V Battery
15.64
14.95
14.67
14.40
13.95
13.37
31.28
29.90
29.33
28.80
27.90
26.75
'' Setting at works

1. Operating Description
1.1 Charging Operation
During charging operation, the solar generator current flows into
the battery at low loss via a high current relay. When the battery has
reached gassing voltage, it is switched to trickle charge operation
with reduced current, to avoid the battery being overcharged (electrolyte loss, damage to the electrodes). If the batteiy voltage drops
below a certain voltage limit dueto self-discharging, to the load
from the connected cdhsurher appliance or to the falling solar
gheratbr current, the full charging operation is switched back.
Thehigh current relay employed is designed for 1 million switching
operations at a maximum current of 16 A. In operation conditions,
the relay only switches 9 A for 12 V and 7.5 A for24 V, so that a high
reliabii'rty is guaranteed.
1.2 Discharging Operation
If the battery voltage drops below the overdischarge voltage
during discharge operation, the load is disconnected from the
battery by an overdischarge relay. The load is automatically
reconnected when a minimum charge of the battery is ensured.
ATTENTION: For safety reasons, the overdischarge protection
has priority. When connecting the unit for the first time, this could
lead to pverdischarge being signalised although the battery is
charged. However, with ah intact battery this reading will disappear
shortly after charging current has flown from the solar generator.
At charge Surges, e.g. when connecting large consumer appliances^ itis possible that the battery voltage drops momentarily below
the bverdischarge threshold, without it being overdischarged. To
avoid the veraischrge alarm responding in such cases, the
charge release takes place after a delay.
1.3 Temperature Follow-up / Temperature Sensor
The gassing voltage of the battery varies with the temperature at a
rate of 5 mV per "G. based on a2 V cell. In most cases where the
ambient temperature of the battery only alters slightly, the overcharge switch-off threshold can be adjusted adequately accurately with a fixed resistor Ro*{see table 1), which is conneaed to
terminal 3 and 4. The units are equipped from works with a 12
kOhm resistor Rg;.this corresponds to a gassing voltage of 14.4 V
forl2V batteries, or 28 8 V for 24 V lead batteries, at an electrolyte
temperature of 25''G. If the temperatures are expected to deviate
really, the the resistor should be adjusted according to table 1.
hould there be strong ternperaturefluctuations,it is recommended to measure the electrolyte temperature diredly- In this case, an
NTC resistor is required (temperature sensor TS1).
which is attached directly to the battery pole and connected to the
terminal instead of the resistor fl-. The temperature sensor can be
used within the range of 5 to 60*0.
WARNING: The temperature sensor follows up the battery voltage

accordingio the electrolyte temperature. When temperatures are
below 25C, this leads to a system voltage of > 14.4 V with 12 V
units or >28.8 V with 28 V units (see table 1). which can cause
damage to various consumer appliances. Therefore, please do
not fail to check the max. allowed operating voltage. When attaching the sensor, make sure the bonding is perfect - high transition
resistances or open contacts cause increased system voltage.
Table 1
1.4 Manual Charge Control

In some cases it is desirable to deactivate the overdischarge
protection momentarily, to be ableto draw current from the battery.
For this purpose, a switch can be connected to terminals 13 and
14 which, when closed, will put back the overdischarge relay. This
should only be used for short periods and while observing the
battery voltage, to prevent the battery from being damaged.
Another possibility is to switch off the load in normal operation at
these terrhinals on purpose.
1.5 Overdischarge Warning Device
Indicators for overdischarge warning can be connected at terminals 11 and 12. The indicators must not exceed a max. current
consumption of 1 A.
1.6 Cut-off Connection
When the cut-off connection (terminal 1 and 2) is used, the battery
voltage can be covered in the error-compensated mode. This is
always necessary when the charg regulator is mounted at a
distance from the battery and thus the charge and load current
cause an unacceptably high voltage drop at the mains leads. If the
cut-off connection is used, the bridges W1 and W2 on the left and
right next to the terminal strip must be switched off beforehand.
2. Installation and Connection instructions
2.1 Order of Connection
There is no particular order of connection to follow. However, it is
advisable to first ensure the power supply and measuring of the
unit, i.e. first connect the cut-off line or the battery so that the'
consumer appliances are not endangered by unacceptably high
voltages.
2.2 Reverse Current Diode
In order for the solar system to be as efficient as possible, reverse
cunent diodes are not installed in these charge regulators. Such
diodes, which liein series to thesolar generator, produce on-state
losses during the charging phase, which are higher than the
reverse cui'rent losses during darkness. Nevertheless, in series
diodes cannot be done without in certain cases, it is especially
advisable with multiple module systems to decouple the single
solar generator strings by means of reverse current diodes. These
can be installed in the solar module connection boxes (see Module
Data Sheet).
2.3 Design of Cable Cross-Section, Cable Lengths
Cable A:
Four-core cable for battery voltage measurement and/or temperature sensor connection. Outer diameter max. 7.5 mm. If the
integrated resistor R. is used and the four-conductor measurement of the battery is not required, then cable A can be left off.
Cable B. C. D:
Two-core cable, 2 x 2.5 mm^ (flexible) or 2 x 4 mm* (solid) for solar
generator, battery and consumer connection. Due to the cable
entry used, the outer diameter of cable B. C. D is max. 13.5 mm. If
the four-conductor measurement of the battery voltage is not
present, attention must be paid to the max. allowable voltage drop
A*
Cable B for the solar generator - charge unit

Cable D for the charge unit - consumer appliance
Cable C for the charge unit - battery
Cable
max.
permissible
cable length
B
C
D
12 V Unit
2x2.5
2x4
mm^
mm*
10.0 m
150 m
1.0 m
1.5 m
3.5 m
5.5 m
U^=10%
U^ = 4 %
U^ = 1 %
24 V Unit
2x4
2x2.5
mm*
mm*
20.0 m 30.0 m
3.0 m
20 m
11.0m
7.0 m
Assumption: Max. permissible voltage flows throughout

Table 2
Electrical Data
CDC
106
206
11
24
A
12
Nominal voltage [V]
25
max. voltage {v)
50
\
max. solar generator capacity (W] 2) 150
240
2)
9
max. solar generator current (A]
7.5
max. load current JA]
10
10
31 14.4 2 %
End load voltage {V] (25''C)
28,8a:2%
31 10,8 3 %
Overdischarge voltage jV]
21.5 3 %
Switch back threshold [v]
after "Load off
12.3 3 %
24.6 + 3%
Power consumption,
nominal operaion [mA]
< 8
< 8
Power consumption
after load release [mA]
<30
<60
Lightning protection as per VDE 0432
Part 2/10.78. Impulse form
and duration 8/20 ^s [V]
1.000
I.OOO
Temperature compensation:
Adjusted to 25C. Adjustable to any other temperature by connecting defined resistors R^ (see table.1) or temperature sensor TBI
If longer cable is required for the installation, the battery voltage

must be measured at the battery terminals (use cable A).
Cable E:
Four-core cable for connecting an overdischarge warning device
and/or a mechanical switch for switching off and on the consumer
appliance; max. diameter 7.5 mm.
Type
NYY-0
NYM-0
H07RN-F
YR
3)
Charge reguiaor for lead batteries.

Valid for E = 1000 mW/m*. T^. = 25C
Voltage thresholds apply for commerciallyavailable leaj
tteries with their permissible charge and discharge curre. ,-
Mechanical Data
2.4 Suitable Cable Types (Selection)

Designation
Underground cable
Plastic-sheathed cable
Rubber hose pipe
Weak current cable
2)
nxA"
2x4
2x4
2x25
4x0.8
for cable
B, C. D
B, C. D
B.C.D
A.E
" n = core number!, A = cross seaion (mm*)

*> not for underground laying, but permitted for laying outdoors
Connection cross-section (mm*)

solid (flexible)
Housing
Dimensions LxWxH (mm)
Weight (kg)
Protection class
Operating temperature range ("C)
Storage temperature ("C)
4 (2,5)
Terluran
160 x 80 x 55
0.4
IP 65
-1 to + 55
-40 to f-80
Tables
rFF^
Control electronics
115^10 A
Lightning
protection
W1
Oil*
K2
I
Fixirtg
wz
fsi m fiytj fiTti mn
m m nil [ta m
:^n
Solar
Load Temp. Cut-off Battery
Generator
Sensor
r
I
L.
Alarm Consumer
Signal Appliariee
Masuremrits
1 _J
PG7
PG135
A
Cut-off
Temp.
sensor
Connectior) Plan
solamova
Produktions- und
Vertriebsgesellschaft mbH
Industriestr. 23-33
D-22880 Wedel
Tel.:04103-602625
10
1-
Principle Circuit Diagram

Cable
for:
Lpl L_
PC13,5
B
C
Solar
Battery
Generator
+
.
11 12 13 U
-1pl
1 1
1
PG13,S
"1
PC7
E
s. 2.3
Consurer Alarm
s. 2.4
signal
Appl.
Load On/Off
SLIDING RAMP
DMF-20
Operating and m a i n t e n a n c e manual

for launching- and retrieval system
of freefall lifeboat
type: FFA
with under oil hydraulic power pack
ERNST
HATECKE
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail: emall@Hatecke.de
www.hatecke.de
Edition 09/06
Index
1 Operation Manual
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Yard and yardnumber

Description of the launching-and retrieval system
Launching instruction
Freefall launching
Launching and recovery by davit (Under deck version)
Launching and recovery by davit (On deck version)
2 Maintenance Manual
2.1
2.2
Hydraulic equipment
2.3
Hydraulic oil & lub plan
2.4.1-3 Recommended oil chart
2.5.1 Weekly inspection
2.5.2 Monthly inspection
2.5.3 Annual thorough examination (ace. to MSC.1/Circ.1206)
2.5.4 5-Years overhaul & testing (ace. to MSC. 1 /Cire. 1206)
2.5.5 Testing according to SOLAS Chapt. Ill, Reg.20.11.1
2.5.6 Log Scheme
2.5.7 Authorized Service Stations
Additional:
General layout
Wires / small parts
Lashing (boat)
Wiring diagram (optional)
Hydraulic plan
Documentation of winch
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fa.x: 0049-(0)4143-9152-40, E-mail: emai!@Hatecke.de, www.hatecke.de
1,1 Yard and yardnumber

The information given in this manual is based on our long experience and "know-how" in the
building of rescue boats, all kind of life boats their equipment and their launching and recovery
systems.
In case of an emergency.also in normal practise it is very important that every body knows how
to handle the boat, the launching system and it's equipment.
All personal should study this manual at lifeboat drills, to make them selves thorougly
conversant with the system and to ensure a speedy and safe launching in an emergency.
In case of enquiries regarding existing boats please quote the details given below:
Type:
FFA 6.5M
Building no.:
10838
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail: emall@Hatecke.de
www.hatecke.de
1.2 In the interest of safety
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counterweights.
2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension
on this parts.
3. Always keep hands and feet clear near moving and rotating mashinery.
4. Before launching close fronthatch and door.
lead to serious injury or dead!
7. Keep off in reach of propeller.
8. Before starting read engine instruction manual.
Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 049-(0)4143-9152-40. E-mail: email@Hatecke.de, www.hatecke.de
1.3 Description of the launching-and retrieval system

This launching and retrieval system is installed in the stern area of the ship to use freefall-lifeboat
as follows:
1. freefall-launch of freefall-lifeboat up to 20 list and 10 trim of the ship from certificated height.
2. controlled launch of the freefall lifeboat up to max. number of persons it is certified by means
of davit arm and winch up to 5list and 2 trim of the ship.
3. recovery of freefall-lifeboat with crew of max. 4persons at a speed of 5m/min (winch) up to
5list and 2 trim of the ship.
Boat wil be turned out or swing in by A-fram. Hoisting and lowering by winch with two falls each for
one hoisting sling of freefall lifeboat.
Sheaves for falls leading out of polyamide and all bolts from stainless steel.
Davit arm as well as winch are powered by hydraulic power pack.
Max. working pressure is 200 bar. Overpressure of hydraulic power pack should be adjusted to
max. 220 bar.
Boat is secured in stowage position by hooks and lashing system.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, w-w-w.hatecke.de
1.4 Launching instruction
Freefall
The boat runs down the launching rannp and on hitting the water submerges briefly before
emerging and moving away from the stern of the ship.
The boat will clear the vessel irrespective of weather conditions or angle of heel. Instructions for
launching procedure on the following page.
Instruction of freefall procedure look at page 5, look also at the manual of the freefall-lifeboat.
Launching by davit
In some cases (shallow water, drift-ice, drifting parts of the cargo) it is necessary to launch the
boat with max. number of persons by davit.
Instructions for launching procedure on the following pages.
Recovery by davit
Freefall-lifeboat with crew of max. 4 persons must be sailed astern under the davit.
Instructions for recovery procedure at page 6 and 7.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(G)4143-915240, E-mail: email@Hatecke.de, www.hatecke.de
1.5 Free fall lamiching

Fasten seat belts.
CAUTION:
EMERGENCY RELEASE:
Operate only when mainrelease system is damaged.
Operate the emergency release pump (pos. 4). (After abt. 30 strokes the locking device will
disengage - the boat is now free.)
CAUTION:
Before replacing the boat in the launching ramp, the hydraulic piston should be brought back
into its housed position by opening the valve screw (pos. 3). After replacing the boat in the
launching ramp the valve (pos. 3) should remain in the open position.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone; 0049-(0)4143-9152-0, Fax: O49-{0)4143-915240, E-mail: email@Hatecke.de, www.hatecke.de
1.6 Launching and recovery by davit
(Under deck version)
Abb./fig.3
@(ii5)(jii2)
( A ) WINDE / WINCH
(5)DAVIT
Abb./flg.1
Abb./fig.2
:A
In
I Free fall launching:

Disengage the boat lashing on the platform and enter the boat - further more information for
launching inside the boat. (Look also page 1.5 of this manual.)
II Launching by davit:
The main switch on the switch board box (fig. 1 ) is switched on. Push in the green button
on the push button box (Fig. 2 ) - now the system is ready for work.
1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling.
2. Disengage the boat lashing on the platform and to the keel.
3. Tighten up the boat falls by winch (lever A fig. 3).
4. Swing out the davit to if s max. outreach (lever B fig. 3).
5. Lower the boat (lever A fig.3 ).
6. Disconnect the falls after the boat is waterborne.
III Recover of the boat (max. 4 persons on board):
The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding
ramp are disconnected.
1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling.
2. Lift on the boat (lever A fig.3) until the distance of the falls counterweights to the stoppers
is about 1 meter.
3. Swing in (lever B fig.3) the davit to ifs resting position.
4. Pull the boat with the winch (lever Afig.3) into it's resting position.
5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the
boat station and tighten up the falls by winch (lever Afig.3).
6. Attach the boat lashings.
7. Switch off the hydraulic unit - push in the red button at the push button box.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0Q49-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.7 Launching and recovery by davit
(On deck version)
I Free fall launching:

Disengage the boat lashing on the platform and enter the boat - further more information for
launching inside the boat. (Look also page 1.5 of this manual.)
II Launching by davit:
The main switch on the switch board box is switched on (must be switched on all the time of
course the heater inside). Push in the green button on the switchboard box - now the system
is ready for work.
1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling.
2. Disengage the boat lashing on the platform and to the keel.
3. Tighten up the boat falls by winch.
4. Swing out the davit to it's max. outreach.
5. Lower the boat.
6. Disconnect the falls after the boat is waterborne.
III Recover of the boat (max. 4 persons on board):
The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding
ramp are disconnected.
1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling.
2. Lift on the boat until the distance of the falls counter weights to the stopper is about 1 meter.
3. Swing in the davit to about it's resting position.
4. Pull the boat with the winch into it's resting position.
5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the boat
station and tighten up the falls by winch.
6. Attach the boat lashings.
7. Switch off the hydraulic unit - push in the red button on the switchboard box.
2.2 Hydraulic equipment

UNDER-DECK POWER PACK:
Power pack with service tank capacity of 90 Itr. is equipped
with fixed mounted starter box (400V/50Hz or 440V/60Hz)
for under deck mounting. All components are mounted to
the tank. Starter box allways shall be in ON-position.
To operate power pack push greenbutton of push button
box on deck. Pressure to hydraulic cylinders and winch
will be handeled by valve station on deck. Working
pressure 200 bar, max. pressure 220 bar should be
adjusted at valve station. Tank of power pack is filled
with hydraulic oil after ventilation of cylinders, winch
motor and piping system max. oil level should controlled
monthly. The water content of the oil has to be controlled
every month by opening the drain screw before starting
operation.
ON-DECK POWER PACK:

Power pack with service tank capacity of 90 Itr. is equipped
with fixed mounted starter box (400V/50Hz or 440V/60Hz,
IP 56) for installation on free deck. Most of the components
are mounted in the tank, under oil. Starter box allways shall
be in ON-position. Hydraulic unit is protected against
overheating. Pressure to hydraulic cylinders and winch will
be handeled by valve station. Max. pressure 220 bar
should be adjusted at power pack . The tank of the power
pack is filled with hydraulic oil after ventilation of cylinders,
winch motor and piping system max. oil level should
controlled monthly. The water content of the oil has to be
controlled every month by opening the drain screw before
starting operation.
mj
HYDRAULIC CYLINDERS:
The working pressure of the cylinders are 200 bar. They
are designed with a very high security with a test pressure
of 400 bar. The rod material is stainless steel, chromium
plated and super finished. Both cylinders are protected with
overcenter valves, which are directly installed in the
welded cylinder bottom.
HYDRAULIC WINCH-MOTOR:
The motor is also protected by an overcenter valve for
opening and closing the brake.
dît=i^
2.3 Hydraulic oil and lub plan

No. : Designation:
1
Hydraulic oil
Oil/grease type:
Quantity(ltrs.) Service:
Look at next page
look at
page 10a, b, c
Make oil control at the hydraulic power pack monthly.

Oil change after 200 -1000 - 2000 operation hours,
but at least every 5 years.
Check outside visually to leakage before each operation.
Oil change after 200 -1000 - 2000 operation hours, but at
least every 5 years.
Gearbox oil
Look at next page
look at
winch manual
Grease
Look at next page
I-
Grease after four weeks
Grease
Look at next page
1-
Grease after four weeks
Greasing of grease points and chainging of gearbox oil of winch should be carried out during docktime with basket.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: G049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: email@Hatecke.de, www.hatecke.de
2.4.1 Recommended oil chart
( winch 07.02.08, and 10.01)
RECOMMENDED OIL CHART

OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA
Ambient teperature for -25 up to +50 deg. C
EST Q T Y UNIT; L.O/SYS. OIL: LTRS.
GREASE: KGS.
No.:
APPLICATION POINT RECOMMENDATION

QTY/SET
SET/SHIP TOTAL/SHIP
hydraulic system
ISO VG 22 HLP
or VG 32 HLP
winch gear *)
O V G 150-200
wire fall
wire fall grease ace.

to lub-oil makers
standarts
10
10
chain
and
falls hook
grease with
EP additives
NLGI - class 2
2,5
2,5
90
a b L 2 / 3 , 5 *)
90
abt. 2 / 3 , 5 *)
*) = depends on winch type,look at winch manual.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4i43-915240, E-mail: email@Hatecke.de, www.hatecke.de
2 . 4 . 2 R e c o m m e n d e c l oil c h a r t
(ZOLLERN winch
4 20)

EST QTY UNIT; L.O/SYS. OIL: LTRS.
GREASE: KGS.
No.:

QTY/SET
hydraulic system
ISO VG 22 HLP
or VG 32 HLP
winch gear
ISO VG 220
wire fall
chain
and
falls hook
SET/SHIP TOTAL/SHIP
90
90
abt. 2
abt.2

to lub-oil makers
standarts
10
10
grease with
EP additives
NLGI - class 2
2,5
2,5
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fa.x: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
2.4.3 Recommended oil chart
(low temperature duty winch 07.02.08, and 10.01)

EST QTY UNIT; L.O/SYS. OIL: LTRS.
GREASE: KGS.
No.:

QTY/SET
hydraulic system
PLANTOLUB POLAR
POLAR 22S
(CLP E 22
to DIN 51502)
winch gear *)
ISO VG 629
wire fall

to lub-oil mal<ers
standarts
10
chain
and
falls hook
grease with
EP additives
NLGI - class 2
2,5
90
SET/SHIP TOTAL/SHIP
1
abt. 2 / 3 , 5 *)
90
1
1
abt. 2 / 3,5 *)
10
2,5
*) = depends on winch type,lool< at winch manual.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, ww-w.hatecke.de
done
remark
1. Visual inspection to ensure the system is ready to use.

2. Check adjusted overpressure (220 bar) of hydraulic power pack.
(Switch on power pack and hoist the davit arm against end position)
done
1.
2.
3.
4.
remark
Check oil level of hydraulic power pack.

Make sure there is no condensed water inside the hydraulic power pack.
Make sure there is no water inside the electrical box of the power pack.
Check adjusted overpressure (220 bar) of hydraulic,
(switch on power pack and hoist the davit arm against end position)
5.
6.
7.
8.
Operate the winch in order to sprincier all inner parts by oil.

Check the Lashing aft & fore.
Grease wire rope falls and chain fore runner.
Visual inspection to ensure that the system is ready to use.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-{0)4143-9152-40, E-mail: email@Hatecke,de, www.hatecke.de
1.2.7.3 Annual thorough examination (acc.toMsc.i/circ.i206)
By manufacturers representative or a person appropriately trained and certified by the manufacturer
annual thorough examination, when carrying out this examination the inspection of these
work to be done.
D a v i t : Examination and check for satisfactory condition and operation
1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

excessive free play.
2. Wires and sheaves, possible damages such as kikns and corrosion.
3. Lubrication of wires and moving parts.
4. Hydraulic system.
5. Hydraulic winch and winch foundation.
6. Dynamic winch brake test with empty boat.
7. Re-inspection of stressed structural parts.
according to manufacturer's checklist (Doc. no. 3001)
1.2.7.4 5-Years Overhaul & Testing (ace toMsci/circi206)
work to be done.
D a v i t : Examination and check for satisfactory condition and operation *
1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

excessive free play.
2. Wires and sheaves, possible damages such as kikns and corrosion.
3. Lubrication of wires and moving parts.
4. Hydraulic system.
5. Hydraulic winch and winch foundation.
6. Dynamic winch brake test with 1,1 times the weight of the Lifeboat and ist full
complement of persons & equipment, or equivalent load.
7. Re-inspection of stressed structural parts.
according to manufacturer's checklist (Doc. no. 3002)
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: emaii@Hatecke.de, www.hatecke.de
2.5.5 Overliauling and testing ace. to SOLAS Chapt.lll, Reg. 20.11.1
Ace. to SOLAS, Chapt.lll, Reg.20.11.1 following has to carried out with the davit system:
"Operationally test under a load of 1.1 times the total mass of the life boat when loaded with its full
complement of persons and equipment whenever the davit system is overhauled. Such
overhauling and test shall be carried out at least once every 5 years"
Overhauling of system has to be carried out ace. to requirements of class or national authority.
Testing with 1.1 times x GA:
After overhauling the davit system has to be tested with 1.1 x GA.
The winch brake of the davit system shall be of sufficient strength to withstand a dynamic test with
a proof load of not less than 1.1 times the maximum working load at maximum lowering speed (5
meters/min.).
Testing has to be carried out under supervision of class or national authority.
WARNING:
During operation of davit be cautious with long links, snap hooks and counter weights.

Note:
Date:
Name:

HATECKEP:";/
Please contact:

Am Ruthenstrom 1
Telefon: +49 - 4143-9152-60
Telefax: +49-4143-9152-44
wiring schedule
(in sea stored position)
S.W.L lowering
S,Wi. hoisting
( 22 persons) A640 kg
( 4 persons) 3290 kg
Non rotating galvanized steel wire

16mm dia.
Breaking load 150 KN
starboard side L =34100 mm
port side
L =32500 mm
LATFORM. LADDER AND

AILING BY YARD
1046
2. DECK
1. DECK
O
IXl
i_n
o
o
A P
vO
Part A
SCALE 1 : 2
POOPDECK
3
4
-frame spacing=700-
"T
8
150
-o^
Mk F,
Fy Mx
iNote
if not ottierwise stated, all weldings are Sbjnm
SECTION C-C
forces / momenfs
Fx (KN)
-91
136
Fz (KN)
122
Fy (KN)
19 bracket
a 250x250x6
18 cover plate pl.6 245x245
ST 3 7 - 2
17 longit. girder D 250x250x6
140
-12
16 spring washer
36
DIN 127 B
15
30
15
hex. nut M20
36
DIN 934
My (KNm)
25
12
14
hex. screw M 20x50
Mx(KNm)
60
13
hex. screw M 20x70
Mz (KNm)
17
27
hot. galv. steel DIN931-8.8

hot. galv. steel QlN93T-ffH
42
GL GRAD A
connection plate
62
GL GRAD A
connection plate
39
ST 5 2 - 3
connection plate
39
ST 52-3
11
material
pieces
SECTION B - B
hydraulic power pack / instalation materials
542
D65MH-33
51
D65ML-33
wire plan
146
DB65M-05
hydraulic winch
270
Type: 07.02.08
hydraulic cylinder
520
ZD/SGe 140/90, stroke 1178
bearings
800,5
DB65m-04
davit arm
1312
DB65M-03/DB65M-10
sliding ramp
1650
DB65M-02
lashings
PLATFORM BY YARD
1^
"7
SECTION E-E
SCALE 1 : 10
34
SECTION A - A
T-'^
ST 52-3
12 connection plate
10
5496.5
ST 52.3
SCALE 1 : 2
no.
usual name of part
weight kg note / draw. no.-.

total weight -. 5497 kg
o
NDI
CO
CSI
It
CM
CM
14
hull no. XZ04-0420-25 added
062/07
14.0a07
U.M.
13
hull na lZ-0415. JLZ04-04T7 * 19 added.
124/06
23.06.06
S.T.
12
distance from d ship to d slidhg ramp dianged from 7155 to 7205
057/06
13.0106
U.M.
11
hull no. 1Z04-0416 added.
009/06
13.0106
S.T.
10
huU no. JD1100TEU-9/10 added.
241/05
17.10.05
S.T.
Length from the steel wre corrected.
22V05
07.09.05
S.T.
hull no. JLZ04-409-14 added.
194/05
13.07.05
S.T.
hull no. KA 401-405 of Kouan S.Y. cancelled
080/05
Ot03.05
U.M.
,__-,
Chain-links removes after JD1100TEU-6. Breaking load corrected.
055/05
03.02.05
S.T.
.^l-^.
hull no. JLZ04-0403*04 added
035/05
25.0105
U.M.
hull no. 1Z04-0401/02 and KA 401-05 added
295/04
nit04
U.M.
hull no. JD1100TEU-5/6/7/8, XZ04-0403-0408 added,
241/04
30.08.04
U.M.
Pos.3 altered. Weight tered.
126/04
OS05.04
S.T.
113/04
23.04.04
([ OF LAUNCHING RAMP
250
o
LH
04
oo,
300
vO
x:
c/i
hull no. added. Weight fron Pos. 6 corrected.
E
a
t
REV. ALTERATION
S.T.
EXECUTED
ALT. No. DATE
EXAWNED
NAME
\s\
CD
CSI
DATE;
- JLZ03-0401-04 at JINLING S.Y

- JLZ04-0401 ^ 25 at JINLING S.Y.
- JD1100TEU-5.10 af jangdong S.Y
-313^315 of Aker Tulcea S.Y.
DRAWH
17.03.04
EXAM}.
/rjs'io^
SCALE:
DOCUMENT TITLE:
1:25/1:10/1:5
1:100
NAME:
ERNST
041A3/9152-0
143/9152-40
emalHarecke.de
wwwhMeckede
HATECKEI
D-21703 Drochtersen . Gainany
"T
FFA 6.5 M
GENERAL LAYOUT FOR HULL JLZ01-0104-07 AT JINLING S.Y.
OOOJMthi (<0
D65MG-33
{D65MG-20)
Hydraulic winch O.VKNm

Winch type; 07.02.08
6 hex. screws M20x55,
DIN 933, galv. s t e e l 8.8
6 spring washers, B22
DIN 127, galv. steel
6 hex, nuts M20
DIN 934, galv. steel, 8
r7>,U^,,rr.
?:;';'I,,
,'fh'f/'/>Thh^//,hh'zzzss:s
<^"'i'<'<"i'^-,hh'^'/,h>^
.1
>.U^^.U^^JJJ:gs^,?Z/-^-^f-/^^-^f-z^->-^.^:,^,\.\.
. .1.1.1,1, . .1. .1. .1,.
iM-^,)j.j^,
J
neu
Jz
IX1.1 wi
^^^:%M.
Schnitt
Washer PA 6G
Weight: 0,31 kgs
section
UUmittHHI^WUHuu.LU.u,|.^^^l,^^;,^^^^^^^^,,^^
'""
,uux..,^..,^n^
Counter weight: lead

Weight: 30,0 kgs
R+V Draw, RV05039-0
Pressing clamp
DIN 3093
Nan rotating galvanized steel wire

16 mm dia.
Breaking load 150 KN
Length starboard 34100
portside
32500
Total weight: 79,92 kgs
ai)
CO
OD
04 O
LH
Pressing clamp
DIN 3093
O
ON
,1
SWL lowering (22 persons) 4725 kgs 2365 kgs each side
SWL lowering (4 persons) 3375 kgs i690 kgs each side
length 792 mm changed to 710 mm
010/06
16.01.06
.M. ^
dimension between pressing clamps changed
086/05
09.03.05
U.M.
Chain replaces by steel rope.
049/05
02.02.05
S.T.
Counterweight corrects
011/05
17.01.05
S.T.
fork shackle, chain and snaphook changed from size 10-8 to size 13-8
213/03
30.06.03
U.M.
08.04.97
bearings
REV. ALTERATION
U.B.
EXECUTED
ALT. No. DATE
EXAMINED
NAME
Weight: 146 kgs

DATE:
Lifeboat snaphook, size 13-8, Code WA32S

WLL 5,3 to
Weight: 1,5 kgs
DRAWN:
02.12.96
EXAMINED;
y/P:^yf^(^
SCALE
DOCUMENT TITLE:
1:10/1:2.5
NAME:
U.B.
^ % ^
f A 6.5 M
WIRE PLAN
ERNST
HATECKEI
)g
0'H43/9152-0
04143/9152-40
emaRHatecke.de
www.halecke,de
Postfach 11 07 . D-21703 Drochtersen . Germany

DOCUMENT NO.:
DB5M-05
ai
"m
(T) Fore lashino :

One wire * 12 mm/1570 N/mm2 with thimble on both ends and a shactde 2.5t on one end and a
turnbuckle with strap on the other end. ( adjustment ring 13/22/80 )
(D(TlAft lashing :
One wire <t) 12 nim/1570 N/mm2 with thimble an both ends and one shackle 1.0t on one end
One wire 12 mm/1570 N/mm2 with thimble on both ends ...
on one end and a turnbuckle with strap. ( adjustment ring 13/22/80 )
m.
-m.
W-
ch
11
ip
11
10 fiull no. JLZ04-0420-25 added

fiull no. JLZ-0415, JLZ04-0417 ^ 19 added.
hull no. JLZ04-0416 added.
hull no. JD1100TEU-9/10 added.
hull no. JLZ04-409-14 af Jingling SY
hull no. JLZ04-0403^04 added
(fo
;1
062/07 14.03.07
124/06 23.06.06
009/06 13,01.06
241/05 17.10,05
194/05 13,07,5
080/05 01,03,05
035/05 25,01,05
295/04 11.11,04
hull no. J D 1 1 0 0 T E U - 5 / 6 / 7 / 8 , J L Z 0 4 - 0 4 0 3 - 0 4 0 8 added. 241/04 30,08.04
hull no. added.
113/04 23,04,04
hull no. J L Z 0 4 - 0 4 0 1 / 0 2 and KA 401-05 added
- JLZ03-0401-04 af JINLING S.Y.

- JLZ04-0401-25 af JINLING S.Y.
REV. ALTERATION
ALT. No. DATE
- JD1100TEU-5^10 al Jiangdong S.Y.
_5_
4
2_
1
no.
piece
17
o/
/o
part ident. no.
11
weights kgs
GL Grad A
GL Grad A
GL Grad A
stainless steel
stainless steel
steel hot galv
material
dwg na: DADLA-14

dwQ no.: DADLA-1A
dwg.no.: DADLH-14
note
S.T.
S.T.
S.T.
U.M.
U.M.
U.M.
U.M.
S.T.
EXECUTED
EXAMINED
NAME
Gewichf: weight: 51 kg
- 313^315 of Aker Tulcea S.Y.

lashing eye
lashings foundation
lashing hQol<, aft
fairlead block
lashing step
lashing hook, fore
usual name of part
S.T.
NAME:
DATE:
DRAWN:
23.03.04
EXAMINED:
x-^.gf^. (py^
SCALE:
DOCUMENT TITLE:
1:25/2,5
ERNST
HTECICE^^^
04143/9152-0
04143/9152-AO
emal@Hatecke.de
www.hafecke.de
D-21703 Drochtersen . Gertnany
FFA 6,5M
Lashing far hull JLZ 01-0104-07 at JINLING S,Y,
DOCUMENT NO.;
D65ML-33
ANLAGEN - DECKBLATT / SUPPLEMENTARY SHEET

ANLAGE / PLANT :
POWER PACK FREIFALL-SYSTEM-OD-12450
KUNDE / CUSTOMER :
HATTECKE
KOMM. NR. / SERIAL NUMBER :
STANDARD UNTEROEL 12450
AUFTRAGS NR. / ORDER NO. :

ZEICHN. NR. / DRAWING NUMBER
12450 El
BAUJAHR / BUILDING YEAR :
2001
SPANNUNG / VOLTAGE :
400/460V AC
FREQUENZ / FREQUENCE :
50-60HZ
STEUERSPG. / CONTR. VOLTAGE :
230VAC
NENNLEISTUNG / POWER :
10,5/13KW
NENNSTROM / NOMINAL CURRENT :
22,7/23.4A
r
nu
L J H Y D R A U L I K :
SYSTEME[_J
Hydrauliksysteme und Anlagenbau GnnbH
Handelshof 24
28816 Stuhr
Tel. 0421 - 898989
Fox. 0421 - 89898-77
Art.Nr. 4292-2EL
BEMERKUNG :
OHNE UNSERE VORHERIGE ZUSTIMMUNG D5RFEN DIESE SCHALTUNTERLAGEN
WEDER VERVIELFZLLTIGT; NOCH DRIHEN Z U G 2 N G L I C H GEMACHT WERDEN UND SIE D5RFEN
DURCH DEN EMPFNGER ODER DRITTE AUCH NICHT IN ANDERER WEISE VERWENDET WERDEN:
^
^
C^DESC^ i^
H V D R A U L_IK S Y S T E M E ' ^
DATE
DRAWN 12.02.01
CHECK
APPR.
NAME
F.R
TITLE
ANLAGEN
SH.
'1
- DECKBLATT / SUPPLEMENTARE SHEET
OF,
Fl
LI L2 L5
Kl
PE
717
PE
FiTIx
o
hQ.
F2r"Ix
F3[Ix
SUPPLY
400V/50H2
460V/60HZ
REV DATE
NAME DESCR. OF REVISION
HYDRAULIK UNIT
EL-MOTOR 10,5kW
13,0KW
^ H V D R A U l _ I K - i i r S T E M E CJ
DATE NAME TITLE

DRAWN 12.02.01 F.R
HYDRAULIC UNIT
CHECK
^
MAIN _(CUIT
APPR.
THERMISTERSCHUTZ
MI
PROJ.
DRAW.-NO.
JOB
12450E2
SH.2
OF 4
REV.
L4
95
F2
Al
F2
96
T>
T i ' T2
A2
XI
XI
3
4
<>Q
S16
Fl
F2
Vi
CL
X
S17 E-\
F5
o
o
I
ro
K^
E2
rJL,X2
Al
K1I
L5
H1
A2
-O-
-o-
MOTOR HYDRAULIK PUMP
ANTI CONDENSAT HEATER
MAINS
DATE
DRAWN
CHECK
3 C- \ /I HA TC
ncTC-OD
r*cr
DC\/icirk
' ^ H Y D R A U L I K S Y S T E M E 1^
12.02.01
NAME TITLE
F.R
HYDRAULIC
UNIT
CONTROL CIRCUIT
THERMISTERSCHUTZ Ml
PROJ.
DRAW.-NO.
JOB
1 94.SnF.^
SH.3
OF 4
REV.
2 4
Q1
'J-NAV^ A
F3
K1\
2A
2
4
OW-MV
T1
100VA
115/230V
F4
0.5A LU
Fl
35A
o o o
OO
U V W PE
L I L2 L3PE
EL. MOTOR HYDRAULIC

10.5kW
13,0KW
SUPPLY
400V/50HZ
460V/60HZ
C ^
REV
DATE
NAME
DESCR.
OF REVISION
L4
L5
CONTOL VOLTAGE
230V AC
i^
V1H Y D R A U I - I K - ^ i K t - S T E M E LJ
DATE
NAME T I T L E
DRAWN 12.02.01 F.R
CHECK
APPR.
HYDRAULIC UNIT
MAIM CIRCUIT
PROJ.
DRAW.-NO.
JOB
12450E4
SH.4
OF 5
REV.
hydraulic hose dimensions
i [ hydraulic pipe dimemsions
062/07 14.03.07
hll no. JLZ04-0420-25 added
124/06 23.06.06 s.T.
hll no. JLZ-0415, JLZ04-0417 - 19 added.
009/06 13.01.06 S.T.
hll no. JLZ04-0416 added.
241/05 17.10.05 S.T.
hll no. JD1100TEU-9/10 added.
194/05 13.07.05 S.T.
hll no. JLZ04-409-14 added.
080/05 01.03.05 U.M.
hll no. KA 401-405 of Kouan S.Y. cancelled
hull no. JLZ04-0403+04 added
035/05 25.01.05 U.M.
length of Pas. 12a+12d changed
331/04 06.12.04 U.M.
hull no. JLZ04-0401/02 and KA 401-05 added
295/04 11.11.04 U.M.
hull no. JD1100TEU-5/6/7/8, JLZ04-0403-0408 added. 241/04 30,08,04 U.M.
hull no. added.
113/04 23.04.04 s.T.
ALTERATION
ALT. No. DATE
EXECUTED
EXAMINED
NAME
Gewicht: weight: 542
S t c k l i s t e Nr.: Bill of material no.: S 6 5 M H - 3 3
ERNST
IN ACCORDANCE TO CONTROL UNIT
CHECK TURNING DIRECTION OF WINCH
mit Bedienrichtung abstimmer

Drehrichtung der Winde
JLZ03-0401-04 at JINLING S.Y.

JLZ04-0401 ^ 25 at JINLING SY.
JD1100TEU-5^10 at Jiangdong SY.
313-315 of Aker Tulcea S.Y.
DRAWN:
22.03.04
EXAMINED:
/f5'.'^.^y
SCALE:
DOCUMENT TITLE: p p y \ ^ ^ 5 ^
1:25/1:10
HATECKEiP^
D-21703 Droctitersen . Germany
HYDRAULIC PLAN FOR HULL JLZ 01-0104-07 at JINLING S.Y.
]
\M
j
]
04143/9152-0
04143/9152-40
eniail@Hatecke.de
www.hatecke.cte
DOCUMENT NO.:
D65MH-33
Teilenr.
Werkstoff
Bemerkung
piece usual name of part
part ident. no.
material
note
Z27/200-110F 3-lO-GD-Ha
Nr.
Anz.
no.
Benennung
power pack with switch

board box 440V/60Hz
2
3
4
5
hydraulic cylinder
winch
pipe dia. 16x2
Gewicht
kc
weight
Q=32 Itrs/min
508
(oil incL)
p=200 bar
p=12,6kW
tank capacity=90 Itrs
/
/
/
7a-r
8 8 screwed coupling
9 2 T-screwed coupling
10 22 pipe cleat with welding
11
12a- d
13
fitting and screw dia. 16

hose cleat with welding
fitting and screw DN 12
hose dia. SN-12x
(270)
10
3
2
look at chart on d vg. 10
Continental AC/Uniroyal
F^ 70x15
ST 37
power pack foundation
12 hvdr. cylinder changed to ZD/SGe 140/90-1178
11
10
8
7
6
hull
hull
hull
hull
hull
5
4
3
2
1
no.
no.
no.
no.
no.
(520)
ZD/SGe 140/90-1178
Niro Cr 1/2"
type: 07.02.08
X5CrNi18 9 look at chart
seamless
on drawing
G 16 PS
T 16 PS
RA 16
JLZ04-0420-25 added
JLZ-0415, JLZ04-0417 ^ 19 added.
JLZ04-0416 added.
JD1100TEU-9/10 added.
JLZ04-409-14 added.
(7)
JLZ03-0401-04 at JINLING S.Y.

JLZ04-0401-14 - 25 at JINLING S.Y.
JD1100TEU-5-10 at Jiangdong S.Y.
313^315 of Aker Tulcea S.Y. ^ ^ . .
071/07 21.03.07 u.M.
062/07
124/06
009/06
241/05
194/05
14.03.07
23.06.06
13.01.06
17.10,05
13.07.05
U.M.
S.T.
S.T.
S.T.
S.T.
080/05 01.03.05 U.M.
hull no. JLZ04-0403+04 added
035/05 25.01.05 U.M.

hull no. JLZ04-0401/02 and KA 401-05 added
295/04 11.11.04 U.M.
hull no. JD1100TEU-5/6/7/8, JLZ04-0403-0408 added. 241/04 30.08.0^ U.M.
hull no. added.
113/04 23.04.0^ S.T.

EXECUTED
ALT. No. DATE
REV. ALTERATION
EXAMWED
NAME
Gewicht: weighh 542 kg

DATE:
ERNST
NAME:
DRAWN:
22.03.04
EXAMINED:
2Z.<P7.^?-
SCALE:
DOCUMENT TITLE: p p ^ 6 , 5 M
S.T
^
FS
HATECKEiV"V
^
04143/9152-0
04143/9152-40
email@Hateckde
wwwJiafecke.de
D-21703 Orachtersen . Germany

440V/60HZ
HYDRAULIC PLAN FOR HULL JLZ 01-0104-07 at JINLING S.Y.
[ DCUMENT NO.:
S65MH-33
DMF-07
OPERATION AND MAINTENANCE MANUAL

FOR
WINCH
TYPE: 07.02.08
ERNST
il
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-{0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
EDITION: 09/06
Index
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5.1
1.1.5.2
1.1.5.3
1.1.5.4
1.1.6
1.1.7
1.1.8

Specification
Drawing
Part list
Weekly inspection
Monthly inspection
Annual thorough examination (ace. to MSC.1/Circ.1206)
5-Years overhaul & testing (ace. to MSC.1/Circ.1206)
Grease and service points
Oil chart
Orderform for spare parts
Additional: gearbox manual
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de

READ THIS MANUAL BEFORE USING THESE WINCH..
This manual contains important safety, operation and maintenance information.
Make this manual available to all persons responsible for the operation, installation
and maintenance of these winch.
A WARNUNG
Do not use this winch for lifting, supporting, or transporting people or lifting or supporting loads over!
Always operate, inspect and maintain this winch in accordance with the Eropean Machine Derectives
and any other applicable codes and regulations.
Make sure that their are minimum 3 layers wire rope on the winch drum before lifting!
Check the wire rope cleats on winch drum for tightness!
During operation of the davit be cautions with long links, snap hooks and c o u n t e r w e i g h t s !
D O N O T put your hands on snap hooks, long links, c o u n t e r w e i g h t s and falls with tension on this parts!
Always keep hands and feet clear near moving and rotating mashineryl
Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
1.1.2 Specifications
line pull second layer
speed
capacity
hydraulic motor
gearbox
brake
flow
pressure
hoist
lower
winch type: 07.02.08
44 KN
48,5 KN
5 mtr/min
dia. 16 in 2 layers
MB 100
ED2065MN or RE 812TS 31.6
FL 635 or FL 75
22 l/nnin
170 bar
Boatyard Emst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
1.1.3
Drav\fing
^
5 < -
CD
O)
CD
CL
C
O
CD
î
O
^c/)
_^
,i _ .
m
CL
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-maii: email@Hatecke.de. www.hatecke.de
CD
3
>
3
Nr,
An2.
no
piece usual name ut pari
1
1A
IB
1C
ID
2
2A
2B
2C
2D
2E
2F
3
1
1
1
1
1
1
1
2
6
6
6
6
1
i,
AA
i,
5
5A
5B
5C
SD
6
7
8
9
10
11
1
1
2
1
2
1
Benenliuncj
Bemerl^yng
Gewicht
Nr.
Anz.
Teilenr,
Werksioll
Bemerkung
nole
weight
no.
piece usual name ol pari
pan ioeni, no
malerial
nole
12
13
24
DIN 125
ST, galv
SBST
SBST
SBST
SBST
SBST
SBST
SBST
SBST
wincli sidelrame pl,20.0

winch sidetrame pl20.0
winch midtrame pl,150
bearing foundation
bearina support pl,20,0
baseplate pi, 20,0
bracl<el pt,10,0
hex. screw, M20 x 60
Grade
523
Grade
Grade
Grade
Grade
Grade
Grade
A
pipe 267,0 X 20,0
12
hex, nut M14
14
15
Dynamic Dil
hydro-drive MSS10D or PARKER MB 100

hydraulic brake FL635
allemali.el, ^ ^ ^ ^ . ^ ^ ^ ^ ^^^^^^
16
17
18
19
20
BREVINl
^^ Q ^ 2 T S 31,6 F 2 4 A 2 5
RANDER + CO
BREVINl
Dynamic Dil
p,^ 7 5
BREVINl
RANDER * CD
adaptor tlanoe
1
overcenter 0MS-60L or PARKER MB 60L
conneclion Hange FR065
shaft cover RDF065
RANDER * CO
RANDER CO
hydraulic
RANDER * CD
l u b e PHD
(A
round 0 2 0 0
A
A
A
(D
D 15 X 15
INA PME60
galv.
galv.
galv.
galv.
galv.
ro
b
n
8
7
PDS.13 und 15 gendert.
153/05 20,05,05 U.B.

12,02,59
F.H.
Seilklemme auf Mitlelflansch versetzt
153/05 20,05,05
62/99 1202,99
U.B.
62/99
8
7
Pos,13 und 15 gendert.
Seilklemme auf Milleltlanscl'i versetzt
Pos. 3 (Passung g6)
135/98 13,10,98
D.t^.
Pos, 3 (Passung g6)
135/98 1310,98
U,M,
POS SEr ON M u s 185; POSJA'SA SECTCNS COMPLETED

Pos^ aut Radius 185 Desetzl.Pos2A*5A Schnitle erweiterl
09,12,97 KKleine
POS, SET ON PADllS 165 ; P0S2A.5A SECTIONS COMPLETED

Pos, aul Radius 185 aesel?I.Pos2A*SA Schnille erweiierl
P0S,5 CHANGED.POSI TAKEN Off
15,09,97 IKleine
/,
24,06,97 iKleine
07,05,97 KKleine
1612,96 KKleine
3
2
1
Pas 9 qeanderl.PDS 10 tierausnenomfên

MLASURL CHANCLO FROM 20 10 35 P0S.5D
Ma von 20 aul 35 qeanderl P0S.5
HYDR0-M0TOP.GEAl?,BfiAKE,0vERCEN[ER TURNEO
Hvdro-Motor.Gelrietje.Bremse und Overcenter aeretit
m. 1A LENGTH EHA(Et),P(K,l8.Er,!A Itv
PLANES,P0S5A WJLDHG PPEPAR.SE. C-C
POS lA Lance ueanderLPDSIBCiA.SA Flachen ar<iesn.PDS5A Kanlenvorher.SclYiill C-C
REV, ALTERATION
ALT, No,
EXAMNED
[XKUIED
DATE
nut
corresponding drawing : Vi66M-02
RAWM
washer M14
gear E02065MN
Gewictit
kc
weigni
XSCrNi 18 9
SBST Grade A
DIN 933 - 8 8 ST,
ST,
DIN 125
DIN 912 - 8 8 ST,
\H 933 - 8,8 ST,
DIN 934 - m8 ST,
Benennung
allemaltel, ^^^^
A
A
A
A
A
A
SBST Grade A
DIN 933 - 8 8 ST, galv.

DIN 934 - m8 ST, galv.
hex nut M20
washer 20Fnm
ST, galv.
DIN 125
bearing shall
42CrMo4V
rope clamp
SBST Grade
inner hexscrew M10x30
DIN 912 - 8,8 ST, galv.
bearing-/drivefoi,indatiDn
SBST Grade
bearing/drivesupporf pl,20
SBST Grade
baseplate pi, 20,0
SBST Grade
21,
WerkstDlt
material
wincti
winding drum
holder f, hvdr,pipe pi, VO

distance piece
bearing case
hex, screw M16 x 40
washer 16[nm
inner hex, screw, 1^12x40
hex screw, MIA x 55
'.
/,
Teielir,
pan (Tent no
DAIEi
fJAMC'
12,0996
H.
Kleine
ERNST
2a
oû;)/9i5Z-o
HATECKEBPV^
ra
ef?j(@H3'BCki? de
^r .
r n
POS CHANGEOPOS TAKEN OFP
15,0997 iKleine
Pns9 neandert,Pos10 herausoenommen

MEASUISE CHAteO FROM 20 10 35 P0S5D
MaB von 20 aul 35 neanoeri PDS,5D
24,06,97 KKleine
HYDRO-MOTOR.GEAR.BRAKE.OVEPCENTER TUONEO
07,05,97 HKleine
Hvdro-Molor Gelriet)e,Brefnse und Dvercenler qedrehl.

Pas 1A LEIJGTH CIIANGB,P0S,,C,0,2A.5A NEW PLANES,POSSA wElE PfiEPAll,SL E-C
16,1296 KKleine
PDS 1A Lance qeSnderl,P0S,'B,ca2A,5A Flachen anqesD,P055A KanlenvorbecSchnill C-C
REV. ALTERATION
ALT, No,
^,
DXUMENT N,:
FFA 5,/ 66M
STEEL PLAN WINCH TYPE 07,02,08
DRAWN:
DATE:
NAME
12,09,96
H.
Kleine
r-i
^ ^ K/
EXAMftU
D-21703 Orothferseti. Germany

IXlEiUMENT TITLE:
091297 KKleine
cxEmiU)
DATE
EXMMD
NMC
corresponding drawing : V^66M-02
EXAM^
SCAIE-
F,H
SCALE:
ERNST
0A1V3/91G2-0
HATECKEMIV
FHM
emM@HatBCXi?dp
0 - 2 1 7 0 3 Dr-ocniersen , Germany
DOCUMENT TITLE:
r-f*
DOCUMENT NO:
FFA 5,/ - 6,6M
s W66M-02
STEEL PLAN WINCH TYPE 07,02,08
S W66M-02
Qualification level
By supervision of a senior ships officer in accordance with the infonnation provided by the
manufacturer.
done
remark
1. Visual inspection of the winch
1.1.5.2 iVIonthiy inspection
Qualification level
By supervision of a senior ships officer in accordance with the information provided by the
manufacturer.
done
remark
1 .Visual inspection of the winch.

2. Operate the winch in order to sprincler all inner parts by oil.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.5.3 Annual thorough examination (ace toMsci/circ 1206)
By manufacturers representative or a person appropriately trained and certified by
the manufacturer. Look at page 1.2.7.6 Authorized service stations.
work to be done.
W i n c h : Examination and check for satisfactory condition and operation *
1. Hydraulic winch & winch foundation

2. Dynamic winch brake test with empty boat
' according to manufacturer's checklist (Doc. no.0301)
1.1.5.4 5-Years overhaul & testing (ace toMsci/circi206)
By manufacturers representative or a person appropriately trained and certified by
the manufacturer. Look at page 1.2.7.6 Authorized service stations.
work to be done.
W i n c h : Examination and check for satisfactory condition and operation *
1. Hydraulic winch & winch foundation

2. Dynamic winch brake test with 1,1 times the weight of the Lifeboat and ist full complemen(t
of persons & equipment, or equivalent Load.
* according to manufacturer's checklist (doc. no.0302)
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
mounting side SB. Side view
view drive side SB.
0>
o
(S
>
3
30
mounting side SB. Top view
view drive side PS.
0)
(D
<
5'
(D
cD
u
O
pressure port
(/)
yearly
(@
Check oil level in the gear box of the winch

Check foundation bolts of winch
Change oil of gear box
5 yearly
j filling and breather plug
(r_j) brake breather plug
^ ^
oil level plug
( U ) brake oil level plug
^ ^
magnetic drain plug
( W ) brake drain plug
1 Brake releasing plug
t
3
O
3"
<
(D
O
b
b
00
1.1.7 Recomanded oil chart

OIL LIST FOR WINCH TYPE: 07.02.08
Ambient temperature -25 up to +50 C
EST Q T Y UNIT; L.O/SYS. OIL: LTRS.
GREASE: KGS.
No.:

QTY/SET
01
hydraulic system
02
03
winch gear
winch bral<e
04
grease points
05
ISO VG 22 HLP
or VG 32 HLP
ISO VG 150-200
ISO VG 22 HLP
or VG 32 HLP
grease with
EP additives
NLG! - class 2
SET/SHIP
TOTAL/SHIP
90
01
90
abt.2
abt.1
01
01
abt.2
abt.1
2,5
01
2,5
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-{0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.8 Orderform for spareparts for winch type: 07.02.08

No.
Description of the part
Page in manual:
No.:
Piece:
1
2
3
4
5
6
7
8
9
10
Building no. of boat:

Yard and hull no. of the ship:
Order address: r.
Hatecke Service GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-60
Fax: 0049-(0)4143-9152-44
E-mail: service@hatecke.de
vwww.hatecke.de
Invoice address:
Delivery address:
Requested time of delifery:
i-jmo
brewini
power
irangiuifsou
Division of Brevini Group
Manuale di installazione e manutenzione

Riduttori Gamma Base e serie "S"
wewtm
Installation and maintenance manual - Standard series and "S" series gear units
Notice d'installation et d'entretien - Rducteurs gamme standard et serie "S"
Installations - und Wartungshandbuch - Getriebe in Serienausfhrung und Serie "S"
Manual de instalacin y mantenimiento - Reductores gama base y Serie "S"
Manual de instalaô e manutenô - Redutores Gamma Base e serie S.
PLANETARY PARTNER
421IIII lir(;GIO I' Mn.l \ - II:,!} - \ n 11 ,1:111.1 14

'Ifl.^.WIlf22'j;i - SoLs Vi\ +.">it?21')l}i.'m
niiL +39 n22<>2K2r)i)
mtv.liri'Miii.iiin',
1irf\iiM^^lin-iiniJL
Lubrewana
riduori
PLANETARY PARTNER
1. INTRODUCTION:
1.1 How to consult the inanual
1.2 Scope of the manual
1..3 Warranty
1.4 General warnings
1.5 Reproduction and copyright restrictions
1.6 Revisions
2. TECHNICAL DATA:
2.1 Code description
2.2 Configurations
2.3 Versions of gear-coupling unit with active clutch safety systeni
Page
Page
Page
Page
Page
Page
Page
32
32
32
32
32
33
33
Page
Page
Page
Page
33
34
34
36
3. SUPPLY CONDITION:
Page 37
4. PACKING, HANDLING, RECEIVING, STORAGE:
Page 37
4.1 Packing
4.2 Handling
4.3 Receiving
4.4 Handling the machine witliout packing
4.5 Storage
5. INSTALLATION:
5.1 General instructions
5.2 Installation instructions fortlange moimted gear unit
5.3 Installation instructions for foot mounted gear unit
5.4 Installation instructions for shaft moiuited gear unit
5.4.1 Mounting the reacdon arm on the gear unit
5.4.2 Installing the gear unit with an FS outpiu
5.4.3 Disassembling the torque coupling and gear unit
5.4.4 Installing the gear unit with an FP output
5.4.5 Disassembling the gear luiit with an FP output
5.5 Installing the gear luiit type "RPR"
5.6 Installation instructions for gear unit-coupler assembly with active clutch safety system
5.7 Accessory installation instructions
6. START-UP OF AUXILIARIES (BRAKES - CLUTCHES- ETC.):

6.1 Negative multi-disc brake
6.2 Disk brake
6.3 Installation instrucons for gear unit-coupler assembly with active clutch safety system
7. LUBRICATION:
7.1 Gear unit lubrication
7.1.1 Viscosity
Page
Page
Page
Page
Page
37
37
38
39
39
Page 40
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
40
41
41
41
41
41
42
42
43
43
44
44
Page 44
Page 44
Page 44
Page 45
Page 45
Page 45
netmon
7.1.2 Additives
7.2 Expansion tank
7.3 Brake lubrication
7.4 Grease features
7.5 Lubricant table
7.6 Diagrams and oil checking with auxiliary cooling system
8. CHECKS:
Page
Page
Page
Page
Page
Page
45
46
47
47
48
48
Page 49
8.1 First start-up checks

8.2 No-load tests
Page 49
Page 49
9. MAINTENANCE:
Page 50
9.1 Routine maintenance

9.2 Oil Change
9.3 Unscheduled maintenance
Page 50
Page 50
Page 50
10.MAINTENANCE OF AUXILIARIES (BRAKES - CLUTCHES- ETC.):

10.1 Procedure to replace disks or seals for muki disc brake
10.2 Proceduie to replace disc brake pads
10.3 Maint. proc. for hydr. power pack on gear unit-coupler assembly with active clutch safety
system
11. SCRAP DISPOSAL:
Page 50
Page 50
Page 51
2.5.4 Installation instructions tor shafl mounted gear unit (see chapter 5.4)
2.5.4.1 Mounting the reaction arm on the gear unit (see chapter 5.4.1)
2.5.4.2 Installing the gear unit with an FS output
2.5.4.3 Disassembling tlie torque coupling and gear unit
2.5.7 Accessory installation instructions (see chapter 5.7)
2.6. START-UP OF AUXILIARIES

(BRAKES - CLUTCHES- ETC.): (see chapter 6)
2.7. LUBRICATION: (see chapter 7.)
2.8. CHECKS: (see chapter 8.)
2.9. MAINTENANCE: (see chapter 9.)
2.10. MAINTENANCE OF AUXILIARIES
(BRAKES - CLUTCHES- ETC.): (see chapter 10.)
2.11. SCRAP DISPOSAL: (see chapter 11.)
2.12. PROBLEMSAND RELATIVE SOLUTIONS: (see chapter 12.)
2.13. LEGISLATIVE STATEMENTS: (see chapter 13.)
2.14. SERVICE NETWORK: (see chapter 14.)
Page 41
Page 41
Page 52
Page 53
Page 44
Page 44
Page 45
Page 49
Page 50
Page 50
Page 51
Page 51
Page 159
Page 161
Page 51
Page 51
Page 51
Page 51
11.1 Machine demolition

11.2 Fxology information
12.PR0BLEMS AND RELATIVE SOLUTIONS:
Page 51
13.LEGISLATIVE STATEMENTS:
Pagel59
14. SERVICE NETWORK:
Pagel61
CxDOOCxDOOOOOOODOOOOOOOOOOOOOOOOCSO
2.1.
2.2.
2.3.
2.4.
2.5.
Installation and maintenance "S" series gear units

INTRODUCTION: (see chapter 1.)
TECHNICAL DATA: (see chapter 2.)
SUPPLY CONDITION: (see chapter 3.)
PACKING, HANDLING, RECEIVING, STORAGE: (see chapter 4.)
INSTALLATION:
2.5.1 General instructions (see chapter 5.1)

2.5.2 Installation instnictions for flange mounted gear unit (see chapter 5.2)
ridiMoti
Page 32
Page 33
Page 37
Page 37
Page40
Page 40
Page 41
rittutiori
1. INTRODUCTION:
Brevini Riduttori S.p.A. would like thank you for choosing one of its products and is pleased to include you
among its preferred Customers.
Tlie company hopes you will be satisfied when using
the gear unit.
1.1 How to consult the Manual

It is easy to consult this manual by referring to the table
of contents which can be used to find the subject of interest very quickly. The chapters are organized into a
hierarchical structure that makes it easier to find the required intbrmation.
1.2 Scope of the IManual
This manual provides the Gear unit user with all the
information necessary to ensiue correct installation, use
and maintenance in compliance with the safety restrictions set forth by current standards.
To understand this manual even better, we would like to
describe the following terms used in the document:
HAZARDOUS AREA: area within or in proximity to
the machine in which the presence of an exposed person represents a risk to the safety and health ofthat person.
EXPOSED PERSON: any person who is inside all or
part of a hazardous area.
OPERATOR: person assigned to install, operate, adjust, perform routine maintenance and clean the macliine.
SKILLED TECHNICIAN: a specialized person who
performs unscheduled maintenance or pairs requiring
special knowledge of the machine, its operation, safety
devices and relative operating methods.
ATTENTION: Operator accident-prevention

standards
I WARNING: The machine and/or its parts may be

damaged
o.
I PRECAUTION: Additional information regarding the operation being carried out

NOTE: Provides useful mformation
For any doubts or if the manual has been damaged or

lost, please do not hesitate to contact the BREVINI
RIDUTTORI S.p.A. Technical Service Department.
1.3 Warranty Conditions
BREVINI RIDUTTORI S.p.A. warrants that its products
shall be free from defects for a period of 12 months from
the date the product is shown to have been placed
in operation by original user and/or in any case tor a
period of maxunum 18 months from the date of shipment.
The warranty shall not be valid if the defect or not conformity will prove to be depending on not correct on
not suitable applications of the product, or if the product
has been luicorrecdy placed in operation.
Tlie warranty by BREVINI RIDUTTORI S.p.A. is expressly limited to the repair or replacement of the detected product, which is returned our factory after notification of failure, and thereafter if the product is found
by BREVINI RIDUTTORI S.p.A. to be, in fact, defective.
BREVINI RIDUTTORI S.p.A. shall not be liable for
any damages, either material or economic, resulting from
or caused by any defects. Brevini Riduttori S.p.A. will
only be liable for repair or replacement of the product.
The gearbox is intended to be used in suitable environment and for suitable applications in appliance widi what
has been foreseen at the moment the project has been
studied.
Improper use of the gearbox is forbidden.
Any change or replacement of machine parts, which has
not been authorized by BREVINI RIDUTTORI S.p.A.,
may represent an accident risk and therefore releases
the manufacturer from any civil or penal liabilities, and
makes the warranty unvahd.
1.4 General warnings
Personnel must be informed about the following subjects regarding macliine operating safety:
- Accident risks.
- D.P.I, devices designed to ensure operator safety (individual protection devices: goggles, gloves, hard-hat,
etc.).
- General accident-prevention rules or those set forth
by international directives and by the laws of the country where the machine will be used.
When dehvered, check that the Gear unit has not been
damaged during transport and that any accessories are

complete.
- Before standing to work, the operator must be familiar
with machine features and must have read this entire
manual.
1.5 Reproduction and copyright restrictions
BREVINI RIDUTTORI S.p.A. reserves all rights.
It is prohibited to reproduce all or a portion of the structure and contents of this manual, unless expressly authorized by BREVINI RIDUTTORI S.p.A.. Furthermore, it is prohibited to store such information on any
type of support (magnetic, magnetic-optical, microfilm,
photocopies, etc.).
2. TECHNICAL DATA:
Each gear imit is supplied with an identification nameplate and a manutacmre's declaration (as per the enclosure II B) which have been prepared according to EEC
dhective 392 and subsequent amendments. The identification nameplate contains the main technical data regarding tlie functional and construction features of the
gear unit. Therefore, it must always be visible and undamaged.
1.6 Revisions
Subsequent revisions of the manual will be issued as a
result of machine fimctional changes or replacements.
bwewinL
widfuon=
b=
1) Reduction ratio
2) Serial niunber
3) Type or gear unit/Gear tmit output
4) Year built
5} Gear imit input
6) Gear unit weight
REGGIO EWUA-ltoly
42100 Vh U.Degcla,14
Tel.0522-9281
TYPE OUTPUT
(i>
mpi
S.N.
DATE I r
'ml
lew*
::s2^^.
ifA.
)
IA Code description
Gear unit
family
llnM'iiiil il piio|llii<i
^ l l ' K il p i f l ' l l i l l
83
B6
B7
B8
2.2 Configurations
Hnii/onlalpoiilion
IU0-II90
\'i:rlical posinn
]^ll-8flll
o m 1190
ScnVI'OL
I'O-SOll
hLfi.' I ' l l l ,
V5
V6
B3B
V5B
V6B
B6A
V5A
V6A
B7C
V5D
V6D
B3C
B3D
B7B
B7A
B7D
BSB
B8C
B8D
V5
lUO
B3A
O l LEVEL PLUG
B3B
O
BREATHER END FILLING PLUG
V5C
5" AND 9" BRAKES
fl620 - fl635 BRAKES
B3C
k:ui
^
B 3 ^
V6
V6B
V5
MAGNETIC DRAIN PLUG
BREATHERAND FILLING PLUG
OIL LEVEL PLUG
BRAKE OPENING CONTROL COUPLING
_i L !'ik. L_
3. I.A.I J,
il if I It
V6
23 Versions of gear-coupling unit with active clutch safety system
3. SUPPLY CONDITION:
The exterior of the gear units are painted with a synthetic epoxy primer ("RAL 5010" blue), unless otherwise indicated in the contracts. Such protection can withstand normal industrial environments, including outdoor
sites, while additional synthetic top coats can also be
applied. If the machine will be used under particularly
aggressive environmental conditions, special types of
paints can also be applied.
The machined external parts of the gear unit, such as
the ends of the hollow and non-hollow shafts, support
surfaces, spigots, etc. are protected with rust-inhibitor
oil (tectyl). The internal parts of the gear unit casings
and drives are also protected with rust-inhibitor oil.
All the gear units, unless otherwise indicated in die contracts, are supplied without lubrication (as indicated by
a special adhesive sticker attached to the gear unit
to notify the user of such a supply condition).
4.2 Handling
Note: the weight shown on the nameplate does not include any accessories: such as brakes, motor flanges,
wheelflanges,etc.; consequently, to obtain the gear unit
+ accessories total weight, please add, depending on the
gear unit size, a max approximate extra weight of 40
kg. for input accessories; for output accessories, please
calculate a max value equal to approx. the 8% of the
gear unit weight depending on the unit size.
4. PACKING, HANDLING,
RECEIVING, STORAGE:
( ~ ) BREATHERAND FILLING
^-^ PLUG
^
OIL LEVEL PLUG
0
M I MAGNETIC DRAIN PLUG

^
(o^ SOLENOID VALVE CONTROL
SOCKET
4.1 Pactdng
To move packages, use lifting equipment that is suitable for the type of packing and for which the capacity is
indicated on such equipment.
CIRCUIT PRESSURE GAUGE

SOCKET (1/4 Gas plug)
I Brevini Riduttori S.p.A. products are packed and

shipped in crates or on pallets, depending on the specific case.
- All Brevini products, unless otherwise indicated in the
contracts, are packed with wrapping that can withstand normal industrial environments.
Do not tilt or nun the package upside down while lifting or during transport.
^^^^^^
m,
If die packages are unloaded with a hoist and, in any

case, with a hook, make sure that die load is balanced
and for slinging use lifting accessories that are legally
certified. For packages shipped on pallets, make sure
that the lifting accessories do not damage the machine.
Before removing die machine from its packing

make sure it is solidly attached to die liftmg accessories
so that it cannot slide or flip over. Before handling the
machine, remove die wood blocks inserted in the packing
to keep it stable dmng shipment.
Lift the machine making sure the load remains balanced
during the various operations.
;*;; '-f^- X ^"'-ilfiSlSS-'":'';
4.5 Storage
WM
m-
If the packages are unloaded from a fork-lift truck, make

sure the weight is balanced on die forks.
While lifting and positioning the package, avoid any

violent impacts or bumps.
4.3 Receiving
I <S' si rj'tpt'ffr I?:T j : t*:*;f if _
If necessary, place wooden wedges under the package

to make lifting easier.
4.4 Handling the machine without packing
When the Machine is receiving, make sine the supply

corresponds to what is specified in die order. Also check
that the package and its contents have not been damaged during tiansport.
.-_P^
^:!!.L!..l!..l!,.!b.,..*S.Ji.
I The s&ap holding the product to the packmg is

sharp. It may hit the operator while the product is being
unloaded.
The packing must be eliminated as follows:
- use a pair of shears to cut the straps (warning: the
ends may hit the operator)
- cut or remove the external packing
- cut the internal strap (warning: the ends may hit the
operator)
- remove the machine from the pallets.
If die machine has been damaged or if tliere are any
defects or missing parts, immediately notify the 13REVINI RIDUTTORI S.p.A. Service department; Tel.
++.19-522-9281, Fax ++39-522-928200/928300.
^'l
N'
vm
ii 11 ''i 't
i' !it"!l
l(i' II
Us 111
\
3*11. _ - - ,
If the product must be stored for more dian 2 months,

do the following:
- Protect the shafts and the spigots with a film or grease
and/or nist-inhibitor liquids
- Completely fill the gear unit and any muhi-disk brake
with suitable oil (see tparagraph 7.4)
-Store the machine in a cool place at a temperature ranging from -5C to +30C
- Protect the packages against dirt, dust and moisture.
NOTE: For extended storage of more than 6 mondis.
the rotating seals will no longer be efficienl. It is recommended to check them periodically by turning the
internal gears by and rotating the input shaft. For a negative muhi-disk brake, release the brake by using a hydraulic pump or similar device (see paragraph 8.1 for
the brake opening pressure). It is recommended to replace the gaskets when the machine is started.
leys, belts, etc., according to the ciurent safety standards in force in die country where die machine is used.
- For Gear units installed outdoors, use rust-inhibitor
paint and protect the oil guard and relaUve sliding guides
with water-repellent grease and provide protection
against bad weadier.
Note: BREVINl RIDUTTORI S.p.A. advises against
filling its products with oil prior to installation
Do not stacks pieces on top of each other.

Do not walk on or place pieces on top of the package.
- If possible, insert wooden wedges between the package and the floor.
5. INSTALLATION:
Do not store any material mside the package.
Deep the package away from any passage areas.
5.1 General instructions

Install the Product carefully following the steps listed
below:
- When installing the Gear unit, make sure the oil, breather, level and drain plugs are in the correct position. Their
position will vary according to the assembly position
(see paragraph 2.2 Configurations).
_ If the gear unit is supplied in the multi-disk brake configuration, make sure that the brake oil, breather, level
and drain plugs are in the correct position?. Their position will vary according to the assembly position (see
paragraph 2.2 Configurations).
- The brakes in general must be correctly comiected to
their specific control circuits and, for hydraulically controlled brakes, they must be bled like the hydraulic circuit.
- When installing RPR or MDU series gear units, be
very carefiil not to damage any grease pipes or those
used to empty the oil in the gear unit (located on the
side of the gear unit suppon). They should be positioned
so that it is easy to access the grease gun and any oil
expansion tank (during installation protect the pipes and
the tank).
- The Gear unit is normally supplied with a flange for
couphug die electric, hydraulic and air motors.
- The customer is responsible for installing suitable
guards for the input shafts, as well as coupHngs, pul-
msnssEimm:^SFf\
rj'
ti
5.2 Installation instructions for flange mounted gear

unit
-They must be attached to a rigid structiu-e with a clean
support surface that is perpendicular to die drive axis.
- The spigots and die coupling surfaces of the gear unit
must be clean without any dents. Tlie checks described
above are particularly important ensure perfect alignment between die driven shaft and die output shaft of
the gear imit. This is even more important tor gear units
with a splined fermale output shaft which cannot bear
any radial or axial loads.
- Lubricate all die spigots of die gear unit and die housing seat with grease or oil.
- After having inserted the gear tuiit mto its housing and
having placed it in the correct position, fit the reference
pins in their seats, then tighten die attachment bolts (recommended minimum class 8.8), applying torque as indicated in the table "torque setng" paragraph 8.1, making sure that such torque settings are compatible with
the other parts (nuts and/or strucUue).
NOTE: It is recommended to use class 10.9 or 12.9 bolts
where the application involves severe impacts, frequent
stops, starts, reversals or when it exceeds 70% of die
maximum tolerated torque.
NOTE: Diuing installation, for right angle gear units
with a male input shaft, the input axis may not be in the
ideal position.
To solve this problem, it is recommended to do the following:
- for connections using couplings which can compensate for the misalignments, measure die existing misalignment, check the acceptable misalignment from the
couphng and, if die value is greater, shim the motor to
obtain the acceptable clearances
- for a connection with mechanical devices that caimot
be used to compensate for the clearances, align die mo.r^\
L'>
Is p.
tor using .shims.

5 J Installation instructions for a foot mounted gear
unit
- Make sure diat die assembly feet rest on a flat siuface.
If not, shim diem so that all are level.
- An improper support for the feet may break die unit.
- Attach the unit using bolts with a minimum class 8.8
tightened at the torque settings indicated in paragraph
5.4 Installation instructions for a sliaft mounted gear

unit
Particular attention is required when installing these gear
units, therefore follow the mstructions described below.
5.4.1 Mounting the reaction arm on the gear unit
- Check that spigots of the gear imit and die reacdon
arm are clean, not dented and that there are no traces if
paint.
- Lubricate the couplings and insert die reacdon arm on
the gear imit spigot, dien insert any dowels.
- Attach the reaction arm using minimum class 8.8 bolts.
- It is recommended to use class 10.9 or 12.9 bolts where
the application involves severe impacts, frequent stops
or starts, reversals or when it exceeds 70% of the maximum gear unit torque.
- Check that the reaction arm anchor system does not
lock the gear unit, but allows it to movefi-eelyin space
in order to absorb the movements imposed in it by the
shaft.
For torque settings refer to the table "torque setting"
paragraph 8.1, making svu-e diat such settings are compatible widi die odier parts (nuts and/or attachment suiictures).
5.4.2 Installing the gear unit with an FS output
NOTE: the connection couplings are supplied ready for
installation, dierefore they need not be disassembled
prior to the initial installation.
- Slightly unscrew three bolts of die torque coupling
located at 120 undl die mner ring can just be turned by
and (excessive tightening might deform the inner ring).
- Insert it above the shaft of the gear unit whose external surface was previously lubricated.
"lUij I
Ei
' ^
.i!:i. i sj-aiii^SLii
'Sp.
i:dli]:l;31.J:L!l.
mtt.
'^1
wm
- degrease the internal surface of the gear unit shaft and
the machine shaft.
- Insert the gear unit on the machine shaft or vice versa
(excessive axial force should not be necessary).
- Position the center line of the coupling on the center
line of the useful section of the machine shaft (see fig.
No. 1). During
this operation refer to dimension
"a" which will
vary according to
the size of the
coupling, as indicated here in the
table No. 1
- Use a torque
wrench and gradually tighten all
the bolts in the
coupling in a circular direction (not diametrically opposed) until they are fiiUy tightened at a torque setting
corresponding to the value reported in the table No. 1.
- Check that the 2 rings remain concentric and parallel
while tightening, keeping in mind that the maximum
tolerated parallelism error is 0.25-()..35% of the external
diameter of the couplings.
NOTE: Excessive tightening may permanently deform
the inner ring, thus refer to the torque settings indicated
in the table.
5.4.3 Disassembling the coupling and the gear unit

- Gradually release the attachment bolts in a circular
direction. Initially each bolt must be backed off only a
quarter of a tum to prevent the attachment elements from
seizing and to avoid tilting.
- Remove the gear unit from the driven shaft. To do this
a hole on the gear unit shaft can also be used to pump
oil under low pressm-e so that it can be pulled oif gradually.
- remove the coupling from the gear unit shaft.
btfwtui
nuttoii
Table No. I
BolB
)iraensiun!
Disk type
dsh.
dxD
112
11
Type
Ma
SD62M
50
62x110
29
10
M6x25
12
17
SDIOOM
75
100x170
43
12
M8x35
29
30
S 125 M
90
125x215
52
12
M10x40
58
35
SD140M
100 140x230
58
10
M12x45
100
40
SD 165 M
120 165x290
68
M16x55
240
45
SDI75M
130 I75X.300
68
M16x55
240
45
SDI85M
140 185x330
85
10
MI6x65
240
55
SDI85H
140 185 X.330
112
15
M16x80
240
55
SD220H
165 220 X 370 134
20
MI6x90
240
67
SD240H
180 240 X 405 144
15 M20xlOO 490
72
SD280H
220 280x460
172
20 M20xl20 490
87
SD340H
260 340 X 570 200
20 M24xl20 820
102
SD 390 H
300 390 X 660 212
24 M24xl40 820
120
Ma = Torque setting Nm
5.4.4 Installing the gear unit with an FP output

- Insert the stop ring, if provided, in its housing on the
shat^pos.n"!.
- Grease the seats of the o-rings pos. N2 and 3 on the
cover ps.n4; tlien insert tlie respective o-rings in their
seats; then insert the cover on the shafl.
- Insert the other stop ring pos.n5, then the tongue pos.n6
in their respective seats on the shaft.
- Assemble the torque arm pos. N7 on the
reduction gear.
^
- Suitably Itibricate
both the
shaft and
its seat (reducti0n "
gear fern a 1 e
shaft); then
carry out coupling of the
shafl and the
reduction gear (do not force).
- Place the cover pos. n4, clamping it wii die screws
and the respective dowty wa.shers pos. u8 (supplied with
accessories), taking care to gradually screw the screws in
a circular direction (not in the diametrically opposite direction) imtil completely clamped using a torque given m
the "tightening torque" table, paragraph 8.1 (screw classes
8.8), by means of medium loctyte.
- Assemble all die other screws and relative dowty washers pos.n9 (omitting one at the top),insertftu'therlubricant in the hole which has been left open; then assemble
Ulis last screw as well to thus close the coupling in a lubricated hermetic chamber, by means of medium loctyte.
5.4.5 Disassembling the gear unit with an FP output

- Whilst suitably supporting the reduction gear free the
torque arm.
- Remove the screws pos.n9 replacing them with longer
screws, suitable for the room available.
- Remove the screws pos. N8; then screw the screws
pos. n9 gradually in a ckcular direction (not in the diametrically opposite direction) until the reduction gear is
unlocked.
WARNING: the dowty type washers in pos. N8 and 9
cannot be reused when reassembling the reduction gear
after repairs or any other type of operation; diey must
always be replaced with new washers.
5.5 Installing the gear unit type "RPR"
- The units must be fixed to a rigid structure and the supporting surface should be thoroughly clean, with no trace
of soldering waste, at right angles to the driving axes.
- The centring and coupling surfaces of the gear unit must
be clean and dent free.
The measures described above are essential for ensuring
perfect meshing between the gear pinion and die fifth
wheel.
Fiflh wheel constructors usually mark diree teeth of the
fifth wheel green; the point of major ovality of the pitch
0 used for positioning the gear unit.
ATTENTION It is advisable to contact die constructors
of the fiflh wheel direct if there are no coloured (usually
green) teeth on the fifth wheel, or other distinguishing
marks.
Painted leetli I
responding to die maximum meshing reached between

the pinion and the fifdi wheel; whether die gear unit is
placed inside or outside the fiflh wheel, (see fig.)
The value of clearance between the sides of die pinion
teeth and the fifth wheel, is obtained by multiplying the
value of the teethmg module by the two fixed values of
0.03 and 0.04.
Example: for teething of m=20, simply multiply 20 x
0.03 = 0.6 and 20 x 0.04 = 0.8, to obtain two
values of 0.6 and 0.8; diis means that the clearance of tlie sides of the teetli for perfect meshing
must have a value which falls between 0.6 and
0.8 mm., thus die gear unit is placed with die
notch in correspondence with the three coloured teeth, (usually green), of the fifth wheel,
tum die gear unit to move it clo.ser to the fifth
wheel, inserting die shim value as resulting
from the described calculation in the sides of
die teedi which are meshed widi thefifthwheel
or the pinion; dien clamp the gear unit.
Check the clearance between the sides at different points
around die pitch circle of die fiflh wheel a second time.
After having positioned the gear unit and checked die
situation, tighten the fixing screws (minimum recommended class 8.8) by applying a tightening torque as
shown in the "tightening torque" table, paragraph 8.1,
making sure dial they are compatible with their counterparts (nuts and;' or fixing structiue).
ATTENTION when positioning gear unit with eccentric, all the holes for oil level, load and discharge, engine controls, laminated brake etc .etc.- will be moved
out of place with respect to the "BREVINl" drawings.
If the gear unit is of the type with a rest and an eccentric

to regulate die clearance between die pinion and the ring
gear, then there should be a notch on die fiflh wheel (.see
fig.) which indicates the pomt of major eccentricity, cor
lidutiti
5.6 Installation Instructions for gear unit-coupler assembly with active clutch safety system
When preparing to install this kind of assembly, die first
thing to remember is that the whole internal drive is held
in place by the clutch on the assembly.
Consequently, if the output shaft doesn't rotate, it will
be difficult to install the assembly in its housing if the
gear unit fitting holes do not coincide with the holes in
the interface on the vehicle itself
To Ime up these holes, you have to release die clutch so
that the output shaft can rotate freely.
To do this, use a hand-operated hydrauhc pump, as the
clutch can be opened with a minimum pressure of 3 to 5
bar, then proceed carefiilly with the steps listed below:
(for the location of die symbols see chapter 2.2.1)
- lift the assembly with suitable lifting equipment and
fit the gear unit output shaft into its housing on the vehicle, keeping it supported all the ume and trying to mate
the fitting holes in die assembly with those in the vehicle.
- connect the hand-operated hydraulic pump to the assembly via the 1/4 gas hole
- power up (12 Volt) the solenoid valve on the on the
power pack so that the valve is excited.
- Using the pump, increase the pressure on the assembly slowly and gradually it can be rotated by hand.
ATTENTION: if the solenoid valve is not excited, the
hvdraulic pump simply pumps die oil into the assembly,
- at this point, the assembly can be rotated easily so as
to align the fitting holes widi the interface on the vehicle; this done, insert the pins (if needed) and attachment
bolts (recommended minimum class 8.8), applying torque as indicated in the "torque setting" table, paragraph
8.1, making sure that these settings are compatible with
the nuts and/or structure.
- if Ulis operation is performed with the gear unit output
shatl not inserted in its housing, it will be very difficult
to get the assembly fitting holes in phase widi die shaft
spline, and die only way to set the timing will be by
trial and error.
- After fixing the assembly in position, cut ofl" the cuirent to the solenoid valve, disconnect the hand-operated hydraulic pump and refit the 1/4 Gas plug.
5.7 Accessory installation instructions

Motor Assembly:
While assembling the gear unit on the motor, the coupling must be lubricated with a thin layer of grease or
with a no-grip lubricant.
Carefully insert the motor shaft in to the coupling and
make saie that die motor spigot perfectly matches the
gear unit spigot.
After checking iat the motor is properly centered, tighten all the attachment bolls applyng die torque indicated in the table "torque setting" paragraph 8.1.
Accessory Assembly:
To mount pinions, pulleys or couplings, use suitable
equipment avoid seizing. As an alternative, heat the piece
to80'=-100''C.
Lubricate the grooves with a thin layer of grease or a
no-grip lubricant and tighten attachment bolts applyng
the torque indicated in the table "torque setting " paragraph 8.1.
6. START-UP OF AUXILIARIES
(BRAKES - CLUTCHES- ETC.):
6.1 Negative multi-disk brake
NOTE: The negative multi-disk brake is used only as a
parking brake, or in special situation as an emergency
brake.
- Connect the fittings of the system hydraulic chstiit to
the brake control hole (see paragraph 2.2 "configuration") of all the gear units with these features uistalled
in the system.
- Pressiu'ize the hydraulic circuit and then bleed all
brakes. Slightly unscrew the brake control fitting, and
maintain pressure until only oil is expeloled without any
air. Then re-tghten die fitting.
6.2 Disk brake
- Connect the fittings of the system bralce circuit to tlie
brake control hole "A" (see fig. No. 2) of the brake clamp
located on the gear unit for all the gear units with diese
features installed in the system.
Bleed The brakes after mjecting oil into the circuit (remove the air from the brake circuit).
-At least two persons are needed to carry aout this operation.
NOTE: For the bleeding operation it is recommended,
after having removed the rubber guard of die bieder val-
mm
-1 i^
* ' .ia,.J..e.fe
I -gîr^
^-j
^-^T-J-
ve "B", to attach a piece of rubber hose with

a lenght of about 20 cm
to collect any oil into a
can Cwich should not
be doumped in the environment since such
oil is a major polluttant).
I t! t.1 ll !i I
7.1 Gear unit lubrication

The Brevini gear units are supplied without oil, therefore the user must the lubricant according to what is
indicated in the table shown in paragraph 7.4.
- Slightly unscrew (1
turn) die bleeder valve
"B" and keep activating the brake control until only oil without any oir is
expelled from the vlave. Immediatelly close the valve
and release the brake control.
NOTE: if oil not expelled the first time the brake control is aetived close the bleeder valve and release the
brake control. Then open the valve again and activate
the brake control and continue in this manner until only
oil is expelled.
- Repeat this operation for all gear units with these features installed in die system, then top-up die oil in the
brake circuit.
6.3 Gear unit-coupler assembly with active clutch safety system
- the hydraulic pump used by the power pack is reversible, thus guaranteeing the same constant pressure at all
times, regardless of the direction of rotation
ATTENTION: the pressure relief valve on the power
pack has been pre-set to the right pressure (25.S 2
barl It is absolutely forbidden to alter s valve setting.
- power up die solenoid valve with direct ciurent (12
Volt) via die socket on the power pack (see chapter 2.2.1
for location of symbol)
- to prime the hydraulic pump (after filling the assembly with lubricating oil), simply start the coupler PTC
rotating, as the pump is self-priming.
a.
3->f
h L i^
7. LUBRICATION:
r. iiili a.
45
Basic oil specifications

The basic parameters of the selected oil are:
- viscosity at nommal operating conditions
- additives
The oil must lubricate the bearmgs and the gears and all
these components work mside die same box, In different operating conditions. We will look at diese parameters one by one.
7.1.1 Viscosity
Nominal viscosity is referred to a temperature of 40 C,
but rapidly decreases with an increase in die temperature of the gear unit.
If the operating temperature is between 50 "C and 70
C, a nominal viscosity can be chosen according to the
following guide table, choosing the highest viscosity if
the highest temperature is foreseen.
n,[rpm]
50 C
70 C
>20
<5
<5
VG150
VG220
VG220
VG320
VG320
VG460
7.1.2 Additives
In addition to the normal antlfoaming and antioxidant
additives, it is important to use lubricating oils with addhlves tliat have EP (extreme-pressure) and antiwear
properties, according to ISO 6743-6 L-CKC or DIN
51517-3 CLP Clearly, therefore, products with stronger EP characteristics will have to be found for slower
gear unit speeds. It should be remembered diat die chemical compoimds replacing hydrodynamic lubrication are
formed to die detriment of the original EP load. Therefore, with very low speeds and high loads it is irnportant to keep to the maintenance intervals so as not to
diminish the lubricating characteristics of die oil excessively
..1?l
Checking the oil with non-forced lubrication
If the gear unit is fitted horizontally, the oil level should
be at the centre if proper lubrication is to be guaranteed
(see fig. 7).
ll%
If a gauge is titled tor checking the level visually (or by

means of an electrical signal), this must be fitted as shown
in the diagram in tig. 9. Position die breather cap above
the level mdicator, using a tube of the right length, connecting the upper (empty) part of the gear unit to just below the breather This will prevent oil from spilling out.
Fig. 7
Fig. 9
For applications with a very low output rotation speed
(n, < 5 rpm) it is advisable to fix the level at a value
higher than 50-100 mm (see fig. 8).
To check the oil level, simply use a transparent tube,
positioning it as shown in fig. 8.
If the output speed is extremely low (n^ < 1 rpm), or if
long gear unit downtimes are foreseen, it is advisable to
fill the entire casing. In this case, a special "expansion
tank" must be fitted.
ing phase) it is also posA.

sible to remove one of the
lop of the gear unit.
-As the oil rises to the top
of the open plug in the top
part of the gear unit, reH max
place die plug.
- Continuefillinguntil the
oil reaches the min. visual level plug on the tank
^ min
which should not to be exceeded to provide space
for the volume of the hoi
n"3
oil to expand.
- Replace the plug.
- With the gear unit running under steady-state thermal
conditions, and the oil at its maximum expansion temperature, never exceed the max. level.
- Run tlie gear imit for a few minutes to eliminate any
air pockets, then check the various levels.
Vertical in-line fitting and right-angledfittiii(!with expansion tank

Filing and level
- The gear units are equipped widi oil level, breatlier,
filer and drain plugs and their position changes according to the installation configuration.
- Check the exact position of the plugs using the diagrams on paragraph 2.2 "configuration".
- Unscrew the level-filler plugs, put oil into the Gear
unit and when tliis oil flows out of the level hole, replace the plugs.
- In the RPR or MDU series, one of the support bearings must be lubricated with grease, using the grease
gun located above the gear unit attachment tlange, and
using a generic type of grease with the features indicated in paragraph 7.3.
- The lubricant oil used in the gear imit-coupler assembly with active clutch safety system is the same as the
oil used in the clutch pump.
- Turn the gear luiit a few times to eliminate any air
pockets and then check the various levels.
7.3 Brake lubrication

Multi-disk brake
- The Brevini multi-disk brakes are supplied without oil.
- The user must select die lubricant features.
- To lubricate the multi-disk brake unit, Brevini Riduttori recommends using mineral oils with enhanced heat
and aging resistance and viscosity ISO VG 32. with a
viscositv index greater than or equal to 95.
- Hydraulic oils are suitable, in general.
Multi-disk brake filling and level
- The multi-disk brakes are equipped with oil level, filler and drain plugs and their position changes according
to the installation configuration.
- Check the exact position of the plugs using tlie diagrams on page 7.
- Unscrew the level/filler plugs, put oil into die brake
and when this oil flows out of the level hole, replace the
plugs.
- Turn the brake a few times to eliminate any air pockets and then check the various levels.
Disk brake
- Disk brake do not require any lubrication.
7.4 Grease features
Type of soap:
Consistency:
Base Oil:
Additives:
Viscosity index:
Pour point:
stearaie hydroxide lithium 12 or

equivalent
NLGl No. 2
Mineral oil widi viscosity from
100to320cSTat40C
Rust inhibitors
80 Minimum
-10 C maximum
Fig. 8
7.2 Expansion tank
ATTENTION: make sure the expansion tank is installed
higher than the top part of the gear unit.
For apphcations with an expansion tank, do the following: (see figure 3).
- Remove the plug "A"
- To enhance gear unit ventilation (only diu-ing the fill-
I'^^r.'.ZT',..'.
r,|j.HM'
.-;f I1. iry.k,K...LL,.i.fc.-:,-,
-ipitii ^~^: f'r^-".....!"...y^..li!!,.!M[l
'~n m a i m 1.1.,}=.
v-' '!;i.li...!liljil..i
h'ii li P' ' f'~ i'-''
I jixj.. .f.y...!
I...?..:
liduUoti
7.4 Lubricant table
ISO VG 150
Mineral
ISO VG 220
ISO VG 320
Blasia 150
Blasia 220
Blasia 320
DrgolBGlSO
Digol 6 0 2 2 0
Drgol BG 320
Encrgol GR-XP 150 EncrgolGR-Xf 150 Eneigol GR-XP 150
Alphaniax 150
Alplianiax220
Alpharnax 320
EagrajiajesHPlSO ngTanajesHP220 nsrjnajesllP320
FalcimaPlJO'
falcon C i f 220
falcon Cl.f 320
Agip
Aral
Bf
Caflrol
Cepsa
Dea
Elf Lub.Marillt:
Esso
Fachs
Epoija 1 150
Epoiia Z 220
Eporia Z320
Spartan EP 150
Spartan EP 220
Spartan EP 320
Kcnep Compound l(J4 Rcnqi CoinpouDiJ 1(J6 Itencp Compountl lO
Lubricant
Agip
Aral
Bel-Rav
1SOVG32
RDColFoodlubeHlpowa32
uralHvii32
No-TojllDHYdOil32
Hydnulic oils
ISOVG46
Eural I W 46
No-IoiHDllydOiH
Eural llvd 68
Eaerpar M 32
EneiiiarM4fi
No-TMllDWOil68
EneiparM68
Kfnlonf
Lbr!calaOilfM32
NuloFCIl
NtV'istace SL 32
Lubricating Oil FM 46
NulofO
Nevastane SL 46
Lubricating Oil FM 68
NutofG68
Ne\'astane SL 68
BP
Chevron
Esso
Klbtr
SuiimitHvs\TiFG33
Sununit Hmil FG 46
Suirjnit Hysyii FG 68
Mil
Nib
l)ltfM32
Mizir]2
D1LFM46
Mizar 46
DTLFM6S
Mizar6S
Nils
Palelo
RDJTII Purple
Q8
Ripa'ss EP 150
Gei'llSTISO
OpiigearBMISO
Goya NT 150
Repsol
Shell
Texaco
Siiper Taiiio 150

Omala 150
Meropa 150
ptanol
TotalfinaElf
Tribol
CaiteiEf 150
1100-150
Labiicanl
ISO VG 150
Agip
Aral
Drgol PAS 150
RipicssEP220
Gear HST 220
OpligearBM220
Ripiess EP 320
Gear HST 320
pligearM320
Goya NT 220
Saper Taaro 220
Goya NT 320
Super Tauro 320
Omala 320
Meropa 320
lllala220
Meropa 220
Carter EP 220
1100-220
Synthetic
Carter Ef 320
ISO VG 220
Blasia SX 220
Dtgol PAS 220
ISO VG 320
Blasia SX 320
Optimo!
Shell
Texaco
Itibol
Lubricant
Agip
Aril
1100-320
Btl-Rav
ChevroG
Esso
Kcvsloac
Drgol PAS 320
OplilebllYJ2
OptiltbHy48
OptilcbHYSS
Ntn-liisOJHvljjlclSO); j-riiiOilll)dnuliclS04i \ii-lojOilll,ffliiciS06l
Paly-0nanlfDAJ2
Poly-Guard FDA 46
Poly-Guard FDA 68
Cassia Fluid llf 32
Cygnus Hydnidic Oil 32
food Pmof 1840(32
Cissida Fluid llf 46

Cj'gmLsHydnulicOiI46
ISO VG ISO
ISO VG 220
WfoidHitlllloiiitlSti
tiaa! Gear 150
No-roxS\n Gear 150
BP
Enenyn L \ P 15U
tt
Ne\'iftme EP ISO
Klberoil 4 UHlNliO
Castiol
Cepsa
Alphasyn E U 50
Mobil
DTE FM 150
Eiiersyn XP 220 EnersvnXP320

Alphasyn P 220
Alphasyn EP 320
EngranajesIlfXlSO EngianajesHfX230 Engianajes HPX 320
totorllCLP150
Dea
Inloi IICIP 220
Inlor HCLf 320
E!f LubMaiine
Epona SA 220
Epona SA 320
Spartan SEP 150
Esso
SpailauSP220
Spailan SEP 320
facLs
RHiohnmisjuCLPlia Riiiolinanis)naP220 Rcnalin Ulis CLP 32(1
fuchs Lubritcch OcannaslcrSVNISO Gcann;isicrSyN220 Geamiastei SYN 320
bersviilh EG 4-150 Klbereynlh EG 4-228 Klbcrsynlli EG 4-320
KIQber
Mobil
Nils
Omv
Optimol
Q8
Shell
Texaco
TlaltinalU
Tribol
MobEtiiSHCXkil'liO MobilceirSHCXMPlJO MobilstatSllCXMfls

Atoil synth 220
Gear SHG 320
Gear SllG 220
l^tiêars)TitlieIicA15 OptigearsmeticA 150 Optiieir siittic A liO
El Grcco 150
E.IGKC22
El Greco 320
Omala HD 150
Omala lU) 220
Omala HD 320
Pinnacle EP 150
Pinnacle EP 320
Pinnacle EP 220
tartciSHlSO
Carter 5U 22
Carter SH 320
1510-150
1510-220
ATTENTION: The gear units and any multi- disk

brakes are shipped without oil. The customer is responsible for fiHing such devices (see lubrication chapter paragraph 71.
IS0VG6S
Fachs Lubritcch GcaimMcraPlSO GeannastcrCLP220 GcannaslcrCLP320

Klher
KlheroilGEM 1-150 Klberoil OEM 1-220 Klberoil GEM 1-320
Mobil
MobilgeaiXMPlSO Mohilgcar.KMP220 Mobil(;carXMP320
Omv
ATTENTION: Given the type of brake, the operating

pressure should never drop below the minimum brake
opening pressure to avoid the braking action.
Table of lubricant oils suitable for alimentary use

(Approved according to USDA-Hl and NSF-Hl specifications)
Food Proof 1M046

Gear oils
Cissida fluid HF 68
CjgnusHydKulicOil68
I Food Proof 1840/6!
ISO VG 320
RocolIcHiltillTiti]it)20
Lurdl Gear 220

No-Toj Syn Gear 220
Lubricaiii{OilFM220
Gear Oil FM 220
Nevastane tP 2211
Kliiberoa4UHlN220
DTE FM 220
No-Tox S Gear 330
- Check that all the bolts with ISO metric threads are
correctly tightened (see table "torque setting values").
8. CHECKS:
8.1 First start-up checks
Values Tabic Torque Setting Bolts
Before starting the machine check the following:
- Check that all the oil plug are in the correct position
(see paragraph 2.2 "configuration").
- Check that all oil levels are correct.
- Check that all the grease guns are full of grease.
- Check that the operating pressure (see table on the
right) is sufficient to fully open the multi-disk brake to
avoid overheating and any prematiu'e wear of brake
disks.
Ripress Synt Food 150

Ripress Sjnt Food 220
Ripress S\nt food 320
Opliieb 01J20
Optunol
OptilebGIlSO
OptilebOT220
Piltlo
Non-Iox Oil Gear ISO 150 Nn-To,iOilGcailSO220 Non-Io.i Oil Gear ISO J29
My-GtianlFDAliO
Ply-GuaidFDA220
Ruval Purple
Polv-GuaidfDA320
Cassida Fluid GL 220
Sbtll
Cissida Fluid CL 150
Cassia Fluid GL 320
tVglUK Gear PAO 150
tVgmis Gear PAO 220
lexaco
Food Piool 1810)220
Tribol
Openint; pres.sure
(t ar)
Max.
Mill.
21
26
12
15
10,24
13,28
13,28
10,53
15,80
19,92
16,20
19,90
20,48
25,59
25,59
21,03
14,20
19,92
14,56
19,92
19,92
15,00
18,40
25,59
18,95
25,59
19,49
25,59
15,56
21,98
21,98
15,56
15,56
21,98
15,56
21,98
Type of brake
Nik
FL620/12
FL635/12
FL250.4C
FL250.6C
FL350.6C
FL350.8C
FL45.6C
FL450.8C
FL650.10C
FL650.12C
FL650.14C
FL750.10C
FL750.I2C
FL750.14C
FL96.I2C
FL960.I4C
FL960.I6C
FL960.I8C
Food Proof 1810/320
7.6 Diagrams and oil checking with auxiliary cooling system

Horizontal gear unit
See paragraph 7.1 for levels.
1510-320
Vertical gear unit

See paragraph n 7.2 for definition of levels, also for
right angle gear units
ÎHr|M|
j 1, ! ! il I I 1 1 ; |i fs I ! \
1M
Tyir
\ 'I
TJ
t ll
t
'l
tl I
'I Ij
ll!
ij
'I
11i
I
^
]
Static
torque
(Nm)
210
315
181
186
278
381
360
492
428
528
633
556
684
819
1019
1189
1359
1528
kN
Nm
kN
I.I
2,3
1,8
3,4
2.6
4,0
'2.7
4,1
3.1
6,0
4.5
7.0
Nm
3
5,3
4.4
6.7
6.1
9,8
8,9
11.5
10,4
6.1
6.8
9,4
104 13.8 15,3 16.1 17,9
9.3
9.0
11,5
13.7
17.2 202
25
23.6
13.6
11,5
16,8
17.2
25
25
37
30
12,2
18
18.9
27
28
40
32
18
33
27
50
40
73
47
kN
Nm
kN
3x0,5
1.2
0.9
1.5
4x0.7
2,1
1.6
5x0.8
3.5
3.2
6x1
4.')
5.5
7x1
7.3
9x1.25
9.3
9.9
14,5
14.5 26,6
10x1.5
KlberoiU Ulli N 320

DTE FM 320
8.8
Nm
mm
8x1
Nevastane LP 320
kN
1.8
dtp
5.8
Nm
10.9
12.9
10x1.25
15.8
28
19,5
35
30
53
43
78
51
11x1.75
21,3
46
26
56
40
86
50
127
69
12x1.25
23,8
50
29
62
45
95
65
139
77
14x2
29
73
36
90
55
137
80
201
94
30
44
47
86
91
148
163
235
257
369
393
509
575
719
804
987
14x1.5
32
79
40
96
61
150
90
220
105
16x2
40
113
50
141
76
214
111 314
130
16x1.5
43
121
54
150
82
229
121 336
141
10x2.5
49
157
60
194
95
306 135 435
158
18x1.5
57
178
70
220
110 345
157 491
20x2.5
63
222
77
275
122 432
173 615 203
20x1.5
72
248
89
307
140 482
199 687 133
22x2.5
78
305
97
376
152 502 216 843 253
22x1.5
88
337
109 416
24x3
90
383
112 474
175 744 250 1080 292 1240
24x2
101 420
125 519
196 814 280 1160 327 1360
27x3
119 568
147 703 230 1100 328 1570 384 1840
27x2
131 615
162 760 225 1200 363 1700 425 1990
30x3.5
144 772
178 955 280 1500 300 2130 467 2500
30x2
184
172 654 245 9.32 266 1090
165 850 204 1060 321 1670 457 2370 535 2380
d= boll diameter
kN = axial pre-loading
p= bolt pitch
Nni= lorque settingbolts
8.2 No-load tests

- After a brief period of operation (5-10 minutes) check
the oil levels under no-load conditions, topping up those
levels which have gone down check that nuts and bolts

of the various attachments are properly tightened.
- Check that the brakes lock and release at the right time
and all operate correctly.
9. MAINTENANCE:
Introduction
Maintenance can be "routine or unscheduled".
ATTENTION: All maintenance activities must be carried out under safety conditions.
9.1 Routine maintenance:
The operator is responsible for routine maintenance and
must carry out the following activities.
- After a brief operating period of about 100 hotirs
(breaking-in), change die oil in the gear unit and the
multi-disk brake (if installed) and wash the interior of
the unit with cleaning liquid.
- Check that there are no metallic parts with unusual
dimension in the magnetic plug of the gear unit and in
any multi-disk brake.
- Change the oil in the gear unit while it is hot so that it
is easier to drain.
- Stibsequeut oil changes will be made every 200-2500
hours of operation or, in any case, each year.
- Do not mix different types of oil.
- Periodically check the levels (about once a month) ant
top up if necessaiy.
ATTENTION: when checking the oil levels in gear
units equipped with a mtilti-disk brake or hydraulic
motor or both, if the levels have risen, this means that
oil is penetrating either from the brake seals or from the
motor rotary seal. Contract die "Brevini Service Department".
- For each unit it is recommended to keep a chart that
will be duly filled out and updated each time maintenance in performed.
9.2 Oil Change
- Use die diagrams on paragraph 2.2 "configuration" to
identify the oil plug according to die gear unit configuration and always paragraph 2.2 for the multi-disk brake
configuration.
Unscrew the drain plug and the filler plug to help drain
the oil from die gear unit. Once die oil has been emp-
.:,|1 ..'
tied, replace die drain plug. If the gear unit is equipped

with a multi-disk brake, repeat the same operation with
the multi-disk brake.
- In the MDU series, starting with size "550", a pipe is
supplied to empty the oil in die gear unit, therefore it
must be emped using a suction pump, removing the
plug from the emptying pipe located on the flange attaching the gear unit and fitting to it.
- Wash die interior of the gear unit with a suitable cleaning liquid that is recommended by the lubricant manufacliuer. If die gear unit is equipped with a multi-disk
brake, repeat the same operation with die multi-disk
brake, as follows:
Put liquid into the gear unit and the mtdd-disk brake (if
any), hen replace the filter plugs; run the device for a
few minutes at a high speed, dien remove the cleaning
liquid again from die gear unit and the mul-disk brake,
(if any).
- See paragraph 7 Lubrication for filling mstructions.
9.3 Unscheduled maintenance
Brevini Riduttori prohibits the gear unit to be opened
to carry out any operation that is not included in routine
maintenance procedures. Brevini Ridiutori do not imdertake any Uability for all those operations out of rouUne maintenance which may have caused damages to
people or thhigs. When die need arises, contact the nearest Brevini Service Centres as listed on page 161.
10. MAINTENANCE OF AUXILIARIES

(BRAKES - CLUTCHES- ETC.):
10.1 Procedure to replace disks or seals for
mult! disk brakes
"Brevini
Riduttori
S.p.A." prohibits this
operation to be performed on its units,
dierefore if braking action becomes inefficient
contact die nearest Brevini Service Centres as
listedon page 161.
i:.:,,r.jiri'.'.y l,!il.JIJ.!il J'^t' Ht!L.,..*H!^L.[
10.2 Procedure to replace pads for disk brakes

- Use a screwdriver or similar tool to pry between die
disk and the pad to make die position of the brake clamp
rettact up to the start of die stroke.'Carry out this operation first on one side and then on the odier for both
pistons.
- Use a pin remover and hammer to remove one of die
two pins "A" from its seat (see fig. 4), remove die two
springs "B", then remove the odier pin.
- With a mechanical clamp pull oiu die two worn pads,
use compressed air to clean away any dust from the pad
seats in die brake clamp, then insert the new pads.
- Mount one of the pins "A" in its seat, place the two
springs "B" in dieir position, put them under tension,
them moiuit the other pin hi its seat.
- Activate the brake a few times to re-position die pistons of the brake clamp with the new pads.
- Brake a few times to check if bleeding is required.
10.3 .Maint. proc. for hydr. power pack on gear unitcoupler assembly with active clutch safety system
- The power pack "B" has an inspectable 100 ft bronze
filter, upstream of the
pressiue relief valve.
- With each routine
maintenance job (oil
change) on the gear
unit-coupler assem- ( A )
bly you are advised
either to change the
power pack filter, by unscrewing die cap "A", or at
least to regenerate it by washing
thoroughly with solvent and blowcleanmg inside die filter with air.
- If die power pack "B" has to be replaced; empty the
lubricant oil out of the assembly, cut off the current to
the solenoid valve, disconnect the oil deliveiy tube, unscrew and remove the 4 bolts pos. "C" and then wididraw the power pack for replacement.
- To reassemble, go tlirougli die above steps in reverse
order; see par. 6.3 for resetdng die power pack.
n . SCRAP DISPOSAL:
11.1 Machine demolition
If die machine must be scrapped, it, should become nonoperational:
- Disassemble the various parts.
- Disconnect any motor unit.
But fust after having completely emptied all die oil from
gear imit.
11.2 Ecology information
The disposal of gear unit packagmg materials, replaced
parts, components or the gear unit and lubricants must
comply widi environmental restrictions, widiout polluting the soil, water or air. The party receivuig die materials is responsible for carrying out the operation m conformity with the current standards hi force m the eoimtry m which the machine is used.
Instructions for suitable waste treatment
- Iron, aluminium, copper materials: these are recyclable materials which must be sent a to a special authorized collection center.
- Plastic and rubber materials: diese materials must be
delivered to a dump or to special recycling centers.
- Used oils: dehver to a special C.Di.R.A. (hi Italy the
Consorzio Obbligatorio OUi Esausti).
12, PROBLEMS AND RELATIVE SOLUTIONS:

If maUuncons occur, consult die followmg table.
If die problems contmue, contact the nearest Brevini Service Center as listed on page 161.
tidtaHon
PROBLEM POSSIBLE CAUSE

With motor
ninning the
output shaft
1) Check coupling
bem'cen gear unitfmotor
2) Internal malfunction
malfunction
2) Contact a Service
Center
3) Brake blocked
3) Clieck hydraulic circuit
1) Level too high

Oil leak om 2) Incorrect breather
breather
position
during
3) Possible wear of
opcraliuj)
muhidisk brake seals
or hydraulic motor
I) Clogged breather plug
Oil leak
from seals
Excessive
noise
Excessive
heating
1) Lower oil level

2) Check breather
position
Center
1) Unscrew and thorougly
clean the plug
2) Stiffening of seals due

to prolonged storage
21 Clean the area and

clieck for leakage again
after a few days
3) Damaged or worn
seals
Center
Center
Disk brake does 1) Residual pressure

not release
inhydraulic circuit
Excessive
vibrations
SOLUTION
1) Incorrect motor
assembly
1) Gear unit incorrectly

installed
1) Check the connection

and in-line configuration
2) Coupling structure
weak
2) Strengthen the
structure
Center
1) No ventilation
i) Remove fairing
2) Insert oil circulation
1) No pressure to the
brake
I) Check connection to
hydraulic circuit
2) Contact a Ser\'ice
Center
3) No pressure in the
circuit
3) Check hydraulic circuit
Multi-disk
1) Pressure delivered
to brake

Center
not brake
2) Worn disks
Disk brake
does not
brake
1) No pressure to the
brake
2)ConuiclaService
Center
2) Worn brake pads
INSTALLATION:
diey are all tightened to torque value'T" in uible N 1.

- Set die torque wrench to 3 - 5% above die setting given
in table N 1, diea dghten the coupling bolts to the new
setting.
Table 1
IfpcafeMplliit
S3 00
S4oa
S600
5860
S1200
S1800
53600
S3S00
309-13SX3?0
ilCS-105X320
3A"i8.2!0'G7O
3208 340> 405
J303-2(iOX4EM
SJOfi^JOO.^S-j
320S-J40X570
30.'1-360X5M
as
lli
114
U4
1T2
I;B
2pa
210
X(M)fnr
tji rfireort
<=^
V
0
T
[Nml
WIS
W2D
M20
M2
M24
M24
M2J
M27
290
490
490
490
S4
S40
12S0
1250
^ffi
50
65
55
55
65
65
B
10
iifi
115
115
120
1J
125
125
^
56
5S
53
58
7
70
ti5
85
b a r )
through
the 1/8" G
hole to facditate die detachment of
die gear tmitfromthe machine shaft.
- If this mediod doesn't
free die gear unit (because
of die shaft coupling being unable to hold the
pressure),flien,if diere is
sufficient space, you can
Uy die mediod illustrated
in fig. 5, using hydraulic
pushers, pressing against
1) Check hydraulic
Circuit
2) Iligli thennal power
Mu III-disk
brake does
2.5.
2.5.4.2 Installation of gear unit with FS output

- Glean and degrease the internal surface of the gear imit
shaft and machine shaft.
- Lubricate the coupling housing (fig. 1 [X)int A).
- If the coupling is new there is no need to disassemble it
and grease it.
- If die coupling is being overhauled, disassemble it and
gi'ease die zones marked "C" (see fig. 1).
- Remove cap "Z" (see fig. I) in order to bleed off the air
whenfittingdie sliafl.
- Fit the coiiphng on to the gear unit widiout tightening
die bolts, leaving cap "2" loose (see fig. 1).
2} Replace brake pads
- Set the torque wrench again to setting "T" in tab. 1, dien

recheck the torque on the couplmg bolts, taking care not to
tighten die boltsfitfdier;if this happens, repeat the torqtiing procediue.
- When the fitting of the coupling has been completed
correctly, check die assembly visibly to make sure diat the
front surfaces of die internal and external rings are on die
same plane (see fig. 2 point D).
- If die gear unit is in a vertical working position widi die

output shaft undemeadi, make sure die coupling can't come
out and fall; in any event, never tighten die coupling bolts
before fitting the shaft into its housing.
- Fit the gear unit on to the machine shaft or vice versa
(excessive axial force shouldn't benecessary); there should
be no interference when
assembling, so make sure
die shaft and gear unit are
properly aligned.
- Refit cap "Z" (seefig.2),
dien position the coupling
(see fig. 2 point A)
- Using a torque wrench,
tighten all die bolts gradually in a circular sequence
(i.e. not in a diametrically
opposite sequence) until
2.5.4.3 Disassembling the coupling and gear unit

- Gradually loosen die attachment bolts, proceeding in a
circular direction. Initially, loosen each bolt by just a quarter of a turn to avoid bending and seizing.
Fig. 5
ATTENTION: because of the high axial force, if die bolts

are unscrewed totally in one or two turns diis could caase
the two rings in the coupling to separate violendy, putting
the operators in danger.
die 2 180 bosses on die gasket holder cover, being carefirl

not to exceed the following axial loads:
- If the ciipling rings do not come apart spontaneously after misciewing die bohs,
transfer some of the Isolls (two bolts
at 180 - tbiu bolts at W) into die
internal ring extracLon holes(see
fig. 3).
- Slide die coupling along its axis to
release it and remove cap "Z" (see fig.
4), and inffoduce pressmised oil (max. 1000
S300
S400
S600
S850
S1200
S1800
S2500
S3500
Axial load fNl

30000
30000
45000
50000
70000
80000
100000
115000
Fig. 2
'
ij I
I i : I!
'
', ,i r I' r ! M' I

_|j^^^ll_,l;
.. ;:!'. Jill;
ima
^ ^ ^ f ^ ' '
- If the coupling is assembled a long time before it is started up, then you will have to separate the coupling rings
(after removuig die gear unit) and clean the mating surfaces thoroughly, removing any traces of dirt, rust, etc.
- Before reinstalling the overhauled coupling, top up with
lubricant in the zones marked "C" (seefig.2).
i'-^hntSU
tiduttati
ATTESTATQ DI CONFQRMITA' - UNT EN 10204 - 2.1

CONFORMITY CERTIFICATE - UNI EN 10204 - 2.1
ATTESTATION DE CONFORMITE - NT EN 10204 2.1
KONFORMITTSBESCHEINIGUNG - UNI EN 10204 - 2.1
CERTIFICADO DE CONFORMIDAD - UNI EN 10204 - 2.1
ATESTADO DE CONFORMIDADE - UNI EN 10204 - 2.1
14. RETE DI ASSISTENZA - SERVICE NETWORK - ADRESSES DES CENTRES DE SERVICES

APRES-VENTE-KUNDENDIENST -REDES DE ASISTENCIA -REDE DE ASSISTNCIA
Europi Europe Europe Europa Europa Europa
nenm
hyAoMam
La Brevini Spa dichiara sotto la propria responsabilita, sulla base del risultati ottenuti dai test standard di verifica
effettuati sui prodotti costruiti con gli stessi materiali e con lo stesso metodo di produzione, che il prodotto,
conforme alle prescrizioni dell'ordine ed alle regole tecniche corrispondenti ai regolamenti ufliciali.
DIRETTORE DI PRODUZIONE
Brevini Spa under its own responsability, on the basis of the results of its standard tests aimed to verify products
which are manufactured using the same materials and production method, declares that the products comply
fully with the order requirements and with all technical norms corresponding to the official regulations.
Brevini Hydrosam s j . l .
Via Aldina 24/C
40012 Uppo di Calderara di Reno (BO)
Tel.; +39 - 051 - 725436
Fax: +39 - 051 - 725474
info@brevinihydrosam,com
Brevini Nederland B.V.

Rntgenvêg 24 - BP 429
2408 AB ALPHEN AAN DEN RUN
HOLLAND
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Ultrevmi
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MANUFACTURING DIRECTOR
Lubrevini
piemonte
La St Brevini Spa declare sous son entiere et seule responsabilit, sur la base des resultats obtenus suite aux tests
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rglementations officielles.
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Corso Franda 94
10143 TORiNO
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iSn.it
DIRECTEUR DE PRODUCTION
mrewin
ienirotud
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Lubrcwini
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Brevini EspaAa S.A.
Pol. Ind. "Los Huerteciiios", C/Abedul, s/n
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low TRADE Sp. Z.O.O.
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NAHUM GOLOENBERG Ltd.
16 Melchel St., P.O.Box 72
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Tel.: +972 - 3 - 5347976
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HABERKORN GmbH
Holzriedstrae 33
A-6961 Wolfurt - AUSTRIA
Tel.: +43 - 5574 - 695-0
Fax.+43-5574-84921-8021
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K C W ETERNAL ENTERPRISE Co Ltd.
No. 666, Yung-An St.
702 Tainan
TAIWAN - R.O.C.
Tel.: +886 - 6 - 296 - 5396
Fax: +886 - 6 - 296 - 5700
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Libertad 6206 (1657)
Loma Hermosa
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Fax:+54-11 -47691006
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Purkynova, 99
612 64 BRNO-CZECH Rep.
TeL:+420-5-41122187
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RESCUE BOAT
DMR-31
MANUAL FOR OPERATION,

MAINTENANCE AND TRAINING
FOR
RESCUE BOAT
TYPE: RB 400
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-{0)4143-9152-40
www.hatecke.de
EDITION: 09/06
Index
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
1.1.14
Operation Manual:
Yard and yard number
Description of the boat
Stowage plan for equipment
Alarm
Preperation for lowering
Lower the boat - start engine
Disengage hoisting hook and painter
Turn the capsized boat
Release lifting hook
Pick in lifting hook
Radar reflector
Flash light
Search light (optionally)
1.2
Maintenance Manual:
1.2.2 Recomended maintenance and checks
1.2.2.3 Annual thorough examination (ace. to MSC.1/Circ.1206)
1.2.2.4 5-Years Overhaul & Testing (ace. to MSC.1/Cire.1206)
1.2.3.1 IVIaintenanee of GRP-boats
1.2.3.2 IVIaintenanee of GRP-boats
1.3
1.3.1
1.3.2
1.3.3
1.3.4
Trainings Manual:
Trainings instructions
1.4
Additional:
Engine manual
Lifting hook manual
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1 OPERATION MANUAL
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counterweights!
on this parts!
3. Always keep hands and feet clear near moving and rotating mashinery!
4. Keep off in reach of propeller!
5. Before starting read engine instruction nnanual!
6. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an
odourless and dradly poison!
7. DO NOT store, spill, or use gasoline near an open flame!
8. DO NOT refuel indoors where area is not well ventilated!
9. Avoid skin contact to battery acid (corrosive)!
10. Misuse of the release gear can injure or kill!
1.1.2 Yard and y a r d n u m b e r
The information given in this manual is based on our long experience and "l<now-how" in the
building of all kinds of boats.
In case of an engagement it is very important, that every one knows how to handle the boat.
All personal should study this manual at boat drill, to make themselve thoroughly conversant
with the system to ensure a speedy and safe engagement.
In case of enquiries reguarding existing boats please quote the details given below.
Boat type:
RB400
Hull no.: _
10839
1.1.3 Description of boat
Construction:
The hull is built in round-frame-construction.
Square stern providet to install a outbord engine.
All parts are built of GRP.
Polyurethan foam filled buoancy tanks.
Outside with rubber stripes and grab line.
One twart fore with hatch and equipment locker for the inventory.
Fittings:
At the fore end one painter releaser.
Aft two bollards.
Fittings for hoisting slings.
Engine:
One hand-steered outboard engine,
long shaft.
20 Itrs. fuel tank.
Loose equipment:
Look at page 1.1.4
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-()4143-9152-0. Fax: 0049-(0)4143-9152-4. E-mail: emaii@Hatecke.de. www.hatecke.de
1.1.4 Stowage plan for equipment
@ @ 0-15, 18,23-28^
1 1 bailer
2 1 bucket, 5 Itrs. with lanyard
3 1 Container with distress signals
1 jack knife with tin-opener
1 el. torch with spare bulb and 2 spare batteries
1 whistle
4 1 fire extinguisher
5 1 sea anchor with lanyards
6 1 painter with long link
7 2 buoyant line with ring
8 1 buoyant towing line
9 1 first aid kit
10 1 radar reflector
11 1 boat hook
12 1 search light
13 1 rope ladder
14 2 thermal protective aids
15 1 towing line for liferaft
16 2 paddles
17 1 compass (fixed installed)
18 1 securing wire for outboard engine
19 1 fuel tank
20 1 bilge pump
21 1 hoisting sling
Spare parts for engine:
22 1 spare fuel tank
23 1 cool water pump impeller
24 1 set of sealings
25 2 spark plugs
26 1 starter rope
27 1 flush connection
28 1 bag with tools
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drachtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.5 ALARM
ALARM
At alarm all boat personal went, equiped with

their personal equipment, to their meating
place.
1 <^
^
Boatyard Emst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. wvwv.hatecke.de
1.1.6 Preparation for lowering
Abonding the ship:
CHECK THAT EVERY BODY IS PRESENT!

1. Fasten painter.
2. Davit clear for lowering (study the davit /
crane manufacturers instructions).
3. Remove lashings.
4. Lower the outer end of the boat stowage rest
if necessary.
Board the boat (wait until order is

given),
swing out the davit.
1. The occupants tal<e place on the marl<ed
areas.
Take care for the propper trim of the boat
hanging in the hoisting sling.
2. Swing out the davit (study the instructions
of the davit manufacturer).
1.1.7 Lov\fer the boat - start engine
Lowering.
With the remote control wire it is possible
to operate the boat winch from inside the
boat.
(Study the also the winch manufacturers
instructions).
\FJstart
the engine :
For starting instruction look at the engine

manufacturers handbook in the appendix
of this manual.
A
|xj^
A
riSi
CAUTION:
Keep off of reach of propeller
WARNING:
Always keep hand and feet clear
near m o v i n g and rotating mashinery.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. vww.hatecke.de
1.1.8 Disengage hoisting hook and painter
Release the hoisting hook If the

boat Is waterborn.
1.) Hold the hoisting sling (otherwise it
falls down).
Furter instructions depend on type of
hook in use. Look for instructions
inside the boat or at the davit,
(look also manual in the additional)
Q~n Release painter.

Pull up forceful (arrow direction) the
painter releaser lever.
f I j The boat is now free.

^ - ^ Engage the motorgear to foreward, run
the outboard engine with high speed and
steer away from the vessel.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 049-{0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.9 Turn the capsized boat

In case of capsizing the boat will not right it self.
The swimming boat crew (1) has to enter the boats bottom at the outboard engines side (2) and
to take the grablines. Than they have to swing (3) the boat up and down until it rotates.
4.)
After turning the boat drain it with the bilge pump.
CAUTION: The boat crew must leave the boat during turning, to prevent accidental contact
with the boat.
Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21705 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.10 Release lifting hook

(only to lifting hook "SIMPLEX 1.1", manufacturer: ERNST HATECKE GmbH)
Lowering "OFF-LOAD"
After the boat is waterborn:
1.) Normal release of the release hook OFF LOAD
Pull down "white" handle to release sling from hook.
Releasing "ON-LOAD
II
"ON-LOAD" release should only be done whilst the boat is in the water
Misuse of the release gear can injure or kill.
1.) Emergency release use only when boat is waterborne.

a) Remove safety pin.
b) Pull down "red" handle.
WARNING: Hook can be ACCIDETAL released

ON LOAD in any position !!!
Be carefull when releasing hoisting hool<s "ON-LOAD"
long links and falls leave the hooks with high speed.
s-y.-
WARNING:
Misuse of the release gear can injure or kill!!!
Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone; 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.1.11 Pick in lifting iiooic

(only to lifting hook "SIMPLEX 1.1", manufacturer: ERNST HATECKE GMBH)
Make lifting hook ready for use:
After releasing "ON LOAD" make the lifting hook ready for use again.
1.) Pull down the "white" handle and hold it.
2.) Push back the "red" handle into it's original position let off the "white" handle.
3.) Push in the safety pin.
4.) Push back the hook into it's original position.
Pick in the long link for hoisting:

1.) Check that the hook and release lever are In the correct position
(safety pin In place).
2.) Push the long link Into the hook (the stop pawl is moveable).
ik
WARNUNG:
Keep hands clear when you pick in the long link In the lifting hook.
Boatyard Ernst Hatecke GmbH. Am Ruttienstrom 1.21706 Oractitersen. Plione: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: emailHatecke.de. www.fiatecke.de
1.1.12 Radar reflector
In the equipment of this boat is also a radar reflctor, it is stored in the inventory locker.
Assemble it to the enclosed instruction, erect it on the socket at the forward bulkhead.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1,21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
1.1.13 Flash light
The boat is equiped with a flash light. Swith on the flash light in bad weather condition and in
the night.
1. The flash light fix mounted on the fore deck.
2. The battery of the flash light is fix installed in the inventory locker.
3. To switch on the flash light pull out the wire pin.
4. To switch off the flash light push in the wire pin.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: 8mail@Hatecke.de. www.hatecke.de
1-1.14 Search light (optionally)
In the equipment of this boat is also a search light.

1. The search light is stored in the inventory locker.
2. For function put the plug into the socket of the outboard engine.
Caution: Search light works only with running outboard engine.
Their is no battery the current comes direct from the ignition coil.
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
1.2 MAINTENANCE MANUAL
ERNST
HATECKE I
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counter weights!
on this parts!
5. Before starting read engine instruction manual!
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: O49-(0)4143-9152-40. E-maii: emaii@Hatecke.de. www.hatecke.de
By supervision of a senior sliips officer in accordance witti ttie information provided by tlie manufacturer.
O u t b o a r d e n g i n e : (look also manufacturers manual)
done
remark
1. Test run the engine, demonstrat that the gear box and gearbox train are
engaging satisfactorily.
Miscellaneous:
2. Visual inspection to ensure that the boat is ready to use.
1.2.2.2 MonthBy inspection
By supervision of a senior ships officer in accordance with the infornnation provided by the manufacturer.
^^^^^^^^^^^^^^^^^3^^^^
O u t b o a r d e n g i n e : (look also manufacturers manual)
done
remark
1. Check fuel level in the tank.

2. C h e c k g e a r oil level (Change gear oil at least after one year)
3. Grease the moveable parts.

4. Testrun the engine with the boat in the water, demonstate that the
gear box and gear box train are engaging satisfactory.
Painter releaser:
5. Clean the painter releaser (remove salt deposites)
6. Lubricate and oil moveable part of the painter releaser.

7. Check function.
Miscellaneous:
8. C h e c k t h e t h e f l a s h lights battery v o l t a g e (if necessary change the battery)
9. Lubricate all hinges.

10. Clean the boat with water and soap, flush with fresh water.
11. Check equipment.
12. Visual inspection to ensure that the boat is ready to use.
Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
1.2.2.3 Annual thorough examination (acc.toMSC.1/Circ.1206)
Lool< at page 1.2.2.6 Autliorized service stations.
Items listed in checl<lists for the weel<ly/monthly inspections also form the first part of the
work to be done.
R e s c u e b o a t : Examination and check for satisfactory condition and operation *
1.
2.
3.
4.
5.
Condition of Rescue boat structure including fixed and loose equipment.

Engine and propulsion system.
Manoeuvring system.
Power supply.
bailing system.
R e l e a s e G e a r : Examination and check for satisfactory condition and operation '
6.
7.
8.
9.
10.
Operation devices for activation of release gear.

Excessive free play (tolerances).
Hook fastening.
Operational test of on-load release function.
Operation test of off-load release function.
* according t o manufacturer's checklist (Doc. n o . 0502)
^ ^
1.2.2.4 5-Years Overhaul & Testing
By manufacturers representative or a person appropriately trained and certified by the manufacturer
Look at page 1.2.2.6 Autliorized service stations.
work to be done.
L i f e b o a t : Examination and check for satisfactory condition and operation '
1.
2.
3.
4.
5.
Condition of Rescue boat structure including fixed and loose equipment.

Engine and propulsion system.
IVIanoeuvring system.
Power supply.
bailing system.
Release Gear: Overhaul

6. Dismatling of hook release units.
7. Examination with regard to tolerances and design requirements.
8. Adjustment of release gear system after assembly.
g.Operational test with a load according to SOLAS Reg.111/20.11.2.3.
10. Examination of vital parts with regard to defects and cracks.
replace
hoisting
hook by an
overhauled
one.
* according to manufacturer's checklist (Doc. no. 0502)
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Droditersen. Ptione: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.liatecke.de

Note:
Date:
Name:
Boatyard Ernst Hatecke GmbH. Am Ruttienstrom 1.21706 Droctitersen. Ptione; 0049-(0)4143-9152-0. Fax; 0049-{0)4143-9152-40. E-mail; email@Hatecke.de. www.tiatecke.de
1.2.2.6 Autiiorized service stations

ERNST
A
HATECKEr ~-./
Please contact:

Am Ruthenstrom 1
Telefon: +49-4143-9152-60
Telefax: +49 - 4143-9152-44
1.2.3.1 Maintenance of GRP-boats (GRP- repair)

Even GRP-boats are subject to damage to greater or lesser extent. The most common
damages are scratches in the gelcoat which may also penetrate the laminate.
The gelcoat colours are:
Outer surface: orange
RAL 2004
Inner surface: light green RAL 6019
In case of extensive damage contact the manufacturer.
Sometimes the gelcoat finish looks dull and the colour is faded.
Restore the original finish by sanding the surface with a fine grade water sandpaper of
grade 400 or finer, or using a rubbing compound.
After sanding or rubbing the surface must be waxed. Rubbing should be done by hand or
with a rotary polishing buff. Waxing should always done by hand.
DAMAGES OF GRP SHOULD BE REPAIRED AS SOON AS POSSIBLE,

WATER WILL BREAK IN THE LAMINATE AND DESTROY LARGER PARTS!
LOOK AT SKETCH BELOW
1.1 Small not through going damages.
1.2 Grind the damage with sandpaper or a rasp until you reach unbroken laminate. Repair
procedure as under no. 2.1.
2.1 Through going damages.
2.2 Cut away the broken material with a jig saw and a rasp.
3.1 Sharp the edges with sandpaper.
3.2 Take a piece of wood as a rabbet behind the laminate. Clean the surface with a thinning
agent.
3.3 Start to laminate with resin and glassfibre until the hole is filled up.
3.4 After starching take the wood away (abt. 30-40 min.) and grind the surface before painting.
GREATER DAMAGES, DAMAGES OF HIGHLY STRAINED OR STRESSED PIECES AND
BULKHEADS SHOULD BE REPAIRED BY THE YARD!
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: 0049-{0)4143-915240. E-mail; email@Hatecke.de. www.hatecke.de
1.2.3.2 Maintenance of GRP-boats (GRP- repair)

THE MANUFACTURING FOR REPARATURES WITH GLASSFIBRE STARCHED
POLYESTER RESIN (Not oblygatory terms of reference)
FUNDAMENTAL: For the starching of polyester resin the addition of starching substances
and dispatching substance is necessary. All three substances are highly
inflammable. The starching substance is poisonous and eye corrosive
(CAUTION !) Please be careful, when putting these substances together.
Spots, witch should be repaired, must be dry.
When working with these materials, take care, that you work in a temperature from abt.20C.
Storing capacity: 9 months.
IMPORTANT:
Starching substance and dispatching substance in no case should meet

together (EXPLOSION)!!!!!
Preparing:
On the spot of reparature the loose fabrics should be put away, the brinks
should be bevelled and roughed.
From the glassfibre mat are to be cut out great enough pieces. For to get a
good effect at the brinks the mat is to be pitch out at the ends (1 quire
glassfibre mat will give abt. 1mm material thickness). The polyester resin
could be thinned with monostyrol (abt. 10%) for a better working. The mixing
with starching substance and dispatching substance should be done in the
following proportion:
1000 polyester: 20 starching substance : 5 dispatching substance.
First the polyester resin is to be mixed with the starching substancexactly.
Then the dispatcher is be mixed with the other both substances. Pay
attention, that you don't prepare more materials than you need.
Manufacturing:
The cuted glassfibre mats should be put on the spots of reparature. With a
brush you touch lightly the mixed polyester resin, until the mat is wet. With
the following pieces you do this in the same way, until you have the
necessary material thickness.
After starching (starching time abt.30-40 minutes) you may polish the spot.
if you like painting, please use DD-lacs.
For cleaning the tools, use monostyrol (50%) or aceton (chemically clean).
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-()4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: email@Hatecke.de. www.hatecke.de
1.3 TRAININGS MANUAL
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
1.3.1 Tainings instructions

To the:
"Consolidated text of the International Convention for the Safety of Life at Sea,
1974, Chapter III, Reg.19:"
On-board training and instructions
4.1
On-board training andin the use of the ship's life saving appliances, including survival
craft equipment, and in the use of the ship's fire-extinguishing appliances shall be
given as soon as possible but not later than two weeks after a crew member joins the
ship. However, if the crew member Is on a regularly scheduled rotating assignment to
the ship, such training shall be given not later than two weeks after the time of first
joining theship. Instruction in the use of the ship's fire-extinguishing appliances, lifesaving appliances, and in survival at sea shall be given at the same interval as the
drills. Individual instruction may coverdifferent parts of the ship's life-saving and fireextinguishing appliances, but all the ship's life-saving and fire-extinguishing appliances
shall be covered within any period of two months.
4.2
Every crew member shall be given instructions which shall include but not necessaily
be limited to:
4.2.3 special instructions necessary for use of the ship's life-safing appliances in severe
weather and severe sea conditions; and
*) for more detailed information to all points look the original IMO papers.
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counter weights!
on this parts!
5. Before starting read engine instruction manual!
Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1,21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email@Hatecke.de. www.hatecke.de
Abonding the ship:

CHECK THAT EVERY BODY IS PRESENT!
1. Fasten painter.
2. Davit clear for lowering (study the davit /crane
manufacturers instructions).
3. Remove lashings.
4. Lower the outer end of the boat stowage rest if necessary.
I n Board the boat (wait until order is given),

swing out the davit.
1. The occupants take place on the marked areas.
Take care for the propper trim of the boat hanging in the
hoisting sling.
2. Swing out the davit (study the instructions of the davit
manufacturer).
(I I h Lowering.
^ ~ - - ^ With
\A/ith *hQ
the
ram
remote
control wire it is possible to operate the boat
winch from inside the boat.
(Study the also the winch manufacturers instructions).
V[V/ start the engine :

For starting instruction look at the engine manufacturers
hanilhnnk in thp appsnfliv nf thi.t; manual
A
A
CAUTION:
Keep off of reach of propeller
WARNING:
A l w a y s keep hand and feet clear
near m o v i n g and rotating mashinery.
Release the hoisting hook if the boat is

waterborn.
1.) Hold the hoisting sling (otherwise it falls down).
Furter instructions depend on type of hook in
use. Look for instructions inside the boat or at
the davit, (look also manual in the additional)
( y j ) Release painter.
Pull up forceful (arrow direction) the painter releaser lever.
ID The boat is now free.

Engage the motorgear to foreward, run the outboard engine
with high speed and steer away from the vessel.
Recovery will be done by reverse step VII to I.
1.4 ADDITIONAL
ERNST
HATECKEI
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
www.hatecke.de
mm miMli^
OWN
LIT-18626-05-47
ccinlaitlis
LheniicBls
known
\o
the
dtqts or Kttn^r mprodccive harni.

''>.'.*vriP
Ur-CAUF:?*-!
ci:>
EMU01449
TO THE OWNER
Thank you for choosing a Yamaha outboard motor. This Owner's manual contains information needed for proper operation, maintenance and care. A thorough
understanding of these simple instructions will help you obtain maximum
enjoyment from your new Yamaha. If you
have any question about the operation or
maintenance of your outboard motor,
please consult a Yamaha dealer.
In this Owner's Manual
particularly
important information is distinguished In
thefoHpwing ways.
Gi,
The Safety Alert Symbol means

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instmctions

could result in severe injury or death to
the machine operator, a bystander, or a
person inspecting or repairing the outboard motor.
A GAUTiON indicates special precautions

that rriust be taken to avoid damage to
the outboard motor.
Hm
A NTE provides key information to make
procedure sesier or clearer.
* Yimaha continually seeks advancements- in product design and quality.
Thel'efore, while this manual contains
ith most current product information
available at the time of printing, there
may be minor discrepandes between
your machine and this manual. If there
is any question corieerning this manual,
please; consult your Yamaha dealer.
NTE:
The F15MH, FISPR and their standard
aeeepflsi are used as a base for the
explanations and illustrations in this manual. Therefore, some items may not apply
to every model.
EMU01446
Fi5e
OWNER'S MANUAL
2003 by Yamaha Motor Corporation, USA
1st Edition, April 2003
A|l rights reserved.
Any reprinting or unauthorized use
without the written pemnission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in Japan
P/N UT-18626-05^7
EMA2D010
CONTENTS
/ ' "
cx>
1
GENERAL INFORMATION
^-
BASIC COMPONENTS
"I
.CD
OPERATION
'^-
MAINTENANCE
v_
y-
TROUBLE RECOVERY
N-
AtoZ
1
INDEX
>-
READ THIS OWNER'S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.
cx>
EMB00010
Chapterl
GENERAL
INFORMATION
IDENTIFICATION NUMBERS RECORD. 1-1
Outboard motor serial number
1-1
EM ISSION CONTROL INFORMATION .1-2
Star labels.......
.A- 3
SAFETY INFORMATION
.1-4
IMPORTAN T LABELS
.1.6
BASIC BOATING RULES
.1-7
FUBJNG INSTRUCTIONS
Gasoline
ENGINE OIL.......
...1-11
.........,v....1 -12
1 -13
BATTERY REQUIREMENT
1 -14
PROPELLER SB_ECTION
1-15
STARTÎN-GEARPROTECTION ... ......:1 -16
CE>
IDENTIFICATION NUMBERS
RECORD
PUTBOARD MOTOR SERIAL

NUMBER
YAMAHA MOTOR CO., L T D .

MADE IN JAPAN
PAYS D'ORIGINE JAPON
401012
The ioutboard motor serial number is

mped on the label attached to the port
side of the damp-bracket.
Record your outboard motor serial number inthe spaces provided to assist you in
ordering spare parts from your Yamaha
dealer or for reference in case your outboard motor is stolen.
i 'Outbcrd motor sma\ number
1-1
vD
CE>
EMUCn385
EMISSION CONTROL
INFORMATION
EMU01387
NORTH AMERIGAN MODELS

This
engine
conforms
to
U.S.
Environme ntal Protection Agency (EPA)
regulations for marine SI engines. Seethe
label affixed to your engine for details.
Approval label of Bfnissipn oontrd
certificate
This label is attached to the bottom cowling.
1 Emission contrlinformation label
"5?
BVISaON CONTRLINFORMATION
ENGIhEFMLY.:
C~IIIIZ3
J i S 3 3 N ^ ^ r a R K e D I ~ i y S S ? F E G U L A ] ! C E 3 ? M \ R i r e i ENai^S-
THSBNEatoî\Eia'~rKurcRN/Buissio^
luRwNaNES
FEfeTO^ÊCIIAÊraUrt^lIR3RI*N^BWJCEPEOTCA^lC^^
reb:r
ICiKPEBJ
gTlINNEUlRAl
qj<whr:
PAFteuua'
ggfucfflii
t-KE
ACWERniSEBCWER 1"
5PAMaiJ(KPH):^_'';
HJbLU/ÛUJ
VALVaASIinrt : INT
1 EXr
New Technology ;(4-istroke) EM

Manufactured date label
This label is attached to the damp bracket.
2 Manufactured date label
1-2
CI>
^:^
EMU01389
STAR LABELS
Your outboard motor is labeled with a
California Air Resours Board (GARB)
star label. See below for a description of
your particular label.
1 Star label
000851
One Star - Low Emisapn

The one-star label iclntifis hgihs that
meet the Air Resours Board's 2001
exhaust emission istandaras. Engines
meeting these standards have ' ^ % lower
emissions than corivhtidril carbureted
two-stroke engines. These engines are
equivalent to the U S . EBA-s 2 0 0 6 ^ a n dards for marine engines..
Two Stars -\ireiry Low Britssion

The two-star label identifies engines that
meet thie Air Resources Board's 2004
exhaust emission standards. Engines
meeting these standards have 20% lower
emissions than One Star-Low-Ehfiissio n
engines.
Three Stars - Ultra Low BtiissiOh

The three-star label identifies engines that
meet the Air Resources Board's 2008
exhaust emission standards. Engines
meeting these standards have 65% lower
emissions than One Star-Low-Emissio n
engines.
1-3
cx^
^^
EMU00917.
SAFETY
INFORMATION
8 Before mounting or operating the outboard motor, read this entire manual.
Reading it should give you an understandin g of the motor and its operation.
8 Before operating the boat, read any
owner's or operator 's manuals supplied
with it and all labels. Be sure you understand each item before operating.
8 Do not overpower the boat with this
outboard motor. Overpowering the
boat could result in loss of control. The
rated power of the outboard should be
equal to or less than the rated horsepower capacity of the boat, If the rated
horsepower capadty of the boat is
unknown, consult the dealer or boat
mnufctu rer.
8 Do
not
modify
the
outboard.
Modifications could make the motor
unfit or unsafe to use.
8 Never operate after drinking alcohol or
taking drugs. About 50% of all boating
fatalitie s involve intoxication.
8 Mave an approved personal flotation
device (PFD) on board for every occupant. It is a good idea to wear a PFD
whenever boating. At a minimum, children and non-swimmers should always
wear PFDs, and everyone should wear
PFDs when there are potentially hazardous boating Conditions.
8 Gasoline is highly flammable, and its
vapors are flammable and explosive.
Handle and stre gasoline carefully.
Make sure there are no gas fumes or
leaking fuel before starting the engine.
8 This product emits exhaust gases which

contain carbon monoxide, a colorjss,
odorless gas which may cause brain
damage
or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and cabiri
areas well ventilated. Avoid blocking
exhaust outlets.
8 Check throttle, shift, and steering for
proper operation befpre starting the
engine.
8 Attach the engine stop switch lanyard
to a secure place oh your pipthingv or
your arm or leg while operating. If you
accidental ly leave the helm, the lanyard
will pull from the switch, stopping the
engine.
8 Know the rharin laWs and regulations
where you will be boating - and obey
them. Refer to "RULES OF THE ROAD"
section for basic boating rules.
8 Stay informed about the weather.
Check weather forecasts before boating.
Avoid boating in hazardous weather.
8 Tell someone where you are going:
leave a Float Han with a responsible
person. Be sure to cancel the? Float Ran
when you return.
8 Use common sense and good jdgmeht
when boating. Know your abilities, and
be sure you underhand how your boat
handles under the different boating
condition s you may:encounter; Operate
within your limits, and the limits of your
boat. Always operate at safe speeds,
and keep a careful watch for obstacles
and other traffic.
8 Always watch carefully for swimmers
during the engine pperatipn.
8 Stay away from swimming areas.
1-4
v
'^
cx>
8 When a si/vimmer is in the water near

you shift into neutral arid shut off the
engine.
8 Be informed about boating safety.
Additiona I publications and information
can be obtained from many organizations, including the following:
United States Coast Guard
Consumer ffairs Staff (G-BG)
Office of Boating, Rublic, and Consumer
Affairs
U.S. (3oast Guard Headquarters
Washington, D.C. 20593-0001
Boating Safety Hotline: 1-800-368-5647
National iyiarihe Manufacturers
Association (NMMA)
401 N.Michigan Ave.
Chicago, 1160611
Marine Retailers Association of America
155 N.Michigan Ave.
Chicago, 1160601
1-5
va
CD
^d^
EMB30011
IMPORTANT LABELS
WARNING LABELS
1
WARNING
This engine is equipped
with a neutral starting device.
The engiie will not start unless the shift control is
in neutral position.
-
6E0.836 27.41
WARNING
* Be sure shift control is in neutral
before starting engine, (expt 2HP)
* [Do not touch or remove electrical parts
when starting or during operation.
* Keep hands,hair.and dothes away from flywheel
arid other rDtating:parts whileengine ismrining.
^ i
SA1.83625-41
CAUTION LABELS
3
CAUTION
Transpoatid storetheengine only as shown
O.therwise^nginedamagecould resultfrom
leaking o.
1-6
CO
CX)
Stand-on vessel
The vessel with the right-of-way has the
duty tP continue its course and speed,
except to avoid ah immediate collision.
When you maintain your direction and
speed, the other vessel will be able to
determine how best to avoid you.
EMB40010
BASIC BOATING RULES

(Rules of the road)
Just as there are rules whieh apply when
you are driving on streets and high ways,
there are waterway rules which apply
when you are driving your boat. These
rules are used internationally, and are
also enforced by the United States Coast
Guard and local agendes. You should be
aware of these rules, and follow them
whenever you encounter another vessel
oh the water.
Give-way veifflel
The veosl which does not have the rightof-way has the duty to take positive and
timely adipn tostay out Ofthe v/ay pfthe
Stand-On vessel. Normally, you should
not cross in front of the vessel with the
right-of-way. You should slow down Or
change directions briefly and pa behind
the other vessel. You should always move
in such a way that the operator of the
Other vessel can see what you are doihjg.
Several sets of rules prevail according to

geographic location, but are all basically
the same asthe International Rules of the
Road. The rules presentejd here in your
Owner's Manual are cGsndensed, and have
been provided for your convenience only.
Consult your local U.S. Coast Guard
Auxiliary
or Department
of Motor
Vehicles for a complete set of rules governing the waters in which you will be
using your boat,
"The gheral pirtidentll alle "

This rule lis called Rule 2
Ihtemtignal Rules arid says,
STEERING AND SAILING RULES AND

SOUND SIGNALS
Whenever two vessels on the water meet
one another, one vessel has the right-ofway; it is called the "stand-on" vessel.
The vessel which does not have the rightof-way is called the "give-way" or "burdened" vessel. These rules determine
which vessel has the right-of-way, and
what each vessel should do.
in
the
'In obeying and construing these rules

due regard shall 'be had to all dangers of
navigation and epilision, and to any special di^cumstnces, which may render a
departure from the above rules necessary
in order to avoid immedite dandr.'
In other Words, follow the standard rules
except when a collision will occur unless
both veels try to avoid each other. If
that is the case, both vessels become
"Give-Way" vee|s.
1-7
CX>
^^
RULES WHEN ENCOUNTERING

VESSELS
will dear one another if you cohtihue on

your set course and speed.
There are three main situations which you

may encounter with other vessels which
could lead to a collision unless the
Steering Rules are followed:
Meeting (you are approaching another
vessel head-on)
Crossing (you are travelling across the
other vessel's path)
Overtaking (you are passing or being
passed by another veel)
In the following illustratioh, your boat is
in the center. You should give the right-ofway to any vessels shown in white area
(you are the Give-Way vessel). Any vessels in the shaded area must yield to you
(they are the Give-Way vessels). Both you
and the meeting vessel must alter course
to avoid each other.
Meeting
If you are meeting another power vessel
head oh, and are close enough to run the
risk of collision, neither of you has the
right-of-way! Both of you should alter
course to avoid an accident. You should
keep the other vessel on your port (left)
side. This rule doesn't apply if both of you
Crossing
When two power driven vessels are
CTOssing each other's path close enough
to run the risk of collision, the vessel
which has the other on the starboard
(right) side m keep out of the way of
the other. If the other vessel is on your
right, you niust keep out of its way; you
are the Give-Way vessel. If the other vessel is on your port (left) side, remember
that you should maintain course and
direction, provided the other vessel gives
you the right-of-way as it should.
Overtaking
If you are passihg another vessel, you are
the "Give-Way" vessel. This means that
the other vesisel is expected to maintain
1-8
%s>
its course and speed. You rnst stay out
of its way until you are dear of it.
Likewise, ifanother vessel ispaing you,
you should maintain your speed and
direction so that the other vessel can steer
itself around you.
OTHER SPECIAL SITUATIONS
There are three other rules you should be
aware of when driving your boat around
other vessels.
Narrow channels a lid bends
When navigiating innarrovtf channels, you
should keep to the right when it is; safe
and practical to do soi If the ofJ^rator of a
power-driven vessel is preparing to go
around abend that may obstruct the view
of other water vessels, the operator
should sound a pirolonged bla on the
whistle (4 to 6 seconds). Ifanother vessel
is around the bend, it too should sound
the whistle. Even if no reply is heard,
however, the vsl should still proceed
around the bend with caution. If you navigate such waters with your boat, you will
need to carry a portable air horn, available from local marine supply tores:
Fishing vessel right-of-way
All vessels which are fiehihg; with nets,
lines or trawls are considered to be "fishing vessels" Under the Ihtfnational
Rules. Vessels with trolling lines are not
considered fishing vessels. Fishing vessels have the right-of-way regardless of
position. Fishing vessels, cannot, however, impede the passage of other vessels in
narrow channels.
CI>
Sailing vessel righf-of-rway
Sailing vessels should normally be given
the right-of-way. The exceptions to this
are:
1. When the sailing vessel is overtaking
the power-driven vessel, the powerdriven vessel has the right-of-way.
2. Sailing vessels should keep clear of
any fishing vessel.
3. In a narrow channel, a sailing vessel
should not hamper the safe passage
of a povêr-drivn vessel whidi can
navigate only in such a channel.
Reading buoys and other markers
The waters of the United states are
rharked for safe navigation by the lateral
system of buoyage. Simply put, bupys
and markers have ah arrangement of
shapes, colors, nurnbers and lights to
show which side of the buo^y a boater
should pass on when navigating in a partieulaf direction. The markings oh these
buoys are oriented from the perspective
of being entered from seaward (the
boater is going towards the port). This
means that red buoys are passed on the
starboard (right) side when proceeding
from open v/ater into port, and black
buoys are to port (left) side. When havigating out of port, your position with
respect to the buoys should be reversed;
red buoys should be to port and black
buoys to starboard.
Many bodies of water used by boaters are
entirely within the boundaries of a particular state. The uniform State Watenway
Marking System has been devised fpr
these waters. This system uses buoys and
signs with distinctive shapes and colors
to show regulatory or advisory information. These markers are white with black
1-9
\S^
cr>
letters and orange boarders. They signify

speed zones, restricted areas, danger
areas, and general information.
Remember, markings may vary by geographic location. Alv\/ays consult local
boating authorities before driving your
boat in unfamiliar waters.
MAIN CHANNEL BUOVS
0
9
UGHTED BUOY (Port Hand)'
Odd runter, increasing ODwanj head ofnavigation.lieave topdrt ft) proceeding upstream.
JL
Vwhite Light
[J
UGHTED BUOY (Starboad Hard)"
Even nurrter.inciEastn gtavaiti head cafna/ig'aon. Leave to slartnanj (righQ pnxeedng upstream
Whce Uglt
SM
P roc ci ng - tcwartl. h ad
of navigation, from seavarl.
OR
UGHTED SAFE WATER BUOY
No itrrtr.' Martfs rridchannel, pass, on t\a

side, Letter has no lateral sigrificance, used for
idertificab on and location purposes-
SECONDARY CHANNEL BUOYS
i|
STARTS NEWNUMBERINC, SYSTEM,

VVtite grt
0"
0"
Red Ught
Top Mark
vvtite ti^t
CAN .BUOY
Odd nuTter. Leave tpport
OR
OR
Ca
RB L-
NUN BUOY
Even nuntier. .Leave to startioail
RG
UGHTED PREFERRED CHANNELTO

PORT BUOY
No mrrter.
Topmost band .red - prefeired
charinel istoleft ofbuoy. Leiter has nolateral
signif icance, used for idmbficstion
arid locatiDh
purposes .
ffl
Red or
I w r i t e Ljght
Red Li git
[XJnev.
No change
îL^^^'ir'
1-10
vSJ
EMB01010
i=UEL)NG INSTRUCTIONS
GASOUNE AND FTS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE

8 Do not smoke when refueling, and
keep away from sparks, flames, or
other sorge of ignition.
8 Stop engine before refueling.
8 Refuelin a well-ventilated area. Refuel
portable fuel tanks olf the boat.
8 Take care not to spill gasoline. If gasoline spills, wipe it up imnriediatly with
dry rags
8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after
refueiihg.
8 If you should swallow some gasoline
inhale kit of gasoline vapor; or get
gasoline in your eyes, get immediate
medical attention.
8 If any gasoline spills onto your skin,
immediately wash wtth soap and
Water. Charige ctothing if gasoline spills
on it.
8 Touch the fuel nozzle tothe filler opening or funnel to help prevent electrostatk: sparks.
Use only new clean ^gasoline which has

been stored in dean containers and is not
Gontaminat ed with water or foreign matter.
1-11
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EMU01804
GASOLINE
Recommended gasoline:
Regular unleaded gasoline with a
minimum octane rating of 86
(Pump Odane Number) =(R+M)/2
If knocking or pinging occurs, use a different brand pfgasplihe or premium unleaded fuel.
EMBS0610
Gasohol
There are two types of gasohol: gasohol
epntainin g ethhl and that isontaining
methanol. Gasohol containing ethanol
eari be used if ethanol content does not
exceed 10% and the fuel meets minimum
octane ratings.
Gasohol
containing
methanol is not recommended by
Yamaha because it can cause fuel system
damage or engine performance problems.
1-1S
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^:^
ENGINE OIL
Recommended engine oil:
4-stroke motor oil with a combination of
corresponding SAE and API as shown in
the chart.
SAE
API
-1
It
U-lT
-ir
tr
4rr
10W-30
1Gfi/V-40
SE
SP
S<3
SH
SJ
>
Engine oil quantity:

See Chapter 4 , " Specificatio hs."
All 4-stroke engines are shipped from the

factory without engine oil.
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1-13
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BATTERY REQUIREMENT
Do rrt use a battery that does not meet

the specified capacity. If a battery which
does n<A meet specifications is used, the
electric system could perform poorly or
be overloaded, causing electric system
damage.
For electric start models, choose a battery
which meets the following specifications.
Minimum cold cranking amps

(CCA/SAE):
245 amps at -18C(-0.4F)
Minimum marine cranking amps
(MCA/ABYC):
323ampsatOC(32F)
Minimum reserve apadty (RG/SAE):
52 minutes
A battery cannot be connected to models

that do not have a rectifier or Rectifier
Regulator.
Models without a rectifier or Rectifier
Regulator F15MH
8 If you w ish to use a battery w ith the
above modelsi, install an optional
Rectifier Regulator.
1-14
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EMU01395
PROPELLER SELECTION
The performance of your outboard motor
will be critically affected by your choice of
propeller, as an incorred choice could
iadversely affect performance and could
also seriously damage the motor. Engine
speed depends oh the propeller size and
boat load. If engine speed is too high or
too low for good engine performance,
this will have an adverse effed on the
fengine.
Yamaha outboard moitprs are fitted With
propellei's chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different
pitch would be more appropriate. For a
greater operating load, a smaller-pitch
propeller is more suitable as it enables
the corred engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable fora smaller operating load.
Yamaha dealers stocl< a range of propellers, and can advise you and install a
propeller on yûr outboard that is best
suited to your application.
1-15
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NOTE:
At fll throttle and under a maximum
boat load, the engine's rpm should be
within the upper half of the full throttle
operatin g range, as listed in "SPECIFICATIONS" on page 4-1. Select a propeller
which fulfills this requirement.
If operating under conditions which allow
the engine's rpm to rise above the maximum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.
1 Propeller diameter (in inches)
2 Ropeiler pitch (in inches)
3 Type of propeller (propeller mark)
Refer to the section "CHECKING PROPELLER" for instructions on propeller
removal and installation.
EMU01209
START-IN-GEAR PROTECTION
Yamaha outboard motors or Yamaha
approved remote
control
units are
equipped with start-in-gear protection
device(s). This feature permits the engine
to be started only when it is Neutral.
Always select NeutraT before starting the
engine.
1-16
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-MEMO-
CD
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EMC00010
Chapter 2
BASIC COMPONENTS
MAIN COMPONENTS
.2-1
OPERATIONS OF CONTROLS AND

.2-2
OTHER FUNCTIONS
2-2
Fuel tank
.2-3
Gear shift lever
2-3
Choke knob
Recoil starterhandle
. ...2-3
2-3
Starter button
Tille r handle
.2-4
2-7
Remote control
Steering frietion adjusting lever.... ...2-1 1
Trim angle adjusting rod...
2-11
Warning Indicator(s)
...2-11
Tilt lock mechanism
2-12
Tilt support knob
....2-12
Tilt support bar
. ...2-12
Power tilt unit
....2-12
Top Gowlihq lock lever.....
...2-13
Flush ihg device
...2-13
WARNING SYSTEM
...2-14
Overheat warning
2 -14
Low oil Dressure warnina
.2-14
CD
MAIN COMPONENTS
00944
701061
101121
1
2
3
4
5
6
7
8
9
O
q
w
* &
it
y
* u
i
* o
* p
* a
* s
Top cowling
Tppcowling locklever
Oil drain bolt
Anti-cavitdion plate
Propeller
Cooling water inlet
Trim angle adjusting rod
Qamp bracket
Recoil starter handle
Choke knob
Warning indicator
Gear shift lever
Tillei'handle
Steering friction adjusting lever
Transom clamp handle
Rope attachment
Tilt lock lever
Rushing device
Starter button
Rower tilt switch
Tilt support knob
Remote control
* May not be exactly as shown; also may not

be included as standard equipment on all
models.
2-1
CT)
EMC20010
OPERAnONS OF CONTROLS
AND
OTHER FUNCTIONS
EMC21012
FUEL TANK
If your model was equipped with a
portabi? fuel tank, its fundion is as follows.
1
2
3
4
u
902051
Fuel hose joint

Fuel meter(lf equipped)
Fuel tank cap
Airventscrew(lf equipped)
Fuel hose joint

This connector is provided for connecting
or disconnecting fuel hose.
Fuel meter
This meter is on the fuel tank cap. It
shows current fuel quantity in the fuel
tank approximaitely.
EMC51010
Fuel tank cap

This cap is for filling fuel. To remove it,
turn it Gounterclockw ise.
EMC610,10
Air vent screw

This screw is on the fuel tank cap. To
loosen it, turn it cxjunterclockw ise.
2-2
CD
GEAR SHIFT LEVER (for Til ler control
model)
Turning the gear-shift lever towards you
engages the clutch with the forward gear
so that the boat moves ahead. Turning
the lever away from you engages the
reverse gear so that the boat moves
astern.
1 Neutral
2 Forward
3 Reverse
EMC42210
GHOKE KNOB
Pulling out this knob (setting it to ON)
supplies a rich mixture required to start
the engine.
aiic*4oio
RECOIL STARTER HANDLE

(If equipped)
PuN the handle gently until resistance is
felt. Then vigorously pull! the handle
raight out to aank the engine to start it.
STARTER BUTTON (for Tiller control

model)
When you push the starter button, the
electric starter motor cranks the engine to
start it.
2-3
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TILLER HANDLE (for tiller control
models)
Moving the tiller handle from side to side
changes the steering diredion. In addition, this handle has the following functions.
1
2
3
4
Throttlecontrol grip
Throttleindieator
Throttle friction adjusting knob/screw
Engine stop button/Enginestop lanyard
switch
5 Power tilt switch (if equipped)
EMC40011
Throttle control grip

The throttle control grip is on the tiller
handle. Turn the grip counterclockwise to
increase speed and clockwise to deaease
speed.
EMC40210
Throttle indicator
The fuel consumption curve on the throttle indicator shows the relative amount of
fuel consumed for each throttle position.
Choose the setting that offers the best
performance and fuel economy for the
desired operation.
1 Throttleindieator
2-4
11
CD
EMU01294
Throttle Friction Adjusting Knob

A fridion device in the tiller handle provides resiance to movement of the
throttle grip. This is adjustable for operator preference.
Resistance
Increase
Decrease
Knob
Turn clockwise
Turn countercloc*njse
When constant speed is desired, tighten

the adjusting knob to maintain the
desired throttle setting.
Do not overtighten the friction adjusting
knob. If there is too much resistance, it
may be difficult to move the throttle grip,
which could result in an accident.
EMC27110'
Engine stop button

Pushing this button opens the ignition circuit and ôps the engine.
EMC28210
Engine stop lanyard switch

The lock-plate on the end of the lanyard
must be attached to the engine op
switch for the engine to run. The lanyard
should be attached to a secure place on
the operator's clothing, or arm or leg.
Should the operator fall oyerbbard or
leave the helm, the lanyard will pull out
the lock plate, stopping ignition to the
engine. This will prevent the boat from
running away under power.
2-5
ci:>
to a secure place on your dothing, your
ami or leg while operating.
8 Do not attach the lanyard to dothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing It from
function! ng.
8 Avoid accidentally pulling the lanyard
during nomial operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects in
the lx)at tol)e thrown forward.
NOTE: .
The engine cannot be started with the
loek-plate removed.
1 Lock-plate
2 Lanyard
EMU01323
Power Tilt Switch

The power tilt adjusts the motor angle in
relation to the transom. The power tilt
switch is located on the tiller handle.
Pushing the switch " U P ' tilts the motor
up, Pressing the switch " D N " tilts the
motor down. When the switch button is
released, the motor will stop in its current
position.
NOTE:
Refer to the section "TILTING UP/DOWN"
for ipstrudions on usage.
2-6
^5
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REMOTE CONTROL
Both
ated
tion,
trical
1
2
3
4
5
6
7
the shifter and the throttle are actuby the remote control lever. In addithis remote control also has the elecswitches.
Remotecontrol lever
Neutral interlock trigger
Neutral throttle lever
Main switch/Ghoke switch
Power tilt switch
Throttlefrietioii adjusting screw
Remote Control Lever

Moving the lever forward from the
Neutral position engages Forward gear.
Pulling the lever back from Neutral
engages Reverse. The engine will continue to run at idle until the lever is moved
about 35 (a detent can be felt). Moving
the lever farther opens the throttle, and
the engine will begin to accelerate.
1
2
3
4
5
6
7
2-7
Neutral
Forward
Reverse
Shift
Fully closed
Throtle
Fully open
=9
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N eut ral Interfpck Trigger
To shift out bf Neutral, the neutral Interlock trigger of the remote control lever
must first be pulled up.
EMU00100
Neutral Throttle Lever

To open the throttle without shifting into
either Forward or Reverse, place the
remote control lever in the Neutral position and lift the neutral throttle lever.
NOTE: ^
The neutral throttle, lever will operate only
when the remote control lever is in
Neutral. The remote control lever will
operate only when the neutral throttle
lever is in the dosed position.
1 Fully open
2 Fully closed
EMU00101
Main switch
The main switch controls the ignition system; its operation isdescribed below.
8 OFF
Bectrical circuits switched off.
(The key can be removed^)
8 ON
Bectrical circuits switched on.
(The key cannot be removed.)
8 START
Starter-motor will turn and start engine.
(When the key is released, it returns automatically to "ON".)
2-8
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Choke Switch
While the hiain switch is being pressed in
at " O N " or "START", the choke system
will switch on, to supply a rich mixture
required to start the engine. (When the
key is released, it Will switch off automatically.)
w
1
1 t
000569
Engine Stop Lanyard Switch

The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine
to run. The lanyard 2 should be attached
to a secure place on the operator's clothing, or arm or leg. Should the operator fall
overboard or leave the helm, the lanyard
will pull out the lock plate, stopping ignir
tion to the engine. This will prevent the
boat from running away under power.
8 Attach the lanyard to a secure place on

your clothing, your ami or leg while
operating.
lanyard in such a way that it could
become entangled, preventing it from
functioni ng.
8 Avoid acddentially pulling the lanyard
during normal operation. Loss of
engine power rneans the loss of most
the boat tobe thrown fonA/ard.
NOTE:
The engine cannot be started with the
lock-plate removed.
2-9
CX)
EMU01316
Power Tilt Switch

The power tilt adjusts the motor angle in
relation to the transom. The power tilt
switch is located on the remote control
lever grip. Pushing the switch "UP' tilts
the motor up. Pressing the switch "DN"
tilts the motor down. When the switch
button is released, the motor will stop in
its current position.
NOTE:
Refer to the section "TILTING UP/DOWN"
for instructions on usage.
Throttle Friction Adjusting Screw

A friction device in the remote control box
provides adjustable resistance to movement of the remote control lever, and can
be set according to operator preference.
An adjusting saew is located onthe front
of the remote control box.
Resista nee
Increase
Decrease
Saew
Turn clockwise
Turn counterclockwise

screw. If there is too much resistance, it
may be difficult to move the lever, which
could result in an accident.
2-10
<x>
EMU 01295
STEE RING FRICTION ADJUSTING

LEVER
A friction device provides resistance to
steering movement. This is adjustable
according to operator preference.
i" 'I l . - ' " . r
Resistance
Increase
Decrease
408033
Lever
Turn to port
Turn to starboard

lever. If there is too much resistance, it
may be difficult to steer, which could
result in an acddent.
EMU01297
TRIM ANGLE ADJUSTING ROD

The position of the trim angle adjusting
rod determines the minimum trim angle
of the outboard motor in relation to the
transom.
EMU01128
WARN IN G INDICATC>R(S)
If the engine develops a condition monitored by the warning system, an indicator
will come on.
Refer to the "WARNING SYSTEM" section for details.
1 Warning indiGator(s)
2-11
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TILT LOCK MEGHANISM (for Manual
tilt model)
The tilt-lock mechanism Is used to prevent reverse thrust from the propeller lifting the outboard motor when reversing.
To lock it, set the tilt-lock lever in the Lock
position. To release it, place the tilt-lock
lever in the Tilt position.
1 Tilt-lock lever
EMU00155'
TILT SUPPORT KNOB

To keep the outboard motor in the tiltdup position, push the tilt support knob
under the swivel bracket.
EM D4801P'
TILT SUPPORT BAR

The tilt support bar 1 keeps the outboard
motor in the tilted up position.
EMU01348
POWER TILT UNIT

This unit tilts the motor up and down and
is controlled via the power tilt switch.
1 Power tilt unit
2 Power tilt motor
Do not step on or exert pressure on the

power tilt motor. The power tilt unit
qouid be damaged as a result.
2-12
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EMD62011
TOP COWLING LOCK LEVER

To remove the engine top cowling, turn
the lock lever. Then lift off the cowling.
When replacing the cowling, check to be
sure it fits properly in the rubber seal.
Then lock the cowling again by moving
the lever upward.
1 Top cowling locklever
FLUSH IN G DEVICE
This device 1 is used to dean the cooling
water passages of the motor using garden hose and tap water.
NOTE:
^ _
Refer
to
"Cleaning
Cooling-water
Passages" in Chapter 4 for instrudions on
usage.
2-13
CD
WARNING SYSTEM
Do not continue to operate the engine if

the warning device has activated. Consult
your Yamaha dealer If the problem cannot be located and corrected.
EMU00T70
OVERHEAT WARNING
This engine has an overheat warning
device. If the engine temperature rises too
high, the warning device will activate.
(1 ); Included ()i N/A
Activation of
warning device
Tiller
control
model
Remote
control
model
The engine speed v\/iil

automatically decrease
to about 2,000 r/min.
The overheat warning

indicator will come on.
Thebuser will sound.
If the warning system has been activated,

stop the engine and check the water inlet
for clogging.
2-14
<x>
EMD86112
LOW OIL PRESSURE WARNING

If oil pressure drops too low, the warning
device will adivate.
(1 ):lncluded ():N/A
Activation of
warning device
Tiller
control
model
Remote
control
model
Enginespeed will
automatically decrease
to about2,(CKX)r/min.
The low oil pressure

warning indicator
will corne on.
Th e b u ^ r wil 1 so u n d.
If the warning system has been activated,

stop the engine as soon as it is safe to do
so. Check oil level and add oil as needed.
If the oil level Is correct, consult your
Yamaha dealer.
Do not continue to run the engine If the
low oil presisure lamp is "ON". Serious
engine damage may occur.
2-15
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EMF00010
Chapter 3
--^
OPERATION
INSTALLATION . ...
.3- 1
Mounting the outboard motor
3-2
Clamping the outboard motor......
.3-4
BREAKING IN (RUNNING IN) ENGINE .3-5
PRE-OPBRATION CHECKS
Checking the engine oil level
FILUNGFUEL
3-6
3-7
.3 -8
STARTING ENGINE
,3-9
WARMING UP BSIGINE
.......3 -16
SHIFTING
Forward
Reverse
..
STOPPING ENGINE.
.3-17
..3-17
. 3-18
...3-19
TRIM MIN G OUTBOARD MOTOR

Adjusting trim angle
TILTING UP/DOWN
...3- 20
3-21
3-24
CRUISING IN SHALLOW WATH?.
.3- 28
CRUISING IN OTHER CONDmONS 3 -31

Cruising in salt water
3 -31
Cruising in turbid water
3-31
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EMF10010
INSTALLATION
Incorre et engine height or ot>structions to

smooth water flow (such as the design or
condition of the boat or accessories such
as transom ladders/depth Ander transducers) can create airborne water spray
while the boat is cruising. Severe engine
damage may result if the mcôr is operated continuously in the presence of airborne water spray.
NOTE:
During water testing check the buoyancy

of the boat, at rest, with its maximum
load. Check that the static water level on
the exhaust housing isilow enough to prevent water entry into the powerhead,
when water rises due to waves when the
outboard is not running.
3-1
CT:>
EMF12012
MOUNTING THE OUTBOARD

MOTOR
Improper mounting of the outboard
motor could result In hazardous oonditjons such as poor handling, loss of control, or fire hazards Observe the following:
8 The infomiation presented in this ction is intended as reference only. It is
not possible to provide complete
instruct ions
for
every
possible
boat/m(4 or
combination.
Proper
mounting depends in part on experience and the specific boat/motor combinatbn.
8 Your dealer or other person experienced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person, [pennanent
mounte d type]
8 Your dealer or other person experienced in proper outboard
motor
mounting should show you how to
mount your motor, [portable type]
Mount the outboard motor on the nter
line (keel line) of the boat, and ensure that
the boat Itself iswell balanced. Othen/vise,
the boat will be hard to steer. For boats
without a keel orwhich are asymmetrical,
consult your dealer.
I J
1 /
1 /
1 1
1 /
1 /
1 Center line (keel line)
iT
104011
1
P
3-2
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Overpowering a boat may cause severe
instabil'it y. Do not install an outboard
motor with more horsepower than the
maximum rating on the capacity plate of
the boat. If the boat does rrat have a
capacity plate, consult the boat manufacturer.
Mount ing Height

To run your boat at opt im urn ffideney,
the water-resistance (drag) of the boat
and outboard motor mu be made as little as possible. The mounting-height of
the outboard motor greatly affeds the
water-resia nee. If the mounting-height
istpo high, cavitation tends to occur, thus
reducing the propulsion; and if the propeller tips cut the air, the engine speed
will rise abnormally and cause the engine
to overheat. If the mounting-height is too
low, the water-resistance will ihaease
and thereby reduce engine efficiency.
IVIount the engine so that the anti-eayitation plate is between the bottom of the
boat and a level 25 mm (1 in.) below it.
NOTE:
8 The optimum mounting height of the
outboard motor is affected by the
boat/motor
combination
and
the
desired use. Test runs at different
heights can help determine the optimum mounting height.
8 Refer to the section "TRIMMING OUTBOARD MOTOR" for instructions on
setting the trim angle of the outboard.
3-3
.-fc^
CT)
CLAMPINGTHE OUTBOARD MOTOR
1)
Haee the outboard on the transom so

that it is positioned as dose to the
nter as possible. Tighten the transom damp SCTews evenly and securely. Check the damp-screws for tightness occasionally during operation of
the motor asthey can work loose due
to engiiie vibration.
L(X)se damp screws could allow the

motor to move on the transom or fall off
the transom. This could cause loss of
control and serious injury. Make sure the
transom screws are tightened securely.
Occasionally check the screws for tightness during operatrn.
2)
An engine restraint cable or chain

should be used. Attach one end to
the engine restraint cable attachment
point and the other to a secure
mounting
point
on the
boat.
Otherwise, the engine could be completely lost if it accidentally falls off
the transom.
Secure the damp bracket to the transom with the bolts provided with the
outboard. For details, consult your
dealer.
Avoid uising bolts, huts or washers other

than those contained in the engine packaging. If used, they must be of at least
the same quality of material and strength
and must be tightened securely. After
tightening, test mn the engine and check
their tightness.
1 Motor mounting parts
3-4
cr>
BREAKING IN (RUNNING IN)
ENGINE
Your new engine requires a period of
break-in (running-in) to allow mating surfas of moving parts to wear-in evenly.
Correct break-in (running-in) will help
ensure proper performance and longer
engine life.
Failure tofollow the break-in (running-in)
procedure rnay result in reduced engine
life Greven severe engine damage.
Break-in (running-in), time: lOhours
EMF53711
Run the engine under load (in gear with a

propeller installed) asfoHws.
1) For the first hour of operation:
Run the engine at 2,000 r/min or at
approximate iy half throttle.
2) For the second hour of operation:
Run the engine at '3,000 r/min or at
approximate Iy three-quarter throttle,
and during this period run it at full
throttle for approximately one minute
every ten minutes.
3) For the next eight hours of operation:
Avoid continuous operation at full
throttle for more than five minutes at
a time.
4) After these first 10 hours:
Operate the engine normally.
3-5
cx>
PRE-OPERATION GHECKS
If any item in the pre-^peratin check is

not working properly, have it inspected
and repaired before operating the outboard motor. Otherwise, an accident
could occur.
Do not start the engine out of water.

Overheating and serious engine damage
can occur.
EMF41liO
Fuel
8 Check to be sure you have plenty of fuel
for your trip.
8 Make sure there are no fuel leaks or
gasoline fumes.
8 Check fuel line connGtions to be sure
they are tight,
8 Be sure the fuel tank i positioned on
secure, flat surface, and that the fuel
hose isnot twisted or flattened, orlikely
to contact sharp objects.
EMF42210
Oil
8 Check the level of the oil in the sump
with the dipîck. If necessary, add oil to
bring the level up to the upper mark.
3-6
/^
cr>
Controls
8 Check throttle, iift, and steering for
proper operation before starting the
engine.
8 The controls should work smoothly,
without binding or unusual free play.
8 Look for loose or damaged connections.
8 Check operation of the barter and stop
switches when the outboard motor is in
the water.
EMF43511
Engine
8 Check the engine andengine mounting.
8 Look for loose or damaged fasteners.
8 Cheek the propeller for damage.
CHECKING THE ENGINE OIL LEVEL

1)
2)
3)
4)
/"
c^
Put the outboard motor in an upright

position (not tilted).
Pull out the oil dipstiek and wipe it
clean.
Completely re-insert the dipstick and
pull out it again.
Check the oil level using the dipstiek
to be sure the level falls between the
upper and lower marks. Fill with oil if
it is below the lower mark, or drain to
the specified level if it is above the
upper rnark
1 Oil dipstick
2 Lower level mark
3 Upper level mark
/ J.
201012
3-7
CX)
FILLING FUEL
1)
2)
3)
Remove the fuel tank cap.

Fill the fuel tank carefully.
Close the cap securely after refueling.
Wipe up any spilled fuel.
Fuel tank capacity:
Referto SPEGIFIGATION S, page 4 - 1 .
EM F21110
Ring Free Fuel Additive

Gasoline is a predse blend of many different substances, eajc^ chosen to give certain characteristics. Gasoline blends have
been changing
in recent
years in
respi3nse to concerns about pollution and
resulting emissions regulations. One of
the most obvious changes has been the
elimination of lead from most fuels.
As gasoline has changed, the amount of
additives such as aromatics and oxygenates has Increased. These additives
iare irnportant for the engines in passenger ears, but they can have detrimental
effects in marine engines, because of
increased deposits in the combustion
chamber. When enough deposits colled,
pision rings begin sticking. Performance
drops and engine wear increases draniatically.
While many additives available may
reduce deposits, Yamaha recommends
the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free
has repeatedly proven its ability to clean
combusti on deposits from inside the
engine, notably the critical piston-ringland area, and fuel system components.
Follow product labeling for use instructions.
3-8
cr>
EMU 01147
STARTING ENGINE
902053
I: '^
*
11
14. ^
304044
8 Before starting the engine, make sure

that the lx>at istightly moored and that
you dan steer dear of any obstructidhs.
Be sure there are no swimmers in the
water near you^
8 When the air verit screw is loosened,
gasoline (petrol) vapor will be released.
Gasoline (petrol) is highly flamrhable,
and its vapors are f|amnnab|e and
explosive. Refresh from smoking, arid
keep away from open flames and
sparks while loosening the air vent
screw.
8 This product emits exhaust gases
which contain carix>n monoxide, a coU
prjess^ odorless gas which may cause
birain damage or death when inhaled.
Symptoms include nausea, dizzinesi^
and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid
blodking exhaust outlets.
1) If there isan air vent screw on the fuel
tank cap, loosen it 2 or3 turns
2) If there is fuel joint on the nitr,
fjrmly connect the fuel line to the
joint. Then firmly connect the other
end of the fuel line to the joint on the
fuel tank.
NOTE:
During engine operation place the tank

horizontally , or fuel cannot be drawn into
the engine.
3) Squeeze the primer bulb with the outlet end up until you feel it become
firm.
3-9
s-
cr>
PROCEDURE FR TILLER CONTROL
MODEL
4) Hace the gear-shift lever in the neutral position.
N011E:
mSi
The start-in-gear protedion device prevents the engine from starting except
when in Neutral.
5)
Attach the engine stop switch lanyard

to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate oh the other end of the lanyard
in the engine stop switch.

to a secure place on your dpthing, your
ami orleg while operating.
that could tear loose^ Do not route the
lanyard where it could become entangled, preventing it from functioning.
8 Avoid acddentally pulling the lanyard
power, the tx>at could slow rapidly.
the boat tobe thrown forward.
6)
3-10
Race the throttle control grip in the

"START" position.
ci:>
Manual start model
7) Pull out theehoke knob completely.
After the engine starts, return the
knob to the original position.
NOTE:
8 It is not necessary to use the choke

when restarting a warm engine.
8 If the choke knob is left pulled out after
the engine starts, the engine will stall.
8) Pull the starter handle slowly until
you feel resi^ânce. Then, give a
strong pull straight out to crank: and
start the engine. Repeat it, if necessary.
9) After the engine starts, return the
starter handle slowly to the original
position befoi' releasing it.
10) Return the throttle to the fully closed
position.
3-11
a^
EMF63511'
Bectric start model

7) Pull out the ehoke knob completely.
choke knob to the original position.
NOTE:
when restarting a warm engine.
8 If the choke knob Is left pulled out, the
engine will stall.
Push the strter-btton to start the
starting motor.
9) Immediately the engine starts, release
the starter-button to return it to the
original position.
10) Return the throttle control grip slowly
to the fully closed position so that the
engine does not stall.
8)
8 Never push the starter-switch while the

engine is running.
8 Do not keep the starter motor tuming
for more than 5 seconds. If the startermotor is turned continuously for more
than 5 seconds, the t>attery will be
quickly discharged, thus making it
impossible to start the engine, If the
engine will nol start after 5 seconds of
cranking, release your hand from the
starter-switc h, and crank the engine
again after an interval of 10 seconds
3-12
CD
EMU00247
N'^
PROCEDURE FOR REMOTE

CONTROL MODEL
4) Race the remote control lever in the
Neutral position.
NOTE:
'^^^"pv
Jn
701015
The start-in-gear protection device prevents the engine from starting except
when in Neutral.
5) Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate on the other end of the lanyard
in the engine op switch.
to a secure place on your dcthing, your
ami or leg vvhile operating.
lanyard v\^here it oould become entangled, preventing from functioning.
8 Avoid acdentally pullihg the lanyard
the boat to be throw n forward.
6) Turn the main switch to "ON",
3-13
>
BectriG Start Model
7) Open the throttle slightly lifting the
neutral throttle lever upwards partially. You may need to change the throttle opening slightly depending on
engine temperature.
throttle to the original position.
NOTE:
8 As a starting point, lift the lever just
until you feel resistance, then lift slightly more.
8 The operation of the neutral throttle
lever is possible only when the remote
control lever is in " N " .
8) Resînand hold themain switch to
opei'afe the remote choke syêm.
(The remote choke switch returns to
its home position when you release
your hand. Therefore, keep the switch
pressed in.)
NOTE:
when the engine is wrm.
8 Set the choke knob to the home position, or the remote choke system will
not operate.
701042
9) Turn the main switch to "START",

and hold it for a maximum of 5 seconds.
10) Immediately after the engine starts,
release the main switch to return it to
"ON".
701041
3-14
cjy
8 Do not tum the main switch; to
"START' when the engine is running.
8 Do not keep the starter-motor tuming
for more than 5 seconds. The battery
will rapidly become exhausted and it
will be irppossible for it to start the
engine. If the engine does not start
within 5 seconds, retum the rnin
switch to "ON", wait 10 seconds;, and
then crank the engine again.
3-15
CT>
EMG0041;1
WARMING UP ENGINE
1)
2)
3)
Before beginning operation, allow the

engine to warm up at idling speed for
3 minutes. (Failure to do this will
shorten engine life.)
Be sure the low oil pressure warning
indicator goes off after starting the
engine.
Check for a steady flow of water from
the coQiing-water pilot hole.
8 If the low oil pressure indicator does

not go off after the engine starts, stop
the engine. Othen/vise, serious engine
damage oould occur. Check the oil level
and add oil if necessary. If the cause for
the low oil pressure warning indicator
canned be found, consult your Yamaha
dealer.
8 A continuous flow of water from the
pilot hole shows that the water pump
is pumping water through the cooling
passages. If water is not flowing out of
the pilot hole at all times while the
engine is running, do not continue to
run the engine. Overheating and serious damage could occur. Stop the
engine and check to see if the water
inlet on the lower caang is blocked- If
the problem cannot be found and corrected, ccMisult your Yamaha dealer.
3-16
Jr
CX)
EMU00261
SHIFTING
Before shifting, make sure there are no

swnnmers orobstades in the water near
you.
To diange the shifting position from forward to reverse or yioe-versa, dose the
throttle firt so that the ertgirte idles (or
runs at bw speeds).
EMU00265
FORWARD
Til ler control rhodl
>\
^1^\
1) Habe the throttle control grip In the

fully dosed position.
2) Turn the gear-shift lever quickly and
firmly from Neutral to Forward,
Remote control model

Pull up the neutral interlock trigger if
equipped and move the remote control
leVer quickly and firmly from Neutral to
Fonward.
3-17
.-fc^
cx>
EMU01326
REVERSE
When operating in Reverse, go slow ly. Do
not open the throttle more than half.
Otherwise, the boat may become unstable, w hich could result in loss of control
and an accident.
1) Rape the throttle control grip in the

fully dosed position (for filler control
model).
2) Check that the tilt-lock lever (for
Manual tilt/lHydro-tilt model) is in the
locked position.
402013*
Tiller control rriodel
3) Turn the gear-shift lever quickly and

firmly from Neutral to Reverse.
U^'f^.^
,.406025
Remote control model

3) Pull up the neutral ihterlock trigger if
equipped and move the remote control levr quickly and firmly from
Neutral to Reverse.
3-18
cx>
EMU00273
STOPPING ENGINE
Let it cool off for a few minutes at idle or
low speed first. Stopping the engine
immediately after operating at high speed
is not recommended.
EMUOOZ77
1) Rjsh and hold the engine ôp button

or turn the rriin switch to "OFF".
~-:*\n
-^- ' ^ J'U

^^='*~
"vSîift.'
''^\u
[ >
2) If the fuel joints are provided, djlcohnect the fuel line from the motor after
stopping the engine.
304045
3) Tighten the air vent screw oh the fuel

tank cap after stopping the engine, if
it is equipped.
4) Remove the key if the boat will be left
unattende d.
NOTE:
The engine can also be stopped by
pulling the lanyard and removing the lock
plate from the engine; stop lanyard switch
(then turning the main switch to "OFF").
3-19
a>
J:
EMU01412
TRIMMING OUTBOARD
MOTOR
The trim angle of the outboard motor
helps determine the position of the bow
of the boat in the water. The correct trim
angle will help improve performance and
fuel economy while reducing rain on the
engine. The correct trim angle dependis
upon the combination of boat, engine,
and propeller. Correct trim is also affected
by variables such as the load in the boat,
sea conditions, and running speed.
Excessive trim for the operating conditions (either trim up or trim down) can
cause tx>at instability and can make
steering the boat more difficult. This
increases the possibility of an accidents If
the boat begins to feel unstable oris hard
to steer, slow down and/or readjust the
trim angle.
NOTE:
,
Refer to the section "ADJUSTING TRIM
ANGLE' for instructions on usage.
1 Trim operating angle
3-20
CF>
ADJUSTING TRIM ANGLE
EMU 00951
Manual tilt model

There are 4 or 5 holes provided in the
damp bracket to adjust the outboard
motor trim angle.
1) Stop the engine.
2) Remove the trim angle adjusting rod
1 from the clamp bracket vyhile tilting
the motor up slightly.
3) Reposition the rod in the desired hole.
To raise the bow ("trim-out"), move the
rod away from the transom.
To lower the bow ("trim-in "), move the
rod toward the transom.
Make test runs with the trim set to different (angles to find the position that works
best for your boat and operating conditions.
8 Stop the engine before adjusting the
trim angle.
8 Use care to avoid being pinched when
removing or installing the rod^
8 Use (utipn when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability or Control problems. Improper trim
angle can cause loss of control.
NOTE: .
The outboard motor trim angle can be

changed approximately 4 degrees by
shifting the trim adjusting-rod one hole.
3-21
cx>
EMU014U
PcwerTilt Model
8 Be sure all people are dear of the outboard motor when adjusting the tilt
angle, also be careful not to pinch any
body parts between the drive unit and
damp bracket.
8 Use caution when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability or control problems Improper trim
angle carl cause loss of control.
8 Use the power tilt switch located on
the
bottorh
engine cowling (if
equipped) only when the boat is at a
comptete stop with the engine off.
1) Hee the geiar-shift lever in the neutral position.
2) Tilt the engine to the desired angle
using the power tilt switch.
NOTE: ^__
Stay within the trim operating angle when
trimming the outboard motor using the
power tilt system.
To raise the bow ("trim-out"), tilt the
engine up.
To lower the bow C'trim-in"), tilt the
engine down.
Make test runs with the trim set to different angles to find the position that works
best for your boat and operating conditions.
3-22
CX>
EMU19160
Tri mangle settings and boat handling

When the boat ison plane, a bow-up attitude results in less drag, greater stability
and efficiency. Tliis Is generally when the
keel line of the boat is up about 3 to 5
degrees. With the bow up, the boat may
have a greater tendency to steer to one
side or the other. Gqmp^
for this as
you steer. The trim tab can also be adjusted to help offset this effect.
1 Optimum angle (leyel keel line)
2 Bow up
3 Bow down
Bow Up
Too much trim-out puts the bow of the
boat too high in the water. Performance
and economy are decreased because the
hll of the boat ispushlng the water and
there is more air drag. EKcessive trim-out
can also cause the propeller to vehtilte,
which reduces performance further, and
the boat may "ppfpoise" (hop in the
water), which could throw the operator
and passengers pyerboard.
Bow Down
When the bow of the boat is down, it is
easier to accelerate from a standing start
onto plane. Too much trimîh causes the
boat to "plow" through the water,
decreasing fuel economy and making it
hard to increase speed. Operating with
excessive trim-in at higher speeds also
makes the boiat unstable. Resistance at
the bow is greatly increased, heightening
the danger of "bow steering" and making
operation difficult and dangerous.
3-23
cx>
NOTE:
Depending on the type of boat, the outboard motor trim angle may have little
effect on the trim of the boat when operating.
EMH10111
TILTING UP/DOWN
If the engine will be stopped for some
time, or if the boat Is moored in shallows,
the engine should be tilted up to protect
the propeller arid casing from damage by
collision with obstructions, and also to
reduce salt corrosion.
8 Before tilting the mcôr; follow the procedures under "STOPPING ENGINE".
Never tilt the motor while the engine is
running. Severe damage from overheating can result.
8 Do not tilt up the engine by pushing
the steering handle as this could break
the handle.
Be sure ail people are dear of the

board motor When adjusting the
angle, also be careful not to pinch
body parts between the drive unit
engine bracket.
outti|t
any
and
Leaking fuel is fire hazard. Disconnect

the fuel line if the engine will befitted for
more than a few minutes. Otherwiise, fuel
may leak, (if the fuel connector is provided on the motor.)
3-24
3z
CT)
EMU00290
PROCEDURE FOR TILTING UP

Mariual tilt model
1) Race the gear shift lever in Neutral.
2) Remove the fuel line connection from
the motor.
^
U--'=-^3) Hace the tilt lock lever in the release
position.
4)
Hold the rear of the top cowling with
_ ^406023*
one hand and fully tilt the engine up.
5) The tilt support bar tui-ns to the
locked position automatically.
403**3
BUIU00300
PROCEDU RE FOR TILTING DOWN

Manual tilt moctel
1) Race the tilt lock lever in the lock
position.
2) Slightly tilt up the engine until the tilt
support bar is released automatically.
3) Tilt down the engine.
3-25
cx>
EMU01312
>^
PROCEDURE FOR TILTING UP

Power tilt model
!'
^5^^^^-^5^"^-
1) Remove the fuel-line connection from

the motor.
.\
304045
-
'\
'.I
m^ . rtM
DN
&i
^m / '
'
2) Push the power tilt switch "UP' until

the outboard has tilted up completely.
p
701034;
3) Push the tilt support knob into the

clamp bracket tosupport the engine.
After tilting the engine, be sure to support it with the tilt support knob.
Otherwise, the erigine could fall back
down suddenly if oil in the power tilt unit
should lose pressure.
3-26
a>
fc^
EMU01313
PRO CE DU RE FOR TILTI N G DOWN

Power titt model
1) Push the power tilt switch "UP' until
the engine is supported by the tilt rod.
2) Pull out the tilt support knob.
3) push the power tilt switch "DN"
(Down) to lower the engine to^ the
desired position.
3-27
CI>
CRUISING IN SHALLOW
WATER
Manual tilt model
The outboard motor can be tilted up partially to allow operation in shallow water.
8 Ra the gear îft in the Neutral position before using the shallow Water
cruising system.
8 Run the boat at the lowest possible
speed when using the shallow water
cruising system. The tilt-lock mechanism does not work while the shallow
water cruising system is being used.
Hitting an underwater obstade coukJ
cause the engine to lift out of the
water, resulting in loss of control.
8 Use extra care when operating in
reverse. Too much reverse thmst can
cause the engine to lift out of the
water, inoeasing the chance of acddent and personal injury.
8 Retum the engine to its normal position as soon ais the boat is back in
deeper water.
Place the gear-shift in the Neutral posi^

tion before ung the shallow water cruising system.
3-28
3-
cx>
PROCEDURE
Manual tilt model
1) Race the gear shift lever in the neutral position.
.406023*
2) Haee the tilt lock lever in the release

position.
3) Slightly tilt up the engine. The tilt-^

support bar will lock automatically,
supporting the engine in, a partially
raised position.
NOTE: ; : ;
,
This motor has 2 positions for shallow
water auising.
:403056
RETURNING TO ORIGINAL POSITION

1) Race the tilt lock lever in the lock
position.
2) Slightly tilt up the engine until the tiltsupport bar automatically returns to
the free position.
3) Then, slowly lower the engine to the
normal position.
3-29
Ir
C>
CRUISING IN SHALLOW
WATER
Power tilt model
The engine can b tilted up partially
allow operation in shallow water.
to
000922
8 Race the gear shift in the Neutral post^

tion before setting for shallow water
cruising.
8 Return the engine to its normal position as soon s the boat is t}ack in
deeper water.
m^ w^
nM~"ij
DN
^gN / ,
Do not tilt up the outboard motor so that

the cooling water inlet of the lower unit
IS above the surface of the water when
setting for and cruising in shallow water.
OthenAîse severe damage from overheating can result.
p
701034
PROCEDURE
1) Hape the gear shift lever in the neutral position.
2) Slightly tilt up the engine using the
power tilt switch.
3-30
fc^
CD
GRUISINX3 IM OTHER
CNITIONS
CRUISING IN SALT WATER
After operating in salt water, wash out the
oling-water passages ,with fresh water
to prevent them from bêeoming dpggedup with salt deposits.
NOTE: ^
Refer to cooling syem flushing in^ruotions in "TRANSPORTING AN STORINlG

OUTBOARD MOTOR".
CRUISING IN TURBID WATER
It is strongly recommended that the
optional chromium-plated water-pump kit
be installed if the outboard is to be used
in turbid (muddy) water conditions.
3-31
cr>
EMK00010
Chapter 4
AINTENANCE
SPECIFICATIONS
.4 -1
TRANSPORTING AND STORING

OUTBOARD MOTOR...........
4-3
Trallefin g outboard motor
4-3
Storing outboard motor.
4-5
PBRIODIG MAINTENANCE
.4-9
Replacement parts
4-9
Maintenance chart
....4- 10
Greasing......
.;,;.......; .^.......4-12
Cleaning and adjusting spark plug ...4-13
Checking top cowling ................ .i.......4-14
Checkirig fuel system
...4-15
Inspecting fuel filter
4-16
Inspecting idling speed
.:4-17
Changing engine oil...
4 -18
Replacing fuse
.........4-20
Checking wiring and connectors...... ,4-21
Exhaust leakage................
.,4-21
Water leakage
4-2 1
Checking power tilt system.v;;^..,.. .....;4-22
Checking propeller...
....4-23
Changing gear oil............
...4-25
Cleaning fuel tank
4 -26
Inspecting and replacing anode(s)....4-27
Chedkihg battery
;4-28
Checking bolts and nuts
4-30
Cleaning cooling-^watef passages .....4-31
Motor exterior
4-32
Coating the boat bottom .........,..;. ...4-32
ay
SPECIFICATIONS
^""'~~"~^~-.,,__^^
Model
Item
^"~'"~~~~~^.^^^^
DIMENSIONS
Overall Length
Overall Width
OverallHeight
Transom height
Weight
Unit
F15IVIHC
mm,(in.)
mm (in )
mm (in.)
mm (in.)
kgOb.;)
S/L
S/L
S/L
1,001(39.4)
427(16.8)
1,080 (42.5)/1,207 (47.5)
440 (17.3)/567 (22.3)
45(99)/47(104)
PERFORMANCE
Fullthrottle operating range
Mximuna: output
Idling speed (Neutral)
ENGINE
Type
Displament
Bore X stroke
Ignition system
Sparkplug
Sparkplug, gap
Gphtrpis/em
Staftihgsystem,
A/alveciearance (cold engine)
r/min
kW (HP):@:r/min
r/miri
cnri^ (cu.i n.)

mm (in.)
NGK:
mm (in.)
IN
EX
Battery
lyiin. coldCTan king amps (CCA/SAE)
Min.marihcrarikingamps(MG'VABYQ
Min. reserve capacity (RG/SAE)
AiternatoF output
Startingcarburetion system
mm (in.)
mmj(in.;)
ampsat-18C(<).4F)
amps at;pC(32F)
minutes
V-A :(W)
4,500 5.500
11.0 (15.0) @5,000
900 -1000
4-strke, OHC, L2
323(19.71)
59.0x59.0(2.32x2.32)
GDI system
DPR6EA-9
0.8 0.9(0.031 0.035)
Til ler control
Manual start
0.15 0.25(0:006 0.010)
0.20 0.30(0.008 0.012)
12-(80)
Choi valve
DRIVENIT
Genpsitiohs
Gearratio
Trim and tilt system
Propellermark
Forward-Neutral-Reverse
2.08(27/13)
Manual tilt
J
FUa.NDOIL
Recommnde d fuel
Feltank capaeity
Recommended engine oil
Engine pil'capacity (withput oil filter)

(with oil filter)
Recorrimended gear oil
Gearoil capacity
P.O.N.
L (US gal, Irnpgal)
API
SAE
L (US qt, Imp qt)
L(USqt, Impqt)
CTn^(USpz, Imp oz)
Regular unleaded gasoline

(Minimum 86)
25(6.60,5.50)
4-strokB motor oil
SESF,SG, SH.SJ
10W-30,10W-40
1.0(1.06,0.88)
1.2(1.27,1.06)
Hypoid gear oil (SAE90)
250(8.45,8.80)
TIGHTENING TORQUE
Sparkplug
Propeilernut
Engine oil drain bolt
Engine oil filter
N-m
N-m
N-m
N-m
(kgf'm,
(kgf-m,
(kgf-m,
(kgf-m,
Ib-ft)
Ib-ft)
Ib-ft)
Ib-ft)
4-1
18(1.8,13)
35(3.5,25)
28(2.8,20)
18(1.8,13)
ci:>
F15EHC
F15PRC
F15PHC
1,001(39.4)
427(16.8)
1,080 (42.5yi,207 (47.5)
440 (17.3)/567 (22.3)
48 (106)/50(110)
643(25.3)
369(14.5)
/1,207(47.5)
/567(22.3)
/54(119)
1,001 (39.4)
427(16.8)
^1,207(47.5)
/567 (22.3)
/55(121)
4,500 5,500
11.0(15.0)@5,000
900 -1000
4,500 5,500
11.0:(15.0)@5,000
900 r1000
4,500 5,500
11.0(15.0) @5,000
900 -1000
4-Etrofe, 0HG,L2
323(19.71)
59.0x59.0(2.32x2.32)
CDI system
DPR6EA-9
0.8 0.9(0.031 0.035)
Tillerebntrbl
Bedricaft
0.15 0.25(0.006 0.010)
0.20 0.30(0:008 0.012)
4-roke, OHC, L2
323(19.71)
59.0x59.0(2.32x2:32)
CDI syem
DPR6EA-9
OS 0.9 (0,031 0.035)
Remote control
Bectric start
0.15 0.25(0;006.10):
0.20 0.30(0:008 0.012)
4-.strote, OHC, L2
323(19.71)
59.0x59.0(2.32x2.32)
CDI system
DPR6B\-9
0.8 0.9(0.031 0.035)
Tiller control
Bedricstart
0.15 0;25(0.006 0.010)
0.20 0.30(0.008 0.012)
245
323
52
12-10
Chote valve
245
323
52
12-10
Choke valve
245
323
52
12-10
Choke valve
Forward-Neutral-Ryerse
2.08(27/13)
Manual tilt
J
Forwrd-Neutral^Reverse
2.08(27/13)
Ftowertilt
J
Forward-Neutral-Reyerse
2.08(27/13)
Fbwer tilt
J

(Minimum 86)'
25 (6.60,5.50)
4-stroke motor oil
SE, SF,SG,SH, SJ
10W-30,10W^0
1.0(1.06,0.88)
1.2(1.27, 1.06)
Hypoid gear oil (SABO)
250(8.45,8.80)
Regular unleaded gasoNnei

(Minimum 86)
25(6.60,5.50)
4-strke motor oil
SE,SF,SG, SH.SJ
10W-30,10W-40
1.0(1.06,0.88)
1.2(1.27,1.06)
Hypoid.gear oil (SAE90)
250(8.45,8.80)

(Minimum 86)
25 (6.60,5.50)
4-stroke motor oil
SE,SF,SG,SH,SJ
10W-30, lOWÔ
1.0(1.06,0.88)
1.2(1.27, 1.06)
Hypoid gear oil (SAE90)
250(8.45,8.80)
18(1.8,13)
35 (3.5,25)
28 (2:8,20)
18(1.8,13)
18.(1.8, 13)
16(1.6, 11)
27(2.7, 20)
18(1.8,13)
18(1.8,13)
16(1.6,11)
27(2.7,20)
18(1.8,13)
4-2
CI>
EMU 01369-
TRANSPORTING AND
STORING OUTBOARD MOTOR
Leaking fuel Is a fire hazard. When transporting and storing the outboard motor,
dose the air vent screw and fuel cock to
prevent fuel from leaking.
EMK20210-
TRILERING OUTBOARD MOTOR

The ^mtor should be trailered and stored
In the normal runhlng positlon. If there is
insuffldent: road dearanee in this position,
then trailer the rnotor in the tilt position
using a motor support device such as a
transom saver bar.
For further details, consult your Yamaha
dealer.
8 Never get under the lower unit while it

is tiKed, even if a motor support bar is
used. Severe injury could occur if the
outboard cdentally faljSL
8 USE CARE when transporting fuel tank,
w hefher in a boat or car.
DO NOT fill fuel container to maximum
capadty. Gasoline will expand conaderably s it wantis up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazards
Do not use the tilt support lever/knob

when trailering the boat. The outboard
m(ôr could shake loose froni the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additk>nal support device to secure it in
the uppositkHi.
4-3
cX>
Clamp handle mounting model
When transporting or storing the outboard motor while removed from a boat,
fold the tiller handle and lean the motor
on the tiller handle tokeep ina horizontal
posit i on.
Keep the power unit higher than the propeller at all times Othen/vise, cooling
water can mn into the cylinder, which
could result in damage.
NOTE:
Place a towel or the like under the outboard motor to proted it from damage.
4-4
cx>
EMK16210'
STORING OUTBOARD MOTOR

When storing your Yamaha outboard for
prolonged periods of time, (2 months or
longer), several important
produres
must be performed to prevent expensive
damage.
It is advisable to have your outboard serviced by an authorized Yamahia dealer
prior to storage. :Howyer; the follovving
procedu res can be performed by you,, the
ov/ner, witli a minimum of tools,
f^^\
jwn^
m
\
000923
MsUtaBLîCiriiMi^^Ê&i^ /
hr==?^^âp^^^^
8 To prevent problems whieh can 'be

caused by oil entering the cylinder from
the sump, keep the engine in the attitude shown w;hen transporting and
storing it.
8 Do not place the engine on its skle
before the coolirtg Water has drained
from it completely, or water may enter
the cylinder through the exhaust port
and cause problema
8 Store the engine in a dry, well-ventilated place, not indirect sunlighti
1 Vertical position
2 HoriaDntal ppsitipn (onthe pprt side)
EMK21010
10206 5
Filling Fuel Tank

Fill the fuel tank with fresh fuel and add
one ounce of "Yamaha Fuel Conditioner
and Stabilizer" (Part No. LUB-FUELC-1200) to each gallon of fuel.
NOTE:
The use of "Yamaha Fuel Gonditioner and
Stabilizer" eliminates the need to drain
the fuel system. Consult your Yamaha
dealer or other qualified mechanic if the
fuel system isto be drained instead.
4-5
CX)
EMU 00338
Flushing Cooling System and Fogging

Engine
Cooling system flushing is essential to
prevent the oling system from clogging
up with salt, sand, ordirt. Inaddition, fogging of the engine is mandatory to prevent expensive engine damage due to
rust. Perform the flushirig and fogging at
the same time.
8 Do not toLK:h or remove electrical parts

8 Keep hands, hair and clothes avvay
from flywheel and other rotating parts
while engine is running.
EMK25610
8 Flushing in a Water Tank
If the fresh water level is below the level

of the anti-cavitation plate, or if the w ater
supply is insufficient, engine seizure may
occur.
1)
2)
Remove the engine top cowling.

Install the outboard motor on the
water tank.
3) Fill the tank with fresh water to above
the level of the anti-cavitation plate.
4) Run the engine at a fast idle for 10-^15
minutes.
5) Just prior to turning off the engine,
quickly spray
"Yamaha Stof-Rite
Engine Fogging Oil" (Part No. LUBSTRRT-12-00) into the silencer cover.
When properly done, the engine will
smoke excessively and almost stall.
4-6
CX)
6)
7)
-nW
^^"^
^ i
Remove the motor from the water

tank.
Install the silencer cover and top
cowling.
1 Water surface
2 Lxwest water level
EM K26011
60524
Lubiicat ion
1) Remove the spark plg(s). Spray a
Yamaha "Stor-Rite Engine Fogging
Oil" into each cylinder for 10 seconds.
Grease the spark plug threads and
reihstall the spark plug(s) and torque
to proper specification. (Refer to the
"GLEANING
AND
ADJUSTING
SPARKPLUG").
Turn the engine over with the stop
lanyard disconneded to work the fogging oil into the piston rings.
3) Change the gear-case oil. (Refer to
"CHANGING GEAR OIL"). Inspect the
oil for the presence of water which
indicates a leaky seal. Seal replacement should be perforrned by an
authorized Yamaha dealership prior
to use.
4) urease all grease fittings. (Refer to
the "GREASING")
2)
EMK27011
Cleaning and Anti-con'osion Measui

1) Wash down the exterior of the outboard with fresh water and dry off
completely.
2) Spray the engine's exterior with
''Yamaha Silicone Protectant" (Part
No. LUB-SILCNE-13-00).
3) Wax the cowling with a non-abrasive
wax such as "Yamaha Silicone Wax"
(Part No. ACC-11000-15-02).
4-7
CX)
EMK290T1
Battery Care
Battery electrolyte is poisonous and dangerous, iusing severe bums, etc It ooritains sulfuric add. Avoid contact with
skin, eyes, or clothing.
Antidote:
EXTERNAL; Flush with water.
INTBÂL; Drink large quantities of
water or milk. Foltow with milk of magnesia, beaten egg, or vegetabte oil. Call
physician immediately.
EYES; Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosiv gases: Keep
sparkle flame, cigarettes, etc aWay.
Ventilate when charging or using in a
ck>sed space. Always wear eye protection
when working near batteries.
KEB> OUT OF REACH OF CHILDREN.
Batteries Vary among manufacturers.
Therefore the following procedures may
not always apply. Consult your battery
manufacAu rer-s instructions.
1) Disconnect and remove the battery
from the boat. Always disconnect the
black negative lead fir^ to prevent the
risk Of shoriing.
2) Clean the battery easing and terminals. Fill each cell to the upper level
with distilled water.
3) Store the battery on a level surface in
ia cool, dry, well-ventilated place out
of direct sunlight.
4) Qnee a month, check the specific
gravity oTthe electrolyte and recharge
as required to prolong battery life.
4-8
PERIODIC MAINTENANCE
Be sure to turn off the engine when you

perfonn maintenance unless otherwise
specified. If the owner is not frnilir wJith
machine servicing, this work should be
done by a Yamaha dealer or other qualified mechanic.
Maintenance, replacement, or repair of
the emission opntrc^ devices and systems
may be perfonned by any marine hgirie
repair establishmerit or individual. All
warranty repairs^ however, including
those to the emission control system,
must be perfonrhed by an authorized
Yamaha marine dealership.
A service manual is available for purchase
through a Yamaha dealer for owners who
have the mechanical skills, tools, and
other equipment necessary to perform
mainte nance not covered by this owner's
manual.
EM K33p11
REPLACEMENT PARTS
If replacement parts are necessary, use
only genuine Yamaha parts or equivalents of the same type and of equivalent
strength and materials. Any part of inferior quality may malfunction, and Vn
resulting loss of control could endanger
the operator and passenger's.
Yamaha genuine parts and accessories
are available from a Yamaha dealer.
4-9
CX)
EMU193B1
MAINTENANCE CHART
Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelineis. Refer to the sections in this
chapter for explanations of each owner-specific action.
The mark (* ) indicates the check-ups which you may carry out yourself.
The mark(1 ) indicates work tobe carried out by your Yamaha dealer.
Initial
Actions
10 hours
(1 month)
Gleaning/ adjustment /
replacement
Greasing
Change
Inspection
Inspectibh / replacement
Item
Spark plug(s)
Greasing poirits
Gear oil
Fuel-system
Fuel filter (disposable)
Fuel tank (Yamaha
portableitank)
Idling speed (earburetor
models)
Anode(s)
Cooling water passages
Propel ler and cotter pi n
Tirhingbelt
Battery
Throttle link/throttle cable
/throttle pick-up timing
Shiftlink/shift cable
Themiostat
Powertri mand tilt unit
Water pump
Engine oil
Oil ,fi Iter (cartridge)
Valve clearance (OHC,
HV>
Cowlingdamp
*
*
* /1
50 hours
(3 months)
E\ry
100 hours
200 hours
(6 months)
(1 year)
*
*
.*
* /1
* /1
Gleaning
Inspection / adjustment
Inspection
Cleaning
Inspection
Inspection
Inspection
* /1
/ replacement
* 71
* /1
*
*
/replacement
/ replacement
/ charging
* 71
*
*
1
* /1
Inspection
1 nspection
Inspection
Inspedion / change
Change
*
1
1
*
Inspection
NQTF:
When operating in salt water, turbid or muddy water, the ehgine shpuld be flushed
with clean water after each use.
4-10
o^
Ifem
Timing belt
Every
500 hours
1000: hours
(2.5 years)
(5 years)
1
Actions
Replacement
4-11
ci:>
EML00011
r'
GREASING
Yamaha marine grease
(Water resistant grease)
f.- --îh
r=^<
fK
4-12
103192
CX)
CLEANING A N D ADJUSTING s PARK
PLUG
When removing or installing a spark plug,

be careful not to damage the insulator. A
damaged insulator oxjld allow external
sparks, which could lead toexpkision or
fire.
The spark plug Js ari important engine
component and is easy to ihspee. The
condition of the spark plug can indicate
something about the condition of the
engine. For example, if the eenter electrode porcelain is very white, this could
indicate an intake air leak or carburetion
problem in that Cylinder. Do hot atterhpt
to diagnose any problems yourself.
Iniead, take the outboard motor Xo a
Yamaha dealer. You should periodically
remove and inspect the spark iplug
because heat and deposits will cause the
spark plug to slowly break dpvyn and
erode. If electrode erosion becomes
exceive,or if carbon and other deposits
are excessive, you should replace the
spark plug with another of the correct
type.
Standard spark plug:
Refer to "SPECIFIGATIO NS", page 4-1.
Before fitting the spark plug, measure the
electrode gap with a wire thickness
gauge; adjust the gap to spedfication if
necessary.
Spark plug gap:
Refer to "SPECIFICATIO NS", page 4 - i .
4-13
CT)
When fitting the plug, alyyays deari the
gasket surface and use a new gasl<et.
Wipe off any dirt from the threads and
screw in the sparl< plug to the correct
torque.
Sparkplug torque:
Refer to " SPECIFICATI NS", page 4-1.
NOTE:
If a torque-wrench is not available when

you are fitting a spark plug, a good egti^
mate of the correct torque is 1/4 to 1J^ a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-Wrench.
Initial of spark plug

I.D. mark
B
C/BK
D
Rug wrench size

21 mm (13/16 in.)
16 mm (5/8 in.)
18:3 mm (23/32 In.)
1 Spark pluggap
2 Spark plug I.D. mark (NGK)
CHECKING TOP COWLING

Check the fitting of the top cowling by
pushing it with both hands.
If the fitting is loose have it repaired by a
Yamaha dealer.
4-14
cr>
EMK38010
CHECKING FUEL SYSTEM

Gasoline (petrol) and Its vapors are highly
flammable and explosive. Keep away
from sparks, dgarettes^ flames or other
sources of ignition.
Check the fuel line for leaks, craete, or
malfunctions. If any problem is found, it
should be repaired immediately by
Yamaha dealer or other qualified mechanic.
^^c
^.
106064
Checking points
8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel cpnnedor leakage.
Leaking fuel can result in fire or explosion.

8 Check for fuel leakage regularly.
8 If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic Improper repairs can make
the outboard unsafe to operate.
4-15
ci:>
EMK50001'
INSPECTING FUEL FILTER

Gasoline (petrol) is highly flammable, and
its vapors are flammable and explosive.
8 If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
8 Do not perform this procedure on a hot
or running engine. Allow the engine to
cool.
8 There will be fuel in the fuel filter. Keep
away from ^rt^s, dgarettesi, flames or
other sources of ignition.
8 Thi s procedure Will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel irnmediately.
8 The fuel jfilter must be reassembled
carefully with O-ring, filter cup, and
hoses in place. Irnproper assembly or
replacement can result in a fuel leak,
which could result in a fire or explosion
hazard.
EMK5P310
Check the fuel filter periodically.

The fuel filter is,a one-piece, disposable
type. If foreign rftatter is found in the filter, replace it. For replacement of the fuel
filter, consult a Yamaha dealer.
4-16
ci:>
INSPECTING IDLINCBSPEED
8 Do not touch or remove electrical parts
8 Keep hands, hair and dpthes away
from flywheel and other rotating parts
w hile engine Is running.
Thi s procedure must be perfomied while

the outtioard motor Is in the water. A
flushirKi ttadirrieint ortest tank can also
be used.
A diagnostic tadiometer shpulcl be used
for this produr. Results may vary
depending on whether testing isconducted with the flushing attachment, in a test
tank, or with the outboard motor in the
water.
1) $tart the engine and allow it to warm
up fully iri neutral until it is running
smoothly. If the outboard motor is
rnounted on a boat, be sure the boat
is tightly moored.
2) Verify whether the idle speed isset to
specification. For idle speed spedfieations, see "Specifications" in this
chapter.
NOTC:
Correct idling speed inspection is only
possible if the engine is fully warmed up.
If not warmed up fully, the idle speed will
measure higher than normal. If you have
difficulty verifying the idle speed, or the
idle speed requires adju^ment, consult a
Yamaha dealer orother qualified mechanic.
4-17
cx>
EMU01415
CHANGING EN GINE OIL

8 Avoid draining the engine oil immediately after stopping the engine. The oil
is hot and should be hap'^'^^ ^^^ ^^^^
to avoid bums.
8 Be sure the outboard is securely fastened to the transom or a stable stand.
8 Change the engine oil after the first 10

hours of operation, and every 100 hours
or at 6-month intervals thereafter.
Otherv\/ise, the engine will wear quickly.
8 Do not overfill the oil, and be sure the
engine isin an upright posftion (n(4 tilted) when checking and changing the
engine oil.
8 If the oil level is above the upper level
mark, drain, until the level meets the
specified capacity. Overfilling the oil
may cause leakage or damage.
^V
1)
2)
oo23
3)
'
/ I
Put the outboard motor in an upright

position (not tilted).
Prepare a suitable container which
can hold a larger amount than the
engine oil capacity. Loosen and
remove the drain bolt i while holding the container under the drain
hole. Let the oil drain completely.
Wipe up any spilled oil immediately.
Rjt a new gasket on the drain bolt.
Apply a light coat of oi! to the gasket
and reinstall thedrain bolt.
Tightening torque:
Referto"SPEGIFICATIO NS", page 4-1
60103 2
4-18
cx>
NOTE:
If a torque wrench is not available when
you are installing the drain plug, finger
tighten the bolt just until the gasket
comes into contact with the surface of the
drain hole. Then tighten 1/4 - 1/2 turn.
Have the drain plug torqued to the correct
value with a torque wrench as soon as
possible.
4)
Remove the oil filler cap 2 . Add the

correct amount of oil through the
filler hole.
Reinstall the filler cap.
Engl ne oil grade/capacity:
Refer to "SPECIFICATIO NS", page 4.1.
5)
Start the engine and watch to make

sure the low oil pressure warning
lamp turns off. Make sure that there
are no oil leaks.
If the oil lamp does not turn off, or If

there are oil leaks, stop tte engine and
find the cause. Continued operation with
a problem could cause severe engine
damage. If the problem cannot be found
and corrected, consult your Yamaha dealer.
6)
Turn off the engine and wait 3 minutes. Recheck the oil level using the
dipstick to be sure the level falls
between the upper and lower marks.
Fill with oil if it is below the lower
mark, or drain to the specified level if
it is above the upper mark.
7) Dispose of used oil according to local
regulations.
4-19
CT)
NOTE:
8 For disposal of used oil consult your
Yamaha dealer.
8 The oil should be changed more often
when the engine is operated under
adverse conditions such as extended
trolling.
EMU01463
REPLACING FUSE
If the fuse has blown on an Bedric start
model, open the fuse holder and replace
the fuse with a new one of proper amperage.
Be sure to use the specified fuse. An

Incorrect fuse or a piece of wire may
allow excessive current flow. This could
cause electrical system damage and a fire
hazard.
NOTE:
If the new fuse blows again immediately,
consult a Yamaha dealer.
1 Fuse holder
2 Fuse(2Qft)
3 Spare fuse (2QA)
4-20
cx>
CHECKING WIRING AND
CONNECTORS
1) Check that each grpunding wire is
prpperly secured.
2) Cheek that each ccnnectcr is engaged
secure ly.
EXHAUST LEAKAGE
Start the engine and check that no
exhaust lea I from the jpints between the
exhaust oover, cylinder head and crank
case.
EMK78210
WATER LEAKAGE
Start the engine and check that no water
leate frpm the jpints between the exhaust
cOvef, cylinder head and crank case.
4-21
CD
CHEGKING POWER TILT SYSTEM
is tilted, even when the tilt-support
knob is locked. Severe injury couM
occur if the outboard accidentally falls
8 Make sure no one is under the outboard before performing this test.
1) Check the power tilt unit for any sign
of oil leaks.
2) Operate each of the power tilt switches on remote control and engine bottom wling (if equipped) to check
that all 9A/itches work.
3) Tilt up the motor and cheek that the
tilt rod 1 is pushed out completely.
4) Check that the tilt rod isfi-ee of corrosion or other flaws.
5) Operate the motor to tilt down. Check
that the tilt rod operates smoothly.
NOTE:
If any operation is abnormal, consult a

Yamaha dealer.
Recommend ed fluid;
Yamaha power trim & tilt fluid or ATF
(DEXRON-E)
4-22
cr>
EML0d013
CHEGKI NG PROPELLER
T^..f^
K;^
t3.
0>^r
is''
210014*
You could be seriously injured if the

engine accidentally starts while you are
near the propeller.
8 Before
inspecting,
removing
or
installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the "OFF" poatk)n and remove the key, and remove
the lanyard from the iigin stop
switch. Turn off the battery cut-off
switch if your boat has orie.
8 Do not use your hand to hold the propeller when bosening ortighteniing the
propeller nut. Rjt a wood bk)ck
t)etween the cavitation plate and the
propeller to preverit the proplir from
tuming.
Propeller ched<ing Point

8 Check each of the propeller blades for
wear, erosion from cavitation or ventilation, or other damage.
8 Check the splines for wear and damage.
8 Check for fish line winding around the
propeller shaft.
8 Check the propeller shaft oil seal for
damage.
EMU077
Removing the Propeller

1) Straighten the Gptter-pin 1 and pull It
out using a pair of pliers.
2) Remove the propeller nut 2 and
washer 3 .
3) Remove the propeller 4 and thru
washer 5 .
4-23
cx>
Installing the Propeller
(C^
^
602053
8 Be sure to Install the thrust washer

before Installing propeller, otherwise,
lower case and propeller boss may be
damaged.
8 Be sure to use a new (xAter pin and
bend
the
ends over securely.
Otherwise, the propeller could come off
during operation and be lost.
1) Apply Yamaha Marine grease or a
corrosion resistant grease to the propeller-shaft .
2) Install the thrust washer and propeller
on the propeller-shaft.
3) Install the washer and tighten the propeller nut to the specified torque.
Tightening torque:
Refer to "SPECIFICATIO NS" page 4-1.
4) Align the propeller nut with the propeller shaft hole. Insert a new cotter
pin in the hole and bend the cotter pin
ends.
NOTE:
^ ^ ^ _
When the propeller nut does not align

with the propeller shaft hole after tightening to the specified torque, then tighten
the nut further to align it with the hole.
4-24
CD
CHAN GIN G GEAR OIL
8 Be sure the outboard motor Is securely
fastened to the transom or a stable
stand, You could be severely injured if
the outboard motor falls on you.
is tilted, even when the tilt support
lever or knob is locked. Severe injury
could occur if the outboard motor accidentally falls.
1) Jilt the outboard rnptor so that the
gear oil drain screw is at the lowest
point possible.
2) Race a suitable eohtaiher under the
gear case.
3) Remove the gear oil drain screw 1 .
4) Remove the oil level plug 2 to allow
the oil to drain completely.
Inspect the used oil after it has been
drained. |f the oil is milky, water is getting into the gear case which can cause
gear damage. Consult a Yamaha dealer
for repair of the lower unit seals
NOTE:
For disposal of used oil consult your
Yamaha dealer.
4-25
cr>
5) With the outboard rnotor ih a vertical
position , and using a flexible or pressurized filling device, Inject the gear
oil into the gear oil drain screw hole.
Gear oil grade and capacity:
See "Spedfieations " in this chapter.
6) When the oil begins to flow out of the
oil level plug hole, insert and tighten
the oil level plug.
7) Insert and tighten the -gear oil drain
screw.
EM L22012
GLEANING FUEL TANK

Gasoline (petrol) Ishighly flammable, and
its vapors are flammable and expbsive.
8 If you have jany question about properly
doing this procedure, consult your
Yamaha dealer.
8 Keep away from sparks^ digarettes^
flames or other sources of ignition
when cleaning the fuel tank.
8 Remove the fuel tank from the boat
before cleaning it. Work only outdoors
in ah area with good ventilation.
8 Wipe up any spilled fuel bnmediately.
8 Reassemble the fuel tank carefully.
Improp er assembly can result in a fuel
leak, \A/hiGh could result in a fire or
explosion hazard.
8 Dispose of old gasoline (petrol)accprdingto local regulations.
1) Empty the fuel tank into an approved
gasoline (petrol) container.
2) Pour a small amount of suitable solvent in the tank. Reinstall the rap and
shake the tank. Drain the solvent
completely.
4-26
cx>
EML22110
Cleaning the Fuel Filter

1) Remove the screws holding the fuel
hose joint assembly .Pull the assembly out of the tank.
2) Clean the filter (located on the end of
the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
3) Replace the gasket with hevy One.
Reinstall the fuel hose joint assembly
and tighten the screws firmly.
V /r^ ' '7
1 ir'
EMUT4622
->_!>
;'-'^v'
V
\
\"\ X
't
604011
"
'
INSPECTING ANE^REPLACING
ANODE(S)
Yamaha outboard motors are protected
from corrosion by sacrificial anodes.
Inspect the external anodes periodieally.
Rem ove scales from the surface's of the
anodes. Consult a Yamaha dealer for
replacement of external andes.
Do not paint anodes, as this would render them ineffective.
NOTE:
Inspect ground leads attached to external
anodes on equipped models. Consult a
Yamaha dealer for inspection and
replacement of internal anodes attached
to the power unit.
4-27
CD
EMU 04041
CHECKING BATTERY (for Electric

start models)
Battery electrolytic fluid is dangerous; it

contains sulfuric add and therefore is poisonous and highly caustic.
Always follow these preventive measures:
8 Avoid bodily contact with electrolytic
fluid as it can cause severe bums or
permanent eye injury.
8 Wear protective eye gear when handling or working near batteries.
Antidote (EXTe?ISIAL):
8 SKIN -Flush with water.
8 EYES - Flush w ith water for 15 minutes
and get imniediate medical attention.
Antidote (INTERNAL):
8 Prink large quantities of water or milk
folk>wed by nriilk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attentk>n.
Batteris also generate explosive hydrogen g^ therefore, you should always: follow these preventive measures:
8 Charge batteries in a well-ventilated
area.
8 Keep batteries av\ây from fire, sparks,
or open flames (^g., welding equipment, lighted cigarettes, etc).
8 DO NOT SMOKE when charging or handling batteries.
8 Kp BATTBRIES AND B-ECTROLYTIC
FLU ID OU T OF REACH OF CHILDRBM.
4-28
CX)
8 A poorly maintained battery will quickly deteriorate.
8 Ordinary tap-water contains minerals
harmful to a battery, and should not be
used for topping-up.
1) Check the electrolyte level at lea
once a.month; Fill to the manufacturer's reGommehded level when necessary. Top up only with distilled water
(or pure de-iohized water suitable to
use in batteries).
2) Always keep the battery in a good
state of charge. Installing a voltmeter
will help you monitor your battery. If
you will not use the boat for a month
bi'more, remove the battery from the
boat and store it in a cool, dark place;
Completely recharge the battery
before using it.
3) If the battery will be stored for longer
than a month, check the specific gravity of the fluid at least once a month
and recharge the battery when it is
low.
NOTE: .
Consult a Yamaha dealer when charging
or re-charging batteries.
EMU01279
Connecting the Battery

Mount the battery holder securely in a
dry, well-ventilated, vibration-free location in the boat. Install a fully charged
battery in the holder.
4-29
CD
8 Make sure the main switch (on applicable models) is "OFF" before working on
the battery.
8 Reversal of the battery leads will damage the rectifier.
8 Connect the RED lead first when
installing the battery and disconnect
the RED lead last when removing it.
OthenA^lse, the electrical system can be
damaged.
8 The electrKal contacts of the battery
and cables must tie dean arxl properly
connede d, or the battery will not start
the engine.
Connect the RED lead to the POSITIVE (+)
terminal first.
Then connect the BLACK lead to the NEGATIVE (-) terminal.
1 Red lead
2 Black lead
3 Battery
EMU01280
Disconneding the Battery

Disco nnec t the BLACK lead from the NEGATIVE (-) terminal first. Then disconnect
the RED lead from the POSITIVE (+) terminal.
EM L40011
CHECKING BOLTS A N D NUTS

1) Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torque.
2) Cheek the tightening torque of other
bolts and nuts.
4-30
a:>
CLEAN IN e GOOLIN G-WATER
PASSAGES
Flushing device equipped model
000936
Perform this procedure right after operation for the most thorough flushing.
1) After shutting off the engine, unscrew
the garden-hose eonnedor 2 from
the fitting 1 on the bottom cowling.
2) Screw the garden-hose connector 2
onto a garden hose 3 which is eonr
nected to a frsh-watr supply.
3) With the engine off, turn on the water
tap and let the watei' flush thro'ugh
the cooling passages for about 15
minutes. Turn off the water and disconnect the garden hose 3 .
4) When flushing is complete, reinstall
the garden-hose connector 2 on the
fitting 1 on the bottom eoyvling.
Tighten the connector securely^
Do not leave the garden-hose connector

loose on the bottom cowlirig fitting or let
the hose hang free during nomnal operation. Water will leak but of the connector
instead of cooling the ertgine^ which can
cause serious overheating. Be sure the
connector is tightened securely on the fitting after flushing the engine.
NOTE:
8 When flushing the engine with the boat
in the water, tilting up the engine until it
is completely out of the vyater will
achieve better results.
8 Refer to cooling
system flushing
instructions in "TRANSPORTING AND
STORING OUTBOARD MOTORS'.
4-31
CX)
MOTOR EXTERIOR
.
<
"
EM L4251i
c
#
001187
Cleaning the Outboard Motor

After use, wash the exterior of the outboard with fresh water.
Flush the cooling system with fresh
water.
NOTE:
^ ^ ^ _
Refer to Flushing Cooling System instruotionsin "TRANSPORTING AND STORING
OUTBOARD MOTOR".
Checking Painted Surface of Motor

Cheek the motor for scratches;, nicks, or
flaking paint. Areas with damaged paint
are more likely to corrode. If necessary,
dean and paint the areas. A touch-up
paint isavailable from Yamaha dealer.
COATING THE BOAT BOTTOM

A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths as possible. If necessary, the boat bottom can be coated with
an anti-fouling paint approved for your
area to inhibit marine growth.
Do not use anti-fouling paint which
includes copper or graphite. These paints
can cause more rapid engine corrosion.
4-32
cx>
-MEMO-
cr>
EMN00010
Chapters
TROUBLE RECOVERY
TROUBLESHOOTING
..5-1
TEM PORR Y ACTION IN

EMERGENCY
5-5
Impact damage;
5-5
Power tilt will hot operate
5-5
Starter will not operate
5-6
Treatment of submerged motbr..........5 -9
cx>
EM U01204
TROUBLESHOOTING
A problem in the fuel, compression, or ignition syems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items
may not apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.
Possible Cause
Trouble
1. Battery capacity weakorlow.
A. iStartervi/.illnot
operate.
2. Battery connections loose or

corroded.
3. Fuse for electric start circuit bipvyn.
4. Starter components faulty.

5. Shift lever in gear.
1.
2.
3.
4.
Fuel tank empty.

Fuel contaminated or stale.
Fuel filter clogged.
Starting procedure incorrect.
5. Fuel pump malfunctions.
B: Bigine will not

start (Starter
operates).
6. Spark plug(s) fouled or incorrect

type.
7. Sparkplug cap(s) fitted incorredly.
8. Ftopr connections or damaged
igriition wiring.
9. Ignition partsfaulty.
10. Engine stop switch lanyard not
attached.
11. Engine innerpartsdamaged.
5-1
Remedy
1. Check battery condition. Use
battery of Tecpnrimndd capacity.
2. tighten batterycables and dean
battery terminals
3. Gh'eckfbr cause, of electric
overbad and repair.Replace fuse
withohebfcorrect amperage.
4. Hayeserviced by a Yamaha
dealer.
5. Shiftto neutral.
1. Fiirtarik'with dean, fresh fuel.
2., Fill tank with dean, fresh fuel.
3. Clearibr replace.filter.
4. Red"STARJING ENGINE"
section.
5 Have serviced by a Yamaha
dealer.6. Ihspeet'spark pi ug(s); Clean or
rpiae with recommended type.
7. Gheckand re-fit cap(s).
8. Ghd<Wires:fpr wearbr breaks.
Tighten all loose connections.
Replaceworn or broken wires.
9. Havesryibed by a Yamaha
dealer.
10. Attach lanyard.
11. Haveserviced by a Yamaha
dealer.
9
Trouble
CD
Possible Cause
1, Sparkpjug(s) fouled or incorrect
type.
2. Fuel system obstructed.
3. Fuel contaminated or stale.

4. Fuel filter dogged.
5. Failed ignition parts.
6. Warning system activated.
7. Sparkplug gap incorrect.
8. Poor opnnections or damaged
ignition wiring.
C. Bigine Idles
irregu|ar|ypr stalls.
9. Specified engine oil not used.

10. Thermostat faulty or clogged.
11. Carburetor adjustments incorrect.
12. Fuel pump damaged.
13. Air vent screw on the fuel tank
dosed.
14. Chote knob pulled out.
15. Motor angletoo high.
16. Carburetor dogged.
17. Fueljoint connection incorrect.
18. Throttle valve adjustment incorrect.
19. Battery lead disconnected.
5-2
Remedy
1. Inspect ,sprkplug(s), Clean or
replacewith recommended type.
2. Checkfor pinched or kinted fuel
lineor other obstructions in fuel
system.
3. Fill tank with dean, fresh fuel.
4. Clean or replace filter.
5. Haveserviced by aYamaha
dealer.
6. Find and correct.cause of warning.
7. Inspect and adjust as spedfied.
8. Check wiresfor wear 0r breaks.
Replace worn pr broken wires.
9. Check and replace oil as spedfied.
dealer.
dealer.
dealer.
13. Open the airverit screw.
14. Return to home position.
15. Return to normal operating
position.
1.6. Haveserviced by aYamaha
dealer.
17. Connect correctly.
dealer.
19. Connect securely.
9
Trob le
CP
Possible Cause
1. Cooling system clogged.
2. Engine oillevellow.
3: Heat range of sparkplug incorrect.
D. Warning buzzer
sounds or
indicator lamp
lights.
5. Engine oil contaminated or

deteriorated.
iS; Ql filter clogged.
7. Ql feed/injection pump
mlfijhctions .
8. Load on^boat improperlydistributed.
9. Water jamp/thermdstat faulty.
1. Propel ler damaged:

2. Propel ler pitch or diameter incorrect.
3. Trim angle incorrect.
Remedy
1. Check water intate for restriction.
2. Fill oil tank with specified engine
oil.
3. Inspect sparkplug and replace it
with recommended type.
4. Check and replace oil with
specified type.
5. Replace oil with fresh, spedfied
type.
6. Have serviced by a Yamaha
dealer,
dealer.
8. Distribute load to place; boat on an
even plane.
dealer.
1. Havepropellerrepairedor
replaced.
2. Install corred propel ler to operate
outboa rd at its recommended
speed (r/min) range.
3. Adjust trim angle to achieve most
effident operation.
E Engine powerloss.
4. Motor mounted at incorrect height

on transom.
5. Warning system activated.
6. Boat bottom fouled with marine
growth.
7. Spark plug(s) fouled or incorrect
type.
8. Weeds or ther^foreigh matter
tangled onrgearhousing.
9. Fuel system obstructed.
10: Fuel filterdgged.

11. Fuel contaminated or stale.
12. Spark plug gap incorrect.
5-3
4. Have motor adjusted to-proper

transom height.
5. Find and corred cause of warning.
6. Clean boat bottom.
7. Insped spark plug(s). Clean or
replace with recommended type.
8- Remove foreign matter and dean
lower unit.
9. Check for pinched or kinked fuel
line or otherpbstrudions in fuel
system.
1Q Clean or replace filter.
11, Fill tank with dean, fresh fuel.
12. Insped and adjust as spedfied.
9
Trouble
CE)
Possible Cause
13; Poor connections or damaged
ignition wiring.
14. Failed ignition parts.
E Engine power loss.
16. thermostat faulty or dogged.

17. Air vent screw dosed.
18. Fuel pump damaged.
19. Fuel joint connection incorrect.
20. Heat rangeof spark plug incorrect.
1. Propeller damaged,
2. Propellershaft damaged.
F. Bigine vibrates
excessively:
3. Weedsor other-foreign matter

tangled on prpiDeller.
4. Motor mounting bolt loose.
5. Steeringpivot loose oi" damaged.
5-4
Remedy
13. Checkwiresfor wear or breaks.
Replace worn or broken wires.
dealer.
15. Check and replace oil with
spedfied type.
16. Haveservieed by aYamaha
dealer.
17. Open the airvent screw.
18. Haveservieed by a Yamaha
dealer.
19. Conned corredly.
20. Insped sparkplug and replace it
with recommended type.
1. Havepropeller repairedor
replaced.
2. Haveservieed by a Yamaha
dealer.
3. Removeand dean propeller.
4. Tighten bolt.
5. Tighten or haveservieed by a
Yamahadealer.
CD
EMN20010
TEMPORARY ACTION IN
EMERGENCY
EMU01432
IMPACT DAMAGE
The outboard motor can be seriously
damaged by a collision while operating
or trailering. Damage could make the outboand motior unsafe to operate.
607011
If the outboard motor hits any pbjed in

the water, follow the procedure below.
1) Stop the engine immediately.
2) Inspect the control system and all
components
for damage. Also,
inspect the boat for damage.
3) Whether damage is found or not,
return to the nearest harbor slowly
and carefully.
4) Have a Yamaha dealer inject the
outboard motor before operating it
asaih.
EMU01321
POWER TILT WILL NOTOPERATE

If the engine cannot be tilted up or down
with the power tilt because of a discharged battery or a failure with the
power tilt unit, the engine can be tilted
manually.
1 Manual valve screw
EMU00421
1) Loosen the manual valve screw counterejockwis e until it stops.

2) Put the engine in the desired position,
then tighten the manual valve screw
clockwise.
5-5
cx>
STARTER WILL NOT OPERATE
If the starter mechanism does not operate
(engine cannot be cranked with the
starter), the engine can be started with an
emergency starter rope.
8 Use this procedure only in an emergenty and only to return to port for
repairs.
8 When the emergency starter rope is
used to start the engine, the start-ingef pj'dfection device does not operate. Make sure the gear shift lever/
remote control lever is in neutral.
Otherwise, the boat could unexpectedly start to rriove, which could result in
an accident.
8 Be sure no one is standing behind you
when pulling the starter rope. It could
whjp behind you and Iryure someone.
8 An unguarded rotating flywheel is very
dangerous. Keep loose dothing and
other objects away when starting the
engine. Use the emergency starter rope
only asinstructed. Do not touch the flywheel or other moving parts when the
engine is running. Do fvA install the
starter mechanism or top cowling after
the engine is running.
8 Do not touch the ignition coil, high
voltage wire, spark plug cap or other
electric I components when starting of
operating the motor. You could be
shocked.
5-6
a>
Bnerg enqr Starting Engine
1) Remove the top cowling.
2) Remove the cable 1 by pulling out it
from the starter if equipped.
, ^^^^^~>i^^
'
"^ /
/ j /
208065*
3) Remove both ends of the choke rink

rod 2 .
fe
^^^..-..
208066
4) Remove the starter/ flywhleei cover

after removing 3 bolts.
Disconne ct the wire leads connected
the starter/ flywheel cover.
5) Prepare the engine for starting. See
"STARTING ENGINE" for procedures.
Be sure the engine is in Neutral and
that the lianyard lock plate is attached
to the engine stop lanyard switch.
6) RJII up the lever 3 on the carburetor

to operate the choke systern when the
engine iscold.
lever to the original position.
5-7
cr>
7)
f.
Mifff^^
#v'W\ W
8)
9)
'208072
:^^^
5-8
Insert the knotted end of the emergency starter rope into the notch in
the flywheel rotor and wind the rope
several turns clockwise.
Pull the rope slowly until resistance is
felt.
Give a strong pull straight out to
crank and start the engine. Repeat if
necessary.
cr>
EMNS0012
TREATMENT OF SUBMERGED
MOTOR
If the outboard motor is submerged,
Imm ediately take it a Yamaha dealer.
Otherwise, some corrosion may begin
almost immediately.
If you cannot immediately take the outboard motor to a Yamaha dealer, follow
the procedure bellow for taking care to
rriinimize engine darnag.
EMN50611
1:) Thoroughly wash away mud, salt,

seaweed, eta with fresh water.
2) Remove the spark plug(s), then face
the spark plug holes downward to
callow any water, mud or contamihantsto drain.
3) brain the fuel from the carburetor,
fuel filter and fuel Nne. Drain the
engine oil completely.
A% Fill the sump with the fresh engine oil
as the same quantity asthe engine oil
capacity.
Engine oil capacity:
Refer to SPECIFICATION S, Page 4-1.
5) Feed engine fogging oil or engine oil
through the carburetr(s) and spark
plug hole(s) while cranking the
engine with the manual starter or
emergency starter rope.
6) Take the outboard motor to a Yamaha
dealer as soon as possible.
Do not attempt to run the motor until it
has been completely inspected.
5-9
CX)
Chaptere
AtoZ
INDEX
INDEX
.6-1
AfoZ
CD
INDEX
Adjusting trim angle

Air vent screw
B
Basic boating rules
Battery care
Battery requirement
Breaking in (running in) engine
...3-21
2-2
1-7
.4-8
. 1 - 14
.3-5
Changing engine oil

4- 18
Changing gear oil.............
^.:4-25
Checking battery
4-28
Checking bolts and nuts .,.,
:4-30
Cheeking fuel syêm ................
4-15
Cheeking painted surface;of motpr...,..4- 32
Cheeking power'tilt system ............... ..4-22
Cheeking propeller.....
...4-23
iGheckihg the engine oil level..
.......3-7
Checki ng top cowling
.4-14
Checking wiring and cohnedors
....4-21
Choke knob
2 -3
Choke switch ....,,...:...;..
2-9
Clamping the outboard motor
3-4
Cleaning and adjusting spark plug ......4-13
Cleaning and hti^crrsin measure ...4-7
Cleaning cooling;-water passages
4-31
Cleaning fuel tank
..4-26
Gleaning the fuel filter
4-27
Cleaning the outboard motor
.......4 -32
Coating the boat bottom
4-32
Connecting the battery.........
4-29
Cruising in other conditions
3-31
Cruising |n salt water...........
..3-31
Cruising in shiallow water
.3-28
Cruisin g in turbid water
3-31
D
Disconnecting the battery
4-30
Emergency starting engine....

.....;5-7
Emission control information..;.. ............1--2
Engine oil
1-13
Engine op button
.....,..;....... .2-5
.2^5 ,2-9
Exhaust leakage
4-21
F
Filling fuel
.3-8
Filling fuel tank.............
.........4-5
Flushing cooling system and fogging
engine.......... ................ ................ ..............4- 6
Flushing device
2-13
Forward...............
..w,.,,..,,.... ...3-17
Fuel hose joint
.2-2
Fuel meter....,
........2-2
Fuel tank.....
........2-2
Fuel tank cap.............
2-2
Fueling instructions
...............1 -11
G
Gasohol
..
1- 12
Gasoline
1-12
Gear shift leVer
:....v.^-2-3
Greasing
4-12
I
Identification numbers record
1-1
Impact damage
5-5
Important labels
.......1-6
Inspecting and replacing anode(s).,..,..4 -27
Inspecting fuel filter................ ..............A -16
Inspecting idling speed
4-17
Installation
................ 3^^
Installing the propeller
4-24
L
Low oil pressure warning
2-15
Lubrication..........
.............: .;..........;... .,..4-7
M
Main components.....
2- 1
Main switch
2- 8
Maintenance chart
4-10
Motor exterior
.4-32
6-1
AtoZ
ci:>
Mounting heigtif
...3-3
Mountin g the outboard motor
3 -1
N
Neutral interlock trigger
2-8
Neutral throttle lever
2 -8
O
Operations of controls and other
fundions
.2-2
Outboard motor serial number
1- 1
Overheat warning ................
2-14
P
Periodic maintenance....,
.........4-9
RDwer tilt switch
2-6 ,2-10
Power tilt: unit
:............. .........2-12
Fbwertilt will not operate.
5- 5
Pre-operation checks
,....3 -6
Propeller cheeking point
4-23
Propeller selection
1-15
R
Recoil starter handle
!2-3
Remote control..
2-7
Remote control lever
2 -7
Removing the propeller
4-23
Replacement parts
4-9
Replacing fuse......
...;............
.4-20
Reverse;
3-18
Ring free fuel additive
3-8
Safety information
Shifting..
Specifications
Star labels
Start-in-gearprotection....
Starter button ..,...,,
Starter willnot operate
Starting engine.....
Steering friction adjusting lever
Stopping engine..
Storing outboard motor
Temporary action in emergency
Throttle control grip............

...2-4
Throttle friction adjusting knob
.....2- 5
Throttle friction adjusting screw .....V..2-10
Throttle indicator
.2 -4
Tiller handle
...:2-4
Tilt lock mechanism
2-12
Tilt support bar
.,..2-12
Tilt support knob
.2-12
Tilting up/down
......3^24
Top cowling lock lever
.........2-13
Trailering outboard motor
4-3
Transpo rting and storing outboard
motor
.4- 3
Treatment of submerged motor........... ,.5-9
Trim angle adjusting rod
2-11
Trim angle settings and boat
handling
.:3-23
Trimming outboard motor
...3-20
Troubleshooting....
5-1
W
Warming up engine.....
.3-16
Warning indicator(s)
.2- 11
Warning system
,....2-14
Water leakage
4-21
...1-4
..3-17
....4-1
.. .1-3
...1-16
...2-3
.5-6
3 -9
2-11
3-19
4-5
5-5
6-2
IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND

CANADA
Welcome to the Yamaha Family!
Congratulations on the purchase of your new Yamaha marine power. Yamaha Is committed to exceptional customer satisfaction, and we want your ownership experience to be
a satisfying one. Please read the following warranty infonmation to help ensure satisfaction with your Yamaha.
Yamaha is ready to stand behind your purchase with strong warranty DVerage. Tb be sure
you reeeiveîrthebenfitsof warranty, pleasetal the fpllowinig St
1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at
the time of sale. Make sure your dealer gives you a copy of the completed Yamaharegistrationcard for your records. If you are unsure whether or not your Yamaha is registered,
complete the Warranty Registration card found inside the cover of the Owner's Manual.
Mail it to the diributor for the country in which you live (see siep 6 for the correct
address). If your Yamaha is not properly registered, a warranty repair could be unnecessarily delayed while registration records are checked.
2. Read the Limited Warranty statement which follows these instructions. This warranty
applies to Yam aha outboardi motors sold in the United States.whetherpurdiased separately or when supplied asbitjiginal equipment by a boat builder. The term s also apply to
original equipment packages sold in Canada, with coverage provided by Yamaha Motor
Canada (see "Warranty Guide" for Canadian models). This warranty explains the conditions of the warranty, including the obligations that your dealer and you as the owner
have under the warranty. For example, your Yamaha outboard must receive a proper
pre-delivery inspection (PDI) by the selling dealer. Failure to take [this important step
COu Id jeo pa rd ize wa rra nty coverage!
3. If you need warranty repairs, you must take your Yamaha outboard to an authorized
Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized
Yamaha dealers. Only authorized dealers have the factory training, special tools, and
Yamaha support needed to perform warranty repairs.
4. If you are away from horne, pr your selling dealer is not an authorized Yamaha dealer,
use the following toll-free numbers to find the nearest Yamaha dealer.
U nited States Dealer Lpcatioris: 1 -800-692-6242
Canada Dealer Locations:
1-800-267-8577
5. Your warranty applies spedfically to repairs niade in the country of purdiase. If your
U .S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local
dealer wheneverpossible. However, some products available in one country may not be
sold or serviced in the other.
6. If you need any additional information about your Yamaha or warranty coverage which
your dealer cannot provide, please contad usdiredly.
Yamaha Motor Corporation, U .S A
P.O. Box 6555
Cypress, CA 90630
Attentip n: Customer Relations Department
Telephone No.
Fax No.
(714)761-7439
(714)761-7559
Yamaha Motor Canada Ltd.

480 Gordon Baker Road
Toronto, Ontario
M2H 3B4
Attention: Customer Relations Department
Telephone No.
Fax No.
(416)498-1911
(416)491-3122
YAMAHA MOTOR CORPORATION, U.S.A.

FOUR-STROKE OUTBOARDMOTOR
THREE-YEAR LIMITED WARRANTY
YamahaMotorCorporationM.S.A.hereby warrantsthat new Yamaha1999ôr-later modelfOrrstrol<eoutbardmdtorsoriginallyJis
tributedby YamahalVlotorCorporationlJ:S.A.willbefreefromdefectsin materialand workm anshlpforthe peri odof tim est ated herein, subjectto certainstated limitatibnsWarranty coverage forputboardsdistributedjy non-LISyamHaaffiliatedcompanieanay be
different.
PERIDOF WARRNTYAny new Yamaha1999-or-later model four-strolceoutboardmotorpurchased'and registered with Yamaha
M otorCorp oration p.S.A. for pleasu reuse in theUnitedStates.willbe warrantedagaihstdefifsin materiabr workm anshiplbr a period of three(3) years fripmthedtebf purchasejubjectto exclusionaotedherdn.Any Yamatiaputboardmbtprpurchasdndutilized
for commercialapplicationwiUbe warranted fpra periodof on^1) year from thedateof purchase,subjectto exclusipnspted herein.
Yam ahaperlp h era! equi pm en ilncludedwithtti emptor, such as gauges.fuel tanks.andhPses.remptecontrplboxes.and wiringexterr;
nal fromfhemotorunit,willbe warrantedfprpne(l) year frpmthedate of purchaseof eitherpleasuredr conimercialjse: Replacement
parts usedih warrantyrepairswillbwaifarifedforthebalhceof theapplicbrewarrantypOTPd.
Thesecondandthirdyear of warranty (if applicabi erhall be limitedo coveringthecostof partsand laborform aipr com poientsonly.
Themajorcomponehtsovered are:
'PowerUhltSection.
8 Power Head
8 Intakeivianifold
8 CartiuretorAssemblyand itsRelatedComponents
8 Ri el Injecti onSystem an dit s Related Com ponents
8 Fuel andOiJPumpAssemblies
8 IgnitonSystem(Standardand Microcomputer)
Lower UnItSectloh
8 B<h u stSystem
8 UpperiSasing
:8 Lower-Unit Assembly
Bracket Section
i8 Bracket System
8 Ppwer tri mandTi It Assembly
WARRANTY REG I ST RATI ONTO beeligiblefor warranty coverage, the outboardmotor mustbe registeredwith Yamaha Motor
eorporatir) U.S.A.Wan-anty i'egistratiohcan be accorriplishedliy anyauthorizedYamahaOtbpardMptpr[>aler::Up,Prirecapt of the
reg i strt ion, an Ow n er' i/Vairan ty Grd w i II b e sen tb y Ym ah at o th ereg i stered p u rch aser.
OBTAINNGREPAIRSUNDWVARRANTY.To receiverepairsunderthiswan-anty, a validOwner'sWarrantyGardmustbe'presentecto
an authbrizedYarriahOutboardMbtrDealer.
Durin gthe periodof warranty, any au thorizedYam ah aputbparddeal er wil I,free Pf charge,i;eipai ror, replace, at Yamaha'sppticn, any
partsadjudgeddefectiveby Yamahedueto faultyj/orkmanshipor maten alf rom thefactory.'Al ireplaced parts willbecometheproperty
bfYamahaMotbrCorporationlJiSrA.
CUSTOM R'SRESPONSIBIlJTVUnder theterms of thiswarranty, the customerwiM be resppnsitJipr ensunngthat the putboard:
motoris properivoperated,maintained3nd storedas specifiedn theapplicabltf)wner'sManual!
TheVownerbf theoutboardnfiotorshallgivenoticeto anauthprizedYamahOutboardMptojDala- pf any and all apparent defects
with inten (10) d ays of disco veryand makethemotoiavailableat thatti m efor i nspectiorandrepairs at thedeal er'splacepf business.
GNHtALEXCLUSIONSFROM WARRANTY.Th i swarranty wil I not cover the repair of damage f thedamageis aresultof abuseor
neglectof theproduct.Examplesof abuseandneglectinclucle,t3tare nbtlimitedto;
1.
Racingbr compîtipnise.mpdificatibrof priginat)arts,abnofma]strain.
;2.
Lack of propeimaintenanceand off season storageas describedn thaOwner'sManualjnstallationof partsor accessoriesthatare
notequivalentn designand qualitigenuinf'amahaparts.
3.
Operatibnbf thenotbrat an rpm otherthan specifiedgseof lubricantor irhatarenotsuitableforbutbbardmotpuse.
4.
Damageas a resultof accidentspollisions5ontactwithforeignmaterials,or submersibn.
5.
Growthof marineorganismon mptPisurfaces.
6.
Nonnalcteteripratipn.
SPEanGPARTSEXCLUDEDFROIVl WARRANTY.Parts rplacddueto nomnaWear or routinanainthancesuch as oil,spark plugs,

shearplns,propeliers)iubs,fuel and olifilters, brushesforthestarter mptorand po\(ertiltrnotor,water pufripirTipllers,and anodes,
are n otcovered by warranty.
Chargsforrenrioval of themtorfrom boatand trahsportinhembtbrto andfronn ah authorlzedt'm'ahOutboafdMbtbrDearer re
excludedfronn warranty coverage.
Specifb partsexcludedfromthesecondandthlrdyear of warranty(ifappllcable>ire:
8 Topand BottomCowling
8 Ej'ectrl cCom p on en t$oth er th an i g n I ti oreystem)
8 RubberComppnentûchas tiosestubes,rubberseals,
fitting sandel amp s)
TRANSFERDFWARRANTY.Transferof thewarrantyfromthe origlnatiurchaserto anysubsequentpurchaseris possibity havihgthe
mptorlhspectedby an authorizedYamahaOutboardMotorDealer and requestingthe dealer to siitimila chngepf registratlohto
Yam ah aMotorCorporation |J.S.A.Withinten (10)days of thetransfer.
YAMAHA MOTORCORPORATIONJJ.S.A.MAKESNO OTHERWARRANTYOF ANY KIND,EXPRESSEDOR IMPUEDALL IMPUED
WARRANTIES OFMERCHANTABIUTY AND FITNESS FOR A PARTICULARPURPOSEWHICH EXCEED Tl^ OmJGATIONSAND
TIME UM ITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION,U^S:A. ND
EXCJDEDFROM THISWARRANTY.
SOMESTATESDO NOTAU.OW UMITATIONSON HOW LONG AN IM PUEDWARRANTY LASTS SO THEABOVE UM ITATIONS
MAY NTAPPLYTO YOU.ALSO EXCLUDED FROM THIS WARRANTYARE ANY INaDENTMJOR CONSEQUENTIAIDAMAGES
INCLDIN3:LOSSOFUSE.SOMESfATESDO NOTALLOW THEEXCUJSIONOR UMITATIONOFINCICENTALOR CONSEQUENTIAL DAMAGES, SO THEABOVEEXCUJSiONMAY NOffiPPLYTO YOU.
THISWARRANTY GIVES YOU SPECIHCLEGALRIGHrS.AND YOU MAY ALSO HAVE OThSRRIGHTSWItCHVARY FROM STATE
TO STATE.
YAIM AHAM OTOICORPORATIONg.S.A.
PostOfficeBox6555
Cyp ress, Cal I f o m I 80630
WARRAN TVQU ESTIONSftN DAN SWERS
Q.
A.
What cpstsare nny responsibilytduringthewarrantypripd?

Thecustomersresponsibilityncludeall costsof normalmaintenanceservlces, non-warrantyepairs, accidentand collisiolamages.
Q.
A.
What are spmeexanriplesof " abnprmartrain,neglect,6r abuse?

Thesetermsare general and overlapeach otherin areas.Specifioexamplesinclude:
Runninhemachineoutof ollpperatingthemachinovitha brokenor damage4)aftwhichcausesanotherpartto fail,damageor
failurdue to irnpropeor carejessti'ansportation.and/ortledown.lf you have any specificquestipnspn operatiorDr maintenance, pleasecontactyourYamahoutboarddealerforadvice.
Q.
A.
Doesthewarrantycover incidentabostssuchas towingor transportatio dueto afailure?

No.Thewarrantyis limitedo repairof themachinatself.
Q.
A.
May I perfprmanyor allof thffecommendedmaintenanceshownin theOwner'sManualinsteadof havingthedealerdo them?

Yes, if youare a qualifiedmechanicandfoHowtheproceduresspecifiedin theOwner'sand Service Manuals.We dorecommend,
hwevff, thatitenisrequiringspecialtoolsor equipmenbe dianeby aYamahaoutboarddealer.
Q.
A.
Willthewarrantybe voidor canceldif Ido nobperateor maintairmy newoutboardexactly as specifiedn theOwner'sManual?

iMo.thewarranty on anew outboardcannotbe "voidedlbr "canceled'However, if aparticularfaiiureis causedby operaton or
maintenanceotherthanas shownin theOwner'sManual,thatfailuremaynotbe coveredunderwarranty.
Q,
A.
WhatresRonsibilitijioesa Yamahaotboarddealerhaveunderthiswan-anty?
EachYamahaoutboarddealeris expectedto:
1, Completeiy up eachoutboariJie sellspriorto delivery.
2. Explaihth eoperation/naintenance,and warranty requiremento yoursatjsfactionat thetimeof sale, an dupbnyour'request
atanylater date.
In additionpach Yam ah aoutboarddealeris hel dresponsiblrforhissetup,service and warrantyrepairwork.
Q.
A.
Is thewarrantytransferableto seconcbwners?
Yes. Th e rem ai n derof an yexi sting warranty can betransferred uponrequest.Theunithasto beinspectedandre-rgisteredby an
authorizedYamahaoutboarddealerforthepolicyto remaineffective.
CUSTOM EIBERVICE
If you rm ach ine requires warranty service, you must take it toanyauthorizedVannahaoutboarddealerwithinthe continentalUnted
States. Be sureto bringyourwarranty registrationidentificationtsr othervalidproofof theoriginaldateof purchaseJf aqustibnor
problenririsesregrdingwarranty, first chtactthebwnerf thedealershipSincell warrahtynfiattei'sare hndledet thedel" level,
this person i s inthebest positlorto helpypu.lfyouare still not satisfiedandrequireadditionalassistancepi ease write
YAMAHAMOTOfCORPORATIOMI.S.A.
CUSTOM EBSELATIOIMSDEPARTMENT
P.O.Ba 6555
Cypress,.Cal iforn i 00630
When contactingYamaha Motor Corporation,U.S:A:!don'tforget to includeany importantinformationsuch as names, addresses,
model,nginserial number .dates, andreceipts.
CHAN GEOF ADDRESS
The federal govern nientrequirescti mmfactu^r^^^ amotrvehicie.to maintaina cmpletejup-tp-datellstpf allfirst purchasers,
against theppssibilit;iDf a safiy-raatddefctand-fc^^^ Thi si ist i s compliecfrom thepurchaseregistrtinssent to YanahaMotop
Corporation U.S.Aby thesellingdealerat thetimeof yourpurchase.
If you shouicfrnoveafter you have purchasedyburiiewputboarclpleaseadviseus ofyornew addressby sendinga postcardlistihg
youroutboardmpdelname.engineriai/numbep/Jeawnum^b^
youiwarranty identificatib/ypurnameandnewmallingaddresS:Mailto:
YAMAHAMOTOFGORPORATIONUS.A.
WRRAN TYDEPARTM ENT
P..Bqce^.
Cypress, Cai if o rn i EB0630
ThiswillensurthatYariiahaMotorCorporatiphlJ.S.Ahasan up-tp-dategistratipnrecprdin accordancewithfederal law.
EMU01178
IMPORTANT WARRANTY INFORMATION

IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA
Welcome to the Yamaha Family!
Congratulations on the purcha of ypur new Yamaha marine power. Yamaha iscommltted toexceptional customer satisfaction, and we want your ownership experience
to bea satisfying one. Please read the following warranty infonmation to help ensure
satisfaction with your Yamaha.
This model was manufactured ais a .SA. spedfication model, and the warranty âtement shown in this manual is for market. To receive the benefits of the warranty that
applies to the country inwhich you use ;your Yamaha, please note the following information.
1.
The warranty on this model i s t h e ^ m e as equivalent models sold in the country

where you will receive service. If you need more information about your warranty
coverage or your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha dealer in your country.
2.
Keep a copy of your sales; contract fbrinvoice for the purchase ofyour Yamaha and
present it if you need warranty repairs. This document should show the date of
purchase, which is important evidence the repairing dealer will need tobe sure
your Yamaha is covered by warranty.
3.
If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in

the country where you are. He will explain how to get warranty service in that
country.
4.
This Yamaha model may not bespld in some countries. Therefore, in some cases
your local dealer may not have all the parts or service information he may need,
which may unavoidably delay repairs. If this happens, we thank you for your
understandin g and assure you wewill attempt to resolve the situation asquickly as
possible.
SYAMAHA
YAMAHA MOTOR CORPORATION, USA
Printed in Japan
April 2003-0.5 X 1 I
66M-28199-17
(F15AMH, F15AEH. F15AEP, FiSAEHP)
m
Printed on recycled paper
YAMAHA
OUTBOARDMOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTI E DU MOTEUR HORS-BORD
Please complete and maM t his card. This information is necessary t o accurately register your unit for warranty.
Vaiillez sigier d-desscus pour attest' que|emontage et I'inspection ont tfaits.dans le respect des directi\Ae5d'inspectiGn et
quelamarche suivre pour l a ^ n t i e et I'entretien at expliquel'acheteur au detal.
OUTBOARD MOTORM ODEL AND SERIAL NU M BER(From LD. label on clam pbracket)
(For D e a l e r U Only)
MODELE ETNO. DE SERIE DUMOTEUR HORS-BORD (sur l'tiquetted'identificatioMe lapresse de fixation) (A l'USagsdU OCnSSicnna^
YAMAHADEALERNUMBER
NO. DU CONCESSiNNAlE
YAMAHA
YAMAHA
I
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
DATESGLD
DATE DE
LIVRAISN
OWNER'S NAME
NOMDU
PROPRITAKE
MONTH
MOIS
YEAR
ANNE
DAV
JOUR
USACE
(ChckOne)
UTILISM1N
(ncocher un.)
FIRST
PRENOM
ADDRESS
DEALERNAME
NOM b u
CONCESSIONNARE
T-]
I'
r-|.
'
PLEASURE
X^QISIR
GOMMERGIAL
COMMERCIAL
LAST
NOM DE FAMILLE
ADR RS SF.
STREET
RUE.
PHONE NUMBER(
)
NUMRODE TELEPHONE
CITY
VILLE
STATBPROVINGE
PROVINCE
ZIP
GODE POSTAL
PLAGE
PG)JI;3E
HERE
ATTN: WARRANTY DEPARTMENT
WEST'MARINEJ
Fiskerihavnsgade 30 - 6700 Esbjerg - Denmark - Tel. +45 75 45 70 44 - Fax +45 75 13 21 48 - info@weSt-marine.clk
Please be aware of the following:

Never start the engine without
sufficient water. It will cause serious
problems and damage the engine
and there is no warranty.
Always remember oil in the
gasoline.

Ernst Hatecke: ::: % P J FT

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MANUAL FOR OPERATION, MAINTENANCE

Survival- & Deck equipment

1.1.14 S p r i n k l e r s y s t e m (only for tanker lifeboats)

1.1 Operation Manual

Survival- & Deck equipment

1.1.1 In the interest of safety

1. Before launching close all hatches and the entrance door.

1.1.2 Yard and yardnumber

Survival- & Deck equipment

1.1.3 Handling and use of freefalMifeboats

Lifting the boat back on board:

1.1.4 Description of GFF-boats

The innerbottom has hatches to the storage and engine compartmen.

1.1.5 Stowageplan for equipment

(27) ( 6 ) (17) (25)

All personal proceed to boat station.

1. Disengage the the boat lashings.

hatch and vent

Close all hatches and openings.

1.1.9 The system instruction for launching

1.1.10 Freefall launching

Close all hatches and vents.

1.1,11 start the engine

To start the engine:

3. Press the START-button.

Bring the gear lever bacl< into the NEUTRAL position

(the grey gear button springs

* Speed and gear box control lever:

1.1.12 Emergency tiller / radar reflector

In case of malfunction of the steering gear it is

The radar reflector is stored in the equipment

1,1.13 Air supply and sprinkler system

Befor launching in case of fire:

1.1.14 sprinkler system

1,1.15 air supply system

1.2 Maitenance Manual

1,2,1 In the interest of safety

1. Before launching close all hatches and the entrance door.

1-2,2 Charging the battery by solar generator

1,2,3 Wiring diagram for battery charging by solargenerator

Nanni Diesel Engine

-'--^v Engine starter

1.2,4 Charging the battery (from the ship)

[connect the charger cable]

Connect the charger cable for 42 Volt AC.

1.2.5 Wiring diagram for battery charging from the ship

Nanni Diesel Engine

1.2,6 Wiring diagram for battery charging from the ship

Nanni Diesel Engine

1.2.7.1 Weekly inspection

1. Check battery charging system.

Only for Tanker Lifeboats:

1.2.7.2 Monthly inspection

1. Check battery charging System.

Hydraulic release gear:

Lubricate all hatch dogs and hinges.

* with boat on even keel

Only for tanker lifeboats:

1.2.7.3 Annual thorough examination

L i f e b o a t : Examination and check for satisfactoiy condition and operation