Manual for operation, maintenance and training for freefall lifeboats doc

Edition 11/05
DMG-40
BUKH
MANUAL FOR OPERATION, MAINTENANCE
AND
TRAINING
FOR
FREEFALL LIFEBOATS
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail:
www.hatecke.de
GFF M
NAME
PORT
ERNST
HATECKE

Index
1.1 Operation Manual
1.1.1 In the interest of safety
1.1.2 Yard and yardnumber
1.1.3 Handling and use of freefall-lifeboats
1.1.4 Description of GFF-boats
1.1.5 Stowageplan for equipment
1.1.6 Alarm
1.1.7 Alarm
1.1.8 Stretcher

1.1.9 Instruction for launching
1.1.10 Freefall launching
1.1.11 Start the engine
1.1.12 Emergency tiller/radar reflector
1.1.13 Air supply and sprikler system (only for tanker lifeboats)
1.1.14 Sprinkler system (only for tanker lifeboats)
1.1.15 Air supply system (only for tanker lifeboats)
1.2 Maintenance Manual
1.2.1 In the interest of safety
1.2.7 Recomended maintenance and checks
1.2.8 Recomended maintenance and checks
1.2.9 Maintenance of GRP-boats
1.2.10 Lubricant-and fuelplan
1.3 Trainings manual:
1.3.1 Trainings instructions
1.3.2 In the interest of safety
1.3.3 Handling and use of freefall-lifeboats
1.3.4 Launching and recovery instructions
1.3.5 Freefall launching
Additional:
Engine manual
Engine certificate
Function description of the charging regulator
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)
(only for tanker lifeboats)
1.2.11 Overhauling and testing acc. to SOLAS Chapt.III, Reg. 20. 11. 2

1.3.6 Simulated launching (from )
1.3.7 Simulated llaunching
MSC/Circ.1137
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de

1.1 Operation Manual
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail:
www.hatecke.de
GFF M
NAME
PORT
ERNST
HATECKE
1.1.1 In the interest of safety
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)4143-9152-40, E-mail: , 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:
Boat type:
Building no.:
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail:
www.hatecke.de
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.
1.1.3 Handling and use of freefall-lifeboats
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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.
1.1.4 Description of GFF-boats

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1. 1 buoyant bailer
2. 2 buckets
3. 2 hatchets
4. 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
5. 2 tin opener
6. 1 fire extinguisher
7. 1 fishing tackle
8. 1 whistle
9. 5 ltrs. containers with drink water (3 ltrs. for each person)
10. lifeboat food ration (one for each person)
11. 2 drink cups
12. 1 sea anchor towing and mooring line
13. 2 painters, 15m long, dia. 14mm
14. 2 buoyant lines, 30m long, dia. 8mm, with buoyant rescue quoits
15. 1 first aid kit for lifeboats with seathickness rations (6 doses for each person)
16. 1 lifeboat compass
17. 1 manual bilge pump
18. 1 radar reflector
19. Diesel-fuel
20. 2 boat hooks
21. 1 search light
22. thermal protective aids (one for 10 persons/min. 2 per boatt)
23. 1 Survival-manual/life-saving signal card

24. 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
1.1.5 Stowageplan for equipment
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1.
2.
1.1.
2.2.
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 Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
3.
4.
1.1.7 ALARM
embarcation hatch
DANGER
CAUTION:
Secure all items fasten seat
hatch and vent
Close all hatches and openings.
Fasten seat belts as soon as seated!!!
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.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.
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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.

1.1.9 The system instruction for launching
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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 mainrelease system is damaged.
Close the valve screw (pos. 3).
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.
1.1.10 Freefall launching
MAIN RELEASE PUMP
EMERGENCY RELEASE PUMP
HYDRAULIC PISTON
LOCKING DEVICE
2
1
4
3
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de

To start the engine:
1. Switch on main power (main swith).
2. With gear lever in NEUTRAL, press the grey button and move lever into Ahead / Start
position.
3. Press the START-button.
4. Bring the gear lever back into the NEUTRAL position (the grey gear button springs
back automatically).
* 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.
START
ON
1.1.11 Start the engine
WW
SS
OO
NN
compass
neutral
"grey button"
START
and ahead
astern
AMPAMP
OILOIL
TEMPTEMP
ON ON
OFF

STOP
START
* speed and gearbox control lever
AMP
OIL
TEMP
ON
OFF
STOP
START
START
main switch
STOP
oil pressure
switch/fuse solar cells
masthead lantern
interior light
engine temperature
searchlight
charging lamp
BUKH ENGINE
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1
2
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 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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.
1.1.13 Air supply and sprinkler system
(only for tanker lifeboats)
freshwater connection
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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.
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.
sea valve

engine

sprinkler pump

sprinkler tube
freshwater connection
1.1.14 sprinkler system
(only for tanker lifeboats)
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
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 1 (50 ltrs.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 5 and connect the high pressure hose
from the compressor. Make sure that the valve 3 is closed. Charge the bottles 1 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.
2
5
7
3
4
6
1
1
1.1.15 air supply system
(only for tanker lifeboats)

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de

1.2 Maitenance Manual
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail:
www.hatecke.de
GFF M
NAME
PORT
ERNST
HATECKE
1.2.1 In the interest of safety
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)4143-9152-40, E-mail: , www.hatecke.de
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 !
Do not top up with water!
Fasten batteries after installation!
1.2.2 Charging the battery by solar generator
solar generator
AMP
OIL
TEMP
ON
OFF
STOP
START
2
1
1. OFF
2. PUSH IN
3. SWITCH BATTERY
SELECTION WEEKLY
CHARGING OF BATTERIES
HATECKE Lifeboat totalpanel type: 2 BUKH stock no. 008E8915
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1.2.3 Wiring diagram for battery charging by solargenerator
Solar generator
5

7
8
6
Overcharge
protection
HATECKE Lifeboat totalpanel type: 2 BUKH stock no. 008E8915
6 mm schwarz/black
Common negative
8
8A
1,5 mm blue
Search light 55W
1
8A
1,5 mm red
Navigational light 25 W
2
8A
1,5 mm brown
/Internal-compas light 60 W
Connection box
50 cm from panel
3
2,5 mm red
8A
OFF
2,5 mm orange
2,5 mm red
2,5 white
ON

2,5 black
STOP START
2,5 blue
2 3 4 6 5 8 1
Multi plug: for engine connections
Multi plug
6mm 6mm 2,5mm 2,5mm 1,5mm 1,5mm 1,5mm 1,5 mm
Intermidiate cable.
Length 4,0 m
black red black blue gray brown yellow/green red
22 33 44 66 55 88 11
Engine STOP
Temperature Switch
Delivery
with panel
Oil pressure switch
1,5 gray
2,5 white
++ ++
6mm black
50mm
12 V 12 V
61
min 63Ah min 63Ah
B- B+
Alternator
Starter
Battery Switch
Dob. charging rectifier
1,5 gray

Electrical charge lamp
1,5 brown
Oil pressure lamp
1,5 yellow/
green
Water temperature lamp
Oil and Water-alarm
5 8 1
X
A
X
X
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
Connect the charger cable for 42 Volt AC.
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!
1.2.4 Charging the battery (from the ship)
Connect the charger cable
HATECKE Lifeboat totalpanel type: 2 BUKH stock no. 008E8915
AMP
OIL

TEMP
ON
OFF
STOP
START
2
1
1. OFF
2. PUSH IN
3. SWITCH BATTERY
SELECTION WEEKLY
CHARGING OF BATTERIES
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1.2.5 Wiring diagram for battery charging from the ship
(Standard)
6A
4A
42 V~
12 V= 1A
Batterie charger
6 mm schwarz/black
Common negative
8
8A
1,5 mm blue
Search light 55W
1
8A
1,5 mm red
Navigational light 25 W

2
8A
1,5 mm brown
/Internal-compas light 60 W
Connection box
50 cm from panel
3
2,5 mm red
8A
OFF
2,5 mm orange
2,5 mm red
2,5 white
ON
2,5 black
STOP START
2,5 blue
2 3 4 6 5 8 1
Multi plug: for engine connections
Multi plug
6mm 6mm 2,5mm 2,5mm 1,5mm 1,5mm 1,5mm 1,5 mm
Intermidiate cable.
Length 4,0 m
black red black blue gray brown yellow/green red
22 33 44 66 55 88 11
Engine STOP
Temperature Switch
Delivery
with panel
Oil pressure switch

1,5 gray
2,5 white
++ ++
6mm black
50mm
12 V 12 V
61
min 63Ah min 63Ah
B- B+
Alternator
Starter
Battery Switch
Dob. charging rectifier
1,5 gray
Electrical charge lamp
1,5 brown
Oil pressure lamp
1,5 yellow/
green
Water temperature lamp
Oil and Water-alarm
5 8 1
X
A
X
X
HATECKE Lifeboat totalpanel type: 2 BUKH stock no. 008E8915
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de
1.2.6 Wiring diagram for battery charging from the ship
(with engine heater, optional)

6A
4A
42 V~
12 V= 1A
Batterie charger
6 mm schwarz/black
Common negative
8
8A
1,5 mm blue
Search light 55W
1
8A
1,5 mm red
Navigational light 25 W
2
8A
1,5 mm brown
/Internal-compas light 60 W
Connection box
50 cm from panel
3
2,5 mm red
8A
OFF
2,5 mm orange
2,5 mm red
2,5 white
ON
2,5 black

STOP START
2,5 blue
2 3 4 6 5 8 1
Multi plug: for engine connections
Multi plug
6mm 6mm 2,5mm 2,5mm 1,5mm 1,5mm 1,5mm 1,5 mm
Intermidiate cable.
Length 4,0 m
black red black blue gray brown yellow/green red
22 33 44 66 55 88 11
Engine STOP
Temperature Switch
Delivery
with panel
Oil pressure switch
1,5 gray
2,5 white
++ ++
6mm black
50mm
12 V 12 V
61
min 63Ah min 63Ah
B- B+
Alternator
Starter
Battery Switch
Dob. charging rectifier
1,5 gray
Electrical charge lamp

1,5 brown
Oil pressure lamp
1,5 yellow/
green
Water temperature lamp
Oil and Water-alarm
5 8 1
X
A
X
X
HATECKE Lifeboat totalpanel type: 2 BUKH stock no. 008E8915
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: , www.hatecke.de