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32 FOOT TRANSPORTABLE
PORT SECURITY BOAT (TPSB)
OPERATOR’S HANDBOOK
July 2012
U.S. Department of Homeland Security
United States
Coast Guard
THESE DATA ARE SUBMITTED WITH LIMITED RIGHTS UNDER GOVERNMENT
CONTRACT NO. HSCG23-09-D-MNQ230. THESE DATA MAY BE REPRODUCED AND
USED BY THE GOVERNMENT WITH THE EXPRESS LIMITATION THAT THEY WILL
NOT, WITHOUT WRITTEN PERMISSION OF THE CONTRACTOR, BE USED FOR THE
PURPOSES OF MANUFACTURE NOR DISCLOSED OUTSIDE THE GOVERNMENT;
EXCEPT THAT THE GOVERNMENT MAY DISCLOSE THESE DATA OUTSIDE THE
GOVERNMENT FOR PUBLICATION AND DISTRIBUTION; PROVIDED THAT THE
GOVERNMENT MAKES SUCH A DISCLOSURE SUBJECT TO PROHIBITION AGAINST
FURTHER USE AND DISCLOSURE.
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Record of Changes
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RECORD OF CHANGES
CHANGE
NUMBER
DATE OF
CHANGE
DATE
ENTERED ENTERED BY
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Table of Contents
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TABLE OF CONTENTS
1. INTRODUCTION .......................................................................................................... 1-1
SECTION A. SAFETY ..................................................................................................................................... 1-1
SECTION B. WARRANTY INFORMATION ............................................................................................... 1-2
2. CHARACTERISTICS ................................................................................................... 2-1
SECTION A. GENERAL DESCRIPTION ...................................................................................................... 2-1 A.1 Design ...................................................................................................................................................... 2-1 A.2 Performance Data ..................................................................................................................................... 2-2
SECTION B. BOAT HULL DESCRIPTION ................................................................................................... 2-3 B.1 Construction ............................................................................................................................................. 2-3 B.2 Fendering System ..................................................................................................................................... 2-3 B.3 Bilge and Voids ........................................................................................................................................ 2-4 B.4 Engine Compartment ................................................................................................................................ 2-6 B.5 Deckhouse ................................................................................................................................................ 2-8 B.6 Hatches and Deck Storage ....................................................................................................................... 2-12 B.7 Deck Fitting ............................................................................................................................................ 2-13 B.8 Weapons and Ammunition ...................................................................................................................... 2-13
SECTION C. TRAILER ................................................................................................................................. 2-15 C.1 Construction ........................................................................................................................................... 2-15 C.2 Specifications ......................................................................................................................................... 2-15 C.3 Equipment .............................................................................................................................................. 2-15
3. BOAT SYSTEMS........................................................................................................... 3-1
Section A. CONSOLE ....................................................................................................................................... 3-1 A.1 Engine Indicators and Controls ................................................................................................................. 3-3 A.2 Helm ........................................................................................................................................................ 3-4 A.3 Throttle Control ........................................................................................................................................ 3-6 A.4 Fuel Flow ................................................................................................................................................. 3-7 A.5 Navigation Equipment .............................................................................................................................. 3-9 A.6 Communication Equipment ..................................................................................................................... 3-10 A.7 Crew Intercom ........................................................................................................................................ 3-12 A.8 Lighting.................................................................................................................................................. 3-13 A.9 Heater/Defrost ........................................................................................................................................ 3-15 A.10 Wiper / Washer ..................................................................................................................................... 3-16
Section B. DC POWER ................................................................................................................................... 3-17 B.1 Power Distribution, 12VDC .................................................................................................................... 3-17 B.2 Engine Power ......................................................................................................................................... 3-19
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B.3 Automatic Charge Relays ........................................................................................................................ 3-20 B.4 Power Distribution Breaker Panels .......................................................................................................... 3-20 B.5 Shore Power/ Battery Charger ................................................................................................................. 3-21
SECTION C. PROPULSION .......................................................................................................................... 3-22 C.1 Engine and Outdrive ............................................................................................................................... 3-22 C.2 Engine Cooling System ........................................................................................................................... 3-23 C.3 Exhaust System ...................................................................................................................................... 3-24
SECTION D. SAFETY EQUIPMENT ........................................................................................................... 3-25 D.1 Fire Extinguishers ................................................................................................................................... 3-25 D.2 Throw Bag ............................................................................................................................................. 3-26 D.3 Ignition Cutoff Safety Lanyard................................................................................................................ 3-26 D.4 Life Ring & Boathook. ........................................................................................................................... 3-27 D.5 First Aid Kit ........................................................................................................................................... 3-28
4. OPERATING PROCEDURES ...................................................................................... 4-1
A.1 Lowering/Raising Top .............................................................................................................................. 4-1 A.2 Installing/ Removing Soft Enclosure ......................................................................................................... 4-4 A.3 Lifting Procedure ...................................................................................................................................... 4-7 A.4 Charging Batteries with Shore Power ........................................................................................................ 4-7 A.5 Launching/Recovering .............................................................................................................................. 4-8 A.6 Basic Maneuvering ................................................................................................................................... 4-9 A.7 Emergency Procedures.............................................................................................................................. 4-9
5. MAINTENANCE / TROUBLESHOOTING ................................................................ 5-1
SECTION A. MAINTENANCE INTERVALS................................................................................................. 5-2
SECTION B. TROUBLESHOOTING ............................................................................................................ 5-11
APPENDIX A ....................................................................................................................... A-1
APPENDIX B ........................................................................................................................ B-1
APPENDIX C ....................................................................................................................... C-1
List of Figures
vii
LIST OF FIGURES
Figure 2-1 Fender Cross Section ............................................................................................. 2-3
Figure 2-2 Fendering System Inflation Point ........................................................................... 2-3
Figure 2-3a Bilge Pump .......................................................................................................... 2-4
Figure 2-3b Bilge Plug ............................................................................................................ 2-5
Figure 2-4 Flotation Foam ....................................................................................................... 2-6
Figure 2-5 Engine Compartment ............................................................................................. 2-7
Figure 2-6 TPSB Top, Raised and Lowered ............................................................................ 2-8
Figure 2-7 Antenna Swivel Mount .......................................................................................... 2-8
Figure 2-8 Soft-Sided Enclosure Panels Installed .................................................................... 2-9
Figure 2-9 Crew Seat ............................................................................................................ 2-10
Figure 2-10 Bow Deck Jump Seat ......................................................................................... 2-11
Figure 2-11 Ballistic Armor .................................................................................................. 2-11
Figure 2-12 Deck Openings ................................................................................................... 2-12
Figure 2-13 Lifting Setup ...................................................................................................... 2-13
Figure 2-14 Weapons & Ammunition.................................................................................... 2-14
Figure 3-1 Console .................................................................................................................. 3-1
Figure 3-2a Port Switch Panel ................................................................................................. 3-2
Figure 3-2b STBD Switch Panel ............................................................................................. 3-2
Figure 3-2c Center Console ..................................................................................................... 3-2
Figure 3-3 Engine Controls ..................................................................................................... 3-3
Figure 3-4 Helm ...................................................................................................................... 3-4
Figure 3-5 Steering Cylinders .................................................................................................. 3-4
Figure 3-6 Steering Power Assist Pump .................................................................................. 3-5
Figure 3-7 Throttle Control ..................................................................................................... 3-6
Figure 3-8 Fuel Cutoff Valves ................................................................................................. 3-7
Figure 3-9 Fuel Flow Diagram ................................................................................................ 3-8
Figure 3-10 Navigation System Circuit Diagram ..................................................................... 3-9
Figure 3-11 Radio Equipment ............................................................................................... 3-10
Figure 3-12 Radios Schematic ............................................................................................... 3-11
Figure 3-13 Gentex LVIS ...................................................................................................... 3-12
Figure 3-14a Lighting Schematic........................................................................................... 3-13
Figure 3-14b Lighting Schematic .......................................................................................... 3-14
Figure 3-15 Heater / Defroster and Access ............................................................................ 3-15
Figure 3-16 Windshield Wiper / Washer ............................................................................... 3-16
Figure 3-17 Power Distribution ............................................................................................. 3-17
Figure 3-18 Battery Disconnect Switch Diagram ................................................................... 3-18
Figure 3-19 Power Distribution Box ...................................................................................... 3-18
Figure 3-20 Battery Disconnect Switches .............................................................................. 3-19
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Figure 3-21a 12VDC Main DC Panel .................................................................................... 3-20
Figure 3-21b 12VDC Circuit Breaker Panel .......................................................................... 3-20
Figure 3-22a AC Battery Charger .......................................................................................... 3-21
Figure 3-22b Shore Power Plug ............................................................................................. 3-21
Figure 3-23 Bravo 1-XR1 Stern Drive ................................................................................... 3-22
Figure 3-24 Engine Cooling System ...................................................................................... 3-23
Figure 3-25 Engine Exhaust System ...................................................................................... 3-24
Figure 3-26 Fire Extinguishers .............................................................................................. 3-25
Figure 3-28 Ignition Kill Switch ............................................................................................ 3-26
Figure 3-29 Life Ring and Boathook ..................................................................................... 3-27
Figure 3-30 First Aid Kit ....................................................................................................... 3-28
Figure 4-1 Hard Top, Stowed and Raised ................................................................................ 4-1
Figure 4-2a Hard Top Bolts ..................................................................................................... 4-2
Figure 4-2b Hard Top Latches ................................................................................................. 4-2
Figure 4-3 Aft Brace Bar & Pin ............................................................................................... 4-3
Figure 4-4 Aft Brace to Engine Bulkhead ................................................................................ 4-3
Figure 4-5 Forward Brace Arm ............................................................................................... 4-3
Figure 4-6 Soft Side Support Channel ..................................................................................... 4-4
Figure 4-7 Twist Locks ........................................................................................................... 4-4
Figure 4-8a Soft Side Enclosure .............................................................................................. 4-5
Figure 4-8b Soft Side Enclosure .............................................................................................. 4-6
Figure 4-9 Lifting the TPSB Using a Crane ............................................................................. 4-7
List of Tables
ix
LIST OF TABLES
Table 2.1 Vessel Specifications .............................................................................................. 2-1
Table 2.2 Trailer Specifications ................................................................................................ 2-
Table 2.3 Engine Compartment ................................................................................................ 2-
Table 5.1 Engine Maintenance ................................................................................................ 5-
Table 5.2 Engine Inspection and Maintenance of EPA Related Parts ........................................ 5-
Table 5.3 Mercury Bravo Sterndrive ........................................................................................ 5-
Table 5.4 Electrical Maintenance ............................................................................................. 5-
Table 5.5 Engine Troubleshooting ............................................................................................ 5-
Table 5.6 Mercury Bravo Sterndrive Troubleshooting .............................................................. 5-
Table 5.7 Helm Troubleshooting .............................................................................................. 5-
Table 5.8 Power Assist Pump Troubleshooting......................................................................... 5-
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Chapter 1: Introduction
1-1
1. INTRODUCTION
This handbook outlines safety and operational procedures for the Coast Guard’s 32’ Transportable Port Security Boat (TPSB). It defines physical characteristics, operational capabilities and limitations, normal operation and emergency procedures, boat fittings, and an outfit list.
IN THIS CHAPTER
SECTION TOPIC SEE
PAGE
A Saftey, Warnings, Cautions and Notes. 1-1
B Warranty Information 1-2
SECTION A. SAFETY
This manual has been written to include a number of safety instructions to ensure the safe operation and maintenance of your vessel. The safety information listed in this manual is not all-inclusive. It may be general in nature in some cases and detailed in others. Commercial Off-the-Shelf (COTS) manuals from the manufacturers of the major components such as engines will be used in conjunction with this manual. The information in this manual and the COTS manuals shall be completely read, and personnel shall have a thorough understanding of all component systems and their proper performance before operating the Boat.
WARNINGS, CAUTIONS, AND NOTES
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout the handbook:
WARNING
CAUTION !
NOTE
Operating procedures or techniques that must be carefully followed to avoid
equipment damage.
An operating procedure or technique that must be emphasized.
Operating procedures or techniques that must be carefully followed to
avoid equipment damage.
Operating procedures or techniques that must be carefully followed to
avoid personal injury or loss of life.
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SECTION B. WARRANTY INFORMATION
Boat operators should consult the Equipment Manufacturer’s Manuals for warranty information regarding specific system components. (See Appendix C.)
Chapter 2 – Boat Hull Description
2-1
2. CHARACTERISTICS
INTRODUCTION
This chapter describes the standard 32ft TPSB features and equipment. All illustrations in this handbook are for familiarization purposes only.
SECTION TOPIC SEE
PAGE
A General Description 2-1
B Hull 2-3
C Trailer 2-15
SECTION A. GENERAL DESCRIPTION
A.1 Design
The Kvichak 32 ft Transportable Port Security Boat (TPSB) is designed and capable of effectively operating in shallow water areas as well as safely operating in sea conditions as outlined below. The TPSB is designed to enable the crew to carry out their mission of Port, Waterways, and Coastal Security, Maritime Law Enforcement and Search and Rescue operations while limiting their exposure from the elements, reducing the physically demands placed on their bodies operating in conditions of high impact and immediate protection from hostile fire. The TPSB is a diesel powered twin engine stern drive mono-hull boat with a continuous, watertight and self-bailing, main deck. It has shock mitigation seating for a crew of four and stations to mount two (2).50cal and/or two (2) M240 machine guns. It also has a watertight stowage compartment amidships for anti-swimmer grenades.
WARNING
This boat is not self-righting. Due care in cargo storage and boat
handling should be taken at all times.
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A.2 Performance Data
Table 2.1
Vessel Specifications
Characteristics Specification
Length 32’ 7 1/2”
Length (Boat On Trailer) 38’ 6 17/32”
Beam 7’ 11 3/8 ”
Beam (Boat On Trailer) 8’ 6”
Height (One trailer with mast lowered) 12’ 5 3/8”
Height (On trailer with top lowered) 10’ 6”
Draft 19in, trimmed up, 24” trimmed in nav. Pos.
Max. Speed 45 Knots
Max. Stopping Time < 12 sec
Engines Twin Yanmar 315 6LPA-STZ C3
Outdrives Bravo1 XR1
Fuel Capacity 150 Gallons
Endurance (with 20% reserve) 8 hrs idle speed and 2 hrs full speed
Boat Weight (Light) 8,426 lbs
Boat Weight (Fully Outfitted Condition) w/
trailer
11,306 lbs.
Towing Capacity 5 tons
Normal Operating Crew 4
Operating Parameters 12 ft seas survivable, 8ft fully capable
Seating 4 Shock mitigating seats with semi-active
dampening +1 fwd seat.
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SECTION B. BOAT HULL DESCRIPTION
B.1 Construction
The TPSB is constructed with a marine grade aluminum hull with multiple strakes to maximize all aspects of performance. The TPSB main decks are watertight and self bailing. The TPSB uses scupper socks on the transom to help prevent water intrusion during backing operations. All fittings on the main deck are flush so as to prevent tripping.
B.2 Fendering System
The fendering system is a hybrid foam/air structure sheathed with a heavy duty reinforced urethane. The fendering has a bonded rub strake from bow to stern at the proudest outboard fendering surface. (Figure 2-1) An inner air bladder is used to add rigidity and absorb shocks. The air bladder is inflated to 8 psi. Inflation points are located directly under the boarding steps, both port and starboard. (Figure 2-2)
Figure 2-1
Fender Cross Section
Figure 2-2
Fendering System Inflation Point
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B.3 Bilge and Voids
Bilge
The TPSB is constructed with a watertight deck over a continuous bilge. All fluids that collect in the bilge flow aft to the engine compartment. When deployed, an electric bilge pump discharges overboard (Figure 2-3a). The bilge pump is powered directly from the house load battery through a 15 A breaker. The bilge pump control switch is located in the STBD switch panel at the coxswains console and can be set to MANUAL, OFF, or AUTO. When trailering, the bilge can be drained through a bilge plug located on the transom (Figure 2-3b).
Figure 2-3a
Bilge Pump
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Figure 2-3b
Bilge Plug
Voids
All voids not being used for equipment or storage are filled with foam. (Figure 2-4)
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Figure 2-4
Flotation Foam
B.4 Engine Compartment
The engine compartment consists of an isolated enclosure holding the two engines and propulsion support equipment. This includes:
Item Qt.
Yanmar 6LPA-STZ C3 marine diesel engines 2
Engine Starter Batteries, 12 VDC 2
House Load Batteries, 12 VDC 2
DC Distribution and Breaker Box 1
115 VAC Breaker and Battery Charger 1
Salt Water Strainers 2
Drive Tilt/Trim Pumps (Electric-Hydraulic) 2
Gear Lube Monitor Bottles 2
Hydraulic Steering Rams 2
Steering Boost Pump 1
Fuel Flow Sensors (2 supply & 2 return) 4
Fuel Filter / Water Separators – Racor 460 MAM 10 2
Transportable Port Security Boat (TPSB) Information BookC
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Figure 2-5
Engine Compartment
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B.5 Deckhouse
The crew compartment consists of a full width center console control station surrounded by ballistic armor and an articulated hard top roof, providing shelter in inclement weather conditions.
B.5.a Hard Top
The roof consists of an aluminum hard top that mounts lights, signal devices, plus the communication and navigation antennas. It is articulated such that it may be lowered for trailering, (Figure 2-6)) In addition, the radio antenna are swivel mounted (Figure 2-7) and can be lowered independently for stowage, low bridge situations, and trailering. See Operations Procedure A1 (page 4-1) for details on lowering the Hard Top.
Figure 2-6
TPSB Top, Raised and Lowered
Figure 2-7
Antenna Swivel Mount
Transportable Port Security Boat (TPSB) Information BookC
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B.5.b Soft Side Panels
The crew is also protected from the elements by vinyl and canvas side panels that zip and snap into place (Figure 2-8). The soft enclosure is easily removed for storage off vessel in appropriate weather or when trailering the boat.
Figure 2-8
Soft-Sided Enclosure Panels Installed
B.5.c Seating
The TPSB features shock-mitigating seating for four crew members within the deckhouse. The coxswain and navigator’s seats fold down for comfortable operation of the TPSB while standing (Figures 2-9). When powered (20A breaker, breaker panel, radio locker), each shock mitigation seat has an individual semi-active shock dampener which is adjustable to both the weight of the occupant (95 to 300 lbs) and the sea state of the boat. (See Coast Dynamics Shoxsdual2 Semi-Active Mitigation System manual for details, listed in Appendix C.)
Transportable Port Security Boat (TPSB) Information Book
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Figure 2-9
Crew Seat
Transportable Port Security Boat (TPSB) Information BookC
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A fifth, jump seat is provided on the bow deck. The seat folds up and out of the way when not in use. (Figure 2-10)
Figure 2-10
Bow Deck Jump Seat
B.5.b Armor
The crew/passenger area is protected with replaceable composite ballistic armor (Figures 2-11). The armor is bolted to the boat and utilizes designed hard-points to interface with predetermined mounting features incorporated in the armor’s design.
Figure 2-11
Ballistic Armor
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B.6 Hatches and Deck Storage
The TPSB has deck access to three below deck storage areas, the engine compartment, the fuel tank, and a forward flotation void. (Figure 2-12)
Figure 2-12
Deck Openings
Transportable Port Security Boat (TPSB) Information BookC
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B.7 Deck Fitting
Deck Cleats and Chocks: Six deck cleats are located along the gunwales (three to port, three to starboard). One chock for the anchor line is located at the bow. Tow Posts: Two posts, one forward and one aft, can be used for towing and anchoring. Each is rated for 10,000 lbs static load. The tow posts also double as Heavy Weapons Mounts. Lifting Fittings: Four fittings, two (port & stbd) on the forward deck, and two (port & stbd) on the transom are provided for lifting the TPSB, with or without the trailer attached. (Figure 2-13)
Figure 2-13
Lifting Setup
B.8 Weapons and Ammunition
Heavy weapons mounts are located on the bow and aft decks. Light Machine Gun mounts are located Port and Starboard behind the deckhouse. Personal weapons storage mounts are attached to the sides of the Shock Mitigation seats. Hot barrel brackets are mounted port and starboard behind the deckhouse, and forward of the deck house console. (Figure 2-14)
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Figure 2-14
Weapons & Ammunition
Transportable Port Security Boat (TPSB) Information BookC
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SECTION C. TRAILER
C.1 Construction
The TPSB trailer is constructed of heavy duty aluminum I-beam. The trailer is a heavy duty commercial built trailer fully capable of making continuous cross country movements with only preventive maintenance requirements. The trailer is designed to be fully capable for submersion during launch without hazards and features fully sealed electrical system and pressurized wheel bearings.
C.2 Specifications
Table 2.3
Trailer Specifications
Characteristic Specification
GVW Rating 13,800 lbs
Max Net Capacity 12,650 lbs
Trailer Net Weight 1800 lbs
C.3 Equipment
The TPSB trailer is equipped with the following:
a. 3500 pound retrieval winch
b. Tie-down points
c. 16 inch spare tire and carrier
d. 8000 pound side wind drop leg jack
e. Submersible LED lights
f. Fresh water flushing system and connections
g. Stainless Steel/Cadmium surge disc braking system
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Chapter 3 Boat Systems
3-1
3. BOAT SYSTEMS
Section A. CONSOLE
The TPSB console is outfitted with the controls and gauges and instruments needed to operate the vessel (Figure 3-1). This includes the following:
1. Propulsion a. Steering b. Throttle and Drive Tilt c. Engine Control & Fuel Monitoring d. Electric Trim Tabs
2. Navigation a. Radar (DSF-4D) b. GPS (GPS-37) c. NavNet Multi Display Integrator / Digital Chart (MFD-12) d. AIS (Automatic Identification System) Radio (L-3 Protec) e. Digital Electronic Heading Sensor / Magnetic Compass f. Network Depth Sounder (DFF1)
3. Communication a. VHF Marine Band Radio b. VHF Tactical Radio c. UHF Tactical Radio d. Secure Radio (USCG supplied)
Figure 3-1
Console
Electrical Switch Panels are located Center and STBD on the console, along with a remote control for the mast mounted search light, and a light dimmer / wiper control panel. (Figures 3.2a, 3.2b, & 3.2c)
Transportable Port Security Boat (TPSB) Information Book
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Figure 3-2a
Port Switch Panel
Figure 3-2b
STBD Switch Panel
Figure 3-2c
Center Console
Transportable Port Security Boat (TPSB) Information Book
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A.1 Engine Indicators and Controls
Analog and digital gauges for the Yanmar 6LPA-STZ C3 engines are located within easy view of the coxswain (Figure 3- 3 below. See Yanmar Operation Manual for details.) In addition, there are indicators for Fuel Level, Fuel Flow, Drive Unit Trim Angle, Salt Water Pump Pressure, Alternator Voltage, and controls for the Electric Trim Tabs,
Figure 3-3
Engine Controls
INDICATOR LIGHT
PANEL
STB
INDICATOR LIGHT
PANEL
PORT
FUEL
LEVEL
TACH
PORT
TRIM GAUGES
OIL
PRESSURE
OIL
PRESSURE
IGNITION IGNITION
Transportable Port Security Boat (TPSB) Information Book
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A.2 Helm
The TPSB uses a SeaStar tilt wheel hydraulic helm (Figure 3-4), with power hydraulic assist. The helm controls both stern drive units; each stern drive is equipped with an individual steering cylinder (Figure 3-5). The electrically powered Hydraulic Steering Assist Unit is located in the Engine Compartment, aft on the STBD side. (Figure 3-6)
Figure 3-4
Helm
Figure 3-5
Steering Cylinders
Transportable Port Security Boat (TPSB) Information Book
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Figure 3-6
Steering Power Assist Pump
Transportable Port Security Boat (TPSB) Information Book
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A.3 Throttle Control
Engines RPM, drive direction (Fwd / Aft) and drive angle (trim angle) are controlled with a Teleflex CH7800 dual throttle control with integrated trim/tilt functions (Figure 3-7).
Figure 3-7
Throttle Control
The handle mounted rocker switches control the hydraulic Trim / Tilt pumps that adjusts the trim of the outboard stern drives. The housing mounted rocker switches are used to tilt the drive units all the way up for trailering / storage. (See the Telexfex CH788 manual for details.)
CAUTION: Only use housing mounted tilt switches for trailering
operations.
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A.4 Fuel Flow
Each engine uses a closed loop, constant flow fuel supply system. Fuel is continuously pumped from the fuel tank, filtered, and sent to each engine, and the excess fuel is then cooled and re-circulated back to the fuel tank. (Figure 3-8) Fuel flow to and from each engine is metered and the difference is displayed on flow meters to the left and right of the Helm, indicating fuel consumption and rate of consumption (Figure 3-9). (See section 3-A.1, Engine Indicators and Controls for meter locations.)
NOTE
Figure 3-8
Fuel Cutoff Valves
Fuel cutoff valves for each engine are located beneath the mid deck
access hatch (between the shock mitigation seats).
Transportable Port Security Boat (TPSB) Information Book
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Figure 3-9
Fuel Flow Diagram
Transportable Port Security Boat (TPSB) Information Book
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A.5 Navigation Equipment
The TPSB is equipped with the Coast Guard’s standard Scalable Integrated Navigation System (SINS) built around a Furuno NavNet radar/char plotter system. (Figure 3-10) The system features an MFD-12 Radar/Video Plotter, DRS4D Raydome, Furuno RD-30 Multi-Display Unit, PG500R heading sensor, GP-37 GPS/DGPS with GPA-019 antenna, DFF1 Network Sounder with transducer, and Richie magnetic compass. The digital navigation displays are located on the console and the compass is directly above the helm. (See the manufactures’ manuals for detailed equipment operation, listed in Appendix C.)
Figure 3-10
Navigation System Circuit Diagram
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A.6 Communication Equipment
The TPSB is equipped with a Motorola XTL-5000 Tactical VHF radio system, XTL-5000 Tactical UHF radio system, and Standard Horizon GX5500S secondary VHF with Digital Selective Calling features. Space is also provided for a Harris PRC-117 secure VHS.
Figure 3-11
Radio Equipment
Transportable Port Security Boat (TPSB) Information Book
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Figure 3-12
Radios Schematic
Transportable Port Security Boat (TPSB) Information Book
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A.7 Crew Intercom
A Gentex Light Vehicle Intercom System (LVIS) provides wired communication between crew members and access to the boat’s radios. Hard-wired connection points are located at each of the four crew seats in the enclosure, at two points on the bow deck, port and stbd, and at the port and stbd aft gunner positions. (Figure 3-13). (See Gentex manuals for detailed information.)
Figure 3-13
Gentex LVIS
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A.8 Lighting
The TPSB lighting consists of navigation lights, flood lights (port & stbd), law enforcement lights (port & stbd), a remotely controlled spotlight, night vision (NVIS) lights (fwd & aft floods & an overhead light), overhead lights in the deckhouse, and courtesy lights illuminating the fwd and aft decks. (Figures 3.14a & 3.14b) Dimmers for the NVIS lights are located on the control console
Figure 3-14a
Lighting Schematic
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Figure 3-14b
Lighting Schematic
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A.9 Heater/Defrost
To provide for crew comfort in all conditions, a Sure Marine REALHEAT heater/defroster (Figure 3-15) is integrated into the coolant system on the starboard engine. Controls for the fan are located on the console under the radar display. The heating unit is located in the starboard side of the console.
Figure 3-15
Heater / Defroster and Access
Transportable Port Security Boat (TPSB) Information Book
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A.10 Wiper / Washer
The TPSB uses a two blade, single motor, wiper / washer to remove spay and dirt from the windscreen. (Figure 3-16) The control switch is mounted to the left of the helm in the middle switch panel). The wipers have a low and a high speed setting. Press the control switch to activate the washer fluid pump.
Figure 3-16
Windshield Wiper / Washer
Transportable Port Security Boat (TPSB) Information Book
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Section B. DC POWER
B.1 Power Distribution, 12VDC
Two battery switches are located on the forward engine compartment bulkhead and turn on power to the engines and household loads (Figure 3-17). Each engine has a dedicated ignition/starter battery while the household loads are powered by a pair of batteries in parallel. Each engine battery and/or the household batteries can be cross connected to provide extra power to start the engines. (Figure 3-18)
Figure 3-17
Power Distribution
Transportable Port Security Boat (TPSB) Information Book
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Figure 3-18
Battery Disconnect Switch Diagram
The DC power distribution box (Figure 3-19) is located forward within the engine compartment on the starboard fwd bulkhead. The battery disconnect switches are mounted through the bulkhead to the outside of the engine compartment bulkhead, accessible from the aft deck. (Figure 3-20)
Figure 3-19
Power Distribution Box
Transportable Port Security Boat (TPSB) Information Book
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CAUTION !
Figure 3-20
Battery Disconnect Switches
B.2 Engine Power
Each engine has a 12 VDC alternator which is used to supply engine and house loads when
underway and charge the various batteries. Two voltage meters (port and stbd) display the
alternator voltage for each engine. (Optimal alternator voltage is 14.2 ± .3 VDC.)
CAUTION !
Operating procedures or techniques that must be carefully followed to avoid
equipment damage. Do not disconnect the batteries or leave them combined while the
engines are running.
Operating procedures or techniques that must be carefully followed to avoid
equipment damage. Only combine batteries as needed to start engines. Do not leave
batteries combined during normal operation or when charging the
batteries with shore power.
Transportable Port Security Boat (TPSB) Information Book
3-20
B.3 Automatic Charge Relays
The ships batteries, both engine batteries and the house load batteries, are automatically kept charged when either engine is running. The Automatic Charge Relays (ACR) cross connect the batteries during charging, and isolate the batteries when they are discharging. Port & Stbd ADR lights located on the middle switch panel, next to the lights dimmer switch, indicate which engine (or both) is charging the boat’s batteries.
NOTE
B.4 Power Distribution Breaker Panels
Power is directed to various onboard house loads from a 12VDC switch panel located in the tunnel, (Figure 3-21a) and a circuit breaker panel (Figure 21b) located under the console, stbd, next to the radios.
Figure 3-21a
12VDC Main DC Panel
Figure 3-21b
12VDC Circuit Breaker Panel
The Automatic Charge Relays are open and the batteries are not cross
connected when the batteries are being charged from shore power.
Transportable Port Security Boat (TPSB) Information Book
3-21
B.5 Shore Power/ Battery Charger
A 12 volt, 20 A battery charger for the boat batteries is located in the Engine Compartment, aft, on the port bulkhead. (Figure 3-22a). A shore power inlet is located stbd on the outside of engine compartment bulkhead. (Figure 3-22b)
Figure 3-22a
AC Battery Charger
Figure 3-22b
Shore Power Plug
Transportable Port Security Boat (TPSB) Information Book
3-22
SECTION C. PROPULSION
C.1 Engine and Outdrive
The TPSB propulsion system consists of twin inboard/outboard Yanmar 6LPA-STZC3 water cooled 4-cycle 6-cylinder 315 horsepower diesel engines with Mercury Bravo 1-XR stern drives (Figures 3.23). See Yanmar STZC Operation Manual for details.
Figure 3-23
Bravo 1-XR1 Stern Drive
Transportable Port Security Boat (TPSB) Information Book
3-23
C.2 Engine Cooling System
The Yanmar diesel engines on the TPSB use a two stage water cooling system. During operation, each engine’s sea water pump draws raw water from the sea, using both the seacock and the cooling inlet on the outdrives. The raw water runs through a seawater strainer before it reaches the pump. and is then pumped to the engine’s heat exchangers; first to the fuel return heat exchanger, then the intercooler, then engine oil cooler, and finally to the fresh water coolant heat exchanger. After exiting the fresh water heat exchanger, some of the raw water is diverted to the wet exhaust manifold to cool the exhaust gases. The remainder is discharged through the outdrive. For additional information, refer to the Yanmar STZC Operation Manual.
Figure 3-24
Engine Cooling System
Transportable Port Security Boat (TPSB) Information Book
3-24
C.3 Exhaust System
The TPSB’s exhaust system is a wet exhaust with an above water exhaust gas bypass. Raw cooling water is pumped through the engine’s heat exchangers and into the wet exhaust elbow to cool the exhaust gas being discharged from the turbo charger. The cooled gas and water mixture is sent to the exhaust horn attached to the outdrive. An exhaust gas bypass allows some of the gas to be discharged directly overboard to reduce exhaust back pressure. For additional information, refer to the Yanmar STZC Operation Manual.
Figure 3-25
Engine Exhaust System
Transportable Port Security Boat (TPSB) Information Book
3-25
SECTION D. SAFETY EQUIPMENT
D.1 Fire Extinguishers
Three fire extinguishers are stowed on board the TPSB; one behind the coxswain’s seat, one behind the navigator’s seat, and one on the forward engine compartment bulkhead, stbd side. (Figure 3-26). Fire Ports into the engine compartment are provided on the forward engine compartment bulkhead (Figure 3-27).
CAUTION !
Figure 3-26
Fire Extinguishers
Figure 3-27 Fire Port
Operating procedures or techniques that must be carefully followed to avoid equipment damage. To use the fire ports, place the discharge horn of the fire extinguisher
against the transparent seal of the fire port. Push in firmly to break the
seal, then discharge the extinguisher into the engine compartment.
Transportable Port Security Boat (TPSB) Information Book
3-26
D.2 Throw Bag
A throw bags is stored in the forward storage compartment and can be clipped on to the hot barrel ring for easy access when underway.
D.3 Ignition Cutoff Safety Lanyard
An ignition dead man switch with attached lanyard is installed and located under the helm console. When the lanyard is attached to the coxswain, it will kill the engines if the coxswain is accidently thrown from their station. (Figure 3-28) Engines can be re-started 30 seconds after the ignition cutoff lanyard is pulled out, without having to reset the switch.
Figure 3-28
Ignition Kill Switch
Transportable Port Security Boat (TPSB) Information Book
3-27
D.4 Life Ring & Boathook.
A life ring and telescoping boathook are stowed under the hard top. (Figure 3-29).
NOTE: Ensure that the Velcro strips on the life ring align with
the Velcro on the mounting bracket with stowing the ring.
Figure 3-29
Life Ring and Boathook
Transportable Port Security Boat (TPSB) Information Book
3-28
D.5 First Aid Kit
A ten-person first aid kit is stowed behind the coxswain’s seat (Figure 3-30)
Figure 3-30
First Aid Kit
Chapter 4: Operating Procedures
4-1
4. OPERATING PROCEDURES
A.1 Lowering/Raising Top
The Hard Top of the TPSB’s enclosure can be lowered to meet height requirements for transportability. (Figure 4-1) Three people can accomplish this task in about five minutes with tools. General steps for lowering the roof are as follow:
1. Ensure that the crew seats are moved all the way forward and that the armrests are all in the lowered position.
2. Remove the hardtop securing bolts in each corner of the console, above the windshield, using proper size wrenches (Figure 4-2a).
3. Release the Hard Top latches (Figure 4-2b) at the top of the windscreen. 4. Remove the quick release pins attaching the two aft brace bars (port & stbd) to the
forward roof support bars (Figure 4-1 & 4-3). 5. With 3 people, one forward center and two aft, lift, pull back, and lower the top to the
stowed position. (Figure 4-1) 6. Secure the two aft brace bars (port & stbd) to the brackets on the engine compartment
bulkhead with the quick release pins. (Figure 4-4) 7. Release the ends of the forward brace arm from the hard top (Figure 4-5) and attach them
to the bracket on each of the forward roof support bars. (Figure 4-1). Secure with quick release pins.
Figure 4-1
Hard Top, Stowed and Raised
Transportable Port Security Boat (TPSB) Information Book
4-2
Figure 4-2a
Hard Top Bolts
Figure 4-2b
Hard Top Latches
Transportable Port Security Boat (TPSB) Information Book
4-3
Figure 4-3
Aft Brace Bar & Pin
Figure 4-4
Aft Brace to Engine Bulkhead
Figure 4-5
Forward Brace Arm
Transportable Port Security Boat (TPSB) Information Book
4-4
A.2 Installing/ Removing Soft Enclosure
The TPSB is equipped with a soft sided enclosure to provide crew comfort. There are 9 individual panels to create this enclosure, three panels port, stbd, and aft. The panels slide into a circular channel along the edge of the roof (Figure 4-6). Adjacent panels can be joined together with zippered seams. The bottoms of the side are secured to the sides with twist lock fasteners Figure 4-7), while the aft panels use tie down straps.
Figure 4-6
Soft Side Support Channel
Figure 4-7
Twist Locks
Transportable Port Security Boat (TPSB) Information Book
4-5
Use the following steps to attach the soft side enclosure: 1. Starting with either side, insert panels 1, 2, then 3 into the support channel (Figure 4-8). 2. Zipper the adjoining edges of the panels together. 3. Secure the bottom of the panels to the boat with the installed twist locks. 4. Repeat steps 1 thru 3 for the other side.
Figure 4-8a
Soft Side Enclosure
Transportable Port Security Boat (TPSB) Information Book
4-6
5. Along the aft edge of the Hart Top, insert panels P, C, and S (Figure 4-8b). 6. Zipper panels P & S into their respective sides. 7. Zipper panel C to panel P and/or S as necessary to seal the deck enclosure.
Figure 4-8b
Soft Side Enclosure
Transportable Port Security Boat (TPSB) Information Book
4-7
A.3 Lifting Procedure
The TPSB has four lift fittings designed and tested for lifting the TPSB, either alone or with its trailer. (Figure 4-9)
Figure 4-9
Lifting the TPSB Using a Crane
A.4 Charging Batteries with Shore Power
1. Make sure that both boat engines are secured. 2. Close the battery switch for each set of batteries to be charged (Engine and/or House
Batteries). 3. Make sure that the Shore Power Breaker is in the open position. 4. Attach the shore power cable to the shore power inlet.
NOTE
5. Close the Shore Power Breaker. The selected batteries should now be charging.
The following breakers on the Main DC Distribution Box
should be closed:
Port & Stbd Charge Input breakers
House Charge Input breaker
Port & Stbd Charge Relay breakers
Transportable Port Security Boat (TPSB) Information Book
4-8
A.5 Launching/Recovering
The steps for launching and recovery of the TPSB are as follows.
NOTE
A.5.a Launching
1. Ensure the bilge plug is installed. 2. Check all bilge areas for water or debris. Check that both Salt Water Intake Valves
(seacocks) are open. 3. Turn on House Battery power and ensure bilge pump is on and functioning properly. 4. Remove transportation straps. 5. Back trailer and boat into water about 2/3 of the way. 6. Follow engine start procedure. 7. Check water flow at strainers and allow engines to warm up to operating temp. 8. Disconnect bow strap from bow eye and with drive legs in half trim, back boat into water. 9. Apply power in reverse and back boat away from trailer.
A.5.b Recovery
1. Ensure trailer is properly attached to truck. 2. Inspect trailer. 3. Back trailer into the water and leave the front 6 inches of the trailer bunks out of the
water. 4. Set parking brake on truck. 5. Carefully maneuver TPSB on trailer. 6. If trailer is located correctly in the water the boat will not go all the way to the stop on the
trailer. 7. Once boat is on the trailer connect the bow strap onto the bow eye. 8. Winch boat up to the stop on the trailer. Power may need to be added by the coxswain to
assist in winching. 9. Follow engine shutdown procedure and secure engines. 10. Once boat is at the trailer stop, pull truck forward until the boat is clear of the ramp. 11. Secure the boat to the trailer with the tie downs. 12. Inspect bilge for fuel or oil. 13. If no fuel or oil is present remove bilge plug and drain water. 14. Check that the trailer is properly connected to truck before driving away.
USCG procedures supersede these instructions.
Transportable Port Security Boat (TPSB) Information Book
4-9
A.6 Basic Maneuvering
A.6.a Starting procedures.
1. Check fluid levels:
a. Oil b. Coolant c. Gear lube d. Power trim/tilt
2. Open seacocks. 3. Turn master engine battery switch on by turning handle to the ON position. (Each engine
battery will be connected to its own engine.) 4. Ensure that fuel cutoff valves are open. 5. Place controls in “Neutral” position by moving the control levers to the detent so the
levers are upright. 6. Set either port or starboard engine ignition switch to the RUN position. The engine
audible alarm should sound and the alternator warning light and low oil pressure warning lights should illuminate. Voltmeter should read at least 12 VDC.
CAUTION !
7. Push and hold START button until engine starts (approximately 10 seconds). Release start switch.
8. Once running, within a short time the voltmeter should read 14.2 ±.3 VDC. 9. Repeat steps 6 & 7 to start remaining engine.
4.6.b Stopping the engines.
1. Place the control levers in neutral. 2. Allow engines to cool gradually and uniformly by idling for 3 to 5 minutes before
shutting off after a full load operation. 3. When ready to shut down the engine, press and hold the Stop button, or turn the ignition
switch to OFF until the engine stops running. 4. Repeat step 3 for remaining engine. 5. Turn engine battery master switch to OFF position. 6. Check the bilge for evidence of fluid leaks.
A.7 Emergency Procedures
Run away engine.
Close fuel valves on fuel tank located under fuel access cover in crew compartment.
Onboard fire.
Use onboard fire extinguishers to extinguish fires.
Operating procedures or techniques that must be carefully followed to avoid
equipment damage.
If the audible alarm does not sound, vessel is considered non-
operational; report to unit maintenance for corrective action.
Transportable Port Security Boat (TPSB) Information Book
4-10
WARNING
In the case of an engine compartment fire, close the engine hatch
covers, then place the discharge nozzle of a fire extinguisher into one
of the two fire ports. Push the nozzle in to break the seal and then
discharge the full contents of extinguisher. Leave the engine hatch
covers closed to allow the extinguishing agent to smother the fire.
Chapter 5: Maintenance / Troubleshooting
5-1
5. MAINTENANCE / TROUBLESHOOTING
INTRODUCTION
This chapter describes the maintenance and troubleshooting procedure to properly maintain the
TPSB. Please note that this chapter does not cover everything to maintain the vessel. Refer to
the appropriate original equipment manufacturer manual for further information.
IN THIS CHAPTER
SECTION TOPIC SEE
PAGE
A Maintenance Intervals 5-2
B Troubleshooting 5-11
Daily and periodic maintenance is important to keep the engine in good operating condition. The
following is a summary of maintenance items by periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil
used, and are hard to establish definitively. The following should be treated only as a general
guideline.
CAUTION !
Operating procedures or techniques that must be carefully followed to avoid equipment damage.
Establish a periodic maintenance plan according to the engine
application and make sure you perform the required periodic
maintenance at intervals indicated. Failure to follow these guidelines
will impair the engine’s safety and performance characteristics, shorten
the engine’s life and may affect the warranty coverage on your engine.
Transportable Port Security Boat (TPSB) Information Book
5-2
SECTION A. MAINTENANCE INTERVALS
Introduction
The following tables allow for proper maintenance of the TPSB. Please refer to the appropriate
OEM manuals for more detail.
Table 5.1
Engine Maintenance
ITEM
DAILY 50
HOURS
125
HOURS
250
HOUR
S
500
HOURS
1000
HOURS
1250
HOUR
S
Whole Visual
inspection of
engine
exterior
X
Fuel system Check fuel
level X
Drain fuel /
water
separator
X
Replace fuel
filter element X
Initial
X
Check fuel
injection
timing
X
Lubricating
System
Check engine
oil level X
Change
engine oil X
Initial
X
Replace oil
filter element X
Initial X
Wash engine
oil cooler X
Transportable Port Security Boat (TPSB) Information Book
5-3
Fresh Water
Cooling
System
Check
coolant level X
Change
coolant X
Clean and
check the
cooling water
passage
X
Clean the
cooling water
system
X
Seawater
Cooling
System
Check
seawater
outlet
discharge
X
During
Operatio
n
Check of
replace
seawater
pump
impeller
X
Check or
replace the
zinc anodes
X
Check and
clean the
seawater
passage
X
Piping Clear or
replace the
exhaust /
water mixing
elbow
X
Check or
replace fuel
line and
rubber hoses
X
Electrical
System
Check the
alarm and
indicators
X
Transportable Port Security Boat (TPSB) Information Book
5-4
Check the
electrolyte
level in the
batteries
X
Adjust the
tension of the
alternator V-
belt or
replace V-
belt
X X
Remote
Control
Handle
Check and
lubricate the
remote
control cable
operation
X
Adjust
control
cables
X
Intake and
Exhaust
System
Wash turbo
charger
blower
X
Clean air
cleaner X
Intake and
Exhaust
System
Continued
Adjust the
intake and
exhaust valve
clearance
X Initial
X
Lap the
intake and
exhaust
valves
X
Miscellaneou
s
Replace the
timing belt X
Transportable Port Security Boat (TPSB) Information Book
5-5
Table 5.2
Engine Inspection and Maintenance of EPA Related Parts
Parts Interval
Clean fuel injector nozzle 1500 hours
Check fuel injection nozzle (adjustment) 3000 hours
Check injection pump adjustment 3000 hours
Check turbocharger adjustment 3000 hours
Check electronic engine control unit and its associated sensors and
actuators
3000 hours
Transportable Port Security Boat (TPSB) Information Book
5-6
Table 5.3
Mercury Bravo Sterndrive
SYSTEM ITEM
DAILY 50
HOURS
100
HOURS
200
HOURS
500
HOURS
1000
HOURS
1250
HOURS
Bravo
Sterndrive
Check propellers
for damage X
Check tie bar
fasteners X
Check gear lube
level X
Check fluid level
in trim pump
reservoir
X
Check steering
system for
binding or loose
components
X
Visually check
all hoses and
fittings
X
Lube propeller
shaft and re-
torque the nut
X
Inspect water
inlets X
Inspect anodes
replace after 50%
eroded
X
Change
sterndrive gear
lube
X
Re-torque gimble
ring U bolts X
Re-torque aft
engine mounts X
Transportable Port Security Boat (TPSB) Information Book
5-7
Check steering
and controls for
loose or damaged
parts
X
Inspect sterndrive
U-joints X
Inspect and
lubricate the
splines on the U-
joint shaft
X
Inspect U-joint
Bellows X
Inspect exhaust
tube X
Inspect shift
bellows X
Inspect clamps
on gimbal
housing
X
Check engine
alignment X
Lubricate the
gimbal bearing
and engine
coupler
X
Transportable Port Security Boat (TPSB) Information Book
5-8
Table 5.4
Electrical Maintenance
SYSTEM ITEM
DAILY 50
HOURS
100
HOURS
200
HOURS
500
HOURS
1000
HOURS
1250
HOURS
Network
Sounder
Check
transducer
cable for
loose or
damaged
connections
X
Check power
cable for
loose or
damaged
connections
X
Check
ground for
corrosion
X
Check power
supply
voltage
X
Clean unit X
Clean / check
transducer
face
X
NAVNET
3D
Check that
all cables are
fastened.
X
Check cables
for corrosion
X
Clean display X
Clean radar
antenna
X
Transportable Port Security Boat (TPSB) Information Book
5-9
RD-30
AND
GP-37
Check
connections
on rear of
unit
X
Check
ground
system.
Ensure it is
free of rust
and corrosion
X
Check
battery
terminals.
Ensure they
are free of
corrosion
X
Check
antenna
X
Clean unit X
Gentex
crew
comm.
Ensure RIIC
and CCP
mounting
hardware is
secure.
X
Ensure RIIC
and CCP
enclosure
covers are
secure.
X
Ensure CCP
headset
connector
protective
caps are
installed and
secure when
not in use.
X
Transportable Port Security Boat (TPSB) Information Book
5-10
Ensure all
support
station
connector
protective
caps are
installed and
secure when
not in use.
X
Ensure all
cables are
dressed and
secure.
X
Clean the
outer surface
of the CCP’s
with fresh
water and a
soft bristle
brush.
X
Rinse the
outer surface
of the CCP’s
with fresh
water after
brushing.
X
Transportable Port Security Boat (TPSB) Information Book
5-11
SECTION B. TROUBLESHOOTING
Introduction
The following tables list common problems and possible solutions. Please refer to the
appropriate OEM manuals for more detail.
Table 5.5
Engine Troubleshooting
TROUBLE PROBABLE CAUSE MEASURE
No charge lamp
No voltage
(Alarm buzzer does not
sound)
1.Faulty battery
2.V-belt is loose or damaged
3.Alternator is not generating
power
1. Check battery.
2. Adjust V-belt tension or
replace belt.
3. Ask for repairs.
C.W. Temp. Lamp goes
on
1. Insufficient Glycol coolant in
coolant tank.
2. Leakage in fresh water
(Glycol coolant) cooling system.
3. Fresh water cooling pump is
damaged.
4. Inside of C.W. system is dirty.
1. Check and replenish
Glycol coolant.
2. Ask for repairs for coolant
leakage.
3. Ask for repairs.
4. Ask for repairs
Low oil pressure
indicator goes on
Insufficient engine oil. Replenish oil.
C.W. level alarm
indicator goes on
Insufficient Glycol coolant in
coolant tank.
Check and replenish Glycol
coolant.
Gear oil alarm indicator
goes on
Insufficient drive oil. Replenish drive oil.
Boost pressure alarm
indicator goes on.
Boost pressure adjustment
device is damaged.
Ask for repairs.
Fuel filter alarm indicator
goes on
Increased fuel filter drain. Drain water separator.
Low pressure on raw
water gages.
1. Insufficient discharge of
cooling seawater.
2. Damaged cooling seawater
pump.
1. Kingston cock is closed.
2. Kingston cock is clogged.
3. Suction hose is damaged
or joints are loose.
4. Check seawater pump
impeller.
Alarm buzzer does not
sound
Circuit broken or buzzer
damaged.
Ask for repairs.
Some alarm lamps do not
light.
Circuit broken or lamp burnt out. Ask for repairs.
Alarm buzzer does not Short circuit Ask for repairs.
Transportable Port Security Boat (TPSB) Information Book
5-12
cut off
Some alarm lamps do not
go out
Damaged sensor or switch Ask for repairs.
Engine doesn’t start 1. No fuel.
2. Air in fuel line.
3. Bad fuel.
4. Clogged fuel filter.
5. Poor fuel injection.
6. Pressure leakage from
intake/exhaust valves.
1. Replenish fuel; bleed.
2. Bleed.
3. Replace fuel.
4. Replace fuel filter.
5. Ask for repairs.
6. Ask for repairs.
Starter does not turn or
turns slowly
1. Insufficient battery charge.
2. Faulty cable connection at
terminal.
3. Faulty starter switch.
4. Faulty starter.
1. Check battery charge.
2. Remove rust from
terminal; retighten.
3. Ask for repairs.
4. Ask for repairs.
Black smoke emitted 1. Overload.
2. Insufficient fuel.
3. Boost pressure low.
4. Faulty spraying of F.O.
injection.
5. Excessive intake / exhaust
valve top clearance.
1. Reduce load.
2. Replace fuel.
3. Wash turbocharger blower.
4. Ask for repairs.
5. Ask for repairs.
White smoke emitted 1. Insufficient fuel.
2. Faulty spraying of F.O.
injection.
3. Fuel injection timing off.
4. Lube oil burns/excessive
consumption.
1. Replace fuel.
2. Ask for repairs.
3. Ask for repairs.
4. Ask for repairs.
Transportable Port Security Boat (TPSB) Information Book
5-13
Table 5.6
Mercury Bravo Sterndrive Troubleshooting
TROUBLE PROBABLE CAUSE MEASURE
Remote control operates
hard, binds, has excessive
free-play, or makes
unusual sounds
Insufficient lubrication on the
shift and throttle linkage
fasteners.
Lubricate.
Obstruction in the shift or
throttle linkages.
Remove obstruction.
Loose or missing the shift and
throttle linkages.
Check all throttle linkages. If
any are loose or missing, ask
for repairs.
The shift or throttle cable is
kinked.
Straighten the cable or ask for
repairs. Replace cable that
cannot be straightened.
Steering wheel turns hard
or jerky
Low power steering pump
fluid.
Check for leak. Refill system.
Insufficient lubrication of the
steering components.
Lubricate.
Loose or missing steering
fasteners or parts.
Check all parts and fasteners.
Replace any missing parts or
fasteners. Tighten any loose
fasteners.
Contaminated power steering
fluid.
Flush system and replace with
new fluid.
Power trim does not
operate. (Electric motor
does not operate)
Blown fuse. Replace fuse.
Loose or dirty electrical
connections or damaged
wiring.
Check all the associated
electrical connections and the
wires (especially the battery
cables). Clean and tighten the
faulty connections. Repair or
replace the wiring.
Power trim does not
operate. (Electric motor
operates but sterndrive unit
does not move.)
The trim pump oil level is
low.
Fill trim pump with oil.
The drive is binding in the
gimbal ring.
Check for obstructions.
Transportable Port Security Boat (TPSB) Information Book
5-14
Table 5.7
Helm Troubleshooting
TROUBLE PROBABLE CAUSE MEASURE
During filling, helm
becomes completely
jammed.
1. Blockage in the line
between the helm and
cylinder.
2. Pro helm with an
unbalanced cylinder.
3. Tilt mechanism to helm
pump wheel shaft nut, NOT
installed properly.
1. Make certain hose/tubing
has not collapsed during
installation.
2. DO NOT use ANY PRO
helm pump with ANY un-
balanced cylinder.
3. Tighten and torque nut.
System is very difficult to
fill.
Air keeps burping out to of
helm, even after system
appears full.
System not being bled
properly/ completely
Consult with your cylinder
installation manual for proper
bleeding.
Cylinder is mounted upside
down, trapping air in the
cylinder body.
Install cylinder with bleed
fittings point UP.
Steering is stiff and hard to
turn, even when the vessel
is not moving.
Mechanical binding of
sterndrives.
Ensure sterndrives move
freely with cylinder
disconnected.
Restriction in hose. See fault 1.
Air in system. See fault 2.
Wrong fluid has been used. Use SeaStar steering fluid, or
fluid that meets MIL-PRF-
5606H
Steering is easy to turn at
the dock, but, becomes
hard to turn when
underway.
Steering wheel is too small. Install larger wheel (28”
MAX)
Cylinder doesn’t provide
enough force to turn drives.
Confirm cylinder installed is
right for the boat.
Incorrectly set, or adjusted
torque tab.
Readjust torque tab.
Mechanical interference. See fault 3.
Transportable Port Security Boat (TPSB) Information Book
5-15
Table 5.8
Power Assist Pump Troubleshooting
TROUBLE PROBABLE CAUSE MEASURE
Power assist unit does not
turn on.
Blown fuse/ breaker. Replace fuse/ breaker.
Wrong electrical connections. Refer to wiring diagram.
Turns the wrong way. Lines reversed. Review the plumbing
diagrams for your system;
confirm that your hoses are
hooked up correctly.
Wheel is bumpy. Air in system. Re-bleed. Concentrate on
remaining air in the P/A unit.
Helm locks up in both
directions.
1. Hoses are installed in the
wrong ports.
2. Kinked or collapsed line.
1. Review the plumbing
diagrams for your system;
confirm that your hoses are
hooked up correctly.
2. Check all lines for sign of a
collapsed or kinked line.
Helm only turns in one
direction and free wheels
in the other.
Port or Starboard line is
connected to the reservoir R
port on the P/A unit.
Review the plumbing
diagrams for your system;
confirm that your hoses are
hooked up correctly.
Steering is very hard (stiff). 1. P/A unit is not turned on.
2. Partially kinked or
collapsed line.
3. H1, H2 or R port screen
filters are plugged with
contamination.
1. See fault 1.
2. Check all lines for a sign
off a collapsed or kinked line.
3. Remove H1, H2 and R
hoses and fittings. Clean
screens located in the adapter
fittings.
No power assist, Lights are
blinking.
Note sequence of blinking
lights.
See page 22 of OEM manual
for details.
Transportable Port Security Boat (TPSB) Information Book
This page intentionally left blank.
Appendix A: Outfit Items & Stowage Plan
Appendix A. 1
Appendix A Outfit Items and Stowage Plan
Item Quantity Location
National Ensign 1 Bucket, fwd stowage
USCG Ensign 1 Bucket, fwd stowage
Flashlight 2 Bucket, fwd stowage
Binoculars 2 Bag next to fwd seats
Bucket 1 Fwd stowage locker
Portable Signal Horn 1 Bucket, fwd stowage
Spare propellant for signal horn 1 Bucket, fwd stowage
Spare part/tool bag 1 Fwd stowage locker
Spare kill switch lanyard 1 Tool bag, fwd stowage
Portable bilge pump 1 Port engine hatch
Life ring 1 Aft deck
Float free light 1 Aft deck
Snap hook for marker light lanyard 1 On light
Throw bag 2 Fwd stowage
Snap hook for throw bag 2 Tool bag, fwd stowage
Pyrotechnics storage container 1 Fwd stowage locker
10 person First Aid kit 1 Tool bag, fwd stowage
Rescue strop 1 Fwd stowage locker
30ftx6/8in mooring lines 6 Fwd stowage locker
Fenders 2 Fwd stowage locker
Boathook 1 Overhead
1 ¼“ shackle 1 Tool bag , Fwd stowage
Navigation Rules International-Inland 1 In nav bag at nav station
Parallel plotter 1 In nav bag at nav station
Dividers 1 In nav bag at nav station
Nautical slide rule 1 In nav bag at nav station
Search pattern wheel 1 In nav bag at nav station
Pencils 5 In nav bag at nav station
Pencil sharpener 1 In nav bag at nav station
Anemometer 1 In nav bag at nav station
Stop watch 1 In nav bag at nav station
Penlight 1 In nav bag at nav station
Chart 1 In nav bag at nav station
Pump, trailer hubs 1 Bucket, fwd stowage
Skiff hook 1 Tool bag, fwd stowage
Hook snap (304, 4.625 3970 SWL) 1 Tool bag, fwd stowage
Pelican MityLight red lens 1 In nav bag at nav station
Anchor line, with 12” eye 1 Fwd stowage, anchor bag
Gentex headsets, w/ext. cords & switches 4 Fwd stowage locker
Transportable Port Security Boat (TPSB) Information Book
Appendix A. 2
Item Quantity Location
Harris battery eliminator 1 Fwd stowage locker
Motorola charger and key loader 1 Fwd stowage locker
Misc. manuals * Fwd stowage locker
Shock cord 35” / 31” Max 54” 1 Fwd stowage locker
Fender inflator 1 Fwd stowage locker
Fender repair kit 1 Fwd stowage locker
Anchor 1 Fwd anchor storage
18” shock cord w/hooks 1 Fwd anchor storage
Bug Screen 1 Fwd stowage locker
Appendix B: Spares List
Appendix B. 1
Appendix B Spares List
DESCRIPTION VENDOR QTY
Engine Spares:
YANMAR 6LPAM-STZC3 ENGINE
IMPELLER, SEAWATER PUMP YANMAR EA 2
FILTER, ELEMENT, AIR YANMAR EA 2
FILTER, FUEL, FOR YANMAR 6LPAM-STZC3 ENGINE
YANMAR EA 2
FILTER, OIL, FOR YANMAR 6LPAM-STZC3 ENGINE
YANMAR EA 2
TIMING BELT YANMAR EA 2
V-BELT YANMAR EA 4
CARTRIDGE, FUEL FILTER/WATER SEPARATOR
RACOR EA 2
ANTIFREEZE, 1 GALLON CONTAINER, 50/50 MIX, ORANGE
CHEVON GL 16
OIL, ENGINE, 15W-40, 1 QT CONTAINER DELO QT 16
FLUID, HYDRAULIC STEERING, 1 QUART SEASTAR QT 4
ANODE, ZINC, FW PS FUEL YANMAR EA 10
ANODE, ZINC, AIR COOLER YANMAR EA 2
Controls Spares:
for: YANMAR 6LPAM-STZC3 ENGINE
30' TELEFLEX CONTROL CABLE TELFLEX EA 2
32' TELEFLEX CONTROL CABLE TELFLEX EA 1
34' TELEFLEX CONTROL CABLE TELFLEX EA 1
Sterndrive Spares:
HIGH PERFORMANCE GEAR LUBE MERCURY MARINE
QT 4
POWER TRIM FLUID MERCURY MARINE
EA 1
U-JOINT & GIMBAL BREARING GREASE 14OZ CARTRIDGE
MERCURY MARINE
EA 1
Transportable Port Security Boat (TPSB) Information Book
Appendix B. 2
DESCRIPTION VENDOR QTY
ENGINE COUPLER SPLINE GREASE 14OZ CARTRIDGE
MERCURY MARINE
EA 1
SPECIAL LUBRICANT 101 8OZ TUBE MERCURY MARINE
EA 1
ALUMINUM ANODE KIT BRAVO 1 DRIVES MERCURY MARINE
EA 2
Sponson Spares:
comes with fender system
SPONSON REPAIR KIT WING EA 1
Additional Spares:
ANODE, TEARDROP, ZINC, 1.000 THICKNESS x 2.000 WIDTH x 5.250 LENGTH, STREAMLINED
CANADA METALS
EA 2
Strap wrench
EA 1
Hand Pump, Jobsco 34060-0130, engine oil drain dipstick connector
EA 1
Alignment tool
MERCURY MARINE
EA 1
Shift cable alignment tool
MERCURY MARINE
EA 1
Flusher kit QUICK SILVER EA 1
Dual water pickup flush kit QUICK SILVER EA 1
Funnel
EA 1
Tire Change Device, Drive on
EA 1
Lug wrench, 4-way
EA 1
Appendix C: OEM Manual List
Appendix C. 1
Appendix C OEM Manual List
Manual Name VENDOR
6500 Cruise Master Flow Scan
6LP2 Maintenance Yanmar
Forespar Ball Valve, Tech Tips Forespar
Furuno DFF1 Furuno USA
Furuno GP37 Furuno USA
Furuno MFD12 Furuno USA
Furuno RD30 Furuno USA
Globemaster Compass Ritchie Navigation
ISCH7800 Throttle Teleflex Marine
Lenco Trim Tabs Lenco Marine
MerCruiser Bravo Outdrive Operation & Maintenance Mercury Marine
Model 2004B & 2012 Strobe Beacons Whelen
NaviLED Instruction Sheet Hella Marine
Racor Product Sheet (Fuel Filter) Parker / Racor
SeaStar Power Assist Pump TeleFlex Marine
SeaStar Steering (070323-R) Teleflex Marine
SeaStar Tilt Helm Teleflex Marine
6500 Cruise Master Flow Scan
6LP2 Maintenance Yanmar
Forespar Ball Valve, Tech Tips Forespar
Furuno DFF1 Furuno USA
Furuno GP37 Furuno USA
Furuno MFD12 Furuno USA
Furuno RD30 Furuno USA
Globemaster Compass Ritchie Navigation
Kvichak Marine Industries, Inc.
469 NW Bowdoin Place
Seattle, WA 98107
COMDNINST M16114.nn
32 FT Transportable Port Security Boat (TPSB)
Boats 32101 through 32180