Fassmer Freefall Lifeboats Type GAR (-T) 6.0 - 8.1 CFL (-T) 66 - 83 Manual

Operator’s Handbook for Fassmer
Freefall- Lifeboat Type

GAR(-T) 6.0 - 8.1 / CFL(-T) 66 - 83 GB
20.0000-019.00.00.6
Fr. Fassmer GmbH & Co. KG

Industriestr. 2
D - 27804 Berne / Germany
Phone: +49 (0)4406 942-0 Fax: +49 (0)4406 942-100
Email: info@fassmer.de
Internet: www.fassmer.de
Art. no. 156336
Operator’s Handbook for
Fassmer Freefall-Lifeboats type GAR(-T) 6.0 - 8.1 / CFL(-T) 66 - 83
Contents Page
1. Introduction .............................................................................................. 4
2. Brief construction description ................................................................... 5
3. Operation of Boat ...................................................................................... 7
3.1 Launching of the lifeboat ...................................................................... 7
3.2 Davit / Crane lowering of lifeboat ........................................................ 17
3.3 Other operating situations .................................................................. 17
3.3.1 Launching from a vessel moving ahead ....................................... 17
3.3.2 Launching into seaway ................................................................. 17
3.3.3 Towing .......................................................................................... 17
3.3.4 Capsizing ...................................................................................... 17
3.3.5 Injured person on stretcher ........................................................... 17
4. Recovery .................................................................................................. 18
5. Operation of Equipment ........................................................................... 21
5.1 Engine plant ........................................................................................ 21
5.1.1 SABB - Engine ............................................................................... 21
5.1.2 BUKH - Engine ............................................................................. 21
5.1.3 Nanni - Engine) ............................................................................. 22
5.1.4 Description of the engine plant ..................................................... 23
5.2 Rudder plant ....................................................................................... 24
5.3 Fuel tank ............................................................................................. 24
5.4 Electric plant ....................................................................................... 25
5.5 Lights .................................................................................................. 25
5.6 Water spray plant ................................................................................ 26
5.7 Self-contained air support system ...................................................... 27
5.8 Bailing ................................................................................................. 29
5.8.1 Manual bilge pump ....................................................................... 29
5.9 Rain water collection ........................................................................... 29
6. Release gear system ................................................................................ 30
Document 20.0000-019.00.00.6 Art. No. 156336 2 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

7. Simulated Launch .................................................................................... 31
7.1 Securing of boat during service or release test

without launching ................................................................................ 31
8. Launching ramp and lashing .................................................................... 32
9. Outfit and loose equipment ...................................................................... 33
10. Periodic servicing and inspection by crew ............................................. 34
10.1 WEEKLY and after every recovery of the boat into the davit ........... 35
10.2 MONTHLY ........................................................................................ 36
10.3 3-MONTHLY ..................................................................................... 37
11. Servicing, inspection, overhaul and testing by Fassmer-certified

service engineer ....................................................................................... 41
11.1 ANNUAL THOROUGH EXAMINATION ........................................... 41
11.2 EVERY 2 YEARS .............................................................................. 45
11.3 EVERY 5 YEARS .............................................................................. 46
11.4 EVERY 10 YEARS ............................................................................ 49
12. Maintenance ........................................................................................... 51
12.1 GRP-maintenance and repair ........................................................... 51
12.2 Engine plant maintenance ................................................................ 54
12.3 Electric plant maintenance ................................................................ 54
12.4 Doors and Hatches maintenance ..................................................... 56
12.5 Water spray plant maintenance ........................................................ 56
12.6 Self-contained air support system maintenance ............................... 57
12.7 Release gear system maintenance .................................................. 27
13. First installation ...................................................................................... 58

1. Introduction
A Freefall-Lifeboat is carried for the protection of every person on board. It can,
however, only fulfil its task, if everyone on board is acquainted with the whole
lifeboat, its functions and operation.
Only ongoing practice brings reliability to the lifeboat and prevents handling
errors in a case of danger.
Equally important is the sound technical condition of the boat, which is ob-
tained through regular maintenance.
This instruction manual cannot, of course, be complete, nor can it unequivo-
cally cover all procedures or situations of danger that could arise during the
operation the boats.
Each user of the boat should familiarise himself with the boat before use and
before a situation of danger could arise.
This manual should help you accomplish this.
In the case of further questions, please forward your request to:
Fr. Fassmer GmbH & Co. KG

Industriestr. 2
D - 27804 Berne / Germany
Phone: +49 (0)4406 942-0
Fax: +49 (0)4406 942-100
Email: info@fassmer.de
www.fassmer.de
Quote your order number and build year, stamped on the Fassmer-lifeboat
plate and found behind the steering tower, or shipyard and build year of the
mother ship.
Note:
Additional detail manuals concerning engine, spare part lists,
drawings, certificates etc. can be found in the “Lifeboat Docu-
mentation” delivered with each boat, and found on the mother
ship.
Note:
This manual was established with consideration of:
- SOLAS 74, Chapter III, Edition 2004
- Resolution MSC.152(78)
- IMO MSC CIRC. 1206-MEASURES TO PREVENT ACCI-
DENTS WITH LIFEBOATS-(Consolidated Circ. from 1093
etc)
- MSC1-Circ. 1205-Guideline for Lifeboat System manuals
- GL-“Checklist for maintenance and inspection of safety
equipment” (2005)
- Lloyd’s Register “GUIDANCE NOTES FOR THE PREPERA-
TION OF A LIFEBOAT´S OPERATION INSTRUCTION &
MAINTENANCE MANUALS”

2. Brief construction description:

The complete hull and canopy of the boat is produced in hand-Lay-up GRP
using a self-extinguishing laminate.
All scantlings meet the requirements of “Germanischer Lloyd” or respective
certifying authority.
The boat is of round bilge with a transom stern. It has a platform deck aft for
rescues and recovery by helicopter. The raised foredeck clears the sea well
and gives a large reserve buoyancy to the bow.
The boat has a complete inner shell built of glass-fibre reinforced polyester
(GRP) with single seats, floors and engine foundation.The area between inner
and outer shells is filled with foam (CFC-R11 free polyurethane) keeping the
boat buoyant even when damaged. A Locker forward below floor is used as
stowage room for inventory, provisions etc.
The boat is covered with an enclosed canopy, which contains towards the rear
a raised steering stand, closed with front and side windows.
To enter the boat comfortably from the aft deck, a large door is placed at the aft
bulkhead of the superstructure. An additional hatch forward on the superstruc-
ture makes it possible to operate the painter and sea anchor from inside.
All seats are installed with backrests and four-point safety belts.
An approved water-cooled marine diesel engine with indirect keel pipe cooling
is installed. The exhaust pipe is equipped with a silencer and is led outside
through a goose neck.
Only valid for tanker lifeboats:
Each tanker-lifeboat is equipped with a water spray plant which can be set into
operation by opening a sea water valve in the bottom of the boat in front of the
engine.
The sea water is distributed by an engine driven water spray pump through
pipes and hoses to spray nozzles on the outside surface of the lifeboat cover-
ing it completely with water.
This water shelter curtain around the boat enables it to drive through a fire on
the water surface without major damages to the boat. In addition the water
gives a cooling effect to the interior so that the inside temperature will not rise
significantly during a 10 minute period.
To be safe against fumes and toxious gazes created by the fire all air inlets
must be closed. Air supply for 10 minutes for crew and running engine is pro-
vided by an independent air supply system in the boat.
By opening air bottle and air plant valves compressed breathing air streams
into the boat creating a small overpressure inside to prevent entering of toxious
gazes.
For overall drawings refer to next page

Overall drawing: (GAR 6.7 - 8.1 / CFL 66 - 83 boats)
Fig. 1

3. Operation of Boat
Caution:
For drills follow the recommendations of IMO-MSC1.Circ 1206-
MEASURES TO PREVENT ACCIDENTS WITH LIFEBOATS, for
example:
 Elements of the drill that may involve unnecessary risks need
special attention or may be excluded from the drill.
 The launching of a boat with its full complement of persons is
an example of an element of a drill that may, depending on
the circumstances, involve an unnecessary risk. Such drills
should only be carried out if special precautions are ob-
served.
 Before placing persons onboard a lifeboat, it is recom-
mended that the boat first be lowered and recovered without
persons onboard to ascertain that the arrangement functions
correctly. The boat should then be lowered into the water
with only the number of persons onboard necessary to oper-
ate the boat.
 To prevent heaving wires or gripes from getting entangled,
proper release should be checked before launching the boat.
3.1 Launching of the lifeboat

The following description contains the general procedure for abandoning ship.
Circumstances may be unique onboard different vessels or the concerning
situation may require different action. The description is formed as a checklist,
which shall be used when required. (Items marked *S should be simulated
when carrying out drills)
1. When the abandon ship signal is given all those aboard, clothed head
to toe, with solid shoes, and carrying lifejackets must proceed to the mus-
ter station. The designated persons should bring a SART (Search and
Rescue Radar Transponder, *S), portable VHF radio (having verified its
operation) and additional fuel, water, clothing, blankets plus any other ad-
ditional equipment (*S) to the muster area. The assigned crew members
will then prepare the boat for launching:
2. Open side lashing plates by pulling rope on platform deck.
3. Disconnect the charging cable, if fitted.

(see overall drawing Fig. 1)
Charging plug

4. Check if heaving wire long link(s) are disconnected from davit, resting in
the support, secured with belt (1).
5. Check if lifelines (1) are secured to canpoy
Fig. 2
6. Check if boat and launching ramp (Fig.3) are free of obstructions and
lashings.
Fig. 3
7. Ensuring release hook closure

Check that release hook rests at least 15mm onto stop pawl (1)

8. Before opening the door

 Remove release hook safety pin (1) from the release gear (1)
 Put it into support at door and secure it (2)
1 2
SECURING FOR  Open the door and secure it by placing the lower door handle
DOOR in its retainer.
TURN LOWER HANDLE

BEHIND DOOR STOPPER
9. Ensuring release handle closure

 Check release handle (1) is secured with release handle safety pin (2)
1 2
10. Switch the battery change-over switch (1) to battery 1 or 2.

1
1+2
2
(see chapter 2, overall drawing Fig.1 or Fig.2)
OFF
Battery Battery
1 2
Battery change-over switch
WARNING: Use only Battery 1 or 2. Both together only in
emergency. Don´t switch off when engine is running.
Danger of generator damage!

11. The engine should be regularly maintained and ready for starting, i.e.:
 Fuel tank filled and uncontaminated
 Fuel valve open
Diesel
 Drive shaft greased
 Batteries fully charged
Fuel valve If possible, examine before launching!

Check additionally to above mentioned items:
 Check sea water valve (1) in front of engine and spray pump
at the bottom is open, shown is the closed position
 In USCG boats, a remote lever (2) to operate the sea water valve is
installed at the helmsman position
1 2
 Open valves at all air bottles (1). USCG boats are equipped with two
air bottles and all other boats are equipped with three air bottles.
 Check that the outlet valve (2) at the air supply control is closed
 Check that the re-filling connection cap (3) is in place
and screwed down
Start air supply:
open valve
3 2
1

12. The following actions are carried out by the crew on ship’s deck:
 Ensure all additional equipment is given to the crewmen in the boat
 Prepare the launching ramp, lashings etc. for launching according to
Launching instructions
 When clear, contact the bridge and report “ready for boarding”.
 The bridge will give the order to board and launch the boat.
If there is a fire, smoke, or fumes to ensure constant water flow on the
whole surface, check additionally to the above mentioned items:
 All parts outside the boat (ropes, fenders, dirt, etc)
have to be removed
 Flushing connection for water spray plant have to be closed
13. Board lifeboat and take a seat filling farthest from the door first to ensure
all seats are used. Place arms under the shoulder straps and secure the
safety belt by connecting the square ring to the pelican hook. Close the
pelican hook and pull at the loose end of safety belt to tighten it. Always
use the same seat and adjust the belt for your body size:
Warning:
Danger of Injury:
 Don’t wear rigid lifejackets during launching.
 Put lifejacket on the knees during launching:
 Use handgrips in front of your seat.

ES S ES S
PR PR
 Press yourself into the seat by means of safety belt.
 Press head tight against the head cushion during launching.
 Close the aft door and hatches, if fitted

If there is a fire, smoke, or fumes after boarding when doors and hatches
are closed, close additionally to the above mentioned item:
 Close air flap in door
 Close other openings and ventilations (if fitted)
Never:
Never close air flap without running air plant to avoid danger of
suffocations
Lack of fresh air will increase CO2-content inside the lifeboat.
This can result in uncontrolled sleeping followed by DEATH

14. Control by helmsman before launching:

 safety belts of all persons
 closing of all hatches, door and openings
 All loose items secured
 water entry area free of obstructions.
 Rudder on “straight-ahead”- position
 Instruction by helmsman:
„PREPARE FOR LAUNCHING!“
15. Launching the boat (see instruction on next page)
Note:
Boat is designed to launch at max. +/- 10° trim and 20° list of
ship (30° for special ships). Launches in other conditions are not
covered by approval. Water depth in launching area should be
equal or more than boat’s length.

Operation normal freefall release:
Warning:
Operation by Coxswain only
Faulty operation will drop the boat! Operation of release system
should only be carried out by the coxswain. Do not enter, launch
or hoist the boat before the correct positioning of the hook and
release handle are checked.
Note:
Ensure before freefall release
 Everybody has taken seat and seat belts are fastened.
 Entrance door is closed and water is free of barricades.
 Take out release handle safety pin (1)

 Close bypass valve (2)
 By operating the release handle (3) app. 5 to 10 times the hydraulic
plunger (4) opens the stop pawl (5) until the release hook (6) is open
 The boat slides down the launching ramp
3 1 2 4 6 5
Emergency freefall release:
Note:
If the hydraulic system doesn’t work the release system can be
opened manually.
 Remove glass (1)

 Open bypass valve (2)
 Take out handle for emergency release (3) and screw in emergency re-
lease bolt (4) by turning it clockwise app. 20 turns until stop pawl (5) opens
the release hook (6)
 The boat slides down the launching ramp
3 2 6 5
4 1

Engine Control Lever 16. Starting the engine:

N (Neutral)
The engine will be either started with a turn-button (Fig. 4) or with

a push-button (Fig. 5 and Fig. 6)
F (Forward) R (Reverse)
Turn-button Sabb- engine):
Hold in red button when
 Move the engine control lever to the neutral position. (1)
 Turn the engine on at the switchboard (turn switch one step to the
setting speed control lever
to disengage propeller
right). (2)
 Start the engine: turn switch to right end position and hold until en-
gine runs. (2) (for details refer to engine instructions)
Fig. 4
Push-button Bukh-engine):
 Move the engine control lever to the neutral position. (1)
 Switch to run position. (2)
 Push the start button until engine runs (3)
(for details refer to engine instructions).
1 2
Fig. 5

Push button Nanni-Engine:

 Move the engine control lever to the neutral position (1)
 Push the on/stop button once (a signal is sounding) (2)
 Push the Heat/start button to middle position for heating the en-
gine.(3)
 After at least 20 sec. push the Heat/Start button fully to start the en-
gine (for details refer to engine instruction (3)
1
3
Fig. 6
If there is a fire, smoke, or fumes after engine starting or at the most
5 min. after closing ventilations:
 Open outlet valve (1) at the air supply unit (The air supply in the air
bottles is good for 10 minutes maximum).

Engine Control Lever 17. Sailing:

N (Neutral)
 Push the engine control lever to the “Forward” position (F) and travel
away from the ship.
 Weather permitting the door/hatch can stay open providing fresh air
F (Forward) R (Reverse)
inside
 For further procedures refer to the “Survival Manual” which is stored
Hold in red button when
setting speed control lever
to disengage propeller
in the equipment box.

 Stay at a safe distance from the ship and bring out the sea anchor.

Driving through fire:
When boat is waterborne and is free of the ship:
 Engage coupling and drive away immediately with full speed. (Only at
full speed full water coverage of surface is provided)
 Take shortest way out of fire, i.e. drive against wind direction. If in
doubt use compass.
 The air supply is sufficient for max. 10 minutes, i.e. one nat. mile at a
speed of 6 knots
Caution:
During fire do not touch metal fittings or screws which have con-
nections to outside the boat. They might be hot and cause inju-
ries.
When fire is passed or air bottles are empty (high pressure ma-
nometer about 10 bar):
 Open air flap in aft door again
 Stop water spray plant by closing sea water valve
(bypass valve remains open)
Never:
Never close air flap without running air plant to avoid danger of
suffocations
Lack of fresh air will increase CO2-content inside the lifeboat.
This can result in uncontrolled sleeping followed by DEATH

3.2 Davit / Crane lowering of lifeboat (secondary launch)

If launching of the boat not possible (f.e. a person is seriously injured and can
not seated in seat) the lifeboat can be lowered into water by davit / crane.
For lowering of the boat refer to davit / crane instruction.
3.3 Other operating situations:

3.3.1 Launching from a vessel moving ahead:
All Freefall-Lifeboats are designed for launching with the vessel making head-
way of up to 5 knots or under the influence of a corresponding heavy current or
wind. If possible the ship’s propeller should be disengaged to minimise turbu-
lences behind the ship.
3.3.2 Launching into seaway:

It may be necessary to launch into rougher seas where the rise and fall of the
water level will cause severe motions and possibly damage the boat. Once
waterborne the boat will pitch and heave making immediate departure very
important. The following point can help in such a situation:
 Choose a moment for launching where the boat enter a relatively even wa-
ter surface and not a breaking wave.
3.3.3 Towing:
Attach towing ropes and dock lines only on the draining hole of the release
hook or on the front hoisting fitting. If the boat itself is being towed, use front
hoisting fitting to attach the towing rope. The maximum towing speed for life
rafts is 3 kts, for the boat max. 5kts.
3.3.4 Capsizing:
Should the boat capsize with all hatches and doors closed it will re-right itself if
all persons have fastened their seat belts. Otherwise, the unbelted persons
have to move to one side of the boat in order to re-right the boat.
3.3.5 Injured person on stretcher:

A stretcher with an injured person can be stowed in forward part of the aisle,
with feet to forward end of boat, after the persons in adjacent seats nearby the
stretcher have taken place.
The Stretcher should be secured with suitable straps or ropes from stretcher to
safety belt fittings of adjacent seats.
Warning:
 During freefall launching the injured person should be seated
and secured in a freefall seat. Otherwise there is danger of
life to this person.
 If person is so seriously injured that it can not be seated in
freefall seat, davit launch instead of freefall launch is strongly
recommended.
Refer to chapter 3.2 Davit / crane lowering of lifeboat

4. Recovery:
Caution:
Retrieval of Freefall-Lifeboats under seaway is extremely difficult.
Therefore, this is only recommended for action in harbours or in
very sheltered waters with the ship making no headway.
Max. 3 Persons are allowed to stay on board during heaving
 Drive boat under davit / crane

 Hang in lifting eye(s) into crane / davit hook(s) while standing on platform
deck.
 Lift boat
Caution:
During heaving crew should be secured in their seats!
Caution:
When lifting the boat control that wires, chains or shackles are
straight and not turned and do not jam at boat parts like forward
hatch f.e.!
 Ensure that side-lashing plates of launching ramp are open (hinged down)!
 Return boat to launching ramp according to davit/crane instructions
Caution:
Boat to be lowered in such way that launching ramp has full con-
tact with all rollers before retaining chain takes load of the boat.
Lever forces might damage otherwise launching rail in roller
area.
 Place retaining chain (1) into open release hook

 Close release hook by lifting it and “arrest” the retaining chain
 Open bypass valve by a second person
 Ensure that the hydraulic plunger returns the stop pawl
to closed position.

Mandatory:
Check that stop pawl has completely returned and release hook
lies about 15 mm on stop pawl. (1)
Note:
 Insert release handle safety pin into release handle (1)
 Bypass valve has to be open (2)
Caution:
The bypass valve of the hydraulic plunger has to be OPEN
CONSTANTLY, otherwise DANGER of unintended launching
 Disconnect lifting eye(s) from davit/ crane, hang them into their holder(s)
and secure them with belt.
 Close side lashings again by pulling and securing lashing plate wires.
 Re- stow all loose equipment
 Remove all parts, which do not belong to the boat equipment (portable
VHF, SART etc.)
 Reconnect charging cable if any

 Open drain plug drain bilge if necessary
 Refill fuel and other consumed items
 Rudder on “straight-ahead”- position
 Every problem or damage experienced during the test should
Charging plug be settled immediately
 Switch off battery switch when leaving the boat

 Close Door and insert release handle safety pin into release hook and se-
cure it (1).
Warning:
Always ensure that:
 Release hook is closed correctly
 Release hook safety pin is inserted to hook and secured

If boat is in stowed position:
 Flush water spray plant with fresh water and drain it
 Open sea water valve to be prepared for next launch
 Check if bypass valve of water spray plant is open
 Refill air plant if necessary
 Close valves on all air bottles
Caution:
At recovery take special care that spray nozzles are not dam-
aged by heaving equipment!

5. Operation of Equipment:
5.1 Engine plant
5.1.1 SABB-Engine (Fig. 7)
5 7
Engine starting:
 Move the engine control lever to the
neutral position. (1)
 Turn the engine on at the switchboard
( turn switch one step to the right ) (2)
 Start the engine: turn switch to right end position
and hold until engine runs. (2)
(for details refer to engine instructions)
Engine stopping:
 Turn off the engine at the switchboard. (2)
1 6 2
Fig. 7
5.1.2 BUKH-Engine (Fig. 8) 5 7 2

Engine starting:
neutral position (1).
 Switch to run position (2)
 Push the start button until engine runs (3)
(for details refer to engine instructions)
Engine stopping:
 Push the stop button until the engine stops. (4)
 Switch to off position (2)
1 4 3
6
Fig. 8

5.1.3 Nanni-Engine (Fig. 9)

2 6 3
Engine starting:
neutral position (1)
 Push the on/stop button (2) (a signal is sounding
and the heating lamp goes on) (3)
 Push the Heat/Start button (4) up to the middle for
heating the engine at least 20 sec. (3)
 After at least 20 sec. push the Heat/Start button (4)
to start the engine (for details refer to engine instruc-
tion) (3)
Engine stopping:
 Depress the on/stop (2) button until
the engine stops
1 4 5 7
Fig. 9
Note:
During sailing the boat the following alarm lights and sound might
occur, indicating engine problems:
 Oil pressure (5)
 Cooling water temperature (6)
 Alternator (7)
In case of occurrence refer to engine manual
For tests or maintenance the engine can idle for about 5 minutes with the boat
out of the water.
Never:
NEVER turn the main battery switch OFF whilst the engine is
running. This can destroy the alternator.

5.1.4 Discription of the engine plant

A water-cooled diesel engine with reverse gear is installed in the Fassmer free-
fall lifeboats. (Fig. 10)
Three different engine makers are in use: BUKH, SABB and Nanni.
Mandatory:
Quick shifting from full ahead to full astern may damage trans-
mission, circuits or engine. To avoid this, let the engine idle for
about 5 seconds before shifting.
All engines are fitted with a single circuit keel-pipe cooling.The cooling pipes
are situated below engine area alongside the keel. This cooling enables all
engines to run out of the water for five minutes (test run).
The cooling system is filled with anti-freeze fluid suitable down to -35°C.
A stainless steel shaft turns in greased bronze bearings, operating a bronce
propeller.
The exhaust system works without water injection.
Warning:
Exhaust temperatures can exceed 500°C. Do not touch any
components of the hot exhaust system.
If the insulation is wet the boat should be moored with open doors and hatches.
Run the engine at full speed with a disengaged propeller for about an hour. Try
to find the cause of the wet insulation and tighten any leakages.
Fig. 10
For maintenance refer to chapter 12.2 Engine plant maintenance

5.2 Rudder plant

The rudder system (Fig. 11) consists of a steering device and a nozzle rudder
with shaft. A bowden wire connects them. Should a steering device fail, an
emergency tiller can be attached to the rudder stock. If the bowden wire is
blocked remove the bolt and safety ring.(Detail Z below)
Emergency tiller
disconnect steering for use
rudder stock
rudder stopper
emergency stock
Detail Z
self lubricating
plastic bearing
rudder nozzle
bowden wire
rudder shoe
Fig. 11
Mandatory:
When driving with hard rudder and high rpm forwards or back-
wards a strong force may be required to turn the steering wheel.
For this reason speed must be reduced for manoeuvring, or the
steering system may be damaged.
5.3 Fuel tank

The fuel tank is located aft on centre line. Its capacity is sufficient for 24 hours
engine operation at full speed.
The fuel capacity can be either checked on the tank level gauge at the fuel tank
or steering stand, (if fitted) or by inserting a measuring rod into the tank
(Fig.12).
Fig.12

5.4 Electric plant

A 12VDC electrical system is installed.
For the wiring scheme refer to “Lifeboat documentation”.
The system will be activated with the battery switch (1): switch EITHER to
“BATT. 1” OR “BATT. 2” to keep the second battery as spare.
Position “BOTH” switches both batteries together for combined power: use
ONLY if one battery alone is not strong enough to start the engine
For maintenance refer to chapter 12.3. Electric plant maintenance
Never:
NEVER turn the main battery switch OFF whilst the engine is
running. This can destroy the alternator.
5.5 Lights
On the boat are one allround light outside and interior lights. With the electrical
light switches (Fig. 13) on the switchboard the following lights can be switched
on/off.
 Switch 1: allround light
 Switch 2: interior lights
2
1
Fig. 13

5.6 Water spray plant:

The tanker lifeboat is equipped with a water spray plant which can be set into
operation by opening a sea water valve in bottom of the boat in front of the
engine. (Fig. 14)
The sea water is distributed by an engine driven water spray pump through
pipes and hoses to spray nozzles on the outside surface of lifeboat covering it
completely with water. For nozzles arrangement refer to spray plant drawing in
“Lifeboat documentation”
This water shelter curtain around the boat enables it to drive through a fire on
the water surface without major damages to the boat. In addition the water
gives a cooling effect to the interior so that the temperature inside the boat will
not rise significantly during a 10 minute period.
The pump is permanently attached to the engine by a fixed coupling or by
means of vee-belts. It is therefore permanently running.
At the deepest point of the pump a hose is connected to a bypass valve at the
bottom.
Mandatory:
This bypass valve must always be open to prevent overheating
of running spray pump without sea water and to allow complete
self draining of water spray system.
A closed bypass valve can damage the pump or block it in case
of freezing. Close only in case of water entry.
Fig. 14
For maintenance information refer to Chapter 12.5

5.7 Self-contained air support system:

The system is to be used in case the boat has to drive through a fire on
the water surface or if toxious gazes are in the atmosphere.
The tanker-lifeboat is equipped with a self contained air support system stored
in 200 bar or in case of USCG boats 300 bar high pressure air bottles in the
bottom of the boat. The air bottles are connected to each other and to the air
distribution plant by high pressure hoses. Each air bottle has a shut off valve
at the bottle´s head.
The air distribution unit is installed within the reach of the helmsman. It consists
of an air pressure reducer, a filling connection with non- return valve and safety
cap to refill the plant, a stop valve, an air outlet with silencer and an high- and
low pressure manometers. Further an air flap and over- and under pressure
valves are installed in the air duct of the aft entrance door.
Operation:
To prepare the air plant for use all air bottle valves must be opened. The sys-
tem is now under pressure up to the stop valve which must still be closed (lever
transverse to pipes). Outlet of air at the filing connection is prevented by an
integrated non- return valve and an additional safety cap which must always be
fitted with exception of filling.
Additional doors, hatches, all other openings and the air flap in the aft door
must be closed to prevent loss of air supply to outside.
Two under pressure valves are integrated in this flap. They will open if danger-
ous under pressure occurs in the boat by engine operation or other reason
(rubber membrane moves upward).
Note:
This valves only prevent strong under pressure in the boat. They
are not sufficient to provide enough air supply for the occupants!
Never:
Never close air inlet without running air plant to avoid dan-
ger of suffocation.
Lack of fresh air will increase CO2-content inside the
lifeboat. This can result in uncontrolled sleeping fol-
lowed by DEATH!
When starting engine or latest 5 minutes after closing air flap plant must be set
into operation by turning stop valve lever for 90°. Air will now stream into air
reducer where the pressure and outcoming volume is reduced to an amount
which is sufficient to provide a small overpressure in the boat when the engine
is running at full speed. This overpressure prevents entry of toxious gazes from
outside through small leakages in the boat.
The volume is regulated at the air reducer by the boat yard by an air supply
test for each individual boat and sealed after setting.
Note:
DON’T OPEN SEAL AND CHANGE THIS SETTING

The air stream out into boat through the silencer and distributes it into
the boat providing fresh and cold air for occupants and engine. The
outcoming pressure can be seen on the manometer behind the air re-
ducer, the normal range is between 1,5 and 4 bar.
The high pressure manometer shows the contents of the air bot-
tles, starting at 200 bar, in the case of USCG boats at 300 bar with
full bottles reducing to 0 bar within about 10 minutes, i.e. about
each 20 bar or in case of USCG boats 30 bar mean about 1 minute
of operation time!
Warning:
Due to expanding air all parts of air system will become very cold
and covered with ice!
DON’T TOUCH, DANGER OF FREEZING!
Although a spring loaded over pressure valve is located in the air duct
in the aft door to prevent uncomfortable over pressure:
Caution:
DON’T STOP ENGINE WHILE AIR PLANT IS IN OPERATION!
Caution:
DON’T FORGET TO RE- OPEN AIR FLAP AFTER AIR SUP-
PLY HAS STOPPED!

5.8 Bailing
Water inside the boat will gather at the bilge. From there it can be bailed out
using the installed manual bilge pump (see chapter 5.8.1).
Water in other areas can be removed with a bailer.
To drain the air cases, at least one drain plug is fitted at deepest point outside
on the hull and inside at the canopy air cases.
AIR CASE DRAINING
5.8.1 Manual bilge pump

If water is in the bilge then:
 connect the pump lever (1) into the socket (2)
 move lever to bail out the water of the bilge
1
2
5.9 rain water collection

Rain water collection is used to increase the drinking water storage.
Rain water is collected by a gutter (1). It is guided to inside the boat by a valve
or hose. The rain water is to be stored in the drinking water cannister.
Mandatory:
To prevent that dirt and salt can get into the drinking water, the
valve should be stay closed for the first few minutes of raining.
Open the valve plug (3) only when it is raining, otherwise dirt and
salt could reach into the rain water collecting tank.

6. Release gear system:

For operation refer to chapter 3 Operation of Boat item 15.
The GAR / CFL boats consist of a hydraulic gear system. The hydraulic gear
system is equipped with a release handle (1), hand-hydraulic release pump (2),
hydraulic oil tank (3), hydraulic hose (4) and the hydraulic plunger (5). The
hydraulic plunger is equipped with a return spring inside. If spring tension is no
more sufficient to return stop pawl totally it can be exchanged by opening aft
cap after draining hydraulic oil of piston.
Mandatory:
 Check release hook for tender spots of chain. (1)
 Grind smooth if there are any tender spots, otherwise hook
may not open!

7. Simulated Launch
7.1 Securing of boat during service or release test without launching
 Connect hoisting wires to crane or davit and pull them tight acc. to their in-
structions.
 Secure boat additionally with applicable ropes or chains from shackle of
forward hoisting fitting downwards aft to launching ramp on both sides and/
or through drain cut- outs of release arrangement to ship side retaining de-
vice.
A special simulated launching kit is available as optional equipment This kit

allows the simulated launch more easy than the described above.
Caution:
Do not work or release the release arrangement without launch-
ing without having above securing tight. Release test without
launching WITH HELMSMAN ONLY
acc. to chapter 3.1

8. Launching ramp and lashing:

The launching ramp consists of steel square pipes with welded rollers. The
rollers are made of polyamide and turn on stainless-steel axles. They are self-
lubricating. For damages on rollers: remove axle holder and pull out roller.
Lashings at the stern of the boat: The boat is connected to the launching
ramp with a connection link. As this connection link is going down at an angle
of 15° to the horizontal it prevents the boat jumping on the launching ramp in
heavy sea way. The bow of the boat is secured against jumping with one lash-
ing plate on each side. Additional lashings might be fitted. In this case applica-
ble extra signboards on the boat have to be observed.
During re-insetting of the boat by davit or crane, side lashing has to be opened
by pulling rope on platform deck.
Float free arrangement: If the ship should sink, the buoyancy of the complete
Lifeboat will act on the lashing plate, which will break by that load. The bow of
the boat will float free. After that, the retaining chain can slip off the lashing
bollard, which is open at the top, and the boat will float free.

9. Outfit and loose equipment:

Loose equipment and provisions are stowed in the inventory case.
Water rations are provided in loose water canisters or in water tank(s).
Boat hooks are secured PS in the boat.
A rope ladder is also provided as part of the loose equipment. For boarding
from the water hang it onto the rowlock at the transom.
ROPE LADDER
ROPE LADDER
FITTING OF
RADAR REFLECTOR The radar reflector is found in the inventory case. After assembly, attach it
(Stored in inventory box)
to boat hook and fit it to one of the railing stanchions or the pipe fitting aft.
Secure the radar reflector with rope to a clamp.
Rope ladder is to knot at rope eye
railing and hoisting hook
Put boat hook into railing

or special support
A Compass is fixed installed close to helmsman position
Caution:
When stowed on steel ships a magnetic compass is permanently
influenced by the ship’s magnetic field and therefore, does not
display correctly! Even after leaving the ship this influence can
affect the compass for several weeks, or it may even have
caused permanent damage. A faulty compass can, therefore, not
be accepted as a guarantee.
Door and hatches: All entrances and doors can be opened from inside and
SECURING FOR
DOOR outside. The door is equipped with an integrated air vent.
Never:
NEVER close all air inlets to avoid danger of SUFFOCATION!
TURN LOWER HANDLE
BEHIND DOOR STOPPER
It is strongly recommended that entrances and hatches be opened as wide as

reasonable in the particular situation to provide fresh air inside. In this case life
jackets and seat belts must be worn.
Warning:
A lack of fresh air will increase the CO-content inside the lifeboat.
This can result in uncontrolled sleeping followed by DEATH!
Caution:
Before using a hatch/door, ensure that it is well secured in an
open position. A poorly secured hatch/door can cause injury.
Some hatches are fitted with self-stopping hinges instead of a
hatch-securing device. If they are loosened, the hinges can be
adjusted.
For maintenance information refer to Chapter 12.4

10. Periodic servicing and inspection by crew

General safety precautions:
 Inform Officer in duty when starting and finishing work on the lifeboat.
 Ensure that the boat is safely secured to the davit, and that there is safe access to boat.
 Never smoke inside a lifeboat.
 Open doors and hatches for ventilation.
 Do not touch any part of the release gear before special safety precautions have been taken
(i.e. A “hanging-off-pendant” fitted).
 Do not the run engine for more than 5 minutes
Mandatory:
 When CLEANING the boat, especially windows, plastic, retro- reflective tape and covered
aluminium DO NOT USE SOLVENTS OR SOLVENT BASED CLEANERS!
 When flushing the boat with water hose:
 NEVER direct hose towards engine exhaust outlet – water might enter into engine
and damage or destroy it.
 NEVER use water hose inside of boat – parts or electric system might be damaged.
 Water hose pressure might damage retro-reflective tape outside.
Note:
Maintenance and inspection is not restricted to the above mentioned items. Items and proce-
dures not listed need to be inspected and maintained according to good seamanship, so long
as they are not part of the service, which shall only be carried out by Fassmer-certified
service engineers (see Chapter 11 ).
Service Qualification level according to SOLAS III Reg. 20.11.2.2 and IMO MSC CIRC. 1206:
Weekly and monthly inspections and routine maintenance …
… may be done by the crewmembers under direct supervision of a senior ship’s officer, in accordance
with these instructions.
In case of annual service by Fassmer-certified lifeboat service engineers, the weekly and monthly inspec-
tions and routine maintenance part of the service shall be executed by the crew for training and instruction,
supervised by the service engineer.
All other inspections, servicing and repair …

… should be conducted by Fassmer’s representative or a person appropriately trained and certified by
Fassmer for the work to be done.
Reports and records

The following checklists should be correctly filled out and signed by the person who carries out the inspec-
tion and maintenance work and should also be signed by the company’s representative.
Mark checklist as following:
 ok  not ok: if item was checked / done and found to be in order

 ok  not ok: if item was NOT checked / done
if item was checked / done and found NOT to be in order, fault was NOT settled: in
 ok  not ok:
such case note the fault in the checklist.
if item was checked / done and found NOT to be in order, fault was SETTLED: in
 ok  not ok:
such case note the fault and kind of settlement in the checklist.
Records of inspections, servicing, repairs and maintenance should be updated and filed onboard the ship.
When repairs, thorough servicing and annual servicing are completed, a statement confirming that the life-
boat is fit for purpose should be issued by Fassmer’s representative.

10.1 WEEKLY and after ever y recovery of the boat into the davits:
Note:
The following inspections and maintenance procedures (when required)have to be exe-
cuted during the WEEKLY INSPECTIONS of the life saving appliances acc. to SOLAS,
Chapter III, reg. 20.6.1!
Notes:
Lifeboat visual inspection
 ok not ok
(SOLAS-requirement)
Start engine and idle it for about 5 min. En-
 gage propeller ahead and astern, check ok not ok
engine circuits (SOLAS-requirement).
Check proper attachment of handrails and
 ok not ok
grips.
Open door and hatches to ventilate for
 ok not ok
approx. 2h.
Check working order of the steering system,
 ok not ok
look for damages.
Release gear:
 Check correct position of stop pawl ok not ok
 Check correct position of release safety bolt ok not ok
Ensure that release handle in secured posi-
 ok not ok
tion with safety bolt inserted
Water spray plant:
Sea water- and bypass valve open, flushing
 connection closed ok not ok
Self-contained air support system:
All valves and safety caps closed
Date Service engineer name (printed + signature) Boat no. Signature of company´s representative
Ship´s name:

10.2 MONTHLY:
Note:
The following inspections and maintenance procedures (when required) should be car-
ried out during the MONTHLY INSPECTIONS acc. to SOLAS, Chapter III, reg. 20.7 (in
addition to above weekly inspections)
Notes:
Lifeboat abandon ship drill (at least one
 boat launched and engine started) (SOLAS ok not ok
III/19.3.3-requirement)
Loose equipment complete and in good
 ok not ok
condition (SOLAS III/20.7-requirement)
 Check fuel level and top up if necessary. ok not ok
Ship´s name:

10.3 3-MONTHLY (Items marked with „#“ also after every operation of the boat in the water)
Note:
The following checks and maintenance procedures (when required) should be carried out
EVERY 3 MONTHS during launching and sailing the lifeboats acc. to SOLAS, Chapter
III, reg. 19.3.3.3. (in addition to above weekly and monthly inspections)
Notes:
EACH Lifeboat launching and trial trip (SO-
 ok not ok
LAS Chapter III, reg. 19.3.3.3-requirement)
Check pressure of fire extinguisher (if
 ok not ok
gauge is fitted).
Check expiry date of fire extinguisher.
 IF EXPIRED: arrange service and fitting of a ok not ok
new label by an authorised workshop!
Check expiry date of emergency signals.
 ok not ok
IF EXPIRED: Replace!
Check expiry date of First aid kit.
 IF EXPIRED: Replace or arrange inspection ok not ok
by authorised institution!
 Check expiry date of emergency rations. ok not ok

IF EXPIRED: Replace
Replace drinking water (incl. Silver based
water disinfectant like Micropur or similar).
 ok not ok
SEALED WATER RATIONS ONLY:
Check expiry date. IF EXPIRED: Replace!
# Drain bilge and clean bottom valve ok not ok
Open air case drain valves in bilge or at hull
 and canopy air cases inside and close after ok not ok
draining.
Inspect working order of the bailing pump,
 ok not ok
check for leakages, clean bailing hose inlet.
Check compass fitting and function
 ok not ok
( see Caution chapter 9 )
 Examine life lines and fittings ok not ok
Clean windows with mild soap and fresh
# ok not ok
water, NO SOLVENTS!
 Inspect window wiper. ok not ok
Check retro reflective material, replace if
 ok not ok
damaged.
Check all fittings, equipment etc. Clean,
 ok not ok
grease or oil as applicable.
Clean the boat inside and out with mild
soap and fresh water. A wax and polish is
# ok not ok
recommended for the outside surfaces at
least once a year.
Check/grease doors and hatch sealing,
 hinges and tightness, adjust door catches if ok not ok
necessary. ( see Chapter 12.4 )

Check all screws and nuts are tight. Screws

can loosen with operation, vibration or sim-
ply from “setting” under load.
 ok not ok
Pay special attention to the release system,
seat bolts, engine foundation and rudder
plant.
Check that exhaust pipe insulation is com-
 ok not ok
plete and dry.
 Check cooling water level. ok not ok
Check stern tube for leakages whilst ma-
# ok not ok
noeuvring.
Turn stern tube grease gun about 10 times
# after boat test or if leaking. Fill grease gun if ok not ok
empty.
If stern tube leaking continues, tighten stuff-
 ok not ok
ing box.
 Check propeller and mounting. ok not ok
 Drain water from fuel tank. ok not ok
 Check fuel lines for leakages. ok not ok
 Check lights inside and out, and searchlight. ok not ok
 Check batteries are charged. ok not ok
Check battery charging fuse (if fitted) is not
 ok not ok
broken.
 Inspect batteries. ( see chapter 12.3 ) ok not ok
Test the battery switch. CAUTION: DO NOT
 SWITCH OFF WITH THE ENGINE RUN- ok not ok
NING!
®
Clean and apply Vaseline to the battery
 charging socket (if fitted) and all free electri- ok not ok
cal connections.
Check working order of the engine
 ok not ok
switchboard.
Inspect battery charger/solar generator (
 ok not ok
to be cleaned!).
Hydraulic steering: Check pump oil level,
 refill or vent if necessary. Check hydraulic ok not ok
system for leakages.
Check expiry date of torch batteries.
 IF EXPIRED (or annually if no date is fitted): ok not ok
Replace!

Launching ramp:
Check moveability of rollers, Clean and
 grease if necessary. ok not ok
Replace damaged rollers
 Check that side lashings are closed ok not ok
Check moveability of side lashings. Clean
 ok not ok
and grease if necessary
Check correct position of aft
 ok not ok
lashing / retaining chain
Release gear:
 Check easygoing of all moveable parts ok not ok
Warning:
LEVER DROPS BOAT
ok not ok
Check only when boat is not
connected to release system!
Check hook for tender spots grind smooth if

 ok not ok
necessary. Check chain
AFTER EACH LAUNCHING:
 Flush hoisting hook with fresh water (but not ok not ok
more than monthly)
Mandatory:
 If stop pawl does not return ok not ok
completely, replace return
spring in hydraulic plunger


Water spray plant:
 Operate water spray plant, repair leakages ok not ok
Ensure correct function of all nozzles, clean
 ok not ok
if necessary
 Flush system with fresh water afterwards ok not ok
 Check filling, refill if necessary ok not ok
Check pressure holding capability (leak-
 ok not ok
ages)
 Check function of reducer ok not ok
 Check function of air flap ok not ok
Check function of overpressure valve
 (check moveability of inner part by moving it ok not ok
with low force with finger)
Check under pressure valves (rubber mem-
 brane undamaged and lying flat on bottom ok not ok
of valve)
Check air bottles and all fittings for major
 ok not ok
corrosion
Note:
Replacement if necessary by
authorised personnel only
Ship´s name:

11. Servicing, inspection, overhaul and testing by Fassmer-certified ser-

vice engineer
11.1 ANNUAL THOROUGH EXAMINATION:
Caution:
All work in this section is only allowed to be carried out by service engineers with
a valid Fassmer-“Certificate of Competence” and Fassmer-ID- card as “Authorized
Service Engineer” for Lifeboats!
Unauthorized manipulations to the lifeboat system void all guarantees and resolve
Fassmer of all responsibility!
Fassmer- service can only be ordered centralized at:
Fassmer Service GmbH & Co. KG

Industriestr. 2
D – 27804 Berne / Germany
Phone: +49 (0)4406 942-0, Fax: +49 (0)4406 942-100
Email: service@fassmer.de
Internet: www.fassmer.de
It is recommended to arrange certified release gear service together with lifeboat service
Remark: which is required at same intervals according to hook manual !
Note:
All general notes in the beginning of chapter 7 regarding safety precautions, service
qualification level and reports and records are also valid for this chapter!
These annual thorough examination MUST be carried out acc. to IMO-MSC/Circ. 1206
during the survey acc. to SOLAS, chapter. I, reg. 7 resp. 8.
Defects have to be solved and defective parts to be replaced. If this is not possible, such
defects have to be listed at the end of this list for quickest possible settlement.
Notes:
Launch EACH Lifeboat into water and exe-
 ok not ok
cute trial trip.
SAFETY NOTE: For launching follow the

recommendations of IMO-MSC1/Circ. 1206/
Annex 2: “Guidance on Safety during aban-
don ship drills using lifeboats”, for example:
 Before placing persons onboard a life-
boat, it is recommended that the boat
first be lowered and recovered without
persons on board to ascertain that the
arrangement functions correctly. The
boat should then be lowered into the wa-
ter with only the number of persons on
board necessary to operate the boat.
 To prevent heaving wires or gripes from
getting entangled, proper release should
be checked before launching the boat.
Check all fittings, equipment etc. Clean,

 ok not ok
grease or oil as applicable.

Open air case drain valves in bilge or at hull

and canopy air cases inside, and close after
draining.
 If greater amounts of water are regularly ok not ok
found in the air cases
 Source the leakages and seal. Please
note that small amounts of water are normal
and no cause for complaint.
Check visibility through polycarbonate win-
 ok not ok
dows. Replace, if blind!
Check all screws and nuts are tight. Screws
can loosen with operation, vibration or sim-
 ply from “setting” under load. Pay special ok not ok
attention to the engine foundation, release
system, and rudder plant.
Check that exhaust pipe insulation is com-
 plete and dry. Replace missing or damaged ok not ok
parts
 Check exhaust line for leakages. ok not ok
Check cooling water level and system for
 ok not ok
leakages
Check propeller shaft for bending etc. as the
 ok not ok
shaft is turning slowly.
Check stern tube for leakages whilst ma-
 noeuvring: tighten stuffing box gland or re- ok not ok
place packing if leaking.
Check propeller and mounting. Replace if
 ok not ok
damaged.
Check batteries are charged.
 ok not ok
( See Chapter 12.3 )
Drain water from fuel tank. If abnormal
 amount of water is in fuel: ok not ok
check the reason and settle it.
Check fuel lines for leakages and repair if
 ok not ok
leaking.
Check lights inside and out, and searchlight.
 ok not ok
Replace bulbs and lights as necessary.
Replace bulb of outside position indicating
light after 12 hours of use ONLY AGAINST
ORIGINAL BULB SUPPLIED BY FASSMER
 ok not ok
(requirement from lamp supplier and his
approval authority. Fassmer- order no.
576283)
Check moving parts, fastenings and the
 ok not ok
safety belt itself.
Repair or replace loose and damaged seat
 ok not ok
cushions (if fitted).
If fitted inspect the electric bilge pump func-
 ok not ok
tion and floater switch by lifting it.

Inspect battery charger/ solar generator (

 ok not ok
to be cleaned!).
Hydraulic Steering: Check pump oil level,
 refill or vent if necessary. Check hydraulic ok not ok
system for leakages.
Check all canopy air cases visually for tight-
 ok not ok
ness. Seal or repair as necessary.
 Engine and gear box  see engine manual. ok not ok
Check inside the fuel tank: If a solid residue
 is present, remove the residue and clean the ok not ok
tank.
 Check elastic engine bearings for damages ok not ok
Check connection of engine control wires.
 Tighten screws and secure with Loctite, if ok not ok
necessary.
Release gear: Refer to separate instruction
 ok not ok
manual!
 Check steering owden wire. ok not ok
Winch brake test done? If a dynamic winch
brake test with the EMPTY BOAT is exe-
cuted acc. MSC/Circ 1093/3.1 for davit ser-
vice, the complete boat, especially all re-
lease gear connections to the boat, bolts,
nuts, surrounding laminate, elastic seams
etc. shall be carefully examined AFTER this
 test to detect any possible damages, loose ok not ok
bolts, cracks or other to the system:
Every damage has to be repaired by CER-
TIFIED service engineer. Depending on
amount of damage, davit brake test and
examination may have to be repeated after
repair.
Broken elastic seams have to be renewed.
Warning:
No person shall be in the boat
during a dynamic winch brake
test. A system failure can drop
the boat and KILL YOU or
cause serious injuries


Water spray plant:
Check all hoses for damages especially at
 ok not ok
connections, replace if necessary
 Clean and degrease boat surface ok not ok
Mandatory:
Don’t polish or wax the boat
because this disturbs water
coverage

Execute self-contained air support system
test acc. to operation described in Chapter 3
Check:
Function of air reducer (smooth and con-
stant air outcome)
Small overpressure in cabin (rubbers of un-
 der pressure valve closed or barometer in ok not ok
cabin rising for max. 20 mbar, then over
pressure valve must open)
Cabin for air leakages (person outside to
hear or feel outblowing air)
Afterwards refill air bottles
Ship´s name:

11.2 EVERY 2 YEARS: applicable not applicable
Note:
In addition to the annually thorough examinations the following items have to be
checked/serviced every two years:
Notes:
 Replace window wiper blade. ok not ok
 Replace stuffing box packing. ok not ok
Ship´s name:

Note:
In addition to the annually / and 2- years thorough examinations the following items have
to be checked/ serviced every five years:
Notes:
 Replace retro reflective material. ok not ok
Replace the rubber membrane and non-
 ok not ok
return valves of the bailing pump.
 Replace all rubber ropes. ok not ok
Inspect/renew all elastic sealing outside with
 ok not ok
MS-Polymer.
Replace all bulbs of inside lamps and
 ok not ok
searchlight.
Replace bulb of outside position indicating
light ONLY AGAINST ORIGINAL BULB
 SUPPLIED BY FASSMER (requirement ok not ok
from lamp supplier and his approval author-
ity. Fassmer-order no. 576283).
Replace position indicating light cover out-
 ok not ok
side (damaged by UV-radiation).
Replace main batteries – use ORIGINAL
 ok not ok
GEL-TYPE BATTERIES ONLY!
Dynamic overload davit winch brake test
done in spite of safety recommendation
below? If a dynamic winch brake test with
the BOAT LOADED TO 110% LOAD is exe-
cuted acc. MSC1/Circ 1206, Annex 1/3.2 for
davit service, the complete boat, especially
all release gear connections to the boat,
bolts, nuts, surrounding laminate, elastic
seams etc. shall be carefully examined AF-
 TER this test to detect any possible dam- ok not ok
ages, loose bolts, cracks or other damages:
Every damage has to be repaired by CER-
TIFIED service engineer. Depending on
amount of damage, a 110% release gear
overload test (refer to release gear manual)
and examination may have to be repeated
after repair.
Broken elastic seams have to be renewed.

Caution:
IMPORTANT SAFETY REC-
OMMENDATION: The five-
yearly dynamic overload davit
winch brake test should be
executed with a PROOF
LOAD and NOT with the boat
(revised SOLAS III/Reg.
20.11.1.3 in Res.
MSC.152(78))
Reason: The forces occurring
during such test can not be
predicted but are usually be-
tween 2 and 3 times the
weight of the fully loaded boat,
sometimes maybe even
higher! This might cause un-
detectable damages in lifeboat
GRP structures which might
lead to later failure when in
use with persons!
Also davit brake failure during
this test will lead to serious
damages to the boat.
FASSMER THEREFORE
REJECTS ANY RESPONSI-
BILITY FOR DAMAGES OC-
CURRED TO THE BOAT
DUE TO USE OF THE BOAT
FOR DYNAMIC OVERLOAD
DAVIT WINCH BRAKE TEST.
Warning:
NO person shall be in the boat
during a dynamic winch brake
test. A system failure can drop
the boat and KILL YOU or
cause serious injuries!
 Replace return spring in hydraulic plunger ok not ok


Air bottle over pressure test in authorised
workshop and new certification by applicable
 ok not ok
authority or exchange of bottles against
newly certified ones
High pressure hoses over pressure test
with 1,5x nominal pressure= 300 bar, in
 case of USCG boats 450 bar in authorised ok not ok
workshop or exchange of hoses against new
ones.
Self-contained air support system over pres-
sure test with 1,5x nominal
pressure= 300 bar, in case of USCG boats
 ok not ok
450 bar
Replace of membrane and service in author-
ised workshop or replace by new one.
Ship´s name:

Note:
In addition to the annually/ 2-years and 5- years thorough examinations the following
items have to be checked/ serviced every ten years: (In addition to above annually and 2
Years and 5 Years thorough examinations)
Notes:
If fitted replace the electric bilge pump and
 ok not ok
floater switch.
 Replace all gaskets in doors and hatches ok not ok
Replace all rope installed outside of boat:
 ok not ok
lifelines, fender cushion lashings etc.
 Replace exhaust gas piping and insulation. ok not ok
Replace fuel hoses between engine and
 ok not ok
tank.
Replace elastic engine bearings for dam-
 ok not ok
ages.
If fitted: replace battery charger resp. solar
 ok not ok
charging panel and regulator.
Replace steering bowden wire resp. hydrau-
 ok not ok
lic hoses for hydraulic steering.
Ship´s name:

This is to confirm that the Freefall lifeboat has been thorough examined and is "FIT FOR PUR-
POSE". The next annual inspection to be latest 12 months after the date below. Following de-
fects (in addition to notes in above check list) have been eliminated/parts were replaced:
This is to confirm that the Freefall lifeboat has been thorough examined and will be "FIT FOR
PURPOSE" AFTER SETTLEMENT OF FOLLOWING DEFECTS. The next annual inspection to
be latest 12 months after the date below.
Date Service company Name of service engineer Authorisation no. Certified Service engineer (signature)
Ship’s name Year of construc- Owner Boat no. Signature of company's representative
tion

12. Maintenance
12.1 GRP-maintenance and repair:
Maintenance:
Should the gelcoat finish appear dull or the colour faded, the original finish can
be restored using an abrasive paste. If necessary sand the surface before-
hand, finishing with a fine wet and dry sandpaper of grade 400 or finer. After
sanding the surface must be waxed and polished. Polishing can be done by
hand or with a rotary polisher. Waxing should always be undertaken by hand.
Fading can be reduced through regular waxing and polishing biannually after
first cleaning the surface. Due to constant exposure to sunlight and exhaust
gasses fading can however not be totally excluded.
Tip:
If the surface is coated with a single pack clear varnish (wood varnish) after
grinding (without wax or polish) it will be protected for a far longer time.
Orange-based colours are particularly susceptible to sunlight; therefore paint-
ing of the surface may be necessary if polishing does not work. Preferably a 2
component coloured paint is to be used. Grind and prepare the surface accord-
ing to the paint suppliers instructions.
Note:
All types of grinding reduce the thickness of the gelcoat. If the
gelcoat is partly removed, a new coating is necessary
for protection.
Gelcoat repairs:
Small gelcoat damages or hairline cracks can’t be avoided during general han-
dling of the lifeboat. They do not have an effect on the strength of the boat, and
are therefore, excluded from the guarantee. However, to avoid the ingress of
water, such areas should be sandpapered and covered with fresh gelcoat,
clear varnish or paint. Deeper scratches may require the use of a filler before-
hand.
The standard gelcoat colours are:

orange: similar to RAL 2009
white: similar to RAL 9010
light grey: similar to RAL 7035

Laminate repairs:
Caution:
Lifeboat damages must be repaired by a FASSMER-authorised
workshop. The following directions are for repairs where there
exists no available workshop. In this case, an authorised work-
shop, Fassmer-certified service engineer or surveyor must check
the lifeboat as soon as possible, to decide about further repairs.
Caution:
Lifeboats must always have sufficient strength, to be lowered to
the water fully manned!
 Remove all broken and loose parts from the damaged area with the use of
a chisel or saw (fig. 1). On cracks which are not fully penetrating the lami-
nate remove laminate in crack area as deep as the crack can be seen.
 The edges of the hole must be bevelled and sandpapered to ensure a large
overlap and good attachment (abt. 100mm). In case of full penetrating
holes a plate of wood, cardboard or sheet metal, covered with wax, paper
or foil should be propped against the hole to keep the
resin in (fig. 2).
 The polyester resin is to be mixed with 1.5-2% Cyclohexanonperoxid
(hardener). The higher the percentage of the hardener, and the higher the
outside temperature is, the faster the resin will harden. Using the above
percentages and with an outside temperature of 14-20°C the mixture will
have a working time from 15-30 minutes.
 Woven rowings and chopped strand mats must be cut to a size suitable for
the hole, laid tier upon tier, and soaked with the mixed resin. There should
be enough glass that the original thickness of the area is achieved. Further
add additional 30% of the layers already applied of glass and roving. Apply
the resin using a brush. For larger damages a grooved roller may be used
to smoothen the surface, and remove any
air bubbles (fig. 3).
 The resin will harden in 2-8 hours depending on the outside temperature.
Unevenness can be touched up, cemented and painted (fig. 4). Keep in
mind, to allow hardening, a minimum temperature of 15°C is needed, and
that the spot to be repaired must be dry, free of grease and well sanded.
Brushes and other equipment must be cleaned immediately
after use in acetone!
Caution:
Ensure good ventilation when working with fibreglass. Avoid
direct contact with skin when handling resin.

1.
Iron, wood or waxed paper sheet
2.
3.
4.
Tools necessary for repair
(not part of lifeboat equipment)
hammer
grooved scales
roller
brush
broach
file spatula
shears saw
bucket

12.2 Engine plant maintenance:
Note:
Engine manual from supplier has priority, in every case, over this
information.
For further information therefore please refer to the
engine manual.
Fuel recommendations:
Marine Gas Oil (MGO) with a cold filter plugging point
(CFPP) -15°C.
If CFPP of fuel can not be assured or if temperatures below -15°C might
occur, you might add Diesel Anti-Freeze-additive (Fassmer order no.
100186) to diesel fuel for use up to -33°C.
If some water is found in the diesel fuel, you might add Diesel & gasoline water
absorber (Fassmer order no. 685771). Burns up to 5% water in fuel, shelters
fuel system against corrosion and mud. Add to tank BEFORE fuel filling!
Water can be separated from diesel either through the drain valve on the un-
derside of the tank or using the water separator integrated in the fuel line (ver-
sion dependant). During maintenance, before the engine is started, or if water
enters through the stern tube, turn the grease gun a few turns to grease the
shaft.
12.3 Electric plant maintenance:

The power supply is provided by 2 x 12V 100 % maintenance-free Gel-
batteries with a capacity of 65Ah each (1). Replace batteries only with
equivalent gel-type batteries. Do not use liquid acid based batteries.
Continuous heat can reduce the battery life.
Battery charge levels:

To determine the charge of the battery it must remain unused for about one
hour i.e. no engine starting, no lights and no battery charging. Switch the bat-
tery change over switch to position “1” and check the first battery with a voltme-
ter at the socket on the steering console (3). Proceed the same way to charge
the second battery.
Voltage:
 10.5V: Battery completely discharged and damaged.
Replace immediately with the same type.
 11.4V: Danger of damage. Charge battery immediately
11.6V: Battery almost empty. Charging recommended.
12.7V: Battery 100% charged
13.8-14.1V: Correct charging voltage with dynamo or battery charger active.
14.4 V: Gasing voltage! Excessive charging voltage.
Danger of damage and explosion through battery gasses

When the engine is running, the battery will be charged through the alternator
on the engine.
For charging aboard, one of the following is installed:
 Trickle charging through an automatic charger aboard the ship:
A charging current of 12V DC will be led through a cable and plug in the
superstructure’s back wall via a charging diode routed to the batteries.
Remove the cable before launching.
 Trickle charging through an automatic charger aboard the lifeboat (3):
A charging current of max. 50V AC will be led through a cable and plug
in the superstructure’s back wall to the charger. Remove the cable be-
fore launching.
 Trickle charging through a solar power plant:
The batteries will be maintained by an individual solar generator per bat-
tery, on the roof of the boat. Charging is automated with a charging regu-
lator. Deeply discharged batteries should be fully charged by the engine
generator or a shipside charger! The solar generator should be cleaned
regularly to provide trouble free service.
Mandatory:
To prevent unintentional discharge and destruction of the batter-
ies, switch off all consumers and the battery switch before leav-
ing the boat.

12.4 Doors and Hatches maintenance:
Note:
If the door is leaky the door-catch can be adjusted. The sealing
must be replaced if necessary. (see Fig. 15)
If the front hatch is leaking, the flange under the door-catch can
be bent down, enabling a stronger contact pressure. If necessary
the sealing must be replaced. (see Fig. 15)
adjustment screw for door catch wedge

door catch
wedge
wedge
door sealing door
Fig. 15
12.5 Water spray plant maintenance:

After use or at maintenance the complete system to be flushed with fresh water
 Close sea water inlet valve
 Close bypass valve
 Connect fresh water hose to hose fitting at spray plant aft (loose counter
piece is part of loose lifeboat equipment
 Flush system at least 10 minutes
 Repeat flushing on the other side of the boat if applicable
 Disconnect flushing hose and close flushing connections
 Open sea water and bypass valve again

12.6 Self-contained air support system maintenance:

Regular check:
Open air bottle valves while stop valve is closed. High pressure manometer
shows air bottle contents which must be abt. 200 bar, and in case of USCG
boats 300 bar. Note pressure and close air bottle valves again. The pressure
should stay at the same value as before for abt. 15 minutes, otherwise there is
a leakage in the system which must be repaired. After that open stop valve,
release pressure and close valve again. Thereby check function of air reducer
for irregularities.
Warning:
EVERY WORKING ON HIGH PRESSURE AIR SYSTEMS CAN
CAUSE DANGEROUS ACCIDENTS; BY AUTHORISED PER-
SONNEL ONLY!
Air bottles have to be pressure- tested and certified every 5-10 years (depend-
ing on authority) in an authorised workshop. The year of last test is stamped
onto bottle.
Filling:
After use or if air pressure is below 180 bar and in case of USCG boats 270
bar the air plant must be refilled: Close stop valve and air bottle valves, remove
safety cap from filling connection and fit filling hose from compressor to filling
connecting (Standard 5/8“ inner thread).
Note:
USE ONLY CLEAN BREATHING AIR.
NO OXYGEN OR SIMILAR.
Caution:
If compressor provides more than 220 bar, in case of USCG
boats 320 bar a safety valve for max. 220 bar or 320 bar for
USCG boats has to be integrated shipside in the filling hose
Open all air bottle valves, start compressor and fill air plant until max. 220 bar,
in case of USCG boats max. 320 bar are reached (pressure will reduce when
air cools down after filling)
Close air bottle valves again, remove filing hose and close safety cap again.
Caution:
Air bottle valves should always be closed, otherwise loss of air
contents is possible!
12.7 Release gear system maintenance:

 Oil level in tank over hand pump to checked regularly.
 When refilling hydraulic oil open venting screw.
 Hydraulic oil acc. to Fassmer lubricant selection table as stated
under „Steering gear“.

13. First installation:

On delivery the Freefall lifeboat is ready for use. All tests including a minimum
2-hour trial run and release gear tests as required by SOLAS/IMO-Resolution
MSC.81(70), part 2, have been carried out.
Preparation for onboard installation:

After receiving the freefall lifeboat and before installation, it should be prepared
and maintained on shore, in accordance with the applicable points in
Chapter 10. Charge the batteries regularly; solar panels must be in sunlight.
Install heaving wires, which are stored inside the boat. Put aft shackles of
heaving wires into middle chain link. In this position the boat fully equipped,
without persons is designed to hang about parallel to launching ramp.
Onboard installation:
Bring the boat under the davit/crane and attach it according to davit instructions
or with the use of a shore crane.
Caution:
Instruction at chapter 4 “Recovery” to be observed!
Caution:
Longitudinal distance between boat transom and stopper at
launching ramp about 40 mm. Vertical distance between boat
gunwale and side lashing plate to be about 10-15 mm. To be
adjusted if different!!
Hook up the provided charging socket (if fitted) to the respective battery charg-
ing cable on the ship. Plug the cable into the socket.
Onboard testing:
Each new boat to be freefall- launched from ship on even keel and in lightest
seagoing condition under survey of responsible authority. Boat to be loaded
with sandbags safely secured in seats to represent 110% weight of the fully
equipped and fully manned boat (SOLAS- requirement).
Usually further freefall tests are executed to introduce ship’s crew into opera-
tion of the boat.
Check and service after installation and test:
Due to load on specific fittings after installation or test, material can bed-in or
deform slightly. Through this process screwed connections may become loose,
or sealing seams may brake (e.g. hoisting fittings, engine etc.). All screwed
connections and elastic seams should therefore be checked, and re-tightened
or sealed after installation and testing, and about 14 days later. This is part of
customer’s commissioning and can not be claimed on the guarantee.

Fassmer Freefall Lifeboats Type GAR (-T) 6.0 - 8.1 CFL (-T) 66 - 83 Manual

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Fassmer Freefall Lifeboats Type GAR (-T) 6.0 - 8.1 CFL (-T) 66 - 83 Manual

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Operator’s Handbook for Fassmer

Freefall- Lifeboat Type

Fr. Fassmer GmbH & Co. KG

2. Brief construction description ................................................................... 5

3. Operation of Boat ...................................................................................... 7

3.1 Launching of the lifeboat ...................................................................... 7

3.2 Davit / Crane lowering of lifeboat ........................................................ 17

3.3 Other operating situations .................................................................. 17

3.3.1 Launching from a vessel moving ahead ....................................... 17

3.3.2 Launching into seaway ................................................................. 17

3.3.3 Towing .......................................................................................... 17

3.3.4 Capsizing ...................................................................................... 17

3.3.5 Injured person on stretcher ........................................................... 17

5. Operation of Equipment ........................................................................... 21

5.1 Engine plant ........................................................................................ 21

5.1.1 SABB - Engine ............................................................................... 21

5.1.2 BUKH - Engine ............................................................................. 21

5.1.3 Nanni - Engine) ............................................................................. 22

5.1.4 Description of the engine plant ..................................................... 23

5.2 Rudder plant ....................................................................................... 24

5.3 Fuel tank ............................................................................................. 24

5.4 Electric plant ....................................................................................... 25

5.5 Lights .................................................................................................. 25

5.6 Water spray plant ................................................................................ 26

5.7 Self-contained air support system ...................................................... 27

5.8 Bailing ................................................................................................. 29

5.8.1 Manual bilge pump ....................................................................... 29

5.9 Rain water collection ........................................................................... 29

6. Release gear system ................................................................................ 30

Document 20.0000-019.00.00.6 Art. No. 156336 2 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

7. Simulated Launch .................................................................................... 31

7.1 Securing of boat during service or release test

8. Launching ramp and lashing .................................................................... 32

9. Outfit and loose equipment ...................................................................... 33

10. Periodic servicing and inspection by crew ............................................. 34

10.2 MONTHLY ........................................................................................ 36

10.3 3-MONTHLY ..................................................................................... 37

11. Servicing, inspection, overhaul and testing by Fassmer-certified

11.1 ANNUAL THOROUGH EXAMINATION ........................................... 41

11.2 EVERY 2 YEARS .............................................................................. 45

11.3 EVERY 5 YEARS .............................................................................. 46

11.4 EVERY 10 YEARS ............................................................................ 49

12. Maintenance ........................................................................................... 51

12.1 GRP-maintenance and repair ........................................................... 51

12.2 Engine plant maintenance ................................................................ 54

12.3 Electric plant maintenance ................................................................ 54

12.4 Doors and Hatches maintenance ..................................................... 56

12.5 Water spray plant maintenance ........................................................ 56

12.6 Self-contained air support system maintenance ............................... 57

12.7 Release gear system maintenance .................................................. 27

13. First installation ...................................................................................... 58

Document 20.0000-019.00.00.6 Art. No. 156336 3 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

Fr. Fassmer GmbH & Co. KG

Document 20.0000-019.00.00.6 Art. No. 156336 4 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

2. Brief construction description:

For overall drawings refer to next page

Document 20.0000-019.00.00.6 Art. No. 156336 5 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

Overall drawing: (GAR 6.7 - 8.1 / CFL 66 - 83 boats)

Document 20.0000-019.00.00.6 Art. No. 156336 6 Mod. 6 (MSC1205) Lange/WZ 22.04.2010

3.1 Launching of the lifeboat

2. Open side lashing plates by pulling rope on platform deck.

3. Disconnect the charging cable, if fitted.

Document 20.0000-019.00.00.6 Art. No. 156336 7 Mod. 6 (MSC1205) Lange/WZ 22.04.2010