Zodiac PRO 500 User manual

Owner's Manual
Volume 2

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VOLUME 2
DESCRIPTION - BUOYANCY CHAMBER
PROPULSION SYSTEM
INSTALLATION AND CIRCUITS
CONTENTS
PAGE
I - GENERAL DESCRIPTIONS
I-1-Technical characteristics ----------------------------------------------------------
2 - 3
I-2-Inventory -------------------------------------------------------------------------------
4
I-3-Location of items---------------------------------------------------------------------
5
I-4-Handling -------------------------------------------------------------------------------
6
II - BUOYANCY CHAMBER
II-1-Setting up the buoyancy chamber –Main steps------------------------
13
II-2-Inflation system--------------------------------------------------------------
13 - 14
II-3-Pressure -----------------------------------------------------------------------
15 -16
III - PROPULSION SYSTEM
17

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DESCRIPTION - Technical characteristics
I-1-TECHNICAL CHARACTERISTICS
Dimensions
(m)
4.70
(ft)
15‘ 5“
(m)
3.38
(ft)
11‘ 1“
(m)
2.05
(ft)
6‘ 9“
(m)
1.05
(ft)
3‘ 5“
(m)
0.50
(ft)
1‘8“
Design category
(Directive 94/25/EC)
C
Capacity
(ISO)
9
Maximum
Kg (1)
1060
lb.(1)
2337
Kg (2)
230
lb.(2)
507
Compartment
5
Engine configuration
Minimum power
recommended
HP (3)
40
KW (3)
30
Maximum power
recommended
HP
50
kW
38
Maximum power
allowed
HP (3)
70
kW (3)
53
Maximum
Maximum engine
weight
Kg
170
Lbs
375
Overall dimensions
a
a (4)
4.70m
15‘ 5“
b (4)
2.05
6‘ 9“
c (4)
1.10
3‘ 7“

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DESCRIPTION - Technical characteristics
NOTE
Dimension tolerance: +/- 4%
NOTE
(1) The maximum payload has been calculated according to ISO 6185
standards. Operating at or near maximum payload is only advised in
calm water and at reduced speeds.
(2)Weight shown not including accessories
(3) The recommended power corresponds to optimum operation of the
boat's capabilities for an average load (9 people.)
(4)Hull dimensions without buoyancy chamber.
Use the maximum authorized power with extreme caution (see "Sailing
advice" chapter of Volume 1 of the manual.)
WARNING
DO NOT EXCEED THE MAXIMUM LOAD INDICATED ON THE
MANUFACTURER'S PLATE. THE MAXIMUM LOAD INCLUDES
THE WEIGHT OF THE ENGINE, FUEL, ACCESSORIES,
PASSENGERS AND THEIR EQUIPMENT AND ANY OTHER TYPE
OF LOAD.

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DESCRIPTION - Inventory
I-2-INVENTORY
HULL
Polyester hull
Counter-moulded non-slip deck
1 Bow ring
1 Anchor locker (capacity approximately 86 litres)
2 traction chain plates
1 Mooring cleat
1 Hull drain hole
1 high flow rate self-bailers with stern well
BUOYANCY CHAMBER
Removable buoyancy chamber
Rails + lashing
Easy push valves
Anti-chafing band with wide profile
External handles
Short cones
OPTIONAL ACCESSORIES
Anchoring tarpaulin
Roll bar
Console
Seat

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DESCRIPTION –Location of items
I-3-LOCATION OF ITEMS
ITEM
REF.
DESIGNATION
1
Buoyancy chamber
2
Anchor locker
3
Chain plate
4
Towing chain plates
5
high flow rate self-bailer
6
Hull drain hole

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8
4
4
4
4
3
11
11
2
12
6
5
1
3
11
11
4
4
3
11
11
2
12
6
8
4
4
5
1
3
11
11
7
10
7
10
7
10

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ITEM
REF.
DESIGNATION
1
Bow roller
2
Anchor locker cover
3
Lashing
4
Handle
5
Mooring cleat
6
Buoyancy chamber
7
AFT Chain plate
8
High flow rate self-bailer
9
Hull drain hole
10
Water shield
11
Easy push valve
12
Tank filler access

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DESCRIPTION - Handling
I-4-HANDLING
I-4-1-Transportation
The trailer installation recommendations are specified in VOLUME I of the owner's manual.
I-4-2-Storage
WARNING
THE BOAT MUST REST ON THE BOW LINE (SEE SKETCH
BELOW).
PRO 9 MAN (dimensions in mm)

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DESCRIPTION - Handling
1-4-3-Lifting
To lift your boat:
You can use a 4-wire sling obtainable from your Zodiac dealer.
To carry out this operation you have to:
a- Remove the aft chain plates and refit them with the ring reversed (facing forward).
b- Fit the bow of the boat with 2 additional chain plates (contact your ZODIAC
dealer). The diagram below shows the areas where the fore chain plates are located
(distances in millimetres).
All these fittings must be made watertight using Sikaflex.
Stiffener area
200 x 200 mm

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DESCRIPTION –Location of accessories
I-5-1-LOCATION OF OPTIONAL ACCESSORIES
I-5-1-1-Console/Seat/Bolster
Your boat can accept certain optional accessories (console/seat/bolster). Position them in
the locations indicated below to optimise use of the boat.
The positioning dimensions are taken from the aft transom (distances in millimetres).
I-5-1-3-Roll bar and boarding ladder
A- A- Roll bar (for use to best advantage comply with the installation
dimensions)
B-
C-
Intersection
between aft
transom and flat
deck
Position
defined in
the
installation
manual
Console
Seat or
bolster

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B- Boarding ladder (recommended position)

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BUOYANCY CHAMBER –Main steps
II-1-SETTING UP THE BUOYANCY CHAMBER –MAIN STEPS
When assembling the boat, it is important that you follow the procedure in the correct order. Proceed
step by step, referring each time to the pages indicated for explanations.
INFLATION PROCEDURE
PAGE
SECTION
1. Make an inventory of all your boat’s components and
learn to recognize them
6 - 8
Inventory
Location
2. Start inflating the boat
using working pressure
14 & 15
Inflating the boat
16 & 17
Air pressure
II-2-INFLATION SYSTEM
THE INFLATION PUMP
a. adaptor
b. tube nozzle
c. tube connector
d. inflation port
a
b
cd
SEMI FLUSH-MOUNTED VALVES
To change position
In inflating position
In deflating position
Push
The membrane is closed, the
knob is up
The membrane is open, the
knob is down
NOTE:
The Easy push valve plugs are designed to be
screwed on or off; they alone provide final
airtightness.

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BOAT INFLATION
Activate all valves in the inflation position.
Attach the hose connector to the inflator inflation
port.
To inflate your boat properly, the inflator should
be correctly placed on the ground.
The boat inflates rapidly if the inflator is used
smoothly and without haste.
WARNING
DO NOT USE A COMPRESSOR OR COMPRESSED AIR CYLINDER.

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BUOYANCY CHAMBER - Pressure
INFLATING THE BUOYANCY TUBE
Place the adapter corresponding to the diameter of the semi built-in valve at the inflator hose
nozzle.
Inflate the buoyancy mechanism, balancing the pressure between the different compartments until
the partitions (a) are no longer visible (pressure = 240 mb)
NEVER PUT A
COMPARTMENT
UNDER PRESSURE
WHILE THE OTHERS
ARE STILL FULLY
DEFLATED
a
100 % 0 % 0 %
1
50 % 50 % 50 %
2
100 % 100 % 100 %
Inflating is complete: Screw on the inflating valve caps.
NOTE:
A slight loss of air is normal before the cap is screwed on.
Only the caps guarantee final air tightness.
II -3-PRESSURE
The correct pressure for the buoyancy chamber is 240 mb/ 3.4 PSI (middle of the green sector of
the pressure gauge).
Your boat is fitted with an ACCESS pressure indicator which provides a quick, efficient readout
during inflation (see explanations for use in the "Inflation system" section).
Temperature of the surrounding air or water
will proportionally influence the level of
internal pressure in the buoyancy tube.
Ambient temperature
buoyancy chamber internal
pressure
+1°C
+4 mb / 0.06 PSI
-1°C
-4 mb / 0.06 PSI
Thus, it is important to anticipate:
Check and adjust the pressure of the inflatable compartments (inflating or deflating according
to the case) according to the temperature variations (especially when there is a considerable
difference in temperature between morning and evening in particularly hot areas) and make
sure that the pressure remains within the recommended pressure range (from 220 to 270 mb /
green sector).

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BUOYANCY CHAMBER - Pressure
RISK OF PRESSURE LOSS:
EXAMPLE: Your boat is exposed to direct sunlight on the beach (temperature=50°C) at the
recommended pressure (240 mb/3.4 PSI). When you launch it (temperature=20°C), the temperature
and internal pressure of the inflatable compartments will drop simultaneously (up to 120 mb) and
YOU WILL THEN NEED TO REINFLATE until you regain the millibars lost due to the difference
between the ambient air and water temperatures. A drop in pressure at the end of the day, when the
outside temperature is dropping, is normal.
RISK OF OVERPRESSURE:
EXAMPLE: Your boat is inflated to its recommended pressure (240 mb/3.4 PSI) at the
beginning or end of the day (low outside temperature = 10°C). Later in the day, your boat is exposed
in the sun on the beach or on a yacht deck (temperature = 50°C). The temperature inside the inflatable
compartments may rise to 70°C (particularly for dark buoyancy chambers), doubling the initial
pressure (480 mb). YOU WILL THEN NEED TO DEFLATE the boat to return to the
recommended pressure.
WARNING
IF YOUR BOAT IS OVERINFLATED, THERE WILL BE UNDUE
PRESSURE ON THE INFLATABLE STRUCTURE THAT MAY
RUPTURE IT.
IN CASE OF OVERPRESSURE
EASY PUSH VALVE:
Release air by depressing the
valve plunger

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PROPULSION SYSTEM
Complies with ZODIAC's recommendations and with the engine manufacturer's
recommendations.
For optimum use of your boat, seek advice from your dealer.