Zodiac PRO 650 User manual

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Owner's Manual
Volume 2

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VOLUME 2
DESCRIPTION – BUOYANCY MECHANISM
PROPULSION SYSTEM
INSTALLATION AND CIRCUITS
CONTENTS
PAGE
ÖI – GENERAL DESCRIPTIONS
I-1-Technical characteristics -------------------------------------------------- 3 - 4
I-2-Inventory---------------------------------------------------------------------- 5
I-3-Item location------------------------------------------------------------------ 6 - 7
I-4-Handling----------------------------------------------------------------------- 8
ÖII – BUOYANCY MECHANISM
II-1-Assembling the buoyancy mechanism on the hull------------------- 9
II-2-Fixing the flap--------------------------------------------------------------- 10
II-3-Inflation mechanism ------------------------------------------------------ 11-12
II-4-Pressure---------------------------------------------------------------------- 13
ÖIII -PROPULSION SYSTEM
15
ÖIV - INSTALLATION AND CIRCUITS
IV-1-Fuel -------------------------------------------------------------------------- 16
IV-2-Electricity ------------------------------------------------------------------ 21
IV-3-Drainage -------------------------------------------------------------------- 24
IV-4-Steering --------------------------------------------------------------------- 26
IV-5-Fire--------------------------------------------------------------------------- 26
IV-6-Anchoring/Mooring------------------------------------------------------- 27
ÖV – INFORMATION AND IDENTIFICATION PLATES
V-1-Safety label and registration plates position ------------------------- 28-30
V-2-Safety label and registration plates description ---------------------
31
ÖVI – POSITIONING / ASSEMBLY OF OPTIONAL ACCESSORIES
VI-1-Console position----------------------------------------------------------- 31-34
VI-2-Feed through-------------------------------------------------------------- 34
VI-3-Bolster position----------------------------------------------------------- 35
VI-4-Seat position area--------------------------------------------------------- 36
VI-5-Examples of possible accessories--------------------------------------- 36-37
VI-6-Position of the bathing ladder------------------------------------------ 38
VI-7-Rollbar position----------------------------------------------------------- 38

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DESCRIPTION - Technical Characteristics
I -1- TECHNICAL CHARACTERISTICS
Dimensions
(m) 6.3
(ft) 20’ 8“
(m) 4.95
(ft) 16’ 3“
(m) 2.5
(ft) 8’ 2“
(m) 1.35
(ft) 4’ 5“
(m) 0.575
(ft) 1’ 11“
Design category
(Directive 94/25/CE) B / C
Capacity
(ISO) C= 15 B= 5
Maximum kg (1) 1740 1020
lb.(1) 3837 2249
kg (2) 480
lb.(2) 1058
Compartment
5
Motorisation
Single Engine Twin Engine
Shaft XL L
Minimum power
recommended CV (3) 90
KW (3) 68
Maximum power
recommended CV 115 2* 80
kW 87 2* 60
Maximum power
authorised CV (3) 150 2* 80
kW (3) 113 2* 60
Maximum
Maximum engine
weight kg 240 2* 175
Lbs 529 2* 385
Hull dimensions
a (4) 5.28 m
17’ 4“
b (4) 1.57 m
5‘ 2“
c (4) 1 m
3‘ 3“
b
c

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DESCRIPTION - Technical Characteristics
Category conception : Your boat has been built for B & C category. It means different
layouts/ passengers and paylaod capacity for each category.
The B category allows to navigate with 5 passengers. Each passengers has to be seated and
have possibility to hold on to the boat.
We recommend you to use the specific Zodiac accessories (contact your dealer).
NOTE
Dimension tolerances: ± 4%
NOTE
(
1
)
The maximum authorized load was calculated to standard ISO 6185.
Navigate carefully when the boat carries the maximum load.
(2) Weight shown not including accessories
(3) The recommended power corresponds to optimum operation of the
boat’s capabilities for an average load.
(4)Hull dimensions without buoyancy mechanism.
Use the maximum authorised power with extreme prudence (see
Volume 1 of the manual "Navigation advice")
CAUTION
DO NOT EXCEED THE MAXIMUM LOAD 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.
CAUTION
DO NOT STORE FLAMMABLE PRODUCTS IN THE AFT
COMPARTMENT. IT IS STRICTLY FORBIDDEN TO STORE A
JERRYCAN.
TUBE - Cleaning
For a better maintenance we recommend to clean the tube with soapy water or ecological
cleaner like Revival, available in your Zodiac dealer shop.
CAUTION
DO NOT USE CLEANER WITH SOLVENT LIKE ACETATE

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DESCRIPTION - Inventory
I -2-INVENTORY
HULL
•Polyester hull
•Built-in non-slip deck
•1 bow ring
•1 anchoring rope locker (capacity: 91 litres approx.) + separation partition
•2 tension chain plates
•1 hull plug hole
•4 quick drain holes
•1 180-litre tank
•1 fuel/water separator filter
•1 battery tank
BUOYANCY MECHANISM
•Removable buoyancy mechanism
•Easypush valves
•Anti-chafing band with wide profile
•external handles
•internal handles
•bolt ropes
•bow roller
STANDARD EQUIPMENT
•2 paddles
•Foot inflation pump
•Manometer cap
•Repair kit
OPTIONAL ACCESSORIES*
•Sling
•Rollbar
•Consoles
•Seat
•Bolster
•Bathing ladder
•4- and 6-cylinder racks
•Electrical inflator, double flow-rate
•Other options available, see your ZODIAC dealer

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DESCRIPTION - Functional Elements
I -3-LOCATION OF ELEMENTS
11
13
14
1
2
34567
8912
1015
1615
18 19 20 21
13
17 23 22 22 23
22 232223
2424
24 24 24

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DESCRIPTION - Functional Elements
MARK DESIGNATION
1 Bow roller
2 Bow ring
3 Anchoring rope locker cover
4 Fuel filling point
5 Tank vent
6 Fuel overflow drainage
7 Tank valve/gauge access hatch
8 Rear chest access hatch
9 Quick drain hole plug
10 Fuel/water separator filter
11 Engine cable feedthrough
12 Cleats
13 Quick drain hole
14 Hull plug hole
15 Rear chain plates
16 Engine trough access hatch
17 Battery tank
18 Tank hatch
19 Tank
20 Buoyancy mechanism
21 Mooring cleat
22 bolt ropes
23 handles

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DESCRIPTION - Handling
I -4- HANDLING
I-4-1-Transport:
yAdvice for fitting to a trailer is given in the owner's manual, Volume 1.
I-4-2-Storage:
CAUTION
THE BOAT MUST REST ON THE BOW (SEE SKETCH
BELOW)
2700
200
1350
940
24.5
1568
344
73
COUPE A-A
29
929
28
1337
398
COUPE B-B
Dimensions in millimetres

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BUOYANCY MECHANISM – Assembly on the Hull
II -1- ASSEMBLING THE BUOYANCY MECHANISM ON THE HULL
1
To facilitate positioning of the buoyancy mechanism, apply liquid soap (A) to the hull rails
2
Place the bolt rope (a) of the buoyancy mechanism in the hull rail (b) located in the
bow of the hull. Pull on the buoyancy mechanism until the mini-bolt rope faces the rail.
3
- Proceed in the same way for the other side of the buoyancy mechanism.
- The two 2 flaps (tightness and outer) must pass over the tip of the hull.
- Fix the sealing flap to the hull using the screws and fabric washers (supplied) lifting the
tip of the buoyancy mechanism.
- Move the tip of the buoyancy mechanism forwards to fold the outer flap down under the
tip of the hull.
- Pull the 2 tabs of the buoyancy mechanism again as far as possible towards the aft end of
the boat, and try to centre the tip with the bow of the hull.
- Slightly inflate the tip of the buoyancy mechanism to check that it has been well centred
and that it matches the hull perfectly. - Begin the operation again if the buoyancy
mechanism is not correctly positioned.

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BUOYANCY MECHANISM - Fixing the flap
II-2-FIXING THE FLAP
4
Install the internal flap
5
Fix the internal flap (screw and washers)
6
After attaching the internal flap on the hull, pull the buoyancy mechanism forwards
slightly to pass the external flap over the bow (but do not attach yet).
NOTE: The buoyancy mechanism is mounted on the hull deflated.
You may inflate the buoyancy mechanism disassembled (pressure
240 mb) and let it stabilize for approximately one hour. Then deflate it.
If the buoyancy mechanism was stored at a temperature lower than 0 °C,
leave it 12 hours at room temperature (20 °C) before folding it.

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BUOYANCY MECHANISM - Inflating System
II-3-INFLATING SYSTEM
II -3-1- The inflation pump
a. adapter
b. nozzle
c. hose base
d. inflating orifice
a
b
cd
II -3-2- Easy push valves
To activate the valves 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 easypush valve caps lock and unlock with a
¼ turn. Never force them: you could unscrew the
entire inflation system.

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BUOYANCY MECHANISM - Inflating System
II -3-3- Pressure indicator
II -3-4- Buoyancy mechanism inflation
Activate all valves in inflating position.
Fix the hose base in the inflator inflating
orifice
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.
CAUTION
DO NOT USE A COMPRESSOR OR COMPRESSED AIR
CYLINDER

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BUOYANCY MECHANISM - Pressure
II -4-1- Buoyancy mechanism inflation
•Place the adapter corresponding to the diameter of the semi-built in valve at the inflator
pipe nozzle.
Inflate the buoyancy mechanism, balancing the pressure between the different
compartments until the partitions (a) are no longer visible (pressure = 240 mb)
Never pressurise a
compartment when the
others are completely
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 air leak is normal before the valve cap is screwed on
Only the caps guarantee final air tightness
II-4-2- Pressure
Operating pressure for the buoyancy mechanism is 240 mb/ 3.48 PSI (middle of the green
zone of the pressure gauge).
Your boat is equipped with an ACCESS pressure indicator that will enable you to read the
pressure quickly and efficiently during inflating (see explanations for use in the section
Inflating System).
The ambient temperature of the air or Ambient Temperature Internal buoyancy
mechanism pressure
water proportionately influences the +1°C +4 mb / 0.06 PSI
level of internal pressure in the
buoyancy mechanism -1°C -4 mb / 0.06 PSI

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BUOYANCY MECHANISM - Pressure
Thus, it is important to anticipate:
Check and adjust the pressure in the inflatable compartments (re-inflating or deflating
as necessary) according to temperature variations (especially when the temperature
varies greatly between the morning and evening in hot climates) and ensure that the
pressure is within the recommended pressure zone (from 220 to 270 mb).
RISK OF UNDERPRESSURE:
EXAMPLE: Your boat is exposed on a beach in the sun (temperature=50 °C) at the
recommended pressure (240 mb/3.48 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 REFLATE 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/3.48 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
mechanisms), doubling the initial pressure (480 mb). YOU WILL THEN NEED TO
DEFLATE the boat to return to the recommended pressure.
CAUTION
IF YOUR BOAT IS OVERINFLATED, THERE WILL BE UNDUE
PRESSURE ON THE INFLATABLE STRUCTURE THAT MAY
RUPTURE IT.
IN CASE OF OVERPRESSURE
EASYPUSH VALVE
Release some air by pressing
the valve knob.

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PROPULSION SYSTEM
Comply with ZODIAC recommendations and engine constructor
recommendations.
For optimum use of your boat, see your dealer.

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INSTALLATION AND CIRCUIT - Fuel
IV-1-FUEL
IV -1-1-Description of essential functional parts:
MARK DESIGNATION
1 Fuel circuit closing valve
2 Gauge transmitter
3 Fuel circuit closing valve
4 Draining hole of the overflow compartment
5 Vent
6 Filling hole
7 Fuel/water separator filter
8 Fuel tank
2 31 456
87

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INSTALLATION AND CIRCUIT - Fuel
MARK DESIGNATION
1 Tank valve/gauge access hatch.
2 Tank maintenance access door
IV-1-2-Réservoir
MARK DESIGNATION
1 Vent
2 Fuel tank filling
3 Fuel circuit closing valve
4 Gauge transmitter
5 Fuel circuit closing valve
2
1
1
2
4
5
3

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INSTALLATION AND CIRCUIT - Fuel
IV-1-3- Water/Fuel separator filter
NOTE:To protect the engine, a water/fuel separator filter is placed on the
fuel supply circuit.
The water/fuel separator filter is located in the aft chest, on the starboard partition:
MARK DESIGNATION
1 Filter head, fixed to the boat
2 Interchangeable filtering element
WARNING
THE CARTRIDGE MUST BE CHANGED EVERY 50
HOURS USE
1
2

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INSTALLATION AND CIRCUIT - Fuel
Changing the filter cartridge:
Comply with Zodiac recommendations and filter manufacturer recommendations
Place a funnel and recovery bowl underneath the cartridge while it is being replaced.
Before changing the filter, make sure the fuel supply line pressure is released.
Please refer to the engine manufacturer's owner manual instructions.
Gasoline is a highly flammable product. TURN THE ENGINE OFF, disconnect the
battery, do not smoke and keep all naked flames well away while you proceed with the
kit installation. Place a funnel and bowl pan underneath the cartridge while it is being
replaced.
Before changing the filter, make sure the fuel supply line pressure is released.
IV-1-4-Using the fuel circuit cut-off valves:
NOTE : - When you are no longer using your boat, close the fuel circuit
valve
- When you are going to use your boat, open the fuel circuit valve
Fuel circuit valve
Open position Fuel circuit valve Closed position

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INSTALLATION AND CIRCUIT - Fuel
IV-1-5-Recommendations:
WARNING
IN CASE OF FUEL LEAK OR FIRE, THE FUEL CIRCUIT
CLOSING VALVE, LOCATED ON THE TANK, ISOLATES
THE TANK FROM THE FUEL CIRCUIT AND MUST
REMAIN CLOSED.
WARNING
;A FULL TANK AVOIDS CONDENSATION ON EACH
OPERATION.
;CLEAN THE TANK EVERY FIVE YEARS.
;CHECK THAT THE CLAMPS ON ALL HOSES ARE
CORRECTLY TIGHTENED.
;WHEN PURGING THE FILTER, DO NOT DUMP
THE WATER IN THE BOAT. USE A
RECOVERY TRAY BELOW THE FILTER.
;CUT THE POWER SUPPLY BEFORE DISMANTLING
THE FILTER CARTRIDGE
;READ THE FILTER MANUAL CAREFULLY
WARNING
;FUEL IS EXTREMELY FLAMMABLE. WHEN
WORKING ON THE FUEL SYSTEM, MAKE SURE THE
ENGINE IS CUT OFF.
DO NOT SMOKE; KEEP FLAMES AND INCANDESCENT
OBJECTS AWAY FROM THE WORKING AREA.
WARNING
;NEVER DRILL THE TANK AREA WITH A BIT
PROTRUDING MORE THAN 30 MM FROM THE DRILL
HEAD (MARK ON THE DECK BY A HATCH) AND DO
NOT USE SCREWS OVER 25 MM LONG.