Hamilton Jet HJ212, Installation And Service Manual

Page: 93 / 198

Installation and Service Manual
Overhaul
Latch assembly, installation and adjustment
Assemble the latch release
Refer to drawing: HJ21207003 Reverse Assembly.

Install the reverse shaft [8] and crank [11] as shown in Section 9.3.1 Reverse Shaft Re-assembly.

Fit the cable mount [20] onto the jet unit and secure with spring washers [49] and screws [50]. Torque
load to the correct torque.

Thread the nut [55] fully onto the brake rod.

Thread the brake rod end [26] onto the reverse shaft ensuring the detent notch is at the opposite end of
the reverse shaft.

Install the drive screws [39] with, spring washers [52] and nuts [40], into the chassis block [29]. Ensure
that the nuts are fitted to the correct holes.

When the chassis block [29] is oriented with the large hole end to port, the drive screws [39] should be to
the bottom of the chassis block facing to the stern of the vessel.

Install the brake release screw [43] with its two nyloc adjustment nuts [45] and the detent plate [23].
Ensure these are fitted correctly.

Insert new nylon shouldered bushes [42] with the shoulder inside the chassis block [29]. Slide the brake
rod [41] through the bushes to check that is slides freely. If necessary ream the bushes with a 12mm
ream or drill.

Assemble the hub [47], brake plates [46] and spring [35] and hold in position inside the chassis block [29].

Ensure that items are placed in the correct position, the large hole in the chassis block [29] to port, the
release screw [43] and the drive screws [39] to the bottom and the threaded end of the hub [47] to the
stern of the vessel.
The spring must be assembled the correct way up or it will jam the latch, the main central loop
should be down, and the two outer loops should be up, so the ends of the spring point down.

Thread the brake rod [41] through the chassis block assembly from the starboard side.

Grease the reverse latch hub [47] where it attaches to the extension on the reverse shaft.

Fit the reverse latch hub [47] to the extension on the reverse shaft [8] and secure in position with special
washer [34], spring washer [19] and screw [37].

Apply Loctite 263 to the threads of screw [37] and secure the reverse latch hub [47] to the reverse shaft
[8].

Torque load screw [37] to the recommended torque.

Rotate the tiller [8] and secure the brake rod end [26] to the cable mount bracket [20] with bolt [36], flat
washers [31] and [32], and the brake rod bush [33] ensuring that flat washer [31] is fitted between the
cable mount bracket [20] and the brake rod end [26].

Mount the reverse cable, taking care to install the rubber washers [44], flat washers [54] and nuts [53] in
the correct order. Tighten the nyloc nuts sufficiently to pinch the rubber but allow some angular
movement between the cable and the chassis block [29]. This allows the chassis block to self-align on the
brake rod [41].

Clamp the cable to the cable mount with Loctite.
Ensure that the cable clamp is secure as failures have occurred when these clamps have come loose.

Inspect the operation of the reverse from the controller, and confirm that the controller gives full reverse
control movement.

Ensure that the reverse duct will lock in any position when operated from the controller.

Ensure that the reverse duct cannot be moved by hand from outside the vessel and that the latch system
locks adequately.

Check the deadband from the controller.

Check the zero speed detent and adjust as necessary. Refer to section: Zero Speed Detent on page 5-12.
9-11