9.4
9 OVERHAUL
9.2 R
EVERSE
A
SSEMBLY
R
EMOVAL
AND
O
VERHAUL
HJ-241 / HSRX
5. The Reverse Cylinder can now be removed from
the Transom by pushing the Cylinder forwards
into the vessel and out of the two Resilient
Mounts [14].
6. Refit Retaining Nut [11] and Washer [13] to
Reverse Cylinder Front Head [15].
7. The Reverse Cylinder can now be removed from
the vessel for further In-depth maintenance.
9.2.4 Reverse Cylinder Overhaul
Drawings
HJ-241-07-001 Reverse Assembly Sht1 &
2
DISMANTLING THE REVERSE CYLINDER
ASSEMBLY:
The Reverse Cylinder need only be dismantled if it
is suspected that a seal has failed and hydraulic
oil is found leaking along the Piston Rod
Assembly at one end of the cylinder or from the
HSRX Spool at the other end. This indicates that
the Seals are defective and must be replaced.
NOTE:
1.This operation should be carried out in a
clean workshop environment where the
cleanliness of components can be
maintained.
2.All marine growth must be removed from the
Reverse Cylinder Shaft using Scotchbrite or
800 and 1200 Grit water paper prior to
dismantling the Reverse Cylinder.
1. Ensure that the Clamp [58] and Shim [58] have
been disconnected from the Cable Mounting
Plate [26].
2. Slacken the Set Screw [30] securing the HSRX
Handle in position and remove the HSRX Handle
from the end of the HSRX Spool [20].
3. Remove the ‘V’ Ring [40] from the end of the
Spool at the Back Head end of the Reverse
Cylinder.
Note the correct orientation of the ‘V’
Ring [40] so that it is refitted correctly.
4. Remove the Pressure Relief Valve [35] from the
Back Head [22]. This is done by:-
a) Unscrewing the Knurled Nut on the top of the
Protective Cover (55).
b) Removing the Protective Cover from over the
Pressure Relief Valve. The pressure Relief
valve can now be unscrewed and removed
from the Back Head.
5. The Nipple [32] and Bonded Seal [33] fitted to the
Front Head [15] and Back Head [22] can be left
fitted unless they require replacing.
6. Remove the M6 Nuts [28] and Spring Washers
[29] securing the Cable Mount Plate [26] to the
Back Head and remove the Cable Mount Plate
from the front of the Reverse Cylinder.
7. Withdraw the Back Head [22] from the Reverse
Cylinder [19].
8. Remove the Bearing [25] from the Back Head
[22].
9. Remove the HSRX Spool [20] from the Cylinder
[19].
10.Remove the Cylinder [19] from the Front Head
[15].
11.Withdraw the Reverse Cylinder Shaft Assembly
[10] from the Front Head [15].
NOTE: The Reverse Cylinder Shaft Assembly is not
to be dismantled any further and should only
be replaced as a complete item.
12.Unscrew the 4 x threaded Reverse Cylinder Tie
Rods [27] from the Front Head [15].
13.Check the Stop Pin [39] fitted to the Back Head
[22], for damage, wear and security of fitment.
This Pin does not need to be removed unless it is
worn, loose or damaged.
14.Remove and discard all O Rings and Seals.
15.Thoroughly clean and inspect all components for
wear and damage and replace as required. If
dimensions do not meet the criteria below,
components must be replaced:-
a) The spool shaft where the Rotary Shaft Seal
(24) contacts, should be free of any damage
and measure no less than ø11.90 mm.
b) The seal bore in the Backhead (22) should
measure no more than ø20.033 mm on MK2
cylinders.
c) The Shaft (10) should measure no less than
ø19.93 mm.
d) Cylinder bore should be no more than ø32.00
mm.
NOTE: Recommendations regarding use and fitting
of Seals:
• Ensure that all metallic particles and other con-
taminants have been removed from the compo-
nent into which the seal is being fitted.
• Ensure that the hydraulic system to which com-
ponents are fitted is free from metallic particles
or other contaminants.
Summary of Contents for HJ241
Page 3: ...www hamiltonjet co nz Installation and Service Manual HJ241 Jet Unit Manual R3A31...
Page 10: ...x INTRODUCTION HJ 241 HSRX...
Page 14: ...xiv INTRODUCTION HJ 241 HSRX...
Page 15: ...Introduction and Product Description System Operation Part A Operator Information...
Page 16: ......
Page 22: ...1 6 1 INTRODUCTION PRODUCT DESCRIPTION 1 3 GENERAL ASSEMBLY DRAWINGS HJ 241 HSRX...
Page 32: ...2 10 2 SYSTEM OPERATION 2 11 HSRX REVERSE SYSTEM HJ 241 HSRX...
Page 34: ......
Page 36: ...3 2 3 DESIGN BASICS 3 2 HULL DESIGN HJ 241 HSRX Figure 9 Loads on the Hull for HJ 241 Jet Unit...
Page 54: ...3 20 3 DESIGN BASICS 3 8 DESCRIPTION OF THE DRY RUN SYSTEM OPTIONAL EXTRA HJ 241 HSRX...
Page 72: ...5 12 5 INSTALLATION 5 8 INSTALLING THE HSRX REVERSE SYSTEM HJ 241 HSRX...
Page 76: ...6 4 6 COMMISSIONING 6 5 AFTER INITIAL TRIALS AFTER ENGINE SHUT DOWN HJ 241 HSRX...
Page 77: ...Fault Finding Maintenance Overhaul Part C Servicing Information...
Page 78: ...HM 811...
Page 104: ...8 18 8 MAINTENANCE 8 8 RECOMMENDED OILS AND LUBRICANTS HJ 241 HSRX...
Page 138: ...9 34 9 OVERHAUL 9 11 HSRX HYDRAULIC REVERSE SYSTEM HJ 241 HSRX...
Page 139: ...Supplementary Technical Information Appendix...
Page 140: ......
Page 142: ...A 2 Appendix HJ 241 HSRX A 2 Loctite Application Guide...
Page 143: ...A 3 Appendix HJ 241 HSRX...
Page 144: ...A 4 Appendix HJ 241 HSRX...
Page 145: ...A 5 Appendix HJ 241 HSRX...
Page 146: ...A 6 Appendix HJ 241 HSRX...
Page 147: ...A 7 Appendix HJ 241 HSRX...
Page 159: ...A 19 Appendix HJ 241 HSRX Comments...
Page 161: ...Technical Drawings Drawings...
Page 162: ......
Page 168: ...SERVICING DRAWINGS D 6 HJ 241 HSRX HJ 241 06 000 Steering Assembly General Arrangment Sht2...
Page 170: ...SERVICING DRAWINGS D 8 HJ 241 HSRX HJ 241 07 001 Reverse Assembly Sht1...
Page 172: ...SERVICING DRAWINGS D 10 HJ 241 HSRX HJ 241 07 002 Blanking Plus No Reverse...
Page 173: ...HJ 241 HSRX SERVICING DRAWINGS D 11 HJ 241 08 001 Installation Details GRP Hull...
Page 177: ...HJ 241 HSRX SERVICING DRAWINGS D 15 HJ 241 09 001 Blanking Plugs For Screen Rake...
Page 178: ...SERVICING DRAWINGS D 16 HJ 241 HSRX HJ 241 09 002 Screen Rake Assembly...
Page 179: ...HJ 241 HSRX SERVICING DRAWINGS D 17 HJ 241 10 004 Hatch Extension...
Page 180: ...SERVICING DRAWINGS D 18 HJ 241 HSRX HJ 241 11 000 Tool Kit...
Page 181: ...HJ 241 HSRX SERVICING DRAWINGS D 19 HJ 241 12 000 Sandtrap engine Cooling...
Page 182: ...SERVICING DRAWINGS D 20 HJ 241 HSRX HJ 241 13 002 Anode Locations...
Page 183: ...HJ 241 HSRX SERVICING DRAWINGS D 21 HJ 241 30 001 General Arrangement...
Page 187: ...HJ 241 HSRX SERVICING DRAWINGS D 25 CT HSE 12 001 Hose Kits...
Page 189: ...HJ 241 HSRX SERVICING DRAWINGS D 27 CT SJK 02 005 Steering Cylinder Seastar...
Page 190: ...SERVICING DRAWINGS D 28 HJ 241 HSRX 61483 Rotary Seal...
Page 200: ...SERVICING DRAWINGS D 38 HJ 241 HSRX 85114 Earth Bonding System Recommendations and layout...
Page 201: ...Notes...