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INTRODUCTION

ONTENTS

vii

HJ-241 / HSRX

8.1 GENERAL .................................................................................................. 8.1
8.2 PRESERVATION: (PRE-INSTALLATION) .................................................... 8.1
8.3 PRESERVATION: (POST-INSTALLATION) .................................................. 8.2
8.4 SERVICING INTERVALS............................................................................. 8.3

8.4.1 Servicing Intervals (Jet) .....................................................................8.3
8.4.2 Servicing Intervals (Hydraulic Reverse System) ................................8.4
8.4.3 Daily “Pre Use” Servicing Checks .....................................................8.5

8.5 SERVICING DETAILS ................................................................................. 8.6

8.5.1 Jet Unit Servicing Details ..................................................................8.6
8.5.2 HSRX Controls Servicing Details .....................................................8.12

8.6 TOOLS .................................................................................................... 8.16

8.6.1 Standard Recommended Tools .......................................................8.16
8.6.2 Special Tools ..................................................................................8.16

8.7 THREADED FASTENERS.......................................................................... 8.16
8.8 RECOMMENDED OILS AND LUBRICANTS............................................... 8.17

9 Overhaul ......................................................................... 9.1

9.1 GENERAL INFORMATION ......................................................................... 9.2
9.2 REVERSE ASSEMBLY REMOVAL AND OVERHAUL .................................... 9.2

9.2.1 Reverse Duct Removal ......................................................................9.2
9.2.2 Reverse Duct Overhaul .....................................................................9.3
9.2.3 Reverse Cylinder Removal ................................................................9.3
9.2.4 Reverse Cylinder Overhaul ...............................................................9.4

9.3 REVERSE ASSEMBLY RE-FITTING ............................................................. 9.7

9.3.1 Reverse Cylinder: Refit to the Jet Unit ...............................................9.7
9.3.2 Reverse Duct: Refit to the Jet Unit ....................................................9.7

9.4 STEERING ASSEMBLY REMOVAL AND OVERHAUL................................... 9.9

9.4.1 Steering Cylinder Removal  ...............................................................9.9
9.4.2 Steering Shaft Removal .....................................................................9.9
9.4.3 Nozzle Assembly Removal  .............................................................9.10
9.4.4 Nozzle Assembly Overhaul  ............................................................9.11

9.5 STEERING ASSEMBLY RE-FITTING ......................................................... 9.14

9.6 BEARING HOUSING ASSEMBLY OVERHAUL ........................................... 9.17

9.6.1 Water Seal Removal .......................................................................9.18
9.6.2 Water Seal Replacement and Re-Fitting .........................................9.19
9.6.3 Re-Assembly of the Bearing Housing ..............................................9.20

9.7 TAILPIPE AREA - OVERHAUL .................................................................. 9.21

9.8 TRANSOM PLATE ASSEMBLY OVERHAUL............................................... 9.27

9.8.1 Transom Plate Removal .................................................................9.27
9.8.2 Transom Plate Re-Fitting ................................................................9.27

9.9 HATCH EXTENSION (OPTIONAL EXTRA)................................................ 9.28

9.9.1 Hatch Extension Fitting. .................................................................9.28
9.9.2 Hatch Extension Removal. ..............................................................9.28

9.10 SCREEN RAKE ASSEMBLY OVERHAUL (IF FITTED) ............................... 9.29

9.11 HSRX HYDRAULIC REVERSE SYSTEM ................................................... 9.31

9.11.1 Removal of the Pump Assembly from the Jet Unit .........................9.31
9.11.2 Re-Fitting the Pump Assembly to the Jet Unit ...............................9.32

Summary of Contents for HJ241

Page 1: ...following changes are included in this amendment _Drawing 85018 updated to revision T _Drawing 85113 updated to revision P _Drawing CTHSE12001 updated to revision C _Drawing CTSJK02005 updated to revi...

Page 2: ...Hamilton Indices as required Hamilton Jet Model front cover and spine insert Ensure correct Jet model Check Jet model text on front cover is right aligned Check for missing images grey boxes Contact...

Page 3: ...www hamiltonjet co nz Installation and Service Manual HJ241 Jet Unit Manual R3A31...

Page 4: ...y any means electronic electrostatic magnetic tape mechanical photocopying recording or otherwise without permission in writing from CWF Hamilton Co Ltd Due to our policy of continuous development spe...

Page 5: ...8 2 10 OPERATING WITH AN ENGINE AND JET UNIT OUT OF SERVICE 2 8 2 11 HSRX REVERSE SYSTEM 2 9 Part B Design and Installation Information 3 Design Basics 3 1 3 1 PROPULSION SYSTEM DESIGN 3 1 3 2 HULL DE...

Page 6: ...ents 5 3 5 3 3 Removal of Other Parts 5 4 5 4 MOUNTING THE JET UNIT 5 4 5 4 1 Mounting the Jet Unit to the Hull 5 5 5 4 2 Assembly of the Transom Plate to the Hull 5 5 5 5 FINAL ASSEMBLY 5 6 5 5 1 Rev...

Page 7: ...14 9 5 2 Re Assemble the Nozzle Nozzle Housing to the Tailpipe 9 15 9 5 3 Steering Shaft Re Fitting 9 15 9 5 4 Steering Cylinder Re Fitting 9 16 9 5 5 Steering Linkages Adjustment 9 16 9 5 6 Steering...

Page 8: ...INTRODUCTION CONTENTS viii HJ 241 HSRX Appendix A 1 CONVERSIONS A 1 A 2 LOCTITE APPLICATION GUIDE A 2 A 3 INSTALLATION CHECKS A 8 A 4 COMMISSIONING CHECKS A 12 A 5 LUBRICATION CHART A 20 Drawings...

Page 9: ...y observed could result in injury or death to personnel This is indicated throughout the Manual as below A Caution is an operation or maintenance procedure practice condition or statement which if not...

Page 10: ...x INTRODUCTION HJ 241 HSRX...

Page 11: ...charges if any incurred All Products removed or replaced under the Warranty shall become the property of Hamilton Jet All Warranty claims shall be lodged with Hamilton Jet or its authorised distributo...

Page 12: ...rts The cost of transporting the vessel to a repair facility and for all related towing harbour docking slippage lifting moorage launching or retrieval charges Damage to surface coatings as may occur...

Page 13: ...e Marketing Department C W F Hamilton Co Ltd PO Box 709 Christchurch New Zealand Fax 64 3 348 6969 Hamilton Jet encourages the Distributor to take responsibility for ensuring the Purchaser and the Dis...

Page 14: ...xiv INTRODUCTION HJ 241 HSRX...

Page 15: ...Introduction and Product Description System Operation Part A Operator Information...

Page 16: ......

Page 17: ...nerally offer lower maintenance longer engine life and simplified installation Hamilton Jet pioneered the commercial development of the modern waterjet system in the early 1950 s and today have over 3...

Page 18: ...ropeller driven vessel and also means increased safety for personnel working in the water near the vessel The waterjet unit is an ideal form of propulsion for vessels working in a marine mammal enviro...

Page 19: ...rated to divide the flow and angle the astern jet stream downwards and to the side to clear the vessel Transom and Intake opening This prevents recycling of flow through the Jet Unit which may be aera...

Page 20: ...1 1 THE HAMILTON WATER JET SYSTEM HJ 241 HSRX NOTE This image is a pictorial illustration of where the various components are located on the HJ 241 Jet Unit and is for illustration purposes only Figur...

Page 21: ...ontrol of the Reverse Cylinder position where it is needed around the Zero Speed Reverse position With the Piston restriction A fully open equal pressure acts on both the rod end and cap end of the HS...

Page 22: ...1 6 1 INTRODUCTION PRODUCT DESCRIPTION 1 3 GENERAL ASSEMBLY DRAWINGS HJ 241 HSRX...

Page 23: ...the Reverse Duct is lowered partially the jetstream is split giving some ahead and some astern thrust At a certain Reverse Duct position the ahead and astern thrusts will be equal so the vessel will n...

Page 24: ...or stopped 2 Never stop the engine or disengage the drive to the Jet when approaching a mooring or at any time when steering will be required 3 The more the throttle is opened the greater the steering...

Page 25: ...Tiller Disconnect the cable from the Steering Arm Refer to Drawing HJ 241 06 000 Steering Assembly General Arrangment Sht1 sht2 Move the Steering Arm by hand as required to move the Steering Nozzle S...

Page 26: ...s with the other hand ONE AHEAD and ONE ASTERN is NOT AS EFFECTIVE 2 USE ONLY LOW ENGINE RPM high RPM will give faster response but makes control more difficult 3 If the bow is rotating to starboard p...

Page 27: ...uct approximately 80 reversed 4 Use the Helm to control turning rotation moments i e for sideways motion to port turn the Helm to starboard to balance the turning moment of the port and starboard Jets...

Page 28: ...should be reduced accordingly 2 6 SHALLOW WATER OPERATION It is important to avoid pumping stones sand etc through the Jet Unit as this will blunt and wear the Impeller The following diagrams illustr...

Page 29: ...it is good practice to steer around such debris where possible as any debris caught in the Intake Screen Impeller or Tailpipe Stator Vanes can affect the Jet Unit s performance 2 9 2 Detecting Blockag...

Page 30: ...WITH AN ENGINE AND JET UNIT OUT OF SERVICE If the vessel is operated with an engine and Jet Unit out of service it is possible for the Jet Unit Mainshaft to rotate due to water flowing through the Je...

Page 31: ...n of the Reverse System at any position other than fully raised is 1000 RPM 4 There is no flow control in the HSRX Reverse System The effect of this is the higher the engine RPM the faster the Reverse...

Page 32: ...2 10 2 SYSTEM OPERATION 2 11 HSRX REVERSE SYSTEM HJ 241 HSRX...

Page 33: ...Design Basics Precautions Against Corrosion Installation Commissioning Part B Design and Installation Information...

Page 34: ......

Page 35: ...m loads Full Ahead Full Reverse Full Steering Full Reverse Full Steering The load situations are described in Figure 9 Loads on the Hull for HJ 241 Jet Unit While the Jet Unit loads can be readily cal...

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 37: ...TA DESCRIPTION SYMBOL UNITS VALUE Maximum Power P Kw 260 Centre Line Height H m 0 284 Mean Inlet Depth h m 0 04 Steering to Base Centre Ds m 0 92 Reverse to Base Centre Dr m 1 25 Transom to Base Centr...

Page 38: ...stability without appendages 3 Displacement speed and warped plane reducing deadrise going aft hulls may need additional directional stability Twin bilge keels are normally sufficient These do not in...

Page 39: ...o that the Jet Units sit well down in the water as indicated in Fig ure 12 Hull Design Recommendations for Multi Hull Vessel below The Reverse Duct when in the up ahead position must not project beyon...

Page 40: ...ble to mount trim tabs under the Jet Unit with control equipment on either side of the Jet Unit The adjacent diagram serves as a guide to the maximum size of trim tab that may be located under the Jet...

Page 41: ...n Co Ltd 2 Critical speed check for whirling of the Driveshaft Consult the driveline supplier Engine to Jet alignment Consult C W F Hamilton Co Ltd 3 Torsional Vibration Analysis consult engine or tor...

Page 42: ...ALLY FLEXIBLE COU PLINGS Examples of such couplings are Centaflex and Megaflex Use a double element torsionally flexible driveshaft with support bearings such as the Centaflex GZ type illustrated The...

Page 43: ...a The gearbox should be mounted rigidly to avoid misalignment 3 3 4 Universal Driveshaft Alignment 1 There are only two allowable configurations for location of centrelines for the Jet Unit and Gearbo...

Page 44: ...3 10 3 DESIGN BASICS 3 3 DRIVELINES HJ 241 HSRX Figure 19 Z Configuration Coupling Figure 20 W Configuration Coupling...

Page 45: ...eline It is the responsibility of the vessel builder to see that either the engine manufacturer or the flexible coupling manufacturer carries this out The Moment of Inertia Data for the Jet Unit is pr...

Page 46: ...owing table lists the angle deviation of the Jet Mainshaft when the Jet base is mounted parallel to the keel line FOR INTAKE BASE PARALLEL TO KEEL LINE B1 Shaft angle in Plan view B2 Shaft slope in El...

Page 47: ...for a deck cleaning hose but the pressure is not high enough to be used for a fire hose CONVENTIONAL WATER PICK UP Alternatively a cooling system separate from the Jet Unit can be fitted to the engin...

Page 48: ...of the HSRX Cylinder As the cap end area is larger than the rod end area the cylinder extends With the Piston restriction A closed the Cylinder retracts At full retraction the Bypass Valve B opens re...

Page 49: ...regard or consult C W F Hamilton Co Ltd 3 7 2 Mounting Mount the engine via mounting feet fixed to the engine bearers The feet and bearers do not have to withstand the propulsion thrust load as this...

Page 50: ...ystems The engine exhaust system can be any conventional system approved by the engine manufacturer Engine exhausts should be sited above the waterline and away from the Jet Units If engine exhausts a...

Page 51: ...t Unit to the Dry Run System The Dry Run Bearing components can be fitted as shown for the normal Marine Bearing replacement in the Jet Unit Manual 3 8 2 Corrosion All the components of the Dry Run Ki...

Page 52: ...sits closest to the Impeller The shell should sit flush with the Tailpipe as shown on the diagram in Section 3 8 6 Parts List 2 The Bearing Sleeve is fitted to the Mainshaft in the same manner as the...

Page 53: ...HE DRY RUN SYSTEM OPTIONAL EXTRA HJ 241 HSRX 3 8 6 Parts List Refer to Drawings HJ 241 01 000 Basic Jet Assem blies Standard and Dry Run Sht 1 2 Figure 26 Dry Run Bearing Assembly DRY RUN BEARING ASSE...

Page 54: ...3 20 3 DESIGN BASICS 3 8 DESCRIPTION OF THE DRY RUN SYSTEM OPTIONAL EXTRA HJ 241 HSRX...

Page 55: ...y banks with cross connect starting capability there must be two heavy conductors between the engines Local standards if appropriate should be complied with A C Systems For a vessel with both AC and D...

Page 56: ...correctly wired polarization transformer in conjunction with a galvanic isolator is acceptable for connecting to an AC shore power system 4 1 2 Earth Bonding System In aluminium and most GRP hulls the...

Page 57: ...or der to ensure adequate corrosion protection for the jet stainless steel trim tabs should be fully painted or electrically isolated from the jet unit or prefera bly both Normally an anode would be f...

Page 58: ...o the Jet Unit are made from zinc alloy to US military specification MIL A 18001K or aluminium alloy to MIL A 24779 SH These anodes are fitted to the Reverse Duct Steering Deflector Reverse Cylinder a...

Page 59: ...quipment installation be guided by your electrician Do not earth electrical equipment to the Jet Unit but to a separate earth 4 3 1 Checking the Insulation The insulation between the Jet Unit s and th...

Page 60: ...4 6 4 PRECAUTIONS AGAINST CORROSION 4 3 EARTH BONDING SYSTEM NOT NORMALLY CURRENT CONDUCTING HJ 241 HSRX...

Page 61: ...contact C W F Hamilton Co Ltd It is assumed that the aluminium plating of the Hull is one of the following types 5083 5086 6061 6063 6101 6202 6151 or 6951 If not consult C W F Hamilton Co Ltd The Int...

Page 62: ...t the forward end Use the weld procedure shown on Drawing 85080 Aluminium Weld Procedure for Hamilton Jet Installation or Repair Ensure that the contours between hull and Intake Block at front and rea...

Page 63: ...the Transom FOR METAL HULLS If the Transom is not close to the angle required cut out the required area reposition at the required angle and re weld back to the Transom with any necessary inserts at...

Page 64: ...e the Jet Unit is installed from inside the hull and the Reverse Duct cannot fit through the Transom hole 2 To fit the Jet Unit complete with the Intake Screen attached using approved lifting equipmen...

Page 65: ...Spring 7 fitted to the Screen Rake Actuator 2 refer to Drawing HJ 241 09 002 Screen Rake As sembly 5 4 2 Assembly of the Transom Plate to the Hull 1 Ensure that the Reverse Duct has been removed from...

Page 66: ...case of multiple Jet installations the outer hole may be used to reduce the helm load if necessary 5 5 4 Assembling the Jet Steering Tillers The Jet Tiller as supplied is pre drilled for attachment o...

Page 67: ...h a slip joint sliding spline Any axial float will be taken up in the Driveshaft Flywheel adaptors may be used to match the driveshaft flange Consult the Sections on JET MAINSHAFT ALIGNMENT and DESIGN...

Page 68: ...ers It is common to use a heat exchanger and a separate cooling water circuit for the engine so that the river or seawater does not enter the engine In this case the cooling water from the jet water o...

Page 69: ...s Refer to Section 3 7 5 Exhaust Systems in the Design Basics Section and Section 5 6 4 Ex haust Systems in the Installation Section of this manual 9 Check that the Hull Trim Tabs if fitted will not i...

Page 70: ...aft Assembly will damage the Cylinder Seals 5 8 1 Remote Operating Systems 5 8 2 Cable Installation The HSRX Reverse System is supplied with a cable mounting plate fitted to the end of the HSRX Cylind...

Page 71: ...ad Stop Screw to achieve this with no excess Lever movement 3 If the Reverse Control Lever has no stops it will be necessary to adjust the Cable mounting position on the Cable Mounting Plate and or th...

Page 72: ...5 12 5 INSTALLATION 5 8 INSTALLING THE HSRX REVERSE SYSTEM HJ 241 HSRX...

Page 73: ...orm the following procedures before the engines are started 1 Check that there are no water leaks a At the Transom Seal b At the Intake Base c From under the Bearing Housing Water Seal leak 2 Check th...

Page 74: ...ervoir 10 Check the System to ensure that it is not overheating It should be possible to hold your hand on any component for at least 2 3 seconds 11 Ensure the Intake is under water either with the bo...

Page 75: ...l temperature at the JHPU oil reservoir Record the temperature reading after a sustained run at cruising speed and also after a period of vessel manoeuvering 7 Record maximum speed using GPS and engin...

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 79: ...The Blockage must be removed Check Water Seal Inspection Cover Hull design Consult C W F Hamilton Co Ltd Sect 2 9 Sect 9 Sect 3 2 A lack of Jet thrust boat speed drops while RPM is high There is some...

Page 80: ...the water drain hole in the Tailpipe Cone inspect and repair the Marine Bearing Check through Inspection Hatch clear obstruction Inspect and repair the driveshaft as per manufacturer s recommendation...

Page 81: ...rs and HJ 241 06 000 Steering Assembly General Arrangment Sht1 11 Main Bearing Housing excessively hot Main Bearing or Seal failure The Bearing Housing operating temperature at the Bearing Housing Cas...

Page 82: ...lowing Back pressure too high As Above As Above 4 Reverse Duct not synchronised with the Reverse Lever Cylinder Rod 180 out of phase Rotate Cylinder Rod so that the dot on the Rod End is uppermost Als...

Page 83: ...e Cylinder Seal failure in the Back Head 22 Suspect Seals are O Ring 24 O Ring 50 V Ring 40 Overhaul the Reverse Cylinder Sect 9 2 4 10 Reverse Cylinder Oil leaking from around the Back Head Front Hea...

Page 84: ...verse Control Lever or Cable is stiff Disconnect the Reverse Control cable at the Lever Check Controller movement and cable movement Lubricate as necessary Check for bent or loose linkages Check cable...

Page 85: ...nd Engine Start Interlock microswitch in accord ance with the manufacturers instructions 19 No hydraulic pressure from the Jet Hydraulic Pump Unit Saginaw Pump Reverse Cylinder is not functioning due...

Page 86: ...m the Steering Arm Check movement of Steering Shaft and clearance on Steering Bushes Rectify to a loose running fit Remove Bolts 11 Bushes 10 and Sleeves 12 Check Bushes and Sleeves for wear Replace w...

Page 87: ...W JET PRESERVATION The following storage requirements must be provided to ensure that no damage or deterioration occurs 1 Temperature must be between 10 C and 40 C and above the dew point i e No conde...

Page 88: ...E FOLLOWING 1 Actively prevent marine growth through the following procedures a Paint the inside and outside of the Jet Unit with antifouling compound b Keep light away from the Jet Unit Moor the vess...

Page 89: ...ng Lubricate 8 5 1 2 Water Seal Check for leaks 8 5 1 4 Anodes Check condition 8 5 1 5 Steering System Check integrity 8 5 1 6 Steering Crank Cotter Check integrity and lubricate 8 5 1 6 4 Steering Ca...

Page 90: ...le has been compiled for normal operating conditions If the vessel is used in severe conditions where the oil is likely to become contaminated the oil should be replaced at more frequent intervals Tab...

Page 91: ...or Impeller damage Reverse Hydraulic Cylinder and Oil Lines Check for oil leaks especially if oil has been added to a system Steering System Check the freedom of movement of the Steering Cable Check f...

Page 92: ...ed ball bearing grease every 30 hours running Refer Drawing 85018 Recommendations for Lubri cants and Oils Normal operating temperature is 50 55 C 120 130 F but the Bearing can operate up to 120 C sat...

Page 93: ...items on the Jet Unit 1 Steering Shaft The Steering Shaft should be removed and checked for straightness particularly at the Crank end of the Steering Shaft 2 Tiller Check that the Tiller is not bent...

Page 94: ...n the Nozzle and the Nozzle Housing is between 0 1 to 0 3 mm Measure between the outer shoulder of the Steering Pivot Bush Sleeve 22 and the inner face of the Thrust Washer 23 This should measure betw...

Page 95: ...essel out of the water The following checks should be carried out a Impeller Blades Check Clearance Remove the Main Inspection Cover Using Feeler Gauges check the clearance between the tips of the Imp...

Page 96: ...sh Guard is secure and has adequate clearance on the Reverse Duct f Steering Cables If fitted Disconnect and remove These items are to be removed in accordance with Section 9 4 2 Steering Shaft Remova...

Page 97: ...d repainting may be necessary depending on water conditions prevailing and extent of use When the vessel is on the slip preferably annually the complete Jet Unit should be inspected internally and ext...

Page 98: ...2 HSRX System Hydraulic Oil Replacement Change the HSRX System Oil every 1000 hrs Oil changes may be varied to suit operating conditions To change the Oil carry out the following procedure 1 Place a s...

Page 99: ...der to Cooler return Hose H2 AT THE COOLER Return Port end 2 Disconnect the Feed Hose H3 to the Oil Cooler AT THE PUMP and ensure the free end remains higher than the Cooler Return Port 3 Place a funn...

Page 100: ...maining air out of the system 5 Top up the Pump Reservoir 6 Check the System to ensure that it is not overheating It should be possible to hold your hand on any component for at least 2 3 seconds 5 HS...

Page 101: ...Belt by levering the Pump body away from the Intake to achieve the tension required above 5 Tighten the Nut 8 at the elongated slot end of the Adjusting Link 4 which secures the Pump 1 to the Adjustin...

Page 102: ...HREADED FASTEN ERS a The tightening torque s for standard fasteners are given on the Drawing 85113 Recommen dations for Fastener Locking Torques and Threading Lubrication Sht 1 b The tightening torque...

Page 103: ...at low temperatures Oil viscosity should be 20cS approximately at 40 C and 4cS at 100 C Normal operating temperature should lie between 30 C and 60 C For recommended oils refer to the drawing referred...

Page 104: ...8 18 8 MAINTENANCE 8 8 RECOMMENDED OILS AND LUBRICANTS HJ 241 HSRX...

Page 105: ...irt or loss of hydraulic oil OVERHAUL PROCEDURE The following procedure describes the main activities when carrying out a complete overhaul but can be used to plan any other type of overhaul 1 Overhau...

Page 106: ...ush 44 from the centre of the Shaft 10 and retain 8 Remove the Reverse Shaft Assembly 10 from Stud 41 on the Reverse Duct ensuring that the Flat Washer 43 fitted between the Reverse Shaft and the Reve...

Page 107: ...s are pressed in evenly and are fully home in the bores 12 Clean off any surplus Loctite from around the replacement Sleeves 13 Refit the Reverse Pivot Bush 5 to the Reverse Pivot Bush Sleeve 50 REVER...

Page 108: ...sure 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 unles...

Page 109: ...erse Cylinder Front Head 15 3 Grease and fit the Piston Seal 21 to the Reverse Cylinder Shaft Assembly 10 ensuring that the Scarf Joints on the Seal Backing Rings are correctly mated 4 Grease and fit...

Page 110: ...e end of the HSRX Spool 22 Fit Set Screw 30 to the HSRX Handle using Loctite 263 and tighten to secure the Handle in position 23 Fit the Pressure Relief Valve 35 to the Back Head 22 ensuring that the...

Page 111: ...07 001 Reverse Assembly Sht1 2 refer REVERSE DUCT 1 Ensure that the threads and surfaces of the Pivot Pins 4 are clean 2 Ensure that the Pivot Sleeves 2 and Reverse Pivot Bushes 5 are clean 3 Coat the...

Page 112: ...rry out a full functional check of the Reverse System to ensure correct operation and full range of movement is obtainable REPOSITIONING THE CABLE MOUNT PLATE Should the Cable Mount Plate be wrongly o...

Page 113: ...n Steering Cylinder Seal replacement 9 4 2 Steering Shaft Removal Drawings HJ 241 06 000 Steering Assembly Gener al Arrangment Sht1 2 refer 1 Remove the Splash Guard 7 and the Reverse Duct as shown in...

Page 114: ...25 securing the JT Steering Lip Seals 24 to the inner face of the Nozzle 15 and ensure that the Lip Seals are free to move 2 Whilst supporting the Nozzle unscrew and remove the upper and lower Nozzle...

Page 115: ...p Seals for adjustment NOTE There is some movement in the Lip Seals 24 when loosely secured with Screws 25 this is to allow the Lip Seals to be adjusted to fit the inside of the Nozzle Housing 9 7 Adj...

Page 116: ...eeve is fitted 6 From the front of the Intake press the forward Steering Shaft Bush Sleeve into the bore in the front Intake boss ensuring that the Sleeve is fully home in the bore 7 Rotate the Sleeve...

Page 117: ...ainted 4 Apply Loctite Activator 7471 to the outside of the replacement Steering Shaft Bush Sleeve 27 and allow to dry Do not apply Activator 7471 to the bore in the Tailpipe NOTE Loctite Activator 74...

Page 118: ...d condition ensure that it has not been painted over 5 If a coating has built up on the Anode scrub the Anode down with a wire brush 9 5 STEERING ASSEMBLY RE FITTING Refer to Drawing HJ 241 06 000 Ste...

Page 119: ...0 6mm clearance to the spherical inner surface of the Nozzle Housing 9 NOTE There is some movement in the Lip Seals 24 when loosely secured with Screws 25 this is to allow the Lip Seals to be adjuste...

Page 120: ...Section of the Controls Manual NOTE If this Jet Unit is fitted with the Seastar Steering Cylinder as a steering option refer to the Seastar Manual supplied with the Steering Cylinder for Overhaul info...

Page 121: ...Washers 16 from Studs 43 attaching the Bearing Housing 8 to the Intake 19 NOTE If the Mainshaft is to remain in the Jet Unit the Water Seal Retaining Pin 15 can remain fitted to the Mainshaft 8 Remov...

Page 122: ...proceed as follows 1 Remove the Nuts 17 and Spring Washers 16 on the 3 Studs 43 attaching the Bearing Housing 8 to the Intake 19 2 While supporting the Mainshaft the complete Bearing Housing Waterseal...

Page 123: ...Water Seal Retaining Pin 15 has been removed insert a new Water Seal Retaining Pin 15 into the hole in the Mainshaft folding the legs closely around the Mainshaft to avoid their fouling with the Seal...

Page 124: ...Ring 37 fitted to the Intake recess and around the Seal Face Holder contact area with the Intake 13 Lightly grease the inner Seal Sleeve 5 and fit over the Mainshaft 1 Push the Seal Sleeve through the...

Page 125: ...ted before proceeding Refer to Section 9 4 2 Steering Shaft Re moval 9 7 1 Impeller Checking for Wear Before dismantling the Tailpipe end of the Jet remove the Inspection Cover 20 or Intake Screen 24...

Page 126: ...for wear on the Wear Ring This should be evident where the Impeller has been running If there is evidence of excessive wear by a 0 5mm lip or signs of corrosion through or beneath the Wear Ring The W...

Page 127: ...htly this reduces the lead in diameter See Step 2 Insertion in Figure 31 Wear Ring Inspection Removal Instructions 2 Gradually feed it inside the Insulator 38 fitted in the Tailpipe until it butts ful...

Page 128: ...nd sometimes cavitation 4 Check the Impeller O D BLADE LEADING EDGE REPAIR PROCEDURE Drawing HJ 241 03 001 Impellers shows the desired blade profile The following information should also be referred t...

Page 129: ...ring and Reverse System Bushes Scrapers and Seals have been replaced prior to re assembly of the Tailpipe and Nozzle Refer to Section 9 4 2 Steering Shaft Removal and Section 9 4 4 Nozzle Assembly Ove...

Page 130: ...the Mainshaft 2 Insert the Impeller Key 11 into the Mainshaft keyway and tap into position with a soft hammer 3 Slide the Impeller onto the Mainshaft ensuring that the Impeller engages fully with the...

Page 131: ...lacken and remove the Screws 9 Nuts 4 Flat Washers 6 and Spring Washers 5 securing the Transom Plate to the Transom 2 Remove the Transom Plate off the Jet Unit Intake 3 Remove the Transom Plate O Ring...

Page 132: ...t As semblies Standard and Dry Run Sht 1 2and torque load to the recommended torque 11 Fit the Inspection Cover 20 to Studs 3 shown on Drawing HJ 241 10 004 Hatch Extension and secure with Spring Wash...

Page 133: ...moval Refer to Drawing HJ 241 09 002 Screen Rake As sembly To remove the Screen Rake Assembly the vessel should be removed from the water to allow access to the underside of the vessel To remove the S...

Page 134: ...orque load the Nuts 11 to the recommended torque 5 From beneath the vessel whilst supporting the Screen Rake and before fitting the Starboard Screen Rake Bearing feed the starboard Screen Rake pivot p...

Page 135: ...ite 263 2 Offer the Screen up to the Studs 21 on the front and rear of the underside of the Intake and secure in position with Flat Washers 29 and Nuts 25 3 Tighten to the recommended torque 9 11 HSRX...

Page 136: ...of the Pump before fitting the elongated slot in the Adjusting Link 4 over the Stud 5 Loosely secure the inboard end of the Adjusting Link with Spring Washer 7 and Nut 8 6 Secure the outboard end of t...

Page 137: ...HYDRAULIC REVERSE SYSTEM HJ 241 HSRX 4 Refill the Reverse System with oil as described in Section 8 5 2 HSRX Controls Servicing Details Item No 3 Filling the HSRX System with Oil 5 Check the HSRX Rev...

Page 138: ...9 34 9 OVERHAUL 9 11 HSRX HYDRAULIC REVERSE SYSTEM HJ 241 HSRX...

Page 139: ...Supplementary Technical Information Appendix...

Page 140: ......

Page 141: ...205 pounds 1 tonne 2205 pounds Liquid Measure Imperial 1 Pint 0 5506 litre 1 gallon 4 546 litres 1 UK gallon 1 201 US gallon 1 litre 0 2199 UK gallons Liquid Measure U S 1 pint 0 473 litre 1 gallon 3...

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 148: ...ant between the base and the mounting surface has not squeezed out into the water passage Trim off any excess gasket and sealant 1 5 Check the Transom Plate Seal is correctly located and secured Do no...

Page 149: ...e not copper based 2 4 Check that the Inspection Hatch Seal is correctly located in the seal groove and that the Inspection Hatch securing bolts are tightened to the correct torque 2 5 Check that the...

Page 150: ...se angle and the number of Jets Refer to the Steering Drawings in the Product Manual 3 2 For manual hydraulic helms ensure that Correct steering ratio 1 to 2 turns of Helm from lock to lock Full lock...

Page 151: ...afts Refer to the Design Basics Section in the Product Manual check Yoke offset angles are in the same plane are equal and are 5 Yokes are in the same plane 4 3 On Bearing supported Line Shafts Refer...

Page 152: ...des have been fitted and that they have not been painted over Refer to Anode Location Drawing 1 4 If the Steering Assembly Tailpipe or Reverse Duct have been removed during jet installation check that...

Page 153: ...l resistance between the hull and the earth pin of the vessel shore power plug A correctly wired isolation transformer or galvanic isolator will result in high electrical resistance 1kohm between the...

Page 154: ...lied to the waterseal and marine bearing before running the Jet Unit 3 2 Ensure the vessel is securely moored fore and aft and in deep clean water 3 3 With the Reverse Controls set to Zero Speed the e...

Page 155: ...k that the Steering Controls are working by monitoring Steering Nozzle position while moving the Helm Check that port helm gives port Nozzle deflec tion starboard helm gives starboard Nozzle deflectio...

Page 156: ...ed by the Seals the Bearing Housing is likely to be warm The temperature should not exceed 80 C 4 5 If practical check the Driveshaft Coupling joint temperatures if fitted Increased joint temperature...

Page 157: ...letion of trials 5 2 For Steel Hulls check that the Jet Unit is insulated from the Hull The resist ance should be approximately 100 ohms but will vary depending on water salinity and hull characterist...

Page 158: ...t Project Number Vessel Displacement Jet Units Serial Number s Jet Model s Gearbox Ratio Impeller Rating Engine Power RPM Engine Model 6 1 Temperature Readings Driveshaft Joints Bearing Housing Hydrau...

Page 159: ...A 19 Appendix HJ 241 HSRX Comments...

Page 160: ...ption Task 1 Thrust Bearing Grease every 100 hours It is preferable that mainshaft is turning when adding grease 2 Hydraulic Power Unit Oil Level Check oil level Daily Change after first 10 to 50 hrs...

Page 161: ...Technical Drawings Drawings...

Page 162: ......

Page 163: ...W ALL DIMENSIONS IN mm UNLESS OTHERWISE SPECIFIED Ra STANDARD AND DRY RUN 0 2 JET CONTROL TYPE ANGULAR HJ241 JET P M W 11 01 2010 W SOLIDWORKS MODEL CREATED PARTS LIST AMENDED No WEIGHT CAST kg MACHI...

Page 164: ...2320 INSPECTION COVER 102320 A6 B6 C5 F1 21 201280 STUDS METRIC 316 STST M10x40 15 20 30637 A2 B2 22 201395 WASHERS SPRING METRIC ST ST 316 M10 N A A2 B2 23 201310 NUTS METRIC ST ST 316 M10 N A A1 B1...

Page 165: ...PICER 1510 1550 HJ24102001 E 1 110398 1 COUPLING HARDY SPICER 1510 1550 1510 1550 HARDY SPICER 110398 D 1 108594 1 COUPLING SCATRA AQUA DRIVE 14200 108594 C 1 108593 1 COUPLING HARDY SPICER 1400 10859...

Page 166: ...7 1 108545 108545 1 IMPELLER TYPE 7 5 108545 PART No QTY DESCRIPTION DWG No 109987 1 IMPELLER TYPE 5 0 108546 109986 1 IMPELLER TYPE 5 5 108546 109985 1 IMPELLER TYPE 5 8 108546 108546 1 IMPELLER TYP...

Page 167: ...8 A2 B2 C2 D2 F2 11 201161 BOLTS METRIC ST ST 316 M16x60 N A A2 B2 C2 D2 F2 12 108475 SLEEVE PIVOT 108475 A2 B2 C2 D2 F2 13 111451 STEPPED ADJUSTING WASHER 111451 A1 B1 C1 D1 E1 F1 14 109515 BUSH STEE...

Page 168: ...SERVICING DRAWINGS D 6 HJ 241 HSRX HJ 241 06 000 Steering Assembly General Arrangment Sht2...

Page 169: ...HJ 241 HSRX SERVICING DRAWINGS D 7 HJ 241 06 004 Blanking Plugs No Steering SPARES ASSY ITEM PART No QTY DESCRIPTION DWG No 4 1 108543 1 BLANKING PLUG 108543...

Page 170: ...SERVICING DRAWINGS D 8 HJ 241 HSRX HJ 241 07 001 Reverse Assembly Sht1...

Page 171: ...R N A B1 D1 22 112235 BACKHEAD H S R X Mk3 HDM8724 112235 A6 F4 23 201309 NUTS METRIC ST ST 316 M8 N A B1 C1 D1 24 065222 12x4 5 Viton O ring N A B1 D1 25 201466 SKF BEARING 6301 N A B1 26 108553 CABL...

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 174: ...TST M10x51 30637 C 4 JDQHXAC 12 NUTS METRIC ST ST 316 M8 N A C 5 JEQKXAC 12 WASHERS SPRING METRIC ST ST 316 M8 N A C 6 JEOZXAF 12 WASHERS FLAT METRIC ST ST 316 M8x16x1 2 N A B 7 JMNGAAR 1 NEUT CURE RT...

Page 175: ...provided on a restricted basis and is not to be used JET ECN BY AMENDMENT DATE Designed Reviewed Certified Name Approvals Standard MATERIAL Cast M C Date Weight kg DWG No N9 EXCEPT AS STATED UNLIMITED...

Page 176: ...is provided on a restricted basis and is not to be used JET ECN BY AMENDMENT DATE Designed Reviewed Certified Name Approvals Standard MATERIAL Cast M C Date Weight kg DWG No N9 EXCEPT AS STATED UNLIMI...

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 184: ...03 A 1 63526 063526 1 MORSE CONTROLLER SINGLE S CTCLV01003 A2 B4 3 203089 4 SCREWS CAP SCREWS IMPERIAL ST ST 304 3 16 UNFx3 4 BUTTON HEAD N A A B 4 63529 063529 1 LABELS UP J DOWN CTCLV01003 A1 B2 5 1...

Page 185: ...JMNGAAY 1 4 SPOKE MORSE C0856 N A A B 2 JMNGAAX 1 BEZEL 90 DEG BLACK MORSE 292842 N A A B 3 JMNGAAW 1 MORSE D0290 SINGLE HELM ASSEMBLY N A A B 4 CABLE 1 CABLE MORSE D0345 CUSTOMER SPECIFIED LENGTH REQ...

Page 186: ...XAN 201280 STUDS METRIC 316 STST M10x40 15 20 30637 A6 7 JEQKXAE 201395 WASHERS SPRING METRIC ST ST 316 M10 N A A6 8 JDQHXAE 201310 NUTS METRIC ST ST 316 M10 N A A1 9 HZQHXBN 201226 SCREWS M C SCREWS...

Page 187: ...HJ 241 HSRX SERVICING DRAWINGS D 25 CT HSE 12 001 Hose Kits...

Page 188: ...SRX CT HSE 12 001 Hose Kits Near End Far End L actual hose length Displacement Angle the angle clockwise to describe the displacement Starting with either end as the near end measure Specified only if...

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 191: ...HJ 241 HSRX SERVICING DRAWINGS D 29 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 1...

Page 192: ...SERVICING DRAWINGS D 30 HJ 241 HSRX 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 2...

Page 193: ...HJ 241 HSRX SERVICING DRAWINGS D 31 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 3...

Page 194: ...SERVICING DRAWINGS D 32 HJ 241 HSRX 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 4...

Page 195: ...206 Impeller Blade Dressing Instructions and Balancng Information Sht 5 Region Dimension Table Jet Dim X Dim Y Dim Z HM422 44 23 31 HM461 48 25 34 HM521 54 29 39 HM571 59 31 42 HM651 68 36 48 HM721 75...

Page 196: ...HYSPIN AWX MULTIGRADE Moble DTE 25 B P HLP HM46 HJ364 HM422 HM461 HM521 HM571 HJ403 HJ364 HJ213 HJ274 HJ292 HJ322 HJ403 HJ241 HM461 HM521 HM571 Hydraulic Systems with Saginaw HPU fluid Fluids meeting...

Page 197: ...HJ 241 HSRX SERVICING DRAWINGS D 35 85080 Aluminium Weld Procedure for Hamilton Jet Installation or Repair...

Page 198: ...orque for the fastener 4 5 N m 9 24 12 18 lbs ft M6 SIZE M10 M8 45 33 M12 NUTS ON 316 ST STL COTTER PINS 11 5 19 8 14 4 5 16 UNC 1 4 UNC 3 8 UNC 89 45 160 66 120 31 5 8 UNC 1 2 UNC 3 4 UNC METRIC IMPE...

Page 199: ...AINLESS THREADS ON MILD STEEL 184 250 M24 X 3 1 1 2 3 4 48 118 96 160 65 130 1 4 3 8 SIZE 1 8 lbs ft 33 35 45 26 N m 9 7 HYDRAULIC FITTING TORQUES FITTINGS EXCEPT IN JET CASTINGS BSPP HYDRAULIC FITTIN...

Page 200: ...SERVICING DRAWINGS D 38 HJ 241 HSRX 85114 Earth Bonding System Recommendations and layout...

Page 201: ...Notes...

Page 202: ...9 Christchurch New Zealand Phone 64 3 962 0530 Fax 64 3 348 6969 E Mail marketing hamjet co nz Web www hamiltonjet co nz European Office Hamilton Jet U K Ltd Unit 4a The Birches Industrial Estate East...

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