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7.4

7 FAULT FINDING

7.2 R

EVERSE

YSTEM

AULTS

HJ-241 / HSRX

7.2 REVERSE SYSTEM FAULTS

Table 6: Reverse System Faults

SYMPTOMS

POSSIBLE CAUSE

SOLUTION

REFER

Reverse Duct is not moving.

Reverse Duct jammed by debris.

Remove debris and then check for correct
operation.

Sect. 9.2.2

Reverse Duct does not go fully down or stay down with high engine RPM.

Back pressure too low.

If the Back Pressure Valve is suspected of
being faulty, it should be removed from the
Reverse Cylinder and returned to a
Hydraulics facility where the Valve can be
checked. The pressure should be 500psi
(34 Bar) at a flow of 9 litres per minute.

Sect. 9.2.4
and Draw-
ing HJ-
241-07-
001 Reverse
Assembly
Sht1

Reverse Duct will not lift out of Reverse with high Engine RPM. Relief Valve Blowing.

Back pressure too high.

As Above.

As Above.

Reverse Duct not synchronised with the Reverse Lever.

Cylinder Rod 180º out of phase.

Rotate Cylinder Rod so that the dot on the
Rod End is uppermost. Also refer to the
Overhaul Section of the Jet Unit Manual).

Sect. 9.2.4.

Excessive heat build-up in the Hydraulic System.

HSRX Lever not touching the Stop Pin

Adjust HSRX Lever

Sect. 5.8.3

Reverse Duct does not move.

• Cannot move the Controller.

Jammed Cable.

• Controller moves freely. Broken Ca-

ble.

Hydraulic Failure:
can be caused by:

Broken Pump Belts.
Belts slipping.
Blockage in the system.
Run out of oil.

Split Hose.

Jammed Cylinder:
can be caused by:

Bent Reverse Cylinder Rod.

Free or replace the Cable.

Replace the Cable.

Replace Belts.
Adjust Belt tension.
Dismantle and clean the system.
Refill the Reservoir and purge the system.
Replace Hose.

Replace the Reverse Cylinder Rod.

Sect. 5.8

Sect. 9.2.1

Sect. 8.5.2

HJ-241-02-
001 Cou-
plings and
Belts .
CT-HSE-
12-001
Hose Kits .

Содержание HJ241

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 16: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 34: ......

Страница 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...

Страница 36: ...3 2 3 DESIGN BASICS 3 2 HULL DESIGN HJ 241 HSRX Figure 9 Loads on the Hull for HJ 241 Jet Unit...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 76: ...6 4 6 COMMISSIONING 6 5 AFTER INITIAL TRIALS AFTER ENGINE SHUT DOWN HJ 241 HSRX...

Страница 77: ...Fault Finding Maintenance Overhaul Part C Servicing Information...

Страница 78: ...HM 811...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 139: ...Supplementary Technical Information Appendix...

Страница 140: ......

Страница 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...

Страница 142: ...A 2 Appendix HJ 241 HSRX A 2 Loctite Application Guide...

Страница 143: ...A 3 Appendix HJ 241 HSRX...

Страница 144: ...A 4 Appendix HJ 241 HSRX...

Страница 145: ...A 5 Appendix HJ 241 HSRX...

Страница 146: ...A 6 Appendix HJ 241 HSRX...

Страница 147: ...A 7 Appendix HJ 241 HSRX...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 161: ...Technical Drawings Drawings...

Страница 162: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 172: ...SERVICING DRAWINGS D 10 HJ 241 HSRX HJ 241 07 002 Blanking Plus No Reverse...

Страница 173: ...HJ 241 HSRX SERVICING DRAWINGS D 11 HJ 241 08 001 Installation Details GRP Hull...

Страница 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...

Страница 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...

Страница 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...

Страница 177: ...HJ 241 HSRX SERVICING DRAWINGS D 15 HJ 241 09 001 Blanking Plugs For Screen Rake...

Страница 178: ...SERVICING DRAWINGS D 16 HJ 241 HSRX HJ 241 09 002 Screen Rake Assembly...

Страница 179: ...HJ 241 HSRX SERVICING DRAWINGS D 17 HJ 241 10 004 Hatch Extension...

Страница 180: ...SERVICING DRAWINGS D 18 HJ 241 HSRX HJ 241 11 000 Tool Kit...

Страница 181: ...HJ 241 HSRX SERVICING DRAWINGS D 19 HJ 241 12 000 Sandtrap engine Cooling...

Страница 182: ...SERVICING DRAWINGS D 20 HJ 241 HSRX HJ 241 13 002 Anode Locations...

Страница 183: ...HJ 241 HSRX SERVICING DRAWINGS D 21 HJ 241 30 001 General Arrangement...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 189: ...HJ 241 HSRX SERVICING DRAWINGS D 27 CT SJK 02 005 Steering Cylinder Seastar...

Страница 190: ...SERVICING DRAWINGS D 28 HJ 241 HSRX 61483 Rotary Seal...

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

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 201: ...Notes...

Страница 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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