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Hamilton Jet HJ241 Manual

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The 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 revision D
• _Reference to Loctite 222 added to section 9.3.2
• _Reverse System Faults item 5 Section 7.2 corrected
• _
• _
• _
• _
Product Manual Change Summary
Manual Type
Part Number
Revision
Amendment
HJ241
089241
R3
30/11/03
A31
31/01/11

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Summary of Contents for Hamilton Jet HJ241

  • Page 1 Product Manual Change Summary Manual Type HJ241 Part Number 089241 Revision 30/11/03 Amendment 31/01/11 The 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 •...
  • Page 2 4 Ring white binder  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 Hamilton jet) ...
  • Page 3 Installation and Service Manual HJ241 Jet Unit Manual R3A31...
  • Page 4 CWF Hamilton & Co Ltd. Due to our policy of continuous development, specifications in this manual are subject to change without notice or obligation Manual Type HJ241 Part Number 089241 Revision 30/11/03...

  • Page 5: Table Of Contents

    HJ-241 / HSRX INTRODUCTION ONTENTS ONTENTS Contents ..................v Warnings & Cautions ..............ix Introduction Limited Warranty ............... xi 1 Introduction & Product Description....... 1.1 Part A Operator Information 1.1 THE HAMILTON WATER JET SYSTEM............1.1 1.1.1 Introduction ..................1.1 1.1.2 Main Components ................1.2 1.2 THE HAMILTON HSRX REVERSE SYSTEM..........
  • Page 6 HJ-241 / HSRX INTRODUCTION ONTENTS 3.8.2 Corrosion ..................3.17 3.8.3 Scope of Use ................. 3.17 3.8.4 Fault Finding ................. 3.18 3.8.5 Maintenance ................. 3.18 3.8.6 Parts List ..................3.19 4 Precautions Against Corrosion ........4.1 4.1 GENERAL ....................4.1 4.1.1 Electrical Wiring System ..............4.1 4.1.2 Earth Bonding System ..............

  • Page 7: Contents

    HJ-241 / HSRX INTRODUCTION ONTENTS 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 .................
  • Page 8 HJ-241 / HSRX INTRODUCTION ONTENTS 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 viii...

  • Page 9: Warnings & Cautions

    INTRODUCTION HJ-241 / HSRX General Safety Notice Warnings & Cautions A Warning: is an operation or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in injury or death to personnel. This is indicated throughout the Manual as below. ARNING A Caution: is an operation or maintenance procedure, practice condition or statement which, if not strictly observed, could result in damage to, or destruction of equipment...
  • Page 10 INTRODUCTION HJ-241 / HSRX...

  • Page 11: Limited Warranty

    Product is free from defects in material and workmanship under normal use and service for the Warranty Period. • In the event that a warranted defect in material or workmanship is disclosed to Hamilton Jet within the Warranty Period, Hamilton Jet's obligation is limited to, at its option, repairing or replacing the defective Product, or component part at its factory or such other location as may be designated by Hamilton Jet.
  • Page 12 • Any repairs or alterations carried out with the use of parts or accessories not manufactured by Hamilton Jet or its authorised representatives. • Items incorporated in any Hamilton Jet Product (other than by Hamilton Jet) when such items have been manufactured by others or are warranted by their respective manufacturers in favour of the purchaser.
  • Page 13 Fax +64 3 348 6969 Hamilton Jet encourages the Distributor to take responsibility for ensuring the Purchaser and the Distributor complete this form at the time of sale and return it to Hamilton Jet. Please complete one form per vessel only. Hamilton Jet...
  • Page 14 HJ-241 / HSRX INTRODUCTION...

  • Page 15: Part A

    Part A Operator Information • Introduction and Product Description • System Operation...

  • Page 17: Introduction & Product Description

    5 to 50 meters in length. acceleration, shallow draft, unrivalled Hamilton Jet is dedicated to the production of the manoeuvrability and smooth, quiet operation. highest quality waterjets and controls systems Whilst conventional propeller powered craft have...

  • Page 18: Main Components

    Jet Unit speeds up to 50 knots. HJ Series waterjets are and is an integral part of the Hamilton Jet design. generally directly driven by high speed diesel The Intake is cast from high silicon aluminium alloy engines.
  • Page 19 Reverse periods with water lubrication. Cylinder. The ahead / astern function of the Reverse Duct is an integral part of the Hamilton Jet package. The split deflector type Reverse Duct is designed to provide maximum astern thrust under all conditions of vessel speed, water depth and throttle setting.
  • Page 20 1 INTRODUCTION & PRODUCT DESCRIPTION HJ-241 / HSRX 1.1 T AMILTON ATER YSTEM 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. Figure 1: HJ-241 Jet Unit General Arrangement...

  • Page 21: The Hamilton Hsrx Reverse System

    HJ-241 / HSRX 1 INTRODUCTION & PRODUCT DESCRIPTION 1.2 T HSRX R AMILTON EVERSE YSTEM 1.2 THE HAMILTON HSRX With the Piston restriction (A) fully open, equal pressure acts on both the rod end and cap end of the REVERSE SYSTEM HSRX Cylinder.

  • Page 22: General Assembly Drawings

    1 INTRODUCTION & PRODUCT DESCRIPTION HJ-241 / HSRX 1.3 G ENERAL SSEMBLY RAWINGS...

  • Page 23: System Operation

    Section 2 YSTEM PERATION 2.1 STARTING UP 2.2 “AHEAD” / “ZERO SPEED” / “ASTERN” CONTROLS Never stop the engine(s), or disengage the drive to the Jet Unit, Selecting ’Astern’ (Crash Stop) when approaching a mooring or at while the vessel is moving ahead any time when control of the at high speed can produce very AUTION...

  • Page 24: Steering

    4. Steering is available at "Zero Speed" as well as all ahead and astern speeds - a feature which gives the Hamilton Jet unrivalled manoeuvrability. When moving ahead at "Zero Speed", or astern, the bow of the vessel will always turn the way the steering wheel is turned.

  • Page 25: Total Hydraulic Failure

    2 SYSTEM OPERATION HJ-241 / HSRX 2.3 S TEERING This means that going astern the vessel has the EMERGENCY MANOEUVERING AND DOCKING:— opposite steering to a motor car, a feature which 1. With a Single Jet Unit. The vessel can be partially can be used to advantage when manoeuvring.

  • Page 26: Manoeuvering And Docking

    2 SYSTEM OPERATION HJ-241 / HSRX 2.4 M ANOEUVERING AND OCKING 2.4 MANOEUVERING AND 2.4.2 Moving Sideways DOCKING WITH TWIN JETS:—Use the following procedure to move the vessel sideways away from the jetty. 2.4.1 Low Speed Manoeuvering Initially both controls are at "ZERO SPEED" and the and Docking vessel is stationary.
  • Page 27 2 SYSTEM OPERATION HJ-241 / HSRX 2.4 M ANOEUVERING AND OCKING 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. This method of sideways manoeuvring should result in 33% more side thrust than if only two Jets were used.

  • Page 28: Cruising

    2 SYSTEM OPERATION HJ-241 / HSRX 2.5 C RUISING 2.5 CRUISING Running at speed with a partially blocked inlet grill or debris on the impeller will result in cavitation damage to the jet unit. AUTION Figure 6: High Speed Planing in Shallow Water Care must be taken to prevent cavitation damage 2.

  • Page 29: Acceleration To High Speed

    2 SYSTEM OPERATION HJ-241 / HSRX 2.7 A CCELERATION TO PEED 2.7 ACCELERATION TO HIGH 2.9 BLOCKAGES (DEBRIS IN THE SPEED JET UNIT) If leaving an area of shallows, or with debris in the 2.9.1 Avoiding Blockages water, ensure Jets are clear of debris before accelerating to high speed.

  • Page 30: Using The Inspection Cover

    2 SYSTEM OPERATION HJ-241 / HSRX 2.10 O PERATING WITH AN NGINE AND NIT OUT OF ERVICE blockage. If this fails to work, repeat actions NOTE: Refer to Drawings HJ-241-10-004 Hatch a) to c) several times. Extension. The Inspection Hatch Extension is an optional extra 3.

  • Page 31: Hsrx Reverse System

    2 SYSTEM OPERATION HJ-241 / HSRX 2.11 HSRX R EVERSE YSTEM 2.11 HSRX REVERSE SYSTEM If in lightweight planing craft, the “Astern” or “Zero Speed” posi- Use of a Waterjet steered vessel is tions are selected with the throttle different from a propeller driven left open and the boat moving for- AUTION vessel as the waterjet mainshaft...
  • Page 32 2 SYSTEM OPERATION HJ-241 / HSRX 2.11 HSRX R EVERSE YSTEM 2.10...
  • Page 33 Part B Design and Installation Information • Design Basics • Precautions Against Corrosion • Installation • Commissioning...

  • Page 35: Part B 3 Design Basics

    Section 3 ESIGN ASICS 3.1 PROPULSION SYSTEM While the Jet Unit loads can be readily calculated, the Hull reaction loads are statically indeterminate. DESIGN Being dependent on the stiffness and rigidity of both the Jet Unit and the Hull structure. JET UNIT SELECTION:—Jet Unit selection is a All loads are transferred to the Hull via the intake complex task and C.W.F.
  • Page 36 3 DESIGN BASICS HJ-241 / HSRX 3.2 H ESIGN Figure 9: Loads on the Hull for HJ-241 Jet Unit...
  • Page 37 HJ-241 / HSRX 3 DESIGN BASICS 3.2 H ESIGN Table 1: Table of Dimensions for HJ-241 Jet Unit HJ-241 JET - RELEVANT DATA ESCRIPTION YMBOL NITS ALUE Maximum Power Centre Line Height 0.284 Mean Inlet Depth 0.04 Steering to Base Centre 0.92 Reverse to Base Centre 1.25...

  • Page 38: Mono Hulled Vessel

    3 DESIGN BASICS HJ-241 / HSRX 3.2 H ESIGN 3.2.2 Mono Hulled Vessel normally sufficient. These do not increase draft or interfere with water flow into the Jet Intake. 1. Aerated water generated by the vessel’s bow 4. Immersion. The Jet must be immersed with the wave must not pass directly aft to the Jet Unit water line at least up to the underside of the Intake(s).

  • Page 39: Multi Hulled Vessel

    HJ-241 / HSRX 3 DESIGN BASICS 3.2 H ESIGN "B" "A" "A" MINIMUM JET CENTERS AT TRANSOM JETS MOUNT FLAT TO HULL AT ALL DEADRISE ANGLES Figure 11: Installation for Multiple Jets 3.2.3 Multi Hulled Vessel ure 12: Hull Design Recommendations for Multi Hull Vessel below.

  • Page 40: Trim Tabs

    3 DESIGN BASICS HJ-241 / HSRX 3.2 H ESIGN 3.2.4 Trim Tabs The adjacent diagram serves as a guide to the maximum size of trim tab that may be located under the Jet Unit. Contact C.W.F Hamilton & Co Ltd if NOTE: Refer to “Precations Against Corrosion”...

  • Page 41: Drivelines

    HJ-241 / HSRX 3 DESIGN BASICS 3.3 D RIVELINES 3.3 DRIVELINES 3.3.1 Requirement of the Driveline 1. The Driveline must accommodate parallel and angular misalignment plus allow axial Loads on Jet Unit Thrust movement. Bearing 2. The Driveline must transmit the torque input to the Jet Unit with an acceptable life expectancy.

  • Page 42: Drive Shaft Options

    3 DESIGN BASICS HJ-241 / HSRX 3.3 D RIVELINES 3.3.3 Drive Shaft Options TORSIONALLY FLEXIBLE COUPLING (TFC): The torsional vibration analysis will determine how The diagrams Figure 15: Double Universal Slip joint- many TFC’s are required and where they should be ed Driveshaft Figure 16: Torsionally Flexible Fly- located.

  • Page 43: Universal Driveshaft Alignment

    HJ-241 / HSRX 3 DESIGN BASICS 3.3 D RIVELINES The curved face teeth couplings are flexible enough Lineshaft supported on pedestal bearings should be to compensate for misalignments and axial used in conjunction with either universal driveshafts movements of coupled shafts. The same type of or torsionally flexible couplings.
  • Page 44 3 DESIGN BASICS HJ-241 / HSRX 3.3 D RIVELINES Figure 19: Z Configuration Coupling Figure 20: W Configuration Coupling 3.10...

  • Page 45: Jet Coupling Flange Details

    HJ-241 / HSRX 3 DESIGN BASICS 3.3 D RIVELINES 3.3.5 Jet Coupling Flange Details 3.3.7 Critical Speed of Mainshaft Refer to Drawing HJ-241-02-001 Couplings and NOTE: Belts, for all relevant Coupling details. 1. In all cases, for the calculation of the "Critical Speed of the Jet Mainshaft"...

  • Page 46: Jet Mainshaft Alignment

    3 DESIGN BASICS HJ-241 / HSRX 3.4 J AINSHAFT LIGNMENT 3.4 JET MAINSHAFT ALIGNMENT table lists the angle deviation of the Jet Mainshaft when the Jet base is mounted parallel to the keel line. (PORT & STARBOARD JETS ONLY). The HJ 241 Waterjet Mainshaft is inclined at an FOR INTAKE BASE PARALLEL TO KEEL LINE: angle of 5º...

  • Page 47: Water Off-Take

    HJ-241 / HSRX 3 DESIGN BASICS 3.5 W ATER 3.5 WATER OFF-TAKE SANDTRAP:—- (Optional Raw Water Sand Filter). Refer to Drawing HJ-241-12-000 Sandtrap & en- gine Cooling. If a gearbox or clutch is fitted to High pressure water from the Jet is piped into the the engine, a conventional hull sand trap before feeding into the engine cooling water pick-up and engine raw...

  • Page 48: Hsrx Reverse System Description

    3 DESIGN BASICS HJ-241 / HSRX 3.6 HSRX R EVERSE YSTEM ESCRIPTION 3.6 HSRX REVERSE SYSTEM The Pump Assembly comprises, Pump, an Integral Tank, Flow Control and Pressure Relief Valves. DESCRIPTION The Hamilton HSRX Reverse System is a self 3.6.1 Basic Hydraylic Circuit contained Hydraulic Reverse Actuation System.

  • Page 49: Layout Of Components

    HJ-241 / HSRX 3 DESIGN BASICS 3.7 E & M NGINE OCATION OUNTING 3.6.2 Layout of Components 3.7 ENGINE LOCATION & MOUNTING Refer to Drawing CT-HPU-01001 Hydraulic Power Unit. 3.7.1 General 3.6.3 Scope of Supply The engine(s) should be located in a position that will give the vessel the most suitable fore and aft THE FOLLOWING LIST OF ITEMS ARE SUPPLIED trim for the proposed boat speed.

  • Page 50: Engine Systems

    3 DESIGN BASICS HJ-241 / HSRX 3.7 E & M NGINE OCATION OUNTING be directly ahead of the Jet Unit intakes and should be well to the side of the area forward and the same If a gearbox or clutch is fitted to width as the intake opening.

  • Page 51: Description Of The Dry Run System (Optional Extra)

    Marine Bearing will heat up rapidly. NOTE: Hamilton Jet Units are not fitted with the Dry Run Kit as a standard fit. The Dry Run Kit THE FOLLOWING LIMITS MUST BE ADHERED TO, is an optional extra which can be fitted to the TO ENSURE GOOD COMPONENT LIFE.

  • Page 52: Fault Finding

    3 DESIGN BASICS HJ-241 / HSRX 3.8 D ESCRIPTION OF THE YSTEM PTIONAL XTRA 3.8.4 Fault Finding Table 4: Fault Finding FAULT CAUSE REMEDY Bearing jambs up when dry Excessive heat buildup. Run in water to cool. running Leave overnight to cool. May have grit in bearing Flush out with clean water.

  • Page 53: Parts List

    HJ-241 / HSRX 3 DESIGN BASICS 3.8 D ESCRIPTION OF THE YSTEM PTIONAL XTRA 3.8.6 Parts List Refer to Drawings HJ-241-01-000 Basic Jet Assem- blies Standard and Dry Run Sht 1 & 2. DRY RUN BEARING ASSEMBLY BEARING SLEEVE ROTARY SEAL ASSEMBLY Figure 26: Dry Run Bearing Assembly 3.19...
  • Page 54 3 DESIGN BASICS HJ-241 / HSRX 3.8 D ESCRIPTION OF THE YSTEM PTIONAL XTRA 3.20...
  • Page 55 Section 4 RECAUTIONS GAINST ORROSION 4.1 General conductor. In This Situation, It is Important to Connect the Engine Block to the Battery Negative with a Heavy Battery Cable. 4.1.1 Electrical Wiring System In installations with two engines and two battery banks with cross-connect starting capability, there An Isolation Transformer or a must be two heavy conductors between the...

  • Page 56: Precautions Against Corrosion

    Only one side of the secondary winding Prevention of corrosion is grounded on the secondary side of the Vessels using Hamilton Jet Units, transformer and the vessel’s grounding circuit is tied must be bonded and wired as in at this point. There must be no DC electrical...

  • Page 57: Corrosion Monitor

    4 PRECAUTIONS AGAINST CORROSION HJ-241 / HSRX 4.1 G ENERAL have a direct path back to the battery negative or the or electrically isolated from the jet unit, or prefera- AC source. bly both. Normally an anode would be fitted to the trim tab to provide corrosion protection to the tab.

  • Page 58: Anodes

    HJ-241 / HSRX 4 PRECAUTIONS AGAINST CORROSION 4.1 G ENERAL 4.1.6 Anodes The Hull anodes should remain immersed at all times. Anodes should not be painted over as they will not function as intended. If the anodes are being eaten NOTE: Anodes fitted on the Transom of a away they are providing protection.

  • Page 59: Earth Bonding System - (Not Normally Current Conducting)

    4 PRECAUTIONS AGAINST CORROSION HJ-241 / HSRX 4.2 E - (N ARTH ONDING YSTEM ORMALLY URRENT ONDUCTING feature which prevents the potential falling below - 4. Every part of the vessel electrical system should 1100mV referenced to a silver / silver chloride have Two wires to it, a positive and a negative reference electrode.Aluminium, G.R.P.
  • Page 60 HJ-241 / HSRX 4 PRECAUTIONS AGAINST CORROSION 4.3 E ARTH ONDING YSTEM ORMALLY URRENT ONDUCTING...

  • Page 61: Installation

    Weld the Intake Block into the Hull using the weld prcedure shown on Drawing Ensure that the engine cooling 85080 Aluminium Weld Procedure for Hamilton Jet water pick up is not directly Installation or Repair. Ensure that the contours...

  • Page 62: Hull Preparation

    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 In Multi Jet Unit installations, Block, at front and rear, are smooth to within 1 mm.

  • Page 63: Transom Preparation

    5 INSTALLATION HJ-241 / HSRX 5.3 E QUIPMENT REPARATION 5.3 EQUIPMENT PREPARATION 9. Smear RTV Sealant [7] on the top of the Gasket [17] and run a bead of RTV Sealant around the Do not unpack the Jet Unit until it is required for internal corner of the prepared recess.

  • Page 64: Removal Of Other Parts

    5 INSTALLATION HJ-241 / HSRX 5.4 M OUNTING THE 5.3.3 Removal of Other Parts 5.4 MOUNTING THE JET UNIT The Jet Unit is shipped with the Controls System fitted. Should it be necessary to remove the Controls In Multi Jet Unit installations, System, refer to the Controls Manual supplied, for each Jet Unit may have been details on the fitting and removal procedures.

  • Page 65: Mounting The Jet Unit To The Hull

    5 INSTALLATION HJ-241 / HSRX 5.4 M OUNTING THE 5.4.1 Mounting the Jet Unit to the 5.4.2 Assembly of the Transom Plate Hull to the Hull G.R.P Hulls; HJ-241-08-001 Installation Details 1. Ensure that the Reverse Duct has been removed GRP Hull.

  • Page 66: Final Assembly

    5 INSTALLATION HJ-241 / HSRX 5.5 F INAL SSEMBLY 5.5 FINAL ASSEMBLY hole may be used to reduce the helm load if necessary. Refer to Drawings HJ-241-01-000 Basic Jet Assem- blies Standard and Dry Run Sht 1 & 2. 5.5.4 Assembling the Jet Steering Tillers 5.5.1 Reverse Cylinder Fitting The Jet Tiller as supplied, is pre-drilled for...

  • Page 67: Centering The Jet(S) Steering

    5 INSTALLATION HJ-241 / HSRX 5.6 D RIVELINE AND NGINE NSTALLATION 5.6 DRIVELINE AND ENGINE Two swivel ended Tie Rods are used to interconnect from the “Adjustable Tiller” fitted to the Center Jet to INSTALLATION “Adjustable Tillers” fitted to the outer Jets. 5.5.5 Centering the Jet(s) Steering GENERAL: The engine(s) should be located in a position that...

  • Page 68: Engine Cooling

    5 INSTALLATION HJ-241 / HSRX 5.6 D RIVELINE AND NGINE NSTALLATION 5.6.2 Engine Cooling 5.6.3 Engine Systems Refer to Section 3.7.4 Engine Systems. If a gearbox or clutch is fitted to 5.6.4 Exhaust Systems the engine, a conventional hull water pick-up and engine raw Refer to Section 3.7.4 Engine Systems.

  • Page 69: Installation Checks For The Jet Unit

    5 INSTALLATION HJ-241 / HSRX 5.7 I NSTALLATION HECKS FOR THE 5.7 INSTALLATION CHECKS FOR JET UNIT: GENERAL: 1. Ensure that the Impeller is fitted to match the THE JET UNIT engine rating. The Impeller part number (Stamped on the Impeller Hub) can be viewed JET UNIT: MOUNTING: through the Main Inspection Cover.

  • Page 70: Installing The Hsrx Reverse System

    5 INSTALLATION HJ-241 / HSRX 5.8 I HSRX R NSTALLING THE EVERSE YSTEM 5.8 INSTALLING THE HSRX 3. Ensure that the dot on the end of the Reverse Shaft Assembly is positioned uppermost. If the REVERSE SYSTEM Shaft Assembly is 180° out of position, with the Cylinder correctly mounted, the HSRX Reverse Refer to Drawings HJ-241-07-001 Reverse Assem-...

  • Page 71: Reverse Control Lever Adjustment

    5 INSTALLATION HJ-241 / HSRX 5.8 I HSRX R NSTALLING THE EVERSE YSTEM 5.8.3 Reverse Control Lever Adjustment Refer to Drawings HJ-241-07-001 Reverse Assem- bly Sht1 & 2 1. With the Reverse Control Lever in the full ahead position, the HSRX Lever should be touching the Stop Pin.
  • Page 72 5 INSTALLATION HJ-241 / HSRX 5.8 I HSRX R NSTALLING THE EVERSE YSTEM 5.12...

  • Page 73: Commissioning

    Section 6 OMMISSIONING 6.2 POST LAUNCH CHECKS This information is intended for use by CWF Hamilton representatives. Refer to the Controls Perform the following procedures before the System manual for details of commissioning engines are started. checks specific to the controls system. 1.

  • Page 74: Engine Running Checks (Vessel Moored)

    6 COMMISSIONING HJ-241 / HSRX 6.3 E NGINE UNNING HECKS ESSEL OORED 6.3 ENGINE RUNNING CHECKS 13.Move the Reverse Control Lever slowly to fully lower and raise the Reverse Duct several times. (VESSEL MOORED) This will purge the hydraulic system of air. 1.

  • Page 75: Vessel Speed And Handling Trials

    6 COMMISSIONING HJ-241 / HSRX 6.4 V ESSEL PEED AND ANDLING RIALS 6.4 VESSEL SPEED AND 6.5 AFTER INITIAL TRIALS (AFTER HANDLING TRIALS ENGINE SHUT DOWN) 1. Refer to Section 8.4“Servicing Intervals” for any after trials maintenance that may be required. If a problem is detected, return to 2.
  • Page 76 6 COMMISSIONING HJ-241 / HSRX 6.5 A FTER NITIAL RIALS FTER NGINE...

  • Page 77: Part C 7 Fault Finding

    Part C Servicing Information • Fault Finding • Maintenance • Overhaul...
  • Page 78 HM-811...

  • Page 79: Jet Unit Faults

    Section 7 AULT INDING HOW TO USE THIS FAULT FINDING TABLE: 3. Use the “REFER” column for more information on each solution. 1. Look for a symptom that is similar to what you have noticed. 4. Try the easiest (first) solution first. 2.
  • Page 80 7 FAULT FINDING HJ-241 / HSRX 7.1 J AULTS Table 5: Jet Unit Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Excessive high pitched rattling, or rattling whine coming from the Jet Unit. Blockage of the Jet Unit. The Blockage must be removed. Sect.
  • Page 81 HJ-241 / HSRX 7 FAULT FINDING 7.1 J AULTS Table 5: Jet Unit Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Low Engine RPM. Problem with engine. Investigate the operation of the engine Refer to engine man- ufacturers manual. Incorrect Impeller and Nozzle selec- Contact C.W.F.

  • Page 82: Reverse System Faults

    7 FAULT FINDING HJ-241 / HSRX 7.2 R EVERSE YSTEM AULTS 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 Sect.
  • Page 83 HJ-241 / HSRX 7 FAULT FINDING 7.2 R EVERSE YSTEM AULTS Table 6: Reverse System Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Reverse Duct creeping down from the up position Reverse Cylinder Seal Failure. Overhaul Reverse Cylinder. Sect. 9.2.4 Suspect Seals Are: HJ-241- Oil Seal [17] 07-001...
  • Page 84 7 FAULT FINDING HJ-241 / HSRX 7.2 R EVERSE YSTEM AULTS Table 6: Reverse System Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Reverse Cylinder: Water Leaking in around the Front Head [15]. Reverse Cylinder Seal failure:Suspect Overhaul the Reverse Cylinder. Sect. 9.2.4 Seals are:- Resilient Mounts [14.1] and [14.2].
  • Page 85 HJ-241 / HSRX 7 FAULT FINDING 7.2 R EVERSE YSTEM AULTS Table 6: Reverse System Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Reverse Controller (Only for HSRX Controls fitted with “Neutral Detent and Engine Start Interlock”). Engine can be started with either “For- Adjust the “Neutral Detent and Engine ward”...

  • Page 86: Steering System Faults

    7 FAULT FINDING HJ-241 / HSRX 7.3 S TEERING YSTEM AULTS 7.3 STEERING SYSTEM FAULTS Table 7: Steering System Faults SYMPTOMS POSSIBLE CAUSE SOLUTION REFER Steering stiff at the Helm Grit jamming Nozzle. Work Nozzle from side to side to release Sect.

  • Page 87: Maintenance

    Section 8 AINTENANCE 8.1 GENERAL 8.2 PRESERVATION: (PRE- INSTALLATION) This Jet Unit has been designed to require the absolute minimum of maintenance. However it is recommended that the Jet Unit be regularly NEW JET PRESERVATION:—The following storage examined for the wear of the Bearings, Seals and requirements must be provided to ensure that no Bushes, etc and checked for corrosion anually as a damage or deterioration occurs:...

  • Page 88: Preservation: (Post-Installation)

    8 MAINTENANCE HJ-241 / HSRX 8.3 P : (P RESERVATION NSTALLATION 8.3 PRESERVATION: (POST- INSTALLATION) Before moving any controls, ensure that any marine growth is removed from the Steering and Reverse Linkage Rods. This will Do not run the jet unit out of the AUTION prevent damage to the Seals that water unless it is fitted with a Dry...

  • Page 89: Servicing Intervals

    HJ-241 / HSRX 8 MAINTENANCE 8.4 S ERVICING NTERVALS 8.4 SERVICING INTERVALS • Complete Jet Unit inspection at 5000 hours (Refer to Section Sect.“8.5.1/17). Please note the following points: 3. Refer to Section 8.5.2 HSRX Controls Servicing 1. Vessel usage is assumed to be 2000 operational Details for servicing of the Control System.

  • Page 90: Servicing Intervals (Hydraulic Reverse System)

    8 MAINTENANCE HJ-241 / HSRX 8.4 S ERVICING NTERVALS 8.4.2 Servicing Intervals (Hydraulic operating conditions. For details, refer to the appropriate section referred to. Reverse System) • Hydraulic Oil change at 1000 hours may be Please note the following points: varied to suit conditions.

  • Page 91: Daily "Pre Use" Servicing Checks

    HJ-241 / HSRX 8 MAINTENANCE 8.4 S ERVICING NTERVALS 8.4.3 Daily “Pre Use” Servicing Checks THE FOLLOWING AREAS SHOULD BE CHECKED ON A DAILY BASIS IF THE VESSEL IS IN REGULAR USE. Table 10: Daily Servicing Checks (Jet) DAILY SERVICING CHECKS (JET) AREA OPERATION Intake Screen...

  • Page 92: Servicing Details

    8 MAINTENANCE HJ-241 / HSRX 8.5 S ERVICING ETAILS 8.5 SERVICING DETAILS 8.5.1 Jet Unit Servicing Details Extreme care is required whenever the Inspection Cover is removed as water may enter the vessel through this opening. ARNING Never leave the Inspection Cover removed without constant monitoring of the water levels.
  • Page 93 HJ-241 / HSRX 8 MAINTENANCE 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Anodes Check the condition of the Anodes every 3 months. Refer to Drawing HJ-241-13-002 Anode Locations. a) All External Anodes. Replace any Anode which is less than half its original size.
  • Page 94 8 MAINTENANCE HJ-241 / HSRX 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Steering Crank Grease - Every 3 Months. Check for security of attachment and grease with water repellent grease. Check for wear in the Crank ball and Nozzle Bush. Refer to Section 9.4.2 Steering Shaft Removal.
  • Page 95 HJ-241 / HSRX 8 MAINTENANCE 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Jet Unit Carry out internal examination of the Jet Unit after the first 2000 hrs of operation and thereafter every 5000 hrs. This examination should be carried out with the vessel out of the water. The following checks should be carried out:- a) Impeller Blades - Check Clearance •...
  • Page 96 8 MAINTENANCE HJ-241 / HSRX 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Jet Unit b) Impeller - Check for Wear and Damage. (Cont’d) (Contd) • Look for signs of corrosion and erosion damage on all surfaces of the Impeller. •...
  • Page 97 HJ-241 / HSRX 8 MAINTENANCE 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Jet Unit i) Jet Unit Paintwork. (Cont’d) (Contd) • The main body of the Jet Unit is constructed from Silicon- Aluminium Alloy (LM6) which is resistant to corrosion from salt water.

  • Page 98: Hsrx Controls Servicing Details

    8 MAINTENANCE HJ-241 / HSRX 8.5 S ERVICING ETAILS 8.5.2 HSRX Controls Servicing Details ITEM NO ITEM OPERATION HSRX Pump Oil Daily; Unscrew the Filler Cap on the top of the Pump Reservoir Check ( The Filler Cap is fitted with an integral Dipstick) and check the oil level.
  • Page 99 HJ-241 / HSRX 8 MAINTENANCE 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Filling the HSRX Sys- The HSRX System is factory tested and delivered tem with Oil completely assembled and filled with oil. The System oil capacity is approximately 0.9 litres of oil. After completion of maintenance on the HSRX system and when the Jet and Pump are first run, the oil level...
  • Page 100 8 MAINTENANCE HJ-241 / HSRX 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION Purging the HSRX Whenever maintenance activities have been carried out on System the HSRX Reverse System, air will be trapped within the system, it is necessary to purge the system. It is important that the following actions are carried out to prevent running the HSRX Oil Pump dry:- ON ENGINE START-UP:...
  • Page 101 HJ-241 / HSRX 8 MAINTENANCE 8.5 S ERVICING ETAILS ITEM NO ITEM OPERATION DJUST THE ENSION To adjust the Belt tension carry out the following procedure:- 1. Slacken the Nut [8] at the elongated slot end of the Adjusting Link [4]. 2.

  • Page 102: Tools

    8 MAINTENANCE HJ-241 / HSRX 8.6 T OOLS 8.6 TOOLS 8.7 THREADED FASTENERS Drawing 85113 Recommendations for Fastener Lock- 8.6.1 Standard Recommended ing, Torques and Threading Lubrication Sht Tools The following tools are required for normal Tightening Torques: maintenance activities: Ensure that all threaded fasteners are tightened to the correct torque 1.

  • Page 103: Recommended Oils And Lubricants

    HJ-241 / HSRX 8 MAINTENANCE 8.8 R ECOMMENDED ILS AND UBRICANTS 8.8 RECOMMENDED OILS AND LUBRICANTS Recommended oils and lubricants required are specified on Drawing 85018 Recommendation for Lubricants and Oils in this Manual. NOTE: Do not use brake fluid or heavier viscosity oils.
  • Page 104 8 MAINTENANCE HJ-241 / HSRX 8.8 R ECOMMENDED ILS AND UBRICANTS 8.18...

  • Page 105: Overhaul

    Section 9 VERHAUL NOTE: The Maintenance operations details in this 2. Overhaul the Reverse Assembly. Section should be carried out when the 3. Overhaul the Steering Assembly. Vessel is on a Slip or in Dry Dock. 4. Overhaul and refit the Bearing Housing area of Overhaul of the Jet Unit should only be carried out the Jet Unit.

  • Page 106: General Information

    9 OVERHAUL HJ-241 / HSRX 9.1 G ENERAL NFORMATION 9.1 GENERAL INFORMATION 9.2 REVERSE ASSEMBLY REMOVAL AND OVERHAUL CARE OF THE JET UNIT PAINTWORK:—All castings on the jet unit are of Silicon - Aluminium 9.2.1 Reverse Duct Removal Alloy (LM6) which exhibits good resistance to salt Refer to Drawings HJ-241-07-001 Reverse Assembly water corrosion.

  • Page 107: Reverse Duct Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.2 R EVERSE SSEMBLY EMOVAL AND VERHAUL 14.Check the Reverse Shaft Assembly attachment 12.Clean off any surplus Loctite from around the Stud [41] fitted to the starboard side of the replacement Sleeves. Reverse Duct, for security of attachment. 13.Refit the Reverse Pivot Bush [5] to the Reverse Replace if loose or worn.

  • Page 108: Reverse Cylinder Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.2 R EVERSE SSEMBLY EMOVAL AND VERHAUL 5. The Reverse Cylinder can now be removed from 5. The Nipple [32] and Bonded Seal [33] fitted to the the Transom by pushing the Cylinder forwards Front Head [15] and Back Head [22] can be left into the vessel and out of the two Resilient fitted unless they require replacing.
  • Page 109 9 OVERHAUL HJ-241 / HSRX 9.2 R EVERSE SSEMBLY EMOVAL AND VERHAUL • Check that the seal housing is free from damage Scarf Joints on the Seal Backing Rings are likely to harm the seal. Remove all sharp edges correctly mated. and burrs from metal parts paying particular 4.
  • Page 110 9 OVERHAUL HJ-241 / HSRX 9.2 R EVERSE SSEMBLY EMOVAL AND VERHAUL 16.Assemble the Cable Mounting Plate [26] to the 30.If possible workshop test the Reverse Cylinder Back Head, ensuring that the Cable Mounting before reinstalling into the vessel. The Plate is correctly located over the Stop Pin [39].

  • Page 111: Reverse Assembly Re-Fitting

    9 OVERHAUL HJ-241 / HSRX 9.3 R EVERSE SSEMBLY ITTING 9.3 REVERSE ASSEMBLY RE- 9.3.2 Reverse Duct: Refit to the Jet Unit FITTING Drawings HJ-241-07-001 Reverse Assembly Sht1 & refer. 9.3.1 Reverse Cylinder: Refit to the Jet Unit REVERSE DUCT: Refer to Drawing HJ-241-07-001 Reverse Assembly 1.
  • Page 112 9 OVERHAUL HJ-241 / HSRX 9.3 R EVERSE SSEMBLY ITTING 16.Raise and support the Reverse Duct and REPOSITIONING THE CABLE MOUNT PLATE: reconnect the Reverse Shaft [10] to the Stud [41] Should the Cable Mount Plate be wrongly orientated on the Reverse Duct, ensuring that Flat Washer for the current fit of the Reverse Cable, carry out the [43] is fitted onto the Stud [41 ] first prior to fitting following procedure to re-position the Cable Mount...

  • Page 113: Steering Assembly Removal And Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.4 S TEERING SSEMBLY EMOVAL AND VERHAUL 9.4 STEERING ASSEMBLY 9.4.2 Steering Shaft Removal REMOVAL AND OVERHAUL Drawings HJ-241-06-000 Steering Assembly Gener- al Arrangment Sht1 & 2 refer. Refer to Drawing HJ-241-06-000 Steering Assembly 1. Remove the Splash Guard [7] and the Reverse General Arrangment Sht1 &...

  • Page 114: Nozzle Assembly Removal

    9 OVERHAUL HJ-241 / HSRX 9.4 S TEERING SSEMBLY EMOVAL AND VERHAUL Crank ball should be checked for excessive REMOVING THE NOZZLE FROM THE NOZZLE wear. The maximum clearance between the HOUSING: Crank ball and the Nozzle Bush is 1.2mm To remove the Nozzle from the Nozzle Housing, (0.047ins).

  • Page 115: Nozzle Assembly Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.4 S TEERING SSEMBLY EMOVAL AND VERHAUL 7. Pivot Sleeve [12]. Check for wear and damage. is to allow the Lip Seals to be adjusted to fit Check the condition of the threads. Replace if the inside of the Nozzle Housing [9].
  • Page 116 9 OVERHAUL HJ-241 / HSRX 9.4 S TEERING SSEMBLY EMOVAL AND VERHAUL Crank before commencing the swaging front Intake boss ensuring that the Sleeve is fully operation. home in the bore. 7. Using a suitable Form Tool or Press, swage the 7.
  • Page 117 9 OVERHAUL HJ-241 / HSRX 9.4 S TEERING SSEMBLY EMOVAL AND VERHAUL NOTE: There are to be NO dry areas between the NOTE: Loctite Activator 7471 must be used to refit centre Steering Shaft Bush Sleeve [26] and the rear Steering Shaft Bush Sleeve [27] the boss in the Intake once the Steering Shaft otherwise the Loctite 680 will not cure and Bush Sleeve is fitted.

  • Page 118: Steering Assembly Re-Fitting

    9 OVERHAUL HJ-241 / HSRX 9.5 S TEERING SSEMBLY ITTING 9.5 STEERING ASSEMBLY RE- the Loctite 325 will not cure and retain the Steering Pivot Bush Sleeves in position. FITTING 4. Apply Loctite Activator 7o75 to the outside of the Refer to Drawing HJ-241-06-000 Steering Assembly Steering Pivot Bush Sleeves [22] and allow to dry.

  • Page 119: Re-Assemble The Nozzle / Nozzle Housing To The Tailpipe

    9 OVERHAUL HJ-241 / HSRX 9.5 S TEERING SSEMBLY ITTING NOTE: The Nozzle Attachment Bolts [11] are fitted is to allow the Lip Seals to be adjusted to fit using Loctite 222. Do not apply Loctite to the the inside of the Nozzle Housing [9]. threads of the Bolts [11] until “Nozzle 3.

  • Page 120: Steering Cylinder Re-Fitting

    9 OVERHAUL HJ-241 / HSRX 9.5 S TEERING SSEMBLY ITTING 3. From outside the vessel, pull the Steering Shaft bly General Arrangment Sht1 & CT-HLM-06-002 [1] rearwards and slide the Steering Crank onto Helm Wheel Options CT-SJK-02-005 Steering the end of the Steering Shaft ensuring that the Cylinder, Seastar for further information.

  • Page 121: Bearing Housing Assembly Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.6 B EARING OUSING SSEMBLY VERHAUL 9.6 BEARING HOUSING Bearing Housing Dismantling Refer to Drawings HJ-241-01-000 Basic Jet Assem- ASSEMBLY OVERHAUL blies Standard and Dry Run Sht 1 & 2. Refer to Drawings HJ-241-01-000 Basic Jet Assem- The Water Seal should not be blies Standard and Dry Run Sht 1 &...

  • Page 122: Water Seal Removal

    9 OVERHAUL HJ-241 / HSRX 9.6 B EARING OUSING SSEMBLY VERHAUL 9.6.1 Water Seal Removal NOTE: Take care during removal of the Waterseal Assembly as the Stationary Face is ceramic Refer to Drawings HJ-241-01-000 Basic Jet Assem- and is quite brittle. blies Standard and Dry Run Sht 1 &...

  • Page 123: Water Seal Replacement And Re-Fitting

    9 OVERHAUL HJ-241 / HSRX 9.6 B EARING OUSING SSEMBLY VERHAUL 7. Waterseal and Stationary Face Assembly (Items [2] & [3] in Drawing 61483). Check the Table 13: HJ-241 Jet Waterseal Components mating faces of Items [2] & [3] are not scored, cracked or chipped.

  • Page 124: Re-Assembly Of The Bearing Housing

    9 OVERHAUL HJ-241 / HSRX 9.6 B EARING OUSING SSEMBLY VERHAUL Housing and Water Seal is complete within 12.Apply marine grease to the ‘O’ Ring [37] fitted to this time. the Intake recess and around the Seal Face Holder contact area with the Intake. 5.

  • Page 125: Tailpipe Area - Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL 9.7 TAILPIPE AREA - OVERHAUL 26.Fit the Coupling Nut [10] to the Mainshaft. 27.Fit the Reaction Arm Tool to the Jet Unit Coupling Refer to Drawing HJ-241-01-000 Basic Jet Assem- to prevent the Coupling from turning. Torque blies Standard and Dry Run Sht 1 &...

  • Page 126: Inspection Of The Tailpipe Marine Bearing And Wear Ring

    9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL 3. Unscrew and remove Nuts [17] and Spring 5. Stator Blades. Check for signs of damage or Washers [16] from the Studs [30] securing the erosion to the leading edges. Dress off any burrs. Intake to the Tailpipe.
  • Page 127 9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL 3. Remove the Insulator [38] and thoroughly clean STEP 2: and degrease the Tailpipe Bore. 4. Place a heavy steel plate against the edge of the Wear Ring (The plate is used to prevent damage to PREPARING A NEW WEAR RING FOR FITTING: the end of the Wear Ring and should cover whole diameter of Wear Ring).

  • Page 128: Impeller Area - Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL back to it's original smooth profile checking against undamaged blades. 3. Inspect the leading edges, excessively worn or blunt leading edges may be built up by welding. INTAKE Blunt Impellers cause loss of performance and sometimes cavitation.

  • Page 129: Tailpipe Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL BALANCING: 4. When pressing in the new marine water bearing, use a wooden block under the nose of the 1. The Impeller must be balanced if welding or Tailpipe to take the load. grinding has been carried out on the Impeller.

  • Page 130: Tailpipe Area Re-Assembly

    9 OVERHAUL HJ-241 / HSRX 9.7 T AILPIPE VERHAUL b) Remove the Bolts [51], Nyloc Nuts [65] and TAILPIPE RE-ASSEMBLY: Spring Washers [28] securing each Anode to 7. Dust the Water Bearing [2] with talcum powder the Anode Mount Plate. or french chalk.

  • Page 131: Transom Plate Assembly Overhaul

    9 OVERHAUL HJ-241 / HSRX 9.8 T RANSOM LATE SSEMBLY VERHAUL 9.8 TRANSOM PLATE ASSEMBLY 1. Slacken and remove the Screws [9], Nuts [4], Flat Washers [6], and Spring Washers [5] securing OVERHAUL the Transom Plate to the Transom. Refer to Drawings 2.

  • Page 132: Hatch Extension (Optional Extra)

    9 OVERHAUL HJ-241 / HSRX 9.9 H ATCH XTENSION PTIONAL XTRA 9.9 HATCH EXTENSION 9. Fit the Hatch Extension over the 2 Studs [58] (shown on Drawings HJ-241-01-000 Basic Jet (OPTIONAL EXTRA) Assemblies Standard and Dry Run Sht 1 & 2 Refer to Drawing HJ-241-10-004 Hatch Extension.

  • Page 133: Screen Rake Assembly Overhaul (If Fitted)

    9 OVERHAUL HJ-241 / HSRX 9.10 S CREEN SSEMBLY VERHAUL ITTED 9.10 SCREEN RAKE ASSEMBLY Refer to Drawing HJ-241-10-004 Hatch Exten- sion. OVERHAUL (IF FITTED) 6. Ensure that the O Ring [34] fitted to the Refer to Drawing HJ-241-09-002 Screen Rake As- Inspection Cover [20] is not cut or perished.

  • Page 134: Screen Rake Re-Fitting

    9 OVERHAUL HJ-241 / HSRX 9.10 S CREEN SSEMBLY VERHAUL ITTED Rake pivot point to clear the starboard Screen 5. From beneath the vessel, whilst supporting the Rake Bearing housing in the Intake. Screen Rake and before fitting the Starboard Screen Rake Bearing, feed the starboard Screen 9.

  • Page 135: Screen Removal

    9 OVERHAUL HJ-241 / HSRX 9.11 HSRX H YDRAULIC EVERSE YSTEM 9.11 HSRX HYDRAULIC REVERSE Should it be necessary to run the Jet Unit without a Screen Rake, Blanking Plugs [1] can be fitted in place SYSTEM of the Port and Starboard Screen Rake Bearings. To fit the Blanking Plugs, carry out the following 9.11.1 Removal of the Pump procedure:...

  • Page 136: Re-Fitting The Pump Assembly To The Jet Unit

    9 OVERHAUL HJ-241 / HSRX 9.11 HSRX H YDRAULIC EVERSE YSTEM 13.Remove the Support Bracket [4] from the Stud on 6. Secure the outboard end of the Adjusting Link, the rear of the Pump ensuring that the Washer loosely with Special Washer [13], Spring Washer [13], fitted between the Adjusting Link [4] and the [7] and Nut [8].
  • Page 137 9 OVERHAUL HJ-241 / HSRX 9.11 HSRX H YDRAULIC EVERSE YSTEM 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 Reverse System for oil leaks. 9.33...
  • Page 138 9 OVERHAUL HJ-241 / HSRX 9.11 HSRX H YDRAULIC EVERSE YSTEM 9.34...
  • Page 139 Appendix • Supplementary Technical Information...

  • Page 141: Appendix A-1 Conversions

    HJ-241 / HSRX Appendix A-1 Conversions Temperature °F °C Fahrenheit Celsius Torque 1 pound foot = 1.3558 newton metres 1 newton metre = 0.7375 pounds foot Distance 1 inch = 2.54 centimetres 1 foot = 0.3048 metre 1 mile = 1.609 kilometres 1 nautical mile = 1.8532 kilometres 1 millimetre = 0.03937 inches 1 metre = 3.2808 feet...

  • Page 142: Loctite Application Guide

    HJ-241 / HSRX Appendix A-2 Loctite Application Guide...
  • Page 143 HJ-241 / HSRX Appendix...
  • Page 144 HJ-241 / HSRX Appendix...
  • Page 145 HJ-241 / HSRX Appendix...
  • Page 146 HJ-241 / HSRX Appendix...
  • Page 147 HJ-241 / HSRX Appendix...

  • Page 148: Installation Checks

    HJ-241 / HSRX Appendix A-3 Installation Checks 1. Jet Unit: Mounting: Item Check to be Carried Out Completed Check the Intake Block is flush with the exterior of the Hull bottom. Check that there are no flow obstructions forward of the Intake (Refer to the Hull details in Jet Designers Manual).
  • Page 149 HJ-241 / HSRX Appendix 2. Jet Unit: General: Item Check to be Carried Out Completed Ensure that the correct Impeller is fitted to match engine duty. Impeller part number (stamped on hub) can be seen through the Jet Unit Inspection Cover. Check that all Anodes are in place and have not been painted over.
  • Page 150 HJ-241 / HSRX Appendix 3. Jet Systems: Steering: Item Check to be Carried Out Completed For Jet Units with Tiller type Steering (e.g. HM-422) check that the Cotter Pins (Tapered Pins which locate the Tiller Arms on the Steering Shaft) are facing the correct direction for the deadrise angle and the number of Jets (Refer to the Steering Drawings in the Product Manual).
  • Page 151 HJ-241 / HSRX Appendix 4. Drive Shaft: Item Check to be Carried Out Completed Ensure driveline details have been approved by CWF Hamilton & Co Ltd. On universal joint Driveshafts (Refer to the Design Basics Section in the Product Manual) check: •...

  • Page 152: Commissioning Checks

    HJ-241 / HSRX Appendix A-4 Commissioning Checks Refer to relevant Controls Product Manual for commissioning of the Controls System. 1 Pre Launch Checks Item Checks to be Carried Out Completed Check that the plastic spiral wrap protective cover (where fitted) has been removed from hydraulic shafts (HM-Models only).
  • Page 153 HJ-241 / HSRX Appendix 2. Post Launch Checks: Item Checks to be Carried Out Completed For grease lubricated Main Bearings (HJ-322 and below), add grease until grease comes out of the front Seal as shown in the ’Initial Bearing Housing Re-Assembly’...
  • Page 154 HJ-241 / HSRX Appendix 3 Engine Running Checks (Vessel Moored): Item Checks to be Carried Out Completed The Water Bearing (Cutless Bearing) must operate wet unless the optional Dry Run Kit has been fitted (Dry Run Kit available for HJ-212 to HJ-364 Jet Units only).
  • Page 155 HJ-241 / HSRX Appendix 3 Engine Running Checks (Vessel Moored): Item Checks to be Carried Out Completed Check that the Jet Unit and Driveshaft are running smoothly (no vibration). Periodically check the Bearing Housing temperature. The temperature should not exceed 80ºC. On multi-Jet installations, all Bearing Housings should be at a similar temperature Check that the Reverse Controls are working by monitoring the Reverse Duct position while moving the Reverse Control Lever(s).
  • Page 156 HJ-241 / HSRX Appendix 4 Vessel Trial: Item Checks to be Carried Out Completed Leave the mooring and check that the steering is operating correctly at "Forward Speed", at "Zero Speed" and going "Astern". Observe the jet stream when going "Dead Ahead" at speed to ensure that it is relatively clean with an even shape.
  • Page 157 HJ-241 / HSRX Appendix 5. After Initial Trials: Item Checks to be Carried Out Completed Refer to the Maintenance Section of the Product Manual for any servicing that may be required on completion of trials. 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 characteristics.
  • Page 158 HJ-241 / HSRX Appendix 6 Jet Unit Trials & Commissioning Data: Commissioning Commissioning Engineer: Date: Vessel Description: Hamilton Jet 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, Hydraulics (If Fitted)
  • Page 159 HJ-241 / HSRX Appendix Comments: A.19...

  • Page 160: Lubrication Chart

    HJ-241 / HSRX Appendix A-5 lubrication chart A.20...
  • Page 161 Drawings • Technical Drawings...
  • Page 163 DRAWING INFORMATION BASE JET ASSEMBLY LATEST AMENDMENT: MATERIAL: W - SOLIDWORKS MODEL CREATED. STANDARD AND DRY RUN PARTS LIST AMENDED. STANDARD: HJ241 JET MAT. CERT REQ.: TRACEABILITY REQ.: HJ241 JET / CONTROL TYPE: WEIGHT; CAST [kg]: MACHINED [kg]: B.B. 11/01/2010...
  • Page 164 108602 110343 IMPELLER / COUPLING KEY 110343 108582 ANODE 108582 111717 SEAL FACE HOLDER MK2 HJ241 & 213 111717 201133 (BOLTS) (METRIC) ST ST 316 M8x45 061483 (JET) ROTARY SEALS (PAC SEAL) # 21-175-06 61483 201278 (STUDS) METRIC (316-STST) M8x35 (12/22)
  • Page 165 HJ-241-02-001 Couplings and Belts COUPLING DIA.A DIA.B DIA.C DIA.D HOLES(E) DIM.F A B C D E Item Kit PartNumber MovexAlias Qty ProductDescription DrawingNbr 108591 2.3/2.1 101.5 A 108632 COUPLING & V-BELT KIT (ELBE 0.112) HJ21302001 108592 2.3/2.15 10.2 101.5 B 108633 COUPLING &...
  • Page 166 HJ-241-03-001 Impellers PART No QTY DESCRIPTION DWG No 109984 IMPELLER TYPE 6.4 108545 109983 IMPELLER TYPE 6.8 108545 109982 IMPELLER TYPE 7.1 108545 108545 IMPELLER TYPE 7.5 108545 PART No QTY DESCRIPTION DWG No 109987 IMPELLER TYPE 5.0 108546 109986 IMPELLER TYPE 5.5 108546 109985...
  • Page 167 A3 B3 C3 D2 E2 F2 201394 (WASHERS) (SPRING) METRIC ST ST 316 M8 A1 B1 C1 D1 111395 NOZZLE HOUSING HJ241(for use with S.S. insert) 111395 A2 B2 C2 D2 F2 10 111398 BUSH FOR STEERING & REVERSE PIVOT...
  • Page 168 HJ-241-06-000 Steering Assembly General Arrangment Sht2...
  • Page 169 HJ-241-06-004 Blanking Plugs (No Steering) SPARES ASSY ITEM PART No QTY DESCRIPTION DWG No 108543 BLANKING PLUG 108543...
  • Page 170 HJ-241-07-001 Reverse Assembly Sht1...
  • Page 171 HJ-241-07-001 Reverse Assembly Sht2 Item PartNumber ProductDescription DrawingNbr HJ24107001 REVERSE GROUP (HYDRAULIC) CONTROL HJ24107001 112080 REVERSE CYLINDER H.S.R.X. MK2 HJ241 HJ24107001 112078 SEALS KIT H.S.R.X. MK2 HJ24107001 112049 HSRX BACKHEAD KIT HJ21307001 112240 HSRX FRONT HEAD KIT HJ24107001 112242 REVERSE DUCT KIT...
  • Page 172 HJ-241-07-002 Blanking Plus (No Reverse)
  • Page 173 HJ-241-08-001 Installation Details GRP Hull...
  • Page 174 HJ-241-08-002 Installation Details Aluminium Hull A B C Item Kit PartNumber Qty ProductDescription DrawingNbr A 108486 INTAKE BLOCK - GRP / ALM 108486 B 108629 INSTALLATION HARDWARE KIT HJ24108001 C 108630 TRANSOM PLATE KIT (ALUM & GRP HULL) HJ24108001 108514 TRANSOM PLATE 108514 108486...
  • Page 175 ITEM 7, RTV SILICON, ADDED TO KIT A Cast UNLIMITED DIMENSIONS TO BE ±0.5 Scale none DESCRIPTION INSTALLATION DETAILS Standard for STEEL HULL Approvals for HJ241 JET. CL316 F.K. DATE 15.03.04 Name Date Sheet 1 of 2. R.J.L 17-10-03 Designed...
  • Page 176 Cast UNLIMITED DIMENSIONS TO BE ±0.5 Scale none DESCRIPTION INSTALLATION DETAILS Standard for STEEL HULL Approvals for HJ241 JET. R.J.L DATE Name Date Sheet 2 of 2. R.J.L 17-10-03 Designed This print is provided on a restricted basis and is not to be used HJ241 08 003 in any way detrimental to the interests of C.
  • Page 177 HJ-241-09-001 Blanking Plugs (For Screen Rake)
  • Page 178 HJ-241-09-002 Screen Rake Assembly...
  • Page 179 HJ-241-10-004 Hatch Extension...
  • Page 180 HJ-241-11-000 Tool Kit...
  • Page 181 HJ-241-12-000 Sandtrap & engine Cooling...
  • Page 182 HJ-241-13-002 Anode Locations...
  • Page 183 HJ-241-30-001 General Arrangement...
  • Page 184 CT-CLV-01-003 Reverse Controller A B C Item Kit PartNumber MovexAlias Qty ProductDescription DrawingNbr 110021 CLV SINGLE LEVER FOR SINGLE JET WITH NEUTRAL INTERLOCK CTCLV01003 110022 CLV TWIN LEVER FOR TWIN JETS WITH NEUTRAL INTERLOCK CTCLV01003 80934 080934 CABLE CLAMP KITSET 80934 63566 063566...
  • Page 185 CT-HLM-06-002 Helm Wheel Options A B Item Kit PartNumber Qty ProductDescription DrawingNbr B 111575 CABLE STEERING WITH STST WHEEL (3" STROKE) CTHLM06002 A 111574 CABLE STEERING WITH SPORTS WHEEL (3" STROKE) CTHLM06002 EXPORTB 1 WHEEL 16" DIAMETER 3/4" TAPER BORE (DESTROYER TYPE) CTHLM04000 JMNGAAY 1 4 SPOKE MORSE C0856...
  • Page 186 CT-HPU-01001 Hydraulic Power Unit Item Kit PartNumber MovexAlias ProductDescription DrawingNbr CTHPU01001 JET HYDRAULIC POWER UNIT (SAGINAW) HSRX SYSTEM CTHPU01001 110857 SAGINAW PUMP & PULLEY ASSEMBLY CTHPU01003 206264 SAGINAW PUMP 206264 108628 DRIVE PULLEY SAGINAW PUMP 108628 108618 SUPPORT BRACKET 108618 108617 ADJUSTING LINK 108617...
  • Page 187 CT-HSE-12-001 Hose Kits...
  • Page 188 CT-HSE-12-001 Hose Kits Near End (L=actual hose length) Displacement Angle Specified only if two elbow fittings are used. Starting with either end as the near end, measure Far End the angle clockwise to describe the displacement.
  • Page 189 CT-SJK-02-005 Steering Cylinder, Seastar...
  • Page 190 61483 Rotary Seal...
  • Page 191 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 1...
  • Page 192 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 2...
  • Page 193 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 3...
  • Page 194 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 4...
  • Page 195 82206 Impeller Blade Dressing Instructions and Balancng Information Sht 5 Region Dimension Table Dim.'X' Dim. 'Y' Dim. 'Z' HM422 HM461 HM521 HM571 HM651 HM721 HM811 HT1000...
  • Page 196 Model (Litres) Litres Grease Lubricate Seastar Manual & Powered Hydraulic Steering Fluid HJ213 HJ212 Grease Type: Marine extreme pressure grease HJ241 HJ213 Fluids meeting MIL H5606c specifications HJ274 HJ241 Do not use: Brake fluid Heavier viscosity fluids HJ292 HJ274 Grease Nipple...
  • Page 197 85080 Aluminium Weld Procedure for Hamilton Jet Installation or Repair...
  • Page 198 85113 Recommendations for Fastener Locking, Torques and Threading Lubrication Sht 1 PROJECTION DO NOT SCALE THIS DRAWING REMOVE ALL SHARP CORNERS ALL DIMENSIONS IN mm. UNLESS OTHERWISE SHOWN NUT TIGHTENING TORQUES SCREW TIGHTENING TORQUES STUD INSTALLATION SIZE lbs.ft SIZE lbs.ft BOLTS &...
  • Page 199 85113 Recommendations for Fastener Locking, Torques and Threading Lubrication Sht 2 PROJECTION DO NOT SCALE THIS DRAWING REMOVE ALL SHARP CORNERS ALL DIMENSIONS IN mm. UNLESS OTHERWISE SHOWN HYDRAULIC FITTING TORQUES TIGHTENING TORQUES FOR LOCKING SCREWS ON KMT OR KMTA NUTS BSPP HYDRAULIC FITTINGS SCREW SIZE lbs.ft...
  • Page 200 85114 Earth Bonding System Recommendations and layout...
  • Page 201 Notes...
  • Page 202 Hamilton Jet is an international company committed to meeting their customer’s needs through the production of waterjet propulsion systems of the highest standards. Dedicated to waterjet propulsion. Hamilton Jet is globally represented by an extensive support network. World Headquarters C.W.F. Hamilton & Co Ltd P.O.

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