Reverse Cylinder Overhaul - Hamilton Jet HJ241 Manual

9 OVERHAUL
9.2 R A R
EVERSE SSEMBLY EMOVAL AND
5. The Reverse Cylinder can now be removed from
the Transom by pushing the Cylinder forwards
into the vessel and out of the two Resilient
Mounts [14].
6. Refit Retaining Nut [11] and Washer [13] to
Reverse Cylinder Front Head [15].
7. The Reverse Cylinder can now be removed from
the vessel for further In-depth maintenance.

9.2.4 Reverse Cylinder Overhaul

Drawings HJ-241-07-001 Reverse Assembly Sht1 &
2
DISMANTLING THE REVERSE CYLINDER
ASSEMBLY:
The Reverse Cylinder need only be dismantled if it
is suspected that a seal has failed and hydraulic
oil is found leaking along the Piston Rod
Assembly at one end of the cylinder or from the
HSRX Spool at the other end. This indicates that
the Seals are defective and must be replaced.
NOTE:
1.This operation should be carried out in a
clean workshop environment where the
cleanliness of components can be
maintained.
2.All marine growth must be removed from the
Reverse Cylinder Shaft using Scotchbrite or
800 and 1200 Grit water paper prior to
dismantling the Reverse Cylinder.
1. Ensure that the Clamp [58] and Shim [58] have
been disconnected from the Cable Mounting
Plate [26].
2. Slacken the Set Screw [30] securing the HSRX
Handle in position and remove the HSRX Handle
from the end of the HSRX Spool [20].
3. Remove the 'V' Ring [40] from the end of the
Spool at the Back Head end of the Reverse
Cylinder. Note the correct orientation of the 'V'
Ring [40] so that it is refitted correctly.
4. Remove the Pressure Relief Valve [35] from the
Back Head [22]. This is done by:-
a) Unscrewing the Knurled Nut on the top of the
Protective Cover (55).
b) Removing the Protective Cover from over the
Pressure Relief Valve. The pressure Relief
valve can now be unscrewed and removed
from the Back Head.
9.4
O
VERHAUL
5. The Nipple [32] and Bonded Seal [33] fitted to the
Front Head [15] and Back Head [22] can be left
fitted unless they require replacing.
6. Remove the M6 Nuts [28] and Spring Washers
[29] securing the Cable Mount Plate [26] to the
Back Head and remove the Cable Mount Plate
from the front of the Reverse Cylinder.
7. Withdraw the Back Head [22] from the Reverse
Cylinder [19].
8. Remove the Bearing [25] from the Back Head
[22].
9. Remove the HSRX Spool [20] from the Cylinder
[19].
10.Remove the Cylinder [19] from the Front Head
[15].
11.Withdraw the Reverse Cylinder Shaft Assembly
[10] from the Front Head [15].
NOTE: The Reverse Cylinder Shaft Assembly is not
to be dismantled any further and should only
be replaced as a complete item.
12.Unscrew the 4 x threaded Reverse Cylinder Tie
Rods [27] from the Front Head [15].
13.Check the Stop Pin [39] fitted to the Back Head
[22], for damage, wear and security of fitment.
This Pin does not need to be removed unless it is
worn, loose or damaged.
14.Remove and discard all O Rings and Seals.
15.Thoroughly clean and inspect all components for
wear and damage and replace as required. If
dimensions do not meet the criteria below,
components must be replaced:-
a) The spool shaft where the Rotary Shaft Seal
(24) contacts, should be free of any damage
and measure no less than ø11.90 mm.
b) The seal bore in the Backhead (22) should
measure no more than ø20.033 mm on MK2
cylinders.
c) The Shaft (10) should measure no less than
ø19.93 mm.
d) Cylinder bore should be no more than ø32.00
mm.
NOTE: Recommendations regarding use and fitting
of Seals:
• Ensure that all metallic particles and other con-
taminants have been removed from the compo-
nent into which the seal is being fitted.
• Ensure that the hydraulic system to which com-
ponents are fitted is free from metallic particles
or other contaminants.
HJ-241 / HSRX