Professional Documents
Culture Documents
HJ292
Jet unit Manual
R1A36
Copyright © 2018 C.W.F. Hamilton Ltd
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted
in any form or by any means; electronic, electrostatic, magnetic tape, mechanical, photocopying, recording
or otherwise, without permission in writing from C.W.F. Hamilton & Co Ltd.
Due to our policy of continuous development, specifications in this document are subject to change without
notice or obligation.
Jet Model HJ292
Part number 089292
Revision R1 01/06/11
Amendment A36 04/12/18
Contents
i
Jet mainshaft alignment___________________________________________________ 3-13
Water offtake ___________________________________________________________ 3-14
Engine location and mounting ______________________________________________ 3-15
General __________________________________________________________ 3-15
Engine shaft rotation _______________________________________________ 3-15
Engine mounting ___________________________________________________ 3-16
Engine systems ____________________________________________________ 3-16
Exhaust systems ___________________________________________________ 3-16
Governor settings __________________________________________________ 3-17
Dry run kit (optional extra) ________________________________________________ 3-17
Scope of use ______________________________________________________ 3-17
ii
5 - Installation _________________________________________________________ 5-1
General _________________________________________________________________ 5-1
Installation drawings ______________________________________________________ 5-2
Hull preparation __________________________________________________________ 5-2
Installing the intake block _____________________________________________ 5-2
GRP hull intake block ______________________________________________________ 5-2
Fixing the intake block to GRP hulls _____________________________________ 5-3
Cut the transom (If required) __________________________________________ 5-5
Aluminium hull intake block ________________________________________________ 5-6
Fixing the intake block to aluminium hulls _______________________________ 5-6
Prepare the transom_________________________________________________ 5-7
Steel hull intake block _____________________________________________________ 5-7
Electrical isolation ___________________________________________________ 5-7
Preparing the hull cutout _____________________________________________ 5-8
Prepare the transom _____________________________________________________ 5-11
Cut the transom hole _____________________________________________________ 5-11
Equipment preparation ___________________________________________________ 5-12
Removal of components _____________________________________________ 5-12
Mounting the jet unit _____________________________________________________ 5-12
Approved lifting points ______________________________________________ 5-13
Preparation _______________________________________________________ 5-13
Mounting the jet unit to the hull ______________________________________ 5-14
Attach the transom plate to the hull ___________________________________ 5-15
Final assembly _____________________________________________________ 5-17
Multiple jet installations _____________________________________________ 5-18
Engine mounting ___________________________________________________ 5-19
Installation checks for the jet unit _____________________________________ 5-20
iii
7 - Fault Finding_______________________________________________________ 7-1
Jet unit faults ____________________________________________________________ 7-1
Engine RPM increases suddenly ________________________________________ 7-1
Engine RPM decreases _______________________________________________ 7-1
Water leaking from the bearing housing _________________________________ 7-1
Loud high pitched rattling whine _______________________________________ 7-2
Excessive vibrations, gradually increasing ________________________________ 7-2
Engine RPM increases gradually over time, Take off performance poor ________ 7-2
Sudden increase in vibration from the jet unit ____________________________ 7-2
Gradual increase in vibration from the jet unit ____________________________ 7-2
Low engine RPM ____________________________________________________ 7-2
Thrust bearing excessively hot _________________________________________ 7-2
Dry run faults ____________________________________________________________ 7-3
Bearing seizes when dry running _______________________________________ 7-3
Changing sound from the jet unit ______________________________________ 7-3
Excessive scouring of the shaft sleeve ___________________________________ 7-3
Reverse system faults _____________________________________________________ 7-3
Reverse duct will not move ___________________________________________ 7-3
Reverse duct creeping down from the raised position ______________________ 7-3
Oil leaking from the reverse cylinder ____________________________________ 7-3
Reverse duct will not go fully down or stay down __________________________ 7-4
Loss of hydraulic oil _________________________________________________ 7-4
Water leaking in around the front head _________________________________ 7-4
Poor reverse thrust __________________________________________________ 7-4
Poor forward thrust _________________________________________________ 7-4
Steering system faults _____________________________________________________ 7-5
Steering nozzle slow to respond _______________________________________ 7-5
Steering jamming ___________________________________________________ 7-5
iv
Preservation (post installation) ______________________________________________ 8-8
Servicing intervals ________________________________________________________ 8-9
HJ Jet unit service intervals ___________________________________________ 8-9
Daily "pre use" servicing checks _______________________________________ 8-10
Jet unit servicing details ___________________________________________________ 8-10
Thrust bearing _____________________________________________________ 8-10
Marine bearing: ___________________________________________________ 8-10
Water seal: _______________________________________________________ 8-11
Anodes: __________________________________________________________ 8-11
Screen rake and bearings ____________________________________________ 8-11
Steering cotter pins_________________________________________________ 8-11
Steering linkages: __________________________________________________ 8-12
Steering shaft and bushes ___________________________________________ 8-12
Steering crank _____________________________________________________ 8-12
Steering nozzle ____________________________________________________ 8-12
Cylinders and Hoses ________________________________________________ 8-12
Reverse cylinder shaft ______________________________________________ 8-12
Driveshaft: ________________________________________________________ 8-12
Insulation checks (steel hulls only)_____________________________________ 8-12
Jet unit ________________________________________________________________ 8-13
Impeller blades: ___________________________________________________ 8-13
Marine bearing: ___________________________________________________ 8-13
Reverse duct: _____________________________________________________ 8-13
Steering and reverse linkages_________________________________________ 8-13
Tailpipe, nozzle and nozzle housing: ___________________________________ 8-13
Jet unit paintwork: _________________________________________________ 8-14
Excessive wear: ____________________________________________________ 8-14
Tools __________________________________________________________________ 8-14
Threaded fasteners ______________________________________________________ 8-15
Thread locking agents _______________________________________________ 8-15
Recommended oils and lubricants __________________________________________ 8-15
Care and storage of spare V-belts ___________________________________________ 8-16
9 - Overhaul____________________________________________________________ 9-1
General information _______________________________________________________ 9-2
Introduction _______________________________________________________ 9-3
v
Servicing hydraulic equipment _________________________________________ 9-4
Recommendations for the fitting of oil seals ______________________________ 9-5
Care of jet unit paintwork ____________________________________________ 9-5
Torqueing sequence of nuts ___________________________________________ 9-6
Anode replacement _________________________________________________ 9-6
Refitting locating dowels _____________________________________________ 9-7
Reverse duct overhaul _____________________________________________________ 9-8
Reverse duct overhaul _______________________________________________ 9-8
Reverse cylinder overhaul ___________________________________________ 9-10
Reverse duct refit to jet unit _________________________________________ 9-21
Steering assembly overhaul ________________________________________________ 9-23
Steering assembly removal __________________________________________ 9-23
Steering shaft removal ______________________________________________ 9-25
Steering shaft bushes _______________________________________________ 9-26
Steering crank bush ________________________________________________ 9-29
Nozzle assembly removal ____________________________________________ 9-30
Nozzle insert ______________________________________________________ 9-31
Steering nozzle removal _____________________________________________ 9-32
Overhaul the steering nozzle _________________________________________ 9-33
Refit the steering nozzle _____________________________________________ 9-34
Adjusting nozzle end float ___________________________________________ 9-35
Lip seal replacement ________________________________________________ 9-36
Nozzle assembly refit to jet unit_______________________________________ 9-36
Refit the steering shaft ______________________________________________ 9-37
Refit the steering cylinder ___________________________________________ 9-37
Adjust the steering linkage ___________________________________________ 9-37
Bearing housing assembly overhaul _________________________________________ 9-38
Remove the oil pump _______________________________________________ 9-38
Removing the coupling ______________________________________________ 9-39
Removing the bearing housing ________________________________________ 9-40
Water seal ________________________________________________________ 9-41
Disassemble the bearing housing______________________________________ 9-44
Refit the bearing housing __________________________________________________ 9-45
Refit the KMT nut __________________________________________________ 9-48
Refit the bearing cap________________________________________________ 9-49
Refit the coupling __________________________________________________ 9-50
Refit the oil pump __________________________________________________ 9-50
Internal intake anode replacement __________________________________________ 9-51
vi
Tailpipe area overhaul ____________________________________________________ 9-52
Impeller - checking for wear __________________________________________ 9-52
Remove the tailpipe ________________________________________________ 9-53
Tailpipe overhaul __________________________________________________ 9-54
Impeller - overhaul _______________________________________________________ 9-56
Remove the impeller _______________________________________________ 9-57
Wear ring removal and replacement ___________________________________ 9-60
Impeller overhaul __________________________________________________ 9-63
Tailpipe area re-assembly ____________________________________________ 9-64
Overflow preventer/hatch extension (optional extra) ___________________________ 9-68
Hatch extension _________________________________________________________ 9-68
Fitting the hatch extension ___________________________________________ 9-69
Screen rake assembly overhaul (if fitted) _____________________________________ 9-70
Remove the intake screen ___________________________________________ 9-71
Screen rake removal ________________________________________________ 9-71
Screen rake reassembly _____________________________________________ 9-72
Screen rake blanking plugs ________________________________________________ 9-74
vii
Temperature readings _____________________________________________ 10-22
Speed trial readings _______________________________________________ 10-22
Aluminium weld procedure _______________________________________________ 10-24
Tightening torques ______________________________________________________ 10-26
Nut tightening torques _____________________________________________ 10-26
Screw tightening torques ___________________________________________ 10-27
Stud installation __________________________________________________ 10-28
Set screws _______________________________________________________ 10-29
Hydraulic cylinder piston ___________________________________________ 10-29
Hydraulic fittings __________________________________________________ 10-30
Thread lubricants _________________________________________________ 10-31
Recommendations for lubricants and oils____________________________________ 10-32
Hydraulic fluids ___________________________________________________ 10-32
Bearing housing lubrication _________________________________________ 10-34
Joint lubrication __________________________________________________ 10-35
Drivers guide __________________________________________________________ 10-38
Starting up _______________________________________________________ 10-38
Ahead, zero speed and astern controls ________________________________ 10-38
Power assisted slowdown __________________________________________ 10-39
Steering _________________________________________________________ 10-39
Manual control of steering nozzle and reverse duct ______________________ 10-40
Emergency manoeuvring ___________________________________________ 10-41
Manoeuvring and docking __________________________________________ 10-41
Cruising _________________________________________________________ 10-44
Shallow water operation ___________________________________________ 10-44
Acceleration to high speed __________________________________________ 10-45
Aerated water ____________________________________________________ 10-46
Blockages (debris in the jet unit) _____________________________________ 10-46
Operating with an engine and jet unit out of service _____________________ 10-47
Shutting down the jet units after use _________________________________ 10-47
viii
HJ292 Product Manual Introduction
1 - Introduction
In This Section
Limited warranty
Terms of coverage
C.W.F. Hamilton & Co. Ltd. (HamiltonJet) warrants to the original purchaser that each new Hamilton Jet
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 HamiltonJet within the
warranty period, HamiltonJet'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 HamiltonJet.
Defective products shall be returned to HamiltonJet or its authorised service representative for
inspection with transportation charges prepaid by the purchaser to the location specified by HamiltonJet.
This warranty only applies where the product is shown, to the satisfaction of HamiltonJet, to be defective
in material or workmanship during the warranty period.
HamiltonJet will supply parts required for warranty repairs free of charge and pay reasonable authorised
labour costs.
To the extent permitted by law, this warranty sets out the original purchaser's exclusive remedies with
respect to the product covered by this warranty. In the event that HamiltonJet determines it is unable to
repair or replace any component part(s) found to be defective in materials and/or workmanship,
HamiltonJet's warranty liability shall be limited to payment by HamiltonJet to the original purchaser of an
amount not to exceed the value of the defective part(s), together with shipping charges, if any, incurred.
All products removed or replaced under the warranty shall become the property of HamiltonJet.
All warranty claims shall be lodged with HamiltonJet or its authorised distributor.
Warranty period
The warranty period for HamiltonJet products is limited to a period of twenty-four (24) months from the
date of original shipment from the HamiltonJet factory, or twelve (12) months from the vessel launch
date, whichever occurs first.
1-1
Introduction HJ292 Product Manual
Limitation of liability
This warranty is extended only to the original purchaser, and is not transferable to or assignable to any
other person or entity, and does not extend to future performance.
In no event will HamiltonJet, its distributors, or affiliates be liable for any incidental, punitive or
consequential losses, inconveniences, damages or other costs resulting directly or indirectly from any
defect in the product covered by this warranty, including, but not limited to, loss of use, revenue or
profit.
HamiltonJet reserves the right to change its product through changes in design or materials without
obligation to incorporate such changes in any products previously manufactured, but any improvement
or changes may be incorporated in replacement product.
Warranty does not extend to failures, damages or defects resulting from the following:
What HamiltonJet determines to be, misuse, abuse, overloading, improper application, improper
transportation or storage, abnormal wear and tear, negligence, carelessness, accident, natural calamity,
vandalism, fouling caused by foreign material, peculiar water conditions or chemicals, or other
circumstances over which Hamilton Jet has no control.
Operation or maintenance in any way other than in accordance with the operating and maintenance
instructions of HamiltonJet.
Vessel-to-shore electrical connections that change the corrosion potential of the vessel. For vessels
equipped with shore power this warranty will not extend to the product unless an isolating transformer
or galvanic isolator is fitted as described in the applicable HamiltonJet Product Manual.
Incorrect installation, as per the applicable HamiltonJet Product Manual and the applicable HamiltonJet
Designer's Manual. This warranty will not extend to the product unless a negative earth bonding system
has been installed in the vessel as specified in the respective HamiltonJet Product Manual, and a Jet
Mainshaft critical speed check carried out to HamiltonJet's written satisfaction.
Warranty does not cover or provide payment or reimbursement for the following:
Any repairs or alterations carried out with the use of parts or accessories not manufactured by
HamiltonJet or its authorised representatives.
Items incorporated in any HamiltonJet product (other than by HamiltonJet) when such items have been
manufactured by others or are warranted by their respective manufacturers in favour of the purchaser.
Used or reconditioned parts.
The cost of transporting the vessel to a repair facility and for all related towing, harbour, docking,
slippage, lifting, moorage, launching or retrieval charges.
Any product which may have been serviced, repaired or altered in any way by anyone other than
HamiltonJet or a HamiltonJet authorised facility.
No representations or express or implied warranty except as herein stated
To the extent permitted by law, this limited warranty is the only warranty extended by HamiltonJet and
is in lieu of all other warranties, EXPRESSED or IMPLIED, oral or written and of all other obligations or
liabilities, including without limitation any IMPLIED WARRANTIES of MERCHANTABILITY or FITNESS for a
PARTICULAR PURPOSE. Except as provided in this warranty the product is sold as is, where is.
No other person or agent or distributor is authorised to modify this warranty, give any other warranty on
behalf of HamiltonJet or to assume for HamiltonJet any other obligation or liability in connection with
the sale of its products.
In the United States and Canada, some states and provinces do not allow limitations on duration of an
implied warranty, or the exclusion or limitation of incidental or consequential damages, so the above
limitations or exclusions may not apply to you. This limited warranty gives you specific legal rights and
you may also have other rights, which vary from state to state.
In other countries outside the United States and Canada, you may have statutory rights which cannot be
affected or limited by the terms of this Warranty.
C.W.F. Hamilton & Co. Ltd. July 2005 [Rev H]
1-2
HJ292 Product Manual Introduction
HamiltonJet 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 HamiltonJet. Please complete one form per vessel
only.
Jet Model
Serial Number(s)
Delivery Date
Vessel/Project
Purchaser
Address
Contact Name
Signed
Distributor
Address
Contact Name
Signed
Logged By
Project Code
Date
1-3
Introduction HJ292 Product Manual
Caution:
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 or loss of mission effectiveness.
Indicated throughout this manual as shown below:
Note:
A note contains additional information that will help clarify a procedure.
Indicated throughout this manual as shown below:
Link:
This symbol informs you where to find additional important information on a topic.
(►Page)
1-4
HJ292 Product Manual Introduction
Symbols
Common symbols used throughout this manual:
Loctite®:
Grade of Loctite will be shown in the illustration
Hydraulic oil
Marine sealant
e.g.
Sikaflex® 291 and 291-LOT
3M® 4200
Terostat® 270-MS
The illustrations used throughout this manual are there to enhance the explanation of the
installation and overhaul procedures.
They may not necessarily reflect the jet model that this manual refers to.
1-5
Introduction HJ292 Product Manual
1-6
HJ292 Product Manual Product Description
2 - Product Description
In This Section
Introduction
Waterjets have rapidly gained acceptance as the leading means of propulsion for all types of high speed
marine craft including ferries, work boats, patrol craft and pleasure boats.
Recent advances in waterjet technology have put them ahead of conventional propeller systems in both high
speed performance and reliability.
Conventional propeller powered craft have several shortcomings, such as vibration, higher engine loading
and susceptibility to damage from water borne debris.
Modern waterjet powered vessels offer many advantages:
High efficiency.
Rapid acceleration.
Shallow draft.
Manoeuvrability.
Smooth, quiet operation.
Lower maintenance.
Longer engine life.
Simplified installation.
No protrusions under the water.
Safety for personal working in the water near the vessel.
The waterjet unit is an ideal form of propulsion for vessels working in a marine mammal environment.
HamiltonJet pioneered the commercial development of the modern waterjet system in the early 1950’s and
today we have over 30,000 units in service worldwide.
2-1
Product Description HJ292 Product Manual
With a complete range of models suitable for power inputs of up to 10000kW per unit, the Hamilton waterjet
is ideally suited to the efficient propulsion of a wide variety of high speed vessels, in either single or multiple
jet configurations.
HamiltonJet is dedicated to the production of the highest quality waterjets and controls systems designed
and manufactured to meet the requirements of the world's leading certifying authorities.
The global HamiltonJet organisation provides full support through factory support staff, regional offices and
an extensive network of factory trained distributors in over 50 locations worldwide.
Equipment description
The HamiltonJet HJ series is a range of highly efficient single stage waterjets suitable for propelling craft
typically up to 20metres in length and 30tonnes displacement, at speeds up to 50knots. Generally, high
speed diesel engines drive HJ series waterjets directly.
The HamiltonJet HM & HT series are larger single stage waterjets suitable for vessels typically up to 65m in
length. Generally, high speed diesel engines drive HM & HT series waterjets via a reduction gearbox.
Mounted partly inboard at the stern of the vessel, the HamiltonJet waterjet consists of a totally integrated,
jet mounted hydraulic steering, reverse and control system package.
The waterjet draws water through an intake screen at the base of the intake. The intake screen mounts flush
with the hull bottom.
The pumping unit (impeller + stator) increases the pressure or "head" of the flow, which is then discharged
at high velocity at the nozzle. The reaction to this high velocity jet stream provides the net thrust force,
which fully transmits through the intake to the hull bottom.
A single piece balanced steering nozzle precisely directs the jet stream as commanded by the helm, providing
high turning forces to either port or starboard. An independent split-duct type reverse duct, directs the jet
stream back underneath the hull to provide powerful astern thrust.
The reverse duct can be set to a "zero speed" position (where the ahead and astern thrusts are balanced) at
which point full steering is still available.
Selecting infinitely variable forward and reverse control by varying the position of the reverse duct combined
with the highly efficient steering results in unparalleled vessel control and manoeuvrability.
2-2
HJ292 Product Manual Product Description
Main components
Intake block
The Intake block forms the inlet for the jet unit. It is either moulded, welded or bolted (depending on hull
material) into an opening in the hull bottom.
Intake
Cast from high silicon aluminium alloy, the intake bolts to the intake block and represents the main structural
body of the jet unit. The intake is capable of transmitting the full thrust of the jet unit to the hull bottom.
Oil cooler
The jet unit is fitted with an integrated oil cooler cast into the side of the intake. This connects to the jet
mounted hydraulic power unit (JHPU) via hoses.
Thrust bearing
Mounted inside the bearing housing, the thrust bearing absorbs the thrust generated by the impeller.
No external thrust bearing is required.
Water seal
The water seal Mounts on the mainshaft aft of the bearing housing and stops water entering the bearing
housing or the vessel.
Impeller
The impeller is a mixed flow type, capable of pumping large volumes of water at relatively low pressures. It
provides high propulsive coefficients at fast vessel speeds. The cast stainless steel impeller runs within a
replaceable stainless steel wear ring located in the rear section of the intake.
Tailpipe
The tailpipe contains a water lubricated bearing supporting the rear of the mainshaft.
The tailpipe contains a vaned stator to remove the rotation of the water flow, allowing a uniform axial flow
to the nozzle.
Steering nozzle
After the water flow passes through the impeller and stator, it is at a high pressure and relatively low
velocity.
Water flow at the nozzle outlet is at atmospheric pressure. This difference in flow pressure converts to flow
velocity in the nozzle.
Correct nozzle sizing is critical to the correct operation of the jet unit.
Steering assembly
Attached to the rear of the tailpipe, the steering assembly consists of a nozzle housing, nozzle insert and
steering nozzle.
The steering nozzle mounts inside the nozzle housing on vertical pivot pins and rotates to port or starboard
by linkages attached to an inboard steering tiller.
The nozzle insert ensures that the flow exiting the stator section reaches the final steering nozzle outlet
without any disturbance by the steering mechanism, thus maximising steering efficiency.
2-3
Product Description HJ292 Product Manual
Reverse duct
Can be positioned up or down by the reverse cylinder.
Incorporated into the reverse duct is a splitter which divides and angles the astern jet stream downwards
and to the sides, clearing the transom and intake opening.
This stops recycling of water flow through the jet unit (which may be aerated or contain sediment) and
excessive disturbance to the bottom of the waterway.
Transom seal
Seals the hole in the transom through which the waterjet passes. The transom seal bolts to the vessel
transom and incorporates a rubber ring which seals around the jet unit.
Screen rake
Available as an optional extra, the dry run system is typically used for man-overboard boats and lifeboats
where the engines need to be started before the vessel is in the water.
The dry run kit consists of a special marine bearing that can operate out of the water for short periods of
time. Standard rubber marine bearings must always be operated wet.
2-4
HJ292 Product Manual Product Description
2-5
Product Description HJ292 Product Manual
2-6
HJ292 Product Manual Design Basics
3 - Design Basics
In This Section
Hull loads
All loads produced by the jet unit result from the difference in momentum of the incoming and outgoing
water. An exception is the torque load on the Stator Vanes as they remove the angular momentum of the
waterjet which was input by the impeller.
The following four cases must be considered when calculating maximum loads:
Full ahead.
Full reverse.
Full steering.
Full reverse & full steering.
While the jet unit loads can be readily calculated, the hull reaction loads are dependent on the stiffness and
rigidity of both the jet unit and the hull structure.
All loads are transferred to the hull via the intake block. No significant loads are taken by the transom.
The following figure and tables give all relevant data for this jet unit.
3-1
Design Basics HJ292 Product Manual
3-2
HJ292 Product Manual Design Basics
HJ292 dimensions
Description Symbol Units Value
Waterjet angle a Degrees 0.0
Centreline height H Meters 0.29
Mean Inlet depth h Meters 0.05
Steering to Base centre Ds Meters 1.036
Reverse to Base centre Dr Meters 1.476
Transom to Base Centre Dw Meters 0.536
Centre to Reverse Arm Da Meters 0.18
For lower design power values, use the following approximate equation to adjust the hull reaction forces.
3-3
Design Basics HJ292 Product Manual
Hull design
Not all hull shapes are suitable for propulsion by waterjet. Contact HamiltonJet for guidelines
on suitable hull shapes, performance and engine matching.
3-4
HJ292 Product Manual Design Basics
Trim tabs
Find more information here (► page 4-4) regarding the fitting of trim tabs.
When moving astern, trim tabs mounted alongside the jet unit, will interfere with the reverse jetstream
reducing thrust. Therefore do not mount trim tabs beside the jet unit.
Mount trim tabs under the jet unit with any control equipment mounted on either side of the jet unit.
The following diagram shows the maximum size and position of the trim tab that may be located under the
jet unit.
Contact HamiltonJet if further information is required.
3-5
Design Basics HJ292 Product Manual
3-6
HJ292 Product Manual Design Basics
Drive lines
Loads on jet unit thrust bearing
The thrust bearing carries thrust loads from the jet unit to propel the craft. It should not be
subjected to excessive loads from other sources as described below:
The thrust bearing will not withstand excessive radial loads caused by adapters and belt
pulleys overhanging the jet coupling flange.
The thrust bearing will not withstand excessive loads produced by rigid drivelines which
do not accommodate misalignment resulting from engine movement or hull flexing.
The driveline must not impose any axial force in the aft direction. On installation there
should be a small gap between the waterjet and driveline coupling that closes when
tightening the bolts.
There is a limit to the driveshaft weight that the jet unit can support.
Always do a torsional vibration analysis on the complete drive train. The vibratory torque should not exceed
10% of the nominal torque for most applications. The resultant torque must always be in the same direction
and carefully checked at engine idle speed.
Engineering checks
Consult all component suppliers (including driveline, engine and jet suppliers) with full driveline details to
ensure suitability and compatibility of components.
Checks must include:
Critical speed check for whirling of the jet unit mainshaft: Consult HamiltonJet.
Critical speed check for whirling of the driveshaft: Consult driveline supplier.
Engine to jet alignment: Consult HamiltonJet and driveline supplier.
Torsional vibration analysis: Consult engine or torsionally flexible coupling supplier.
Critical speed checks should allow safe operation up to the engine's no load governor setting
(or high idle).
3-7
Design Basics HJ292 Product Manual
Driveline options
The above diagram shows the different types of driveline components and their uses. Note that this diagram
is a guide only.
Always contact HamiltonJet before designing the driveline.
Driveline components
Universal driveshafts
These are double universal slip-jointed driveshafts, also called Cardan shafts. They bolt directly to the jet unit
coupling.
Lengths range from approximately 900mm to 3,000mm. The maximum allowable weight at the jet unit
coupling and the critical speed of the mainshaft will limit the length of the driveshaft.
3-8
HJ292 Product Manual Design Basics
If a TFC is not required between the gearbox and the lineshaft, then directly attach the
lineshaft to the gearbox flange using normal propeller shafting criteria.
Mount the gearbox rigidly to avoid misalignment.
3-9
Design Basics HJ292 Product Manual
It is very important to position the engine so that the universal joints of the driveshaft have
equal offset angles.
Refer to the driveshaft manufacturers recommendations for joint angles (typical range is
between 1.5 and 5degrees).
The best method of alignment is to mount pointers on the jet coupling (or output) flange and the engine (or
input) flange. The length of each pointer should be exactly the same and equal to half the nominal distance
between the two flanges.
3-10
HJ292 Product Manual Design Basics
D1 180
D2 810
D3 172
D4 42
D5 776
D6 101
3-11
Design Basics HJ292 Product Manual
To convert to engine speed for torsional vibration analysis calculations, divide moments of inertia
and stiffness values by gear ratio squared.
If a heavy driveline is used then carry out a transverse vibrational analysis of the jet unit mainshaft.
3-12
HJ292 Product Manual Design Basics
This diagram applies only to jet units where the mainshaft is inclined at 5° to the intake
base.
3-13
Design Basics HJ292 Product Manual
Water offtake
A 186kW
B 96kW
C 40kW
D 12kW
E 6kW
F 3kW
The graph shows flow rates
at zero speed
The jet unit is fitted with a water offtake which may be used as a supplementary water supply (e.g. for deck
wash) or engine cooling.
The water offtake is fitted with a 1¼" BSP plug [A].
Fit the supplied 1¼" hose tail [B] to the water offtake to
allow for the connection of a hose.
If used as part of the engine cooling circuit, the designer / builder must satisfy themselves
that the available flow is sufficient for the cooling requirements.
Do not feed the water directly to the engine without a raw water pump unless:
The pressure from the water offtake at idle is sufficient to cool the engine.
and
The engine can withstand the full pressure from the jet offtake.
3-14
HJ292 Product Manual Design Basics
To be sure of correct water flow for engine cooling, use a conventional water pick-up and engine raw water
pump.
It is possible to use the jet water offtake for a deck cleaning hose but the pressure is not high enough to be
used for a fire hose.
If the engine is fitted with a gearbox or clutch, do not use the jet water offtake for engine cooling
since the jet water offtake will provide no water when the jet unit is disengaged.
Make sure that the engine cooling water pick up is not directly ahead of the jet unit intake, but well
to the side to avoid turbulent water flow into the jet unit.
1: Waterjet
2: Engine
A: Clockwise engine shaft rotation
B: Anti-clockwise engine shaft rotation
3-15
Design Basics HJ292 Product Manual
Engine 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 directly transmits from the
jet unit directly to the hull.
Flexible engine mounts reduce vibration and noise. Use these in conjunction with a driveshaft system which
does not cause a radial or side load at the jet coupling as the engine moves.
Engine systems
Follow the manufacturer's recommendations for engine wiring, instrumentation and throttle systems.
Exhaust systems
Engine exhausts should not be located below the waterline near the jet units.
Locate the engine exhausts above the waterline.
Water containing exhaust gasses can enter the jet unit when moving astern causing loss of thrust and
control.
The exhaust system can be any conventional system approved by the engine manufacturer.
1 Exhaust outlets
2 Exhaust Gasses
3 Water Flow
4 Chine
5 Keel
3-16
HJ292 Product Manual Design Basics
Governor settings
The no load governor setting (or high idle) on diesel engines, should be set well clear of the full throttle RPM
achieved when driving the jet unit so that there is no chance of the governor reducing power (and
performance) at full throttle.
To check, select neutral and open the throttle fully. Use a calibrated hand tachometer to measure the RPM.
If there is no gearbox fitted, then disconnect the driveline at the engine flywheel and check RPM.
Example:
If the maximum RPM for driving the jet unit is 2800rpm, then the governor should not begin to operate
until at least 2850rpm. On most diesel engines this means the "no load" governor setting (or "high idle")
should be at least 3050rpm (i.e. 250rpm higher than the loaded maximum RPM).
Ensure that the low idle RPM is set high enough to avoid any vibration in the driveline. Extensive idling with
the driveline vibrating may damage the jet unit.
Scope of use
Because there is no cooling for a dry run system, the water seal and the marine bearing will heat up rapidly
when the vessel in not in the water.
Note the following limits to ensure adequate component life:
The dry run bearing will wear more rapidly than a standard bearing if used continuously in dirty water.
If possible, only use this system in clean water.
If use in dirty water for long periods is expected, then regular checks of the marine bearing wear will be
necessary.
3-17
Design Basics HJ292 Product Manual
3-18
HJ292 Product Manual Precautions Against Corrosion
In This Section
General
Refer to the following technical drawing(s) in the back of this manual:
85114 - Earth Bonding System.
HM00013001 - Corrosion Monitor.
HJ29213003 - Anode Location
To prevent corrosion, vessels using HamiltonJet waterjet units must be bonded and wired as
described in this section.
4-1
Precautions Against Corrosion HJ292 Product Manual
D.C. systems
The DC system should use two insulated "normally conducting" wires, a positive and a negative.
The negative must not run through the frame of any unit, through the hull of the boat, or through the
bonding system. Do not use an earth return system.
It is recommended that engine starter motors or other DC motors should be the two wire type with an
insulated negative terminal rather than having their chassis connected to the battery negative. This is to
ensure starting currents do not pass through the earth bonding system.
In smaller vessels, it is common to use negative ground engine systems in which the starter motor, starter
solenoid, and alternator are single pole devices using the engine block as the local return conductor. In this
situation, it is important to connect the engine block to the battery negative with a suitably sized heavy
duty cable.
In installations with two engines and two battery banks with cross-connect starting capability, there must be
two suitably sized heavy duty conductors between the engines.
A.C. systems
Vessels with both AC and DC circuits, must for safety reasons, use a separate earth wire for the AC system.
If a vessel with bonded aluminium jets is connected to a dock supply, without the protection of an isolation
transformer or a galvanic isolator, the dock potentials through the earth wire will cause the aluminium to
corrode. This will happen at a much greater rate than that experienced in normal sea water regardless of
whether the aluminium is protected by anodes or not.
Shore connections
Using an isolating transformer
If using AC shore supply, install an isolating transformer on board at the incoming line to preventing
potentially serious galvanic or stray current corrosion.
When an isolating transformer is used, there must be no connection between the shore supply earth and the
vessels earth bonding system. The primary winding shield is earthed to shore, while the secondary winding is
grounded on board the vessel. Only one side of the secondary winding is grounded on the secondary side of
the transformer and the vessel’s grounding circuit is tied in at this point.
There must be no DC electrical connection between the shore supply and the on board AC circuit.
Find further information (including circuit diagrams) in American Boat and Yacht Council (ABYC) publication
E-11 AC and DC electrical systems on boats.
4-2
HJ292 Product Manual Precautions Against Corrosion
4-3
Precautions Against Corrosion HJ292 Product Manual
Corrosion monitor
It is recommended that a high impedance corrosion monitor be fitted.
There must be no possibility of an electrical connection between the jet units and the ships batteries.
If the jet units are isolated from the hull, corrosion monitoring of each jet unit external wetted surface and
internal intake duct should be carried out.
If the jet units are electrically connected to the hull, corrosion monitoring of the hull only and each jet unit
internal intake duct should be carried out.
4-4
HJ292 Product Manual Precautions Against Corrosion
Anodes
The Jet unit will be fitted with one or more anodes to protect against corrosion.
The anodes are made from aluminium alloy to MIL-A-24779 (SH).
Do not paint over the anodes as this will prevent their correct operation. If corroding, the anodes are
providing protection and should be inspected regularly and replaced when 2/3 corroded.
It is common for anodes to be partially covered with a very loose scale, the colour of which depends on local
water conditions. Typically this scale will be creamy white, light brown or green and, providing it is loose (i.e.
easily scraped off with a fingernail) is normal.
If the anodes are not corroding when the vessel is in seawater, they are not functioning correctly and the
cause should be investigated. One possible reason could be poor electrical contact between the anode and
the component it is protecting. The electrical resistance should be less than 0.2Ohms.
Poor quality anodes may contain excess iron impurity and will tend to form a dense non-conducting oxide
film (usually charcoal grey in appearance). This condition occurs mainly in fresh water. Test for continuity
between the anode and the jet unit using a multimeter set to ohms. If the anode has to be scraped with a
knife to get a conductive reading, the anode is oxidized and must be replaced. Sanding the anode surface
provides a temporary solution, but will eventually re-oxidize.
Hull anodes
Further anodes should be fitted on the hull, sufficient for hull protection, as determined using a portable
reference electrode and digital voltmeter and / or a corrosion monitor.
The hull anodes should remain immersed at all times.
Anodes fitted to the transom of a planing craft will not be immersed when the craft is at
speed and will not provide protection.
Anti-fouling paint
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
Anti-seize compound
Anti-seize compounds
Do not use anti-seize compounds that contain graphite, nickel, copper or metal flake - these will
cause corrosion.
Anti-seize compounds, usually containing zinc flakes, are available for aluminium.
4-5
Precautions Against Corrosion HJ292 Product Manual
An insulating kit is supplied with the jet unit for steel installations.
For carbon fibre reinforced hulls, an alternative reinforcing fibre (such as glass) must be used in the area
where the jet unit is mounted to ensure that carbon fibre does not contact the jet unit or fasteners.
4-6
HJ292 Product Manual Installation
5 - Installation
In This Section
General
Make sure that the engine cooling water pick up is not directly ahead of the jet unit
intake, but well to the side to avoid turbulent water flow into the jet unit.
Before using any Loctite® product, please read and understand the Loctite® Application
Guide (► page 10-3).
When using marine sealant, bolt and tighten all components within 2 hours of
application.
Once fitted, the intake block becomes part of the hull structure.
It is the designer's responsibility to be satisfied that the strength of attachments and the
integrity of this area are in accordance with hull design criteria and any classification
society or other marine authority involved.
5-1
Installation HJ292 Product Manual
Installation drawings
Refer to the correct installation drawings in the back of this manual when cutting the holes in the hull. Cut-
out sizes and locations will vary depending on hull type, jet configuration etc.
Refer to the relevant Installation drawings as well as these instructions when installing this jet unit.
HJ29208001 Installation Details for GRP Hulls with 0 degree shaft line
HJ29208002 Installation Details for Aluminium Hulls with 0 degree shaft line
HJ29208003 Installation Details for Steel Hulls with 0 degree shaft line
HJ29208011 Installation Details for GRP Hulls with 5 degree shaft line
HJ29208012 Installation Details for Aluminium Hulls with 5 degree shaft line
HJ29208013 Installation Details for Steel Hulls with 5 degree shaft line
Hull preparation
Cut openings in the bottom of the hull to fit the intake blocks
The central longitudinal and keel plate strip should be in position before installing the intake blocks.
The transom should be in place before installation of the intake blocks.
5-2
HJ292 Product Manual Installation
If possible, mount the intake block in the hull mould before moulding.
Mould the hull to form a flat area 90º or 95º angle to the bottom of the intake block.
90° for 0° mainshaft angle
95° for 5° mainshaft angle
For centre-mounted jets, provide a smooth triangular surface in front of the jet unit to form a fairing
between the vee of the hull and the flat of the intake block
Make sure that the contours between the underside of the hull and the intake block, at the front and
rear, are smooth to within 2mm.
5-3
Installation HJ292 Product Manual
The fixing of the intake block, the cross members to the hull and the strength of the
transom must be sufficient to carry the loads imposed by the jet unit on the hull.
5-4
HJ292 Product Manual Installation
An area at the transom must be prepared at the correct angle to accept the transom plate.
If the transom is not at the correct angle, do the following:
Cut out a rectangular section from the transom approximately 100mm larger than the area required for
the transom plate
Re-position this cut out section at the following angle to the bottom of the intake block base.
90° for 0° mainshaft angle
95° for 5° mainshaft angle
Depending on hull type, weld or fibreglass the cut out back to the transom.
The transom thickness adjacent to the jet unit should be a minimum of 20mm.
Brace the cut out all round.
Make sure the bracing of the transom is sufficient to carry the loads imposed by the jet
unit on the hull.
5-5
Installation HJ292 Product Manual
Cut a hole in the bottom of the hull to the dimension and position shown on the Installation drawing
For centre-mounted jets, provide a smooth triangular surface in front of the jet unit to form a fairing
between the vee of the hull and the flat of the intake block
Lift the intake block into the hull and through the hole.
Tack weld the intake block into position so that the bottom of the intake block flange is flush with the
bottom (wet) face of the hull.
Make sure the intake block remains in the correct position while welding
Weld the intake block to the hull as detailed on the installation drawing.
Make sure that the contours between the underside of the hull and the intake block, at the front and
rear, are smooth to within 2mm.
Grind flat where necessary.
5-6
HJ292 Product Manual Installation
Electrical isolation
When mounted in a steel hull, the jet unit and transom plate must be electrically isolated from the hull to
prevent jet unit corrosion.
To achieve this, gaskets and insulating bushes are used.
5-7
Installation HJ292 Product Manual
After welding the angles into the hull, trial fit the intake block.
Lift the intake block from beneath the hull into the recess using 3mm spacers to replace the insulating
gasket.
From below, drill through the dimples in the bottom of the intake block. Make a small mark on the angle
with the drill when it breaks through.
Remove the intake block, countersink and deburr the holes.
5-8
HJ292 Product Manual Installation
5-9
Installation HJ292 Product Manual
The gasket is designed to fold down around the edges of the intake block.
Apply a bead of marine sealant (F) to the bolt holes and under the head of the bolts (F).
Bolt the intake block into position using only 4 bolts, washers and insulating bushes.
Check for electrical isolation between the intake block and the vessel hull. The resistance should be
greater than 1000 Ohms
If satisfactory fit the remaining bolts nuts and washers.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
Recheck the insulation resistance.
Fill any gaps between the intake block and the hull with marine sealant. (F).
Make sure that the contours between the underside of the hull and the intake block, at the front and
rear, are smooth to within 2mm.
Clean off any excess sealant and trim any protruding areas of the insulating gasket.
5-10
HJ292 Product Manual Installation
Once the transom has been prepared, a hole can be cut for the jet unit.
Refer to the appropriate installation drawings for the size of the cutout.
5-11
Installation HJ292 Product Manual
Equipment preparation
Do not unpack the jet unit until it is required for installation. This will prevent mechanical damage and entry
of foreign matter into the jet. Unpack carefully to prevent damage and loss of small items.
Removal of components
The steering crank (A), reverse duct (B) and tailpipe (C) must be removed before installing the jet unit.
The tailpipe can be removed from the intake complete with the reverse duct and steering nozzle still
attached.
Refer to the appropriate area in the overhaul section and assembly drawings for details.
Do not unpack the jet unit until it is required for installation. This will prevent mechanical
damage and entry of foreign matter into the jet. Unpack carefully to prevent damage and loss
of small items.
5-12
HJ292 Product Manual Installation
The above figure shows approved lifting points for hoisting and installing the jet unit.
A minimum of two approved lifting points must be used at any one time.
Only use lifting points C & D or B & D if the reverse duct, tailpipe and steering nozzle have been removed.
Make sure the lifting slings do not foul on the reverse cylinder.
Preparation
Trial fit the jet unit onto the intake block to check the locations of the jet unit and the hole in the transom
From inside the hull, use approved lifting equipment to lower the jet unit onto the intake block.
Make sure the jet unit is correctly located in relation to the transom cutout.
Remove the jet unit from the hull.
Correct the hull preparation if necessary.
5-13
Installation HJ292 Product Manual
Fasten the jet unit intake to the intake block with flat
washers, spring washers and nuts [C, B, A].
Tighten all fasteners to the specified torque. Find
tightening torques for fasteners here (► page 10-26).
Remove any excess marine sealant.
After mounting the jet unit to the intake block, fit the
intake screen [A] from underneath the hull.
5-14
HJ292 Product Manual Installation
5-15
Installation HJ292 Product Manual
5-16
HJ292 Product Manual Installation
Final assembly
Refit the reverse duct.
Refer to the appropriate area in the overhaul section and assembly drawings for details
5-17
Installation HJ292 Product Manual
In multiple jet installations using manual controls, mechanically link the jet units using tie rods.
When fitting the tie rods, the angle between the centre line of the jet unit and the appropriate tie rod
mounting hole on the tiller is equal to the deadrise of the hull.
Refer to the following figures for the correct steering configuration for the appropriate hull deadrise.
Centring the steering
Before fitting the steering tie rods, centre all steering nozzles.
Temporarily clamp the nozzles in position so that the tillers cannot move.
The tie rod length is adjustable to allow accurate centring of the jet.
Twin jet tie rod arrangement
5-18
HJ292 Product Manual Installation
Tillers
A Starboard arrangement
B Centre and port arrangement
1 102834 Cotter
2 102993 M10 special flat washer
3 201395 M10 spring washer
4 201310 M10 nut
Fit the tiller cotter pins must as shown in the above diagram.
Engine 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 directly transmits from the
jet unit directly to the hull.
Flexible engine mounts reduce vibration and noise. Use these in conjunction with a driveshaft system which
does not cause a radial or side load at the jet coupling as the engine moves.
General
Position the engines to give the craft the most suitable fore and aft trim for the proposed boat speed.
For semi-planing and moderate planing speed craft, position the engine(s) well forward towards amidships
for best trim and speed.
For very high speed vessels the position the engine(s) aft, close to the jet unit, to obtain best trim and speed.
Contact your local HamiltonJet distributor for advice or follow the boat designer's recommendations.
5-19
Installation HJ292 Product Manual
Spiral wrap protects all cylinder shafts during shipping. Carefully remove the wrap before
first operation.
Carefully inspect all hydraulic cylinder shafts and pushrods for scratches, paint, weld splatter,
dirt or any other contamination.
To prevent damage to the seals, these shafts must be perfectly clean before operating the
hydraulics.
Anti-fouling paints
HJ274 to HJ364 jet models have optional paint finishes: 'grey gloss' or 'antifoul' schemes.
HJ403 and larger are available with the antifoul scheme only.
The jet unit must have additional coats of antifoul applied typically within two weeks of the
launch of the vessel (refer to the antifoul manufacturers datasheet).
The supplied antifoul coating will require light abrasion and cleaning prior to further
application of antifoul (► page 8-2).
Do not apply copper oxide based anti-fouling paints since these will cause jet corrosion. Only
use antifoul for which the paint manufacturer has stated suitability for use on aluminium
substrates.
Do not paint over the anodes.
5-20
HJ292 Product Manual Installation
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
5-21
Installation HJ292 Product Manual
Drive shaft
HamiltonJet recommends that a qualified driveline specialist install and align the driveshaft.
5-22
HJ292 Product Manual Commissioning
6 - Commissioning
In This Section
The information in this section is for the use of HamiltonJet representatives. Refer to the controls system
manual for details of commissioning checks specific to the controls system.
Securely moor the vessel during commissioning as the jet unit can produce large thrust forces.
Make sure that the bearing housing is filled with the correct amount and grade of grease
(► page 10-32).
6-1
Commissioning HJ292 Product Manual
Pre-launch checks
Spiral wrap protects all cylinder shafts during shipping. Carefully remove the wrap before first
operation.
Carefully inspect all hydraulic cylinder shafts and pushrods for scratches, paint, weld splatter, dirt or
any other contamination.
To prevent damage to the seals, these shafts must be perfectly clean before operating the
hydraulics.
Anti-fouling paints
HJ274 to HJ364 jet models have optional paint finishes: 'grey gloss' or 'antifoul' schemes. HJ403 and
larger are available with the antifoul scheme only.
The jet unit must have additional coats of antifoul applied typically within two weeks of the launch
of the vessel (refer to the antifoul manufacturers datasheet).
The supplied antifoul coating will require light abrasion and cleaning prior to further application of
antifoul (► page 8-2).
Do not apply copper oxide based anti-fouling paints since these will cause jet corrosion. Only use
antifoul for which the paint manufacturer has stated suitability for use on aluminium substrates.
Do not paint over the anodes.
6-2
HJ292 Product Manual Commissioning
With the reverse lever set to zero speed, start the engine(s) and have the engine supplier's
representative can carry out engine checks.
If the jet unit water offtake supplies the engine cooling water, confirm where possible that water is
coming out of the engine exhaust outlets.
Periodically check that the engine is running at the correct operating temperature. This ensures that the
engine is receiving sufficient water from the jet unit water offtake.
Check that the cooling water hoses are secure.
Failure to check cooling water hoses may result in flooding of the vessel.
Check for water leaks around the jet unit while the engine is running particularly under the bearing
housing (mainshaft water seal).
Check that the jet unit and driveshaft are running smoothly (no vibration).
Periodically check the bearing housing temperature. The bearing housing operating temperature should
not exceed 80°C.
Check that the reverse controls are working by monitoring the reverse duct position while moving the
reverse control lever(s).
Check that the steering controls are working by monitoring the steering nozzle position while moving the
helm (check that port helm gives port nozzle deflection, and that all nozzles are steering in the same
direction).
Check that the steering cylinder and not the steering linkages limit the steering travel.
After stopping the engines, check the hydraulic system oil level and refill if required.
6-3
Commissioning HJ292 Product Manual
In the event of any problems, immediately reduce power and return to the mooring. Do not
operate the waterjet until the fault is rectified.
Leave the mooring and check that the steering is working correctly at Forward, Zero Speed and Astern.
When the vessel is moving dead ahead at speed, the waterjet coming from the steering nozzles should be
relatively clean with an even shape.
Check the jet unit and driveshafts are running smoothly (no vibration) over the entire engine operating speed
range (i.e. from idle to full ahead).
Regularly check and record the bearing housing's surface temperature.
Due to friction caused by the seals, the bearing housing will be warm.
Bearing operating temperature should not exceed 80°C.
A faulty bearing can be heard and felt as vibration through the bearing housing and is likely to cause
significant heat build-up.
If possible, check the coupling joint temperatures. Increased joint temperature may indicate driveshaft
misalignment.
Regularly check and record the hydraulic oil temperature at the JHPU oil reservoir:
After an extended run at cruising speed.
After a period of vessel manoeuvring.
Record the maximum speed using GPS and engine revolutions.
Strong currents will result in inaccurate speed readings since the GPS only provides "speed
over ground covered" readings.
At maximum speed, verify the jet unit revolutions using a hand held tachometer at the jet unit coupling.
If possible, record vessel speed at varying engine revolutions.
Record the vessel trim, loading etc.
6-4
HJ292 Product Manual Fault Finding
7 - Fault Finding
In This Section
The following pages contain solutions to problems that may occasionally occur:
Locate a symptom similar to that experienced.
Try each solution, starting with the simplest until the fault is rectified.
For further information refer to the pages indicated.
7-1
Fault Finding HJ292 Product Manual
Engine RPM increases gradually over time, Take off performance poor
Possible cause Solution
Worn or blunt impeller Inspect and repair impeller
Excessive impeller tip clearance
7-2
HJ292 Product Manual Fault Finding
7-3
Fault Finding HJ292 Product Manual
7-4
HJ292 Product Manual Fault Finding
Steering jamming
Possible cause Solution
Grit jamming steering nozzle. Move nozzle from side to side to release grit.
Flush nozzle with water.
Remove nozzle from nozzle housing and check spacers and washers
for wear and damage. Replace as necessary (► page 9-23).
Steering nozzle pivot pins loose or bent. Tighten or replace pivot pins (► page 9-23).
Steering nozzle or steering housing deformed by Remove, rebuild or replace as necessary (► page 9-23).
impact.
7-5
Fault Finding HJ292 Product Manual
7-6
HJ292 Product Manual Maintenance
8 - Maintenance
In This Section
8-1
Maintenance HJ292 Product Manual
General
This maintenance schedule is for normal operating conditions and assumed vessel usage of 2000 operational
hours per year.
If the jet unit operates in an environment which exposes the control equipment to salt spray e.g. an open
vessel, grease all linkages on a weekly basis.
The overhaul section of this manual provides removal and refitting instructions for the various jet unit
components.
Inspection covers
Extreme care is required when removing inspection hatch covers while the vessel is afloat, as
water may enter the vessel through these openings.
Before fully removing the inspection hatch cover nuts, loosen the inspection hatch cover. If
the water level is higher than expected, then the inspection hatch cover can easily be re-
secured.
Never leave inspection covers removed without continuous monitoring of the water levels.
When servicing hydraulic equipment, it is important to read and understand the general notes
in the overhaul section (► page 9-3).
8-2
HJ292 Product Manual Maintenance
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
8-3
Maintenance HJ292 Product Manual
The painted steel and stainless steel components of HamiltonJet waterjet units are coated with a 3-coat
paint system for both the grey gloss and the antifoul schemes, as listed in the table below. The system
consists of:
a surface primer
an epoxy primer tie-coat, and either
a top coat of grey coloured polysiloxane gloss or
a top coat of black coloured Trilux antifoul
8-4
HJ292 Product Manual Maintenance
In October 2012 the grey gloss was changed from a polyester urethane based technology to a polysiloxane
technology. The two products are not interchangeable and cannot be applied over each other. Refer to
Product Bulletin PRB_08_2012 for details.
Any recoating or repair of the International Paints factory applied systems must be done with compatible
products. Refer to the paint manufacturers technical data sheet for the coating compatibility, correct
application thickness and minimum/ maximum recoat times.
System Product Regional Product Name
US & Canada Europe, UK & Asia South America NZ & Australia
Africa
Work Preparation International 950 Super Cleaner Super Cleaner Super Cleaner Awlgr Awlwash
Wash Cleaner
Cleaning
Bare metal Awlprep Plus Awlprep Plus Awlprep Plus Awlprep Plus Awlprep Plus
Solvent Wash Wax and Grease Wax and Grease Wax and Grease Wax and Grease Wax and Grease
Remover T0115 Remover T0115 Remover T0115 Remover T0115 Remover T0115
Aluminium Viny-lux Abrade, then Abrade, then Abrade, then Etch Primer for
Surface Primer Primewash immediately immediately immediately Aluminium Alloys
Aluminium apply Epoxy apply Epoxy apply Epoxy
Grey Gloss
Primer Primer Primer
Systems
Primer Intercure 200 Intercure 200 Intercure 200 Intercure 200 Intercure 200
Grey Gloss Interfine 878 Interfine 878 Interfine 878 Interfine 878 Interfine 878
Aluminium Viny-lux Abrade, then Abrade, then Abrade, then Etch Primer for
Surface Primer Primewash immediately immediately immediately Aluminium Alloys
apply Epoxy apply Epoxy apply Epoxy
Aluminium
Primer Primer Primer
Antifoul Systems
Antifoul Primer Interprotect, Interprotect, Interprotect, Interprotect, Interprotect,
Intergard 263, or Intergard 263, or Intergard 263, or Intergard 263, or Intergard 263, or
Intercure 200 Intercure 200 Intercure 200 Intercure 200 Intercure 200
Primer Intercure 200 Intercure 200 Intercure 200 Intercure 200 Intercure 200
Grey Gloss Interfine 878 Interfine 878 Interfine 878 Interfine 878 Interfine 878
8-5
Maintenance HJ292 Product Manual
Heavy or medium abrasive sweep blasting of aluminium castings will cause excessive material loss
from the casting.
The surface should then be blown down or washed to remove sanding debris followed by a solvent wash to
leave the surface dry and clean. For parts finished with the grey gloss scheme, mask the remaining paint as
applying epoxy primer over the gloss finish is not recommended. Within 30 minutes of abrading the
aluminium surface, a coat of aluminium surface primer (epoxy primer or zinc chromate etch primer) should
be applied to seal the exposed aluminium surface.
It is extremely important to apply the first paint coating within 30 minutes of abrading the bare
aluminium in order to achieve the optimum paint adhesion and therefore paint life.
The use of a zinc chromate etch primer will provide optimum paint system performance in terms of corrosion
protection. Etch primer must only be applied to bare metal, and the coating should be very thin as 'thick'
layers of etch primer lack peel strength - refer to the manufacturer’s specifications and recommendations for
application.
The next step is to apply the epoxy primer. Two coats of epoxy primer are generally required to achieve an
adequate paint dry film thickness.
If filling is required to repair the metal surface, apply a suitable marine epoxy filler. The filler should be
applied after application of the epoxy primer. Sand the filler to achieve a smooth surface and then apply a
further coat of epoxy primer over the filler.
Finally, apply the appropriate top coats to the primed surfaces.
8-6
HJ292 Product Manual Maintenance
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
8-7
Maintenance HJ292 Product Manual
When the vessel is not operational for an extended period, follow procedures below to prevent marine
growth and corrosion problems.
If the jet unit is to be laid-up, do the following:
Clean down the whole jet unit and wash inside and out with fresh water.
Hose the inside of the jet through the intake grill and the nozzle. Allow to dry completely.
Spray with a suitable corrosion protection oil such as Shell Ensis.
Oil and lubricate all moving parts.
If the jet is to remain moored, do the following:
Actively prevent marine growth through the following procedures:
Paint the inside and outside of the jet unit with antifouling compound.
Keep light away from the jet unit.
Moor in deep water.
Place an opaque cover over the steering nozzle to stop light entering the inside of the jet unit.
In shallow water fit an opaque cover over the intake screen.
Before moving any controls, remove any marine growth from the steering and reverse cylinder
shafts or pushrods. This will prevent damage to the seals that the shafts or rods pass through.
8-8
HJ292 Product Manual Maintenance
Servicing intervals
Vessel usage is assumed to be 2000 operational hours per year.
Vary the frequency of the service intervals to suit actual operating conditions.
Carry out a complete examination of the jet unit after the first 2000 hours operation and thereafter every
5000 hours.
Do this examination with the vessel out of the water.
1000 hours
2000 hours
5000 hours
1st 5 hours
100 hours
500 hours
3 months
Monthly
Daily
8-9
Maintenance HJ292 Product Manual
Inspection covers
Extreme care is required when removing inspection hatch covers while the vessel is afloat, as water
may enter the vessel through these openings.
Before fully removing the inspection hatch cover nuts, loosen the inspection hatch cover. If the
water level is higher than expected, then the inspection hatch cover can easily be re-secured.
Never leave inspection covers removed without continuous monitoring of the water levels.
Marine bearing:
The wear should be checked when the jet unit is overhauled (► page 9-54).
Do not run the waterjet out of the water unless it is fitted with a dry run kit, or the marine bearing
and mainshaft water seal are kept wet by some means.
8-10
HJ292 Product Manual Maintenance
Water seal:
Check for water leaks daily:
Visually check for water leaks from under the bearing housing.
Any water found indicates that the water seal is faulty. Replace the water seal as it is not serviceable (►
page 9-41).
Anodes:
Refer to drawing:
HJ29213003 - Anode Location
Check the following:
The earth bonding system:
Check for loose or corroded connections and test to ensure a low electrical resistance (less than 0.2 Ohms).
All sacrificial anodes:
Replace when two thirds corroded (► page 9-6).
For vessels that are continually afloat, check the condition of external anodes every 3 months.
Rapid anode consumption may indicate shore connection problems. Refer here (► page 4-2) for more
information on shore connections.
For trailer boats (and other vessels that are afloat only periodically) anode consumption will be low.
For vessels operating in low salinity water (such as rivers and lakes) the anode consumption will be low due
to the low electrical conductivity of the water.
Cleaning anodes
Typically replace all anodes at the vessels scheduled maintenance haul-out (typically annually). However if
the vessel is only afloat periodically (e.g. trailer boats) or operates in low salinity water then anode
consumption will be low. Clean rather than replace any anode expected to corrode less than two thirds by
the next maintenance haul-out.
Clean the anodes as follows:
Remove marine growth by water blasting.
If a hard scale layer forms on the anodes, then clean them using coarse aluminium oxide sandpaper.
Sand anodes by hand or use an orbital, or disc sander.
Do not use a wire brush since this can cause metallic contamination of the anode, making it
ineffective.
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Maintenance HJ292 Product Manual
Steering linkages:
Visually check monthly
Make sure that all linkages are secure
Check monthly
Make sure there are no missing or damaged pivot pins, split pins or washers
Make sure that all rod ends and clevises are in good condition
Steering crank
Grease every 3 months.
Lightly grease with water repellent grease.
Make sure the crank fits securely.
Make sure the crank is not bent and that there is no wear in the crank ball.
Steering nozzle
Every 100 hours (or 3 monthly whichever comes first):
Make sure the steering arm on top of the nozzle is not bent.
Check the nozzle vertical end float (► page 9-35).
Do not keep pumping grease if resistance is felt as this may force the wiper seal out of the
cylinder retaining nut.
Driveshaft:
Lubricate every 500 operational hours or to suit the manufacturer's recommendations:
Follow the manufacturer's recommendations for the type of driveshaft used.
8-12
HJ292 Product Manual Maintenance
Jet unit
Carry out a complete examination of the jet unit after the first 2000 hours operation and thereafter every
5000 hours.
Do this examination with the vessel out of the water.
It may be necessary to dismantle the jet unit to access some of its internal parts. Refer to the overhaul
section for dismantling and reassembly procedures.
Check the following:
Impeller blades:
Check clearance (► page 9-52):
Carefully remove the inspection hatch cover
Use feeler gauges to check the clearance between the tips of the impeller blades and the wear ring at
each side of the impeller (not top and bottom).
Look for corrosion and damage on all surfaces.
Check the impeller leading and trailing edges for damage or wear.
Marine bearing:
Check the marine bearing for scoring or localized wear. Replace if worn or damaged
To check the bearing for wear:
Push the mainshaft hard from side to side.
Use feeler gauges to measure the total movement at the impeller tips
Replace if necessary.
Diametrical clearance
New min clearance New max clearance Max wear limit
0.06 0.35 0.6
Reverse duct:
Make sure that the reverse duct pivot pins and reverse cylinder attachment points are secure and that
there is no binding in the bushes.
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Maintenance HJ292 Product Manual
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
Anti-seize compounds
Do not use anti-seize compounds that contain graphite, nickel, copper or metal flake - these will
cause corrosion.
Anti-seize compounds, usually containing zinc flakes, are available for aluminium.
Excessive wear:
If excessive wear or damage has been found, then undertake appropriate overhaul as described in the
overhaul section. Schedule the next maintenance period to suit the conditions found during this inspection,
using the following guidelines:
Decrease the time between each maintenance interval if the amount of dirt and sand in the water
increases.
Increase the time between each maintenance interval if amount of dirt and sand in water decreases.
Decrease interval if excessive wear was found in the jet unit internal inspection.
Increase interval if minimal wear was found at the jet unit internal inspection.
Tools
The following tools are required for normal maintenance activities.
Tool Description
Torque wrench ¾"sq/drive Capacity up to 800Nm (590lbf ft) (for impeller nut)
Torque wrench ½" sq/drive Capacity up to 200Nm (145lbf ft)
Ratchet, torque bar and short ½" & 1" sq/drive
extension
Sockets A/F ½" sq/drive 13mm, 19mm, 24mm
Sockets A/F 1" sq/drive 38mm, 70mm
Spanners A/F 1x6mm 1 x 13mm, 2 x 17mm 1 x 24mm
Allen keys 4mm, 6mm, 8mm
Pliers - long nose
Mallet - rubber head
Adjustable wrench 150mm and 300mm
Flat blade screw drivers Small, medium and large
Grease gun
8-14
HJ292 Product Manual Maintenance
Threaded fasteners
Tightening torques
Tighten all threaded fasteners to the correct torque as specified in the appendix (► page 10-26),
and any relevant assembly drawing.
Before using any Loctite® product, please read and understand the Loctite® Application Guide (►
page 10-3).
Anti-seize compounds
Do not use anti-seize compounds that contain graphite, nickel, copper or metal flake - these will
cause corrosion.
Anti-seize compounds, usually containing zinc flakes, are available for aluminium.
8-15
Maintenance HJ292 Product Manual
Belt life:
Well stored V-belts will be fit for service for approximately ten years from date of manufacture (potentially
more in ideal conditions).
Belts stored in machinery spaces such as wrapped emergency spares should typically be fit for service for six
years from date of manufacture.
For example:
The belt in the image displays a manufacturing date of
October 2016.
8-16
HJ292 Product Manual Overhaul
9 - Overhaul
In This Section
9-1
Overhaul HJ292 Product Manual
General information
Inspection covers
Extreme care is required when removing inspection hatch covers while the vessel is afloat, as water
may enter the vessel through these openings.
Before fully removing the inspection hatch cover nuts, loosen the inspection hatch cover. If the
water level is higher than expected, then the inspection hatch cover can easily be re-secured.
Never leave inspection covers removed without continuous monitoring of the water levels.
Loctite®
Before using any Loctite product, please read and understand the Loctite® Application Guide (►
®
page 10-3).
Secure all studs in castings using Loctite® 263.
Anti-seize compounds
Do not use anti-seize compounds that contain graphite, nickel, copper or metal flake - these will
cause corrosion.
Anti-seize compounds, usually containing zinc flakes, are available for aluminium.
Hydraulic oil
On completion of the overhaul make sure to fill all bearing housings, JHPU tanks and oil coolers
with the correct grade and quantity of oil (► page 10-32).
Smear mating surfaces not treated with sealant with a light coating of grease to aid with future
dismantling.
Fasteners that do not require Loctite® are to have grease or anti-seize applied before assembly.
Marine grade anti-seize will reduce the risk of thread galling and is recommended on M20 nuts or
larger.
9-2
HJ292 Product Manual Overhaul
Introduction
Only overhaul components if:
Worn or damaged.
Specified on the maintenance schedule.
Vessel commissioning must be done after any overhaul as adjustments and connections may have
been altered during the process.
Tools:
Refer to the following technical drawing(s) in the back of this manual:
HJ29211000 - Tool Kit.
Special tools are required for the overhaul of the jet unit.
9-3
Overhaul HJ292 Product Manual
9-4
HJ292 Product Manual Overhaul
Remove all metallic particles and other contaminants from the component before fitting seals.
Make sure that the hydraulic system is free from metallic particles and other contaminants before fitting
components.
Check that the seal housing is free from damage likely to harm the seal. Remove all sharp edges and
burrs from metal parts paying particular attention to ports, grooves and threads over or through which
the seal must pass during assembly.
Clean all seal housing areas. Check that other surfaces adjacent to the passage of the seal on fitting are
free of dirt, swarf or other contaminants.
Where the difference between a thread diameter over which as seal must pass and the seal diameter is
small, use some form of protection over the thread, such as a fitting sleeve made of hard plastic.
Do not distort the seals during storage. Store seals in a cool, dry and dark place.
Liberally smear o-rings, seals and metal components with a clean hydraulic fluid of the appropriate type,
or compatible grease, before fitting.
Where sub-assemblies such as pistons, are awaiting further fitting operations, make sure not to subject
the seals to any misaligned or localised loading which will cause local deformation. Ensure sub-
assemblies remain clean.
HamiltonJet does not recommend the use of metal levers. If used however, it is imperative that they are
completely smooth and free from nicks and burrs. Make sure that there is no damage to the metal
surfaces adjacent to the seal.
Anti-fouling paints
Do not apply copper oxide based anti-fouling paints.
Do not paint over the anodes.
9-5
Overhaul HJ292 Product Manual
Anode replacement
Replace the anode if more than two thirds corroded:
Clean the end face of the anode insert, anode and spring
washer mating faces [A] using an abrasive cloth (Scotch-
Brite™) or emery paper [B].
Mount the anode on the stud.
Refit the spring washer and nut using Loctite 243. Find
instructions for the correct use of Loctite® here (► page 10-
3).
Tighten nuts to the specified torque. Find tightening torques
for fasteners here (► page 10-26)
Nyloc nuts fasten some anodes to the stud. Once removed,
discard the old nuts refit using new nyloc nuts.
9-6
HJ292 Product Manual Overhaul
Do not use a wire brush since this can cause metallic contamination of the anode, making it
ineffective.
9-7
Overhaul HJ292 Product Manual
9-8
HJ292 Product Manual Overhaul
Use Loctite® activator 7075 to refit the components otherwise the Loctite 325 will not cure.
There are to be NO dry areas between the bush and the bore once assembled.
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Overhaul HJ292 Product Manual
9-10
HJ292 Product Manual Overhaul
9-11
Overhaul HJ292 Product Manual
9-12
HJ292 Product Manual Overhaul
9-13
Overhaul HJ292 Product Manual
Cap the hydraulics nipples
Thoroughly clean the outside of the cylinder before starting the overhaul.
Remove nuts and spring washers holding the backhead to the cylinder.
Leave the front and backhead nipples in place unless the nipples or bonded seals need replacing
Replace the bonded seals if removing the nipples
Do not remove the grease nipple unless it is being replaced.
Remove the backhead from the cylinder
9-14
HJ292 Product Manual Overhaul
9-15
Overhaul HJ292 Product Manual
When overhauling cylinders, all seals and o-rings must be replaced (► page 9-4).
Using a seal pick tool or sharp spike, remove the wear rings, seals and wipers taking care not to scratch
the seal housings
Do not dismantle the shaft assembly. Replace as a complete unit if required
Front and backheads
Shaft seal
Shaft wiper seal
O-ring
Fronthead extension
Two o-rings
Cylinder retaining nut
Shaft wiper seal
Shaft bush
Shaft piston assembly
Piston seal
When fitting the three part piston seal, it is important that
the two anti-extrusion rings [A] are fitted the correct way
round.
The locating barb on the anti-extrusion ring [B] must fit
into the groove on the sealing ring [C].
Clean and check all parts for wear, corrosion or damage. Repair or replace as necessary.
9-16
HJ292 Product Manual Overhaul
Use a sized suitable drift to press the old gland sleeve from the transom flange. It may be necessary to
apply light heat in the area of the sleeve to break the Loctite® bond.
Clean the bore in the transom flange so it is free of old Loctite® and corrosion.
Check the bore for scoring or damage.
Leave the bore unpainted.
Apply a thin coat of Loctite® 7471 to the outside of the gland sleeve and allow to dry. Do not apply
activator to the bore in the transom flange.
Apply Loctite® 680 to the bore in the transom flange.
From the outside of the transom, press the sleeve evenly into the bore.
Make sure the sleeve is pressed fully into the bore
Clean off any surplus Loctite® from around the sleeve.
Loctite activator 7471 must be used to refit the sleeve otherwise the Loctite
680 will not cure and hold the sleeve in position.
9-17
Overhaul HJ292 Product Manual
Make sure the four studs [A] securely fit into the fronthead extension. Refit with Loctite® 263 if required.
Fit fronthead over studs. Make sure the fronthead nipple and the fronthead extension grease nipple are
aligned.
Lubricate both ends of the cylinder (A).
Push fit the cylinder onto the fronthead.
Lubricate the mainshaft and piston assembly with hydraulic oil (B).
Carefully slide the mainshaft, reverse duct attachment hole first, through the cylinder and fronthead.
Slowly rotate the shaft while inserting so as not to dislodge or damage the seals.
Fit the backhead over the end of the cylinder. Make sure the nipples on the front and backheads are
aligned.
Fit the washers and nuts.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
9-18
HJ292 Product Manual Overhaul
Make sure that the resilient mounts are fitted the correct way round.
9-19
Overhaul HJ292 Product Manual
9-20
HJ292 Product Manual Overhaul
9-21
Overhaul HJ292 Product Manual
Raise the reverse duct and fit the connecting pin through the reverse duct and cylinder shaft.
Fit the washer (s) and secure with the split pin.
9-22
HJ292 Product Manual Overhaul
Do the maintenance described in this section when the vessel is on a slip or in dry dock.
The steering system on this jet unit uses a Seastar® hydraulic cylinder to operate the steering nozzle.
For maintenance and overhaul instructions of the cylinder, please refer to the Seastar® installation and
service manual.
Only dismantle cylinders if there is oil is leaking (seal problems) or there are bent or damaged shafts.
9-23
Overhaul HJ292 Product Manual
Clean the area around the hydraulic fittings, then disconnect and plug all hoses and fittings (label the
hoses to aid with reassembly).
Disconnect the cylinder rod end from the tiller.
Unscrew the cylinder from its mounting bracket
Take care not to lose the anti-rotation bracket (if fitted).
Before dismantling, take the cylinder(s) to a clean workshop environment (► page 9-3)
Check all components for wear or damage and replace or repair as necessary.
Refer to the Seastar installation and service manual for overhaul procedures.
9-24
HJ292 Product Manual Overhaul
When removing the steering shaft, crank or tiller, take note of the orientation of the cotter
pins and tiller. These can vary depending on the position and angle of the jet units.
9-25
Overhaul HJ292 Product Manual
Check the following components for wear or damage and repair or replace as necessary
Bushes
Oil seals
Scraper seals
The bush sleeve and seal housing do not normally require replacing
If the bush is hard to remove, support the area around the bush with a large mass to prevent
damage to the aluminium casting.
Take care not to scratch or damage the sleeve or housing when removing seals or bushes.
9-26
HJ292 Product Manual Overhaul
9-27
Overhaul HJ292 Product Manual
Take care not to scratch or damage the sleeve or housing when removing seals or bushes.
Smear a new oil seal with grease and fit to the front end of the shaft bush housing.
Press a new steering shaft bush, chamfered end first, into the housing until it just touches the oil seal.
Smear a new scraper seal with grease and fit to the housing.
Make sure to fit all seals and or bushes the correct way round
9-28
HJ292 Product Manual Overhaul
Use Loctite® primer 7471 to refit the components otherwise the Loctite 680 will not cure.
There are to be NO dry areas between the bush and the bore once assembled.
Press the bush, tapered end first, into the steering arm.
The bush must sit flush with the bottom of the steering arm.
Wipe away any excess Loctite®
Refit the steering arm to the nozzle.
Tighten fasteners to the specified torque. Find tightening torques for fasteners here (► page 10-26)
9-29
Overhaul HJ292 Product Manual
9-30
HJ292 Product Manual Overhaul
Nozzle insert
9-31
Overhaul HJ292 Product Manual
When removing the lower pivot pin, take care not to lose the thrust washers fitted
inside the pivot bush
Hook out the thrust washer fitted inside the upper pivot bush
Separate the nozzle from the housing.
9-32
HJ292 Product Manual Overhaul
Check the following components for wear or damage and repair or replace as necessary
Pivot pin bush:
The bushes are a press fit and may need to be split and peeled out from the bush sleeve
Take care not to scratch or damage the sleeve or housing when removing seals or bushes.
Press a new bush fully home into the sleeve
Pivot pins:
Steering crank:
Thrust washer:
Lock washers
Do not reuse, discard and replace.
Cotter pins:
Steering nozzle lip seals
Check if still fitted securely and are not worn.
Anode(s):
Check the anode(s) for wear and replace if necessary (► page 9-6)
9-33
Overhaul HJ292 Product Manual
9-34
HJ292 Product Manual Overhaul
Adjust the nozzle vertical end float to achieve a maximum end float of
Spacer washers are available in various thicknesses to achieve this.
Adjust the lower thrust washer thickness until the nozzle sits centrally in the nozzle housing.
Using a feeler gauge, check the vertical end float between the nozzle and nozzle housing (► page 9-35)
Use a suitably thick top thrust washer to set the vertical end float to that specified in the above figure.
Tighten the pivot pins to the specified torque
Rotate the nozzle through its full arc of travel. Make sure there is no touching or binding with the nozzle
insert or nozzle housing.
If the nozzle does not move freely or is outside the vertical clearance limit, re-adjust the spacer washers.
Bend one side of the tab washer up and the other side
down to lock the pivot pins in position. [A]
9-35
Overhaul HJ292 Product Manual
The lip seals can be replaced without separating the nozzle from the nozzle housing.
9-36
HJ292 Product Manual Overhaul
Make sure the cotter pins, tiller and crank are all orientated correctly (this will depend on jet
location and angle and should have been noted when the steering shaft was removed).
This is factory set but if the clevis is changed or disconnected, the clearance must be checked and reset.
This can be done by adjusting the position of the clevis on the steering cylinder.
In multiple jet applications when removing or replacing tie rods, refit the tie rods as detailed here (►
page 5-17).
9-37
Overhaul HJ292 Product Manual
Take extreme care if overhauling the bearing housing with the vessel afloat as water may enter the
vessel through the opening in the intake.
9-38
HJ292 Product Manual Overhaul
Fit the reaction arm to the coupling The reaction arm prevents the mainshaft from rotating while
tightening or loosening the nut
Loosen the coupling nut locking screw.
Unscrew the coupling nut two turns only
9-39
Overhaul HJ292 Product Manual
9-40
HJ292 Product Manual Overhaul
Refit the coupling key and the coupling, complete with the reaction arm attached, and loosely fit the
coupling nut (This will stop the mainshaft rotating while removing the bearing retaining nut).
Using the bearing nut spanner, unscrew the bearing retaining nut.
Remove the coupling nut, puller and coupling etc. from the mainshaft.
Remove the bearing nut and outer seal sleeve.
Slide the bearing housing off the mainshaft.
The water seal fixed components will come away with the bearing housing.
Remove the bearing housing from the jet unit and continue the overhaul in a workshop (► page 9-38)
Water seal
Take extreme care if replacing the water seal while the vessel is afloat as water may enter
the vessel through the intake opening.
Never leave the inspection cover removed.
Only replace the water seal if leaking, or there is insufficient material left to last to the next
inspection.
Do not dismantle the water seal cartridge.
9-41
Overhaul HJ292 Product Manual
Loosen the set screws securing the water seal to the mainshaft.
Carefully slide the water seal off the mainshaft.
Check the wear on the seal face. There must be more than 0.5mm of material on the seal face
Check the mating faces for scoring and chipping.
Check the o-ring(s) for wear, deformation or cuts and replace if necessary.
Any problems detected will mean that the complete water seal assembly will need replacing.
9-42
HJ292 Product Manual Overhaul
9-43
Overhaul HJ292 Product Manual
9-44
HJ292 Product Manual Overhaul
Wet the recess at the rear of the bearing housing with a 20:1 water and household dish washing
detergent mix (H). Do not use oil or grease.
Press the mating ring gasket and mating ring insert into the rear of the bearing housing. Make sure they
locate squarely in the housing.
Smear a new o-ring with grease (A) and fit to the recess in the rear of the bearing housing.
Smear the inner oil seal with grease (A) and press into the bearing housing.
Make sure to fit the seal the correct way round.
9-45
Overhaul HJ292 Product Manual
Carefully fit the bearing housing over the mainshaft and onto the intake studs. Take care not to damage
the mating faces of the water seal.
Grease the outer surface of the inner seal sleeve (A) and slide onto the mainshaft until it rests against the
shoulder.
9-46
HJ292 Product Manual Overhaul
Prepack the bearing with grease (A) then fit it into the bearing housing.
Slide the bearing carrier down the mainshaft and into the bearing.
Tap the bearing carrier with a soft hammer until it sits flush with the face of the bearing.
Slide the outer seal sleeve onto the mainshaft and up against the bearing.
9-47
Overhaul HJ292 Product Manual
Make sure the locking set screws in the bearing retaining nut have been backed off and that the brass
locking pins do not protrude into the thread path.
Lightly apply grease (A) the threads of the retaining nut and the locking screws.
Screw the bearing retaining nut onto the mainshaft. Tighten firmly but do not torque at this stage.
Refit the coupling key and the coupling, complete with the reaction arm attached, and loosely fit the
coupling nut
Using the reaction arm, turn the mainshaft anticlockwise to tighten the retaining nut to the correct
torque. Refer to drawing: HJ29201000 - Base Jet Assembly.
Tighten the locking set screws to the specified torque (► page 10-26).
Remove the coupling nut, puller and coupling etc. from the mainshaft
9-48
HJ292 Product Manual Overhaul
Smear the outer oil seal with grease (A) and press into the bearing cap.
Make sure to fit the seal the correct way round (opposite to normal oil seal orientation).
Lightly grease the contact faces between the bearing cap and bearing housing.
Lightly grease (A) the surface of the outer oil seal sleeve.
Fit the bearing cap over the studs and onto the bearing housing.
Fit nuts using Loctite® 243 and special flat washers.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
9-49
Overhaul HJ292 Product Manual
9-50
HJ292 Product Manual Overhaul
Internal anode replacement should only be done when the vessel is in dry dock.
9-51
Overhaul HJ292 Product Manual
The reverse duct and steering linkages must be removed before proceeding.
Information on the reverse assembly removal can be found here (► page 9-8).
Information on the steering assembly removal can be found here (► page 9-23).
Radial clearance
New min clearance New max clearance Max wear
0.43 0.77 1.08
9-52
HJ292 Product Manual Overhaul
9-53
Overhaul HJ292 Product Manual
Tailpipe overhaul
Replace the marine bearing
Check the fit of the marine bearing sleeve in the marine bearing.
If the bearing sleeve is badly scored or worn it should be replaced.
Replace both the bearing sleeve and the marine bearing if overhauling the impeller or replacing the wear
ring.
Generally it is better to replace both the marine bearing and the sleeve together.
However:
If the marine bearing is still in good condition but the sleeve badly scored, replace the sleeve only.
If the sleeve is still in good condition with wear less than 0.2mm, but the rubber of the marine
bearing badly worn, replace the marine bearing and keep the sleeve.
To avoid damaging the stator blades when pressing the fairing and bearing from the tailpipe, place
a support at the tailpipe hub aft of the bearing and press the fairing out towards the rear.
Turn the tailpipe over and supporting the bearing hub, press the bearing forward out of the tailpipe.
9-54
HJ292 Product Manual Overhaul
When shrink fitting of the marine bearing is required, chilling must be achieved by gradual cooling
to not more than minus 20°F (-28°C) using a freezer or regular ice. Do not use dry ice.
Pounding or shocking the bearing while in a chilled state could cause the rubber to separate from
the shell.
When pressing in a new bearing, make sure the inner hub of the tailpipe is supported to prevent
overloading the stator blades.
When fitting a dry run bearing liner, make sure there is no groove at the bottom of the liner when
fitted in the shell
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Overhaul HJ292 Product Manual
Tailpipe anodes
Remove the anode mount plate complete with anodes attached.
Check the anode(s) for wear and replace if necessary (► page 9-6)
Impeller - overhaul
Repair minor corrosion or pitting by welding.
Grind the weld flush with the original surface.
If the surface wear is more than 1mm deep, a new intake should be fitted.
9-56
HJ292 Product Manual Overhaul
Prevent the mainshaft from turning by fitting the reaction arm to the coupling (► page 9-57).
Loosen the impeller nut securing set screw.
Using the socket provided in the toolkit, unscrew the impeller nut.
If the nut is hard to remove, apply light heat in the area of the nut to break the Loctite® bond.
Remove the bearing sleeve.
Make sure the bearing sleeve is pulled straight from the mainshaft otherwise it could gall and jam.
9-57
Overhaul HJ292 Product Manual
Reaching through the inspection hatch, loosen the 3 x impeller fairing set screws 1 turn.
Screw the impeller puller onto the rear of the impeller hub
9-58
HJ292 Product Manual Overhaul
Turn the forcing screw until the impeller releases from the mainshaft.
Remove the impeller complete with the puller tool from the intake.
Remove the impeller key from the mainshaft.
Make sure that the locating dowel remains fitted to the mainshaft. Refit if necessary (► page 9-7).
Remove the impeller seal and impeller fairing. Discard the impeller seal.
9-59
Overhaul HJ292 Product Manual
Step 2
Force a thin screw driver between the wear ring and the
insulator, next to the joint.
Keep forcing until the end of the wear ring comes free.
1 Intake
2 Insulator
3 Screw driver
4 Wear ring
Step 3
Pull the free end of the wear ring inwards and remove it
from the impeller race.
Remove the insulating strip.
Thoroughly clean and degrease the impeller race bore.
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HJ292 Product Manual Overhaul
The wear ring may not fit without filing the mating ends slightly to reduce the circumference.
Do not remove too much metal from the ends of the wear ring.
The wear ring must be a tight fit once the insulator is fitted.
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Overhaul HJ292 Product Manual
Place a heavy steel plate of the correct size, against the end
of the wear ring (the plate prevents damage to the end of
the wear ring and should cover the whole diameter) [A].
Using a large hammer, drive the wear ring evenly into the
impeller race
Continue driving until the wear ring sits flush with the inner
recess of the impeller race.
The wear ring must not contact any part of the jet unit
except for the insulating strip.
After fitting, check the electrical insulation between the
wear ring and the impeller race. The resistance should be
greater than 1000 Ohms.
The wear ring is in the correct position when it sits flush with the forward and rearward faces of the
impeller race as shown in the figure below. This gap (X) must be maintained to prevent electrical contact
between the wear ring and the tailpipe / intake of the jet unit.
1 Intake
2 Wear ring insulator
3 Wear ring
The wear ring must sit flush with the aft end of the intake.
There must be a gap greater than 0.8mm between the forward end of the wear ring and the
impeller race.
This gap is necessary to prevent electrical contact between the wear ring and the intake
9-62
HJ292 Product Manual Overhaul
Impeller overhaul
Avoid using excessive heat during welding.
Impellers are stainless steel type CF8M conforming to ASTM A 743 or 316 to BS 3100.
Filler metal should have a chemical analysis similar to AISI 316L (carbon content less than 0.03%).
Post weld heat treatment is not required.
Inspection
Check the impeller surfaces for corrosion.
Weld repair damaged areas and dress back to a smooth surface.
Check the impeller leading and trailing edges for damage.
Straighten and dress bent or dented blades using suitable tools.
Bring the blade back to its original smooth profile checking against undamaged blades.
Check the leading edges.
Build up worn or blunt leading edges up by welding.
Sharpen the leading edges as shown on the drawing.
Blunt impellers can cause loss of performance and cavitation.
Check the impeller O.D.
Blade leading edge repair procedure
Dress the edge back to a smooth curve, removing the minimum amount of metal.
Weld repair damaged edges.
Dress both faces of the blade. Take slightly more metal off the rear side until the leading edge is the
correct thickness.
Blend well back into the original blade surface.
Both front and rear surfaces are to be a smooth uniform curve with no sudden bumps or change in
direction.
Grind or file a smooth radius along the leading edge.
Impeller outside diameter (O.D.) repair procedure
Build up an excessively worn impeller OD by welding.
After welding, turn on a mandrel to the correct OD. Use light cuts to avoid blade distortion.
Dress the faces back flush with the original surfaces.
File and polish.
New max diameter New min diameter Worn min diameter
287.8 287.6 287.0
Balancing
Balance the impeller after any welding or grinding.
Balance the impeller statically, on a suitable mandrel set on horizontal knife edges or bars to within the
maximum out of balance specified.
Weld 316 stainless steel balance weights to the inside of the impeller hub. Grinding is permitted.
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Passivation
Wear appropriate safety glasses, protective gloves and clothing to prevent skin exposure to
nitric acid.
Impeller refitting
9-64
HJ292 Product Manual Overhaul
Smear a light coating of grease (A) over the mainshaft from the impeller taper up to the impeller nut
threads.
Slide the impeller fairing and impeller seal over the mainshaft past the taper.
Fit the impeller key making sure that the locating dowel fits securely in the keyway.
Slide the impeller onto the mainshaft and over the impeller key.
Fit the marine bearing sleeve.
When fitting a new impeller onto the mainshaft, lap the impeller taper to the
mainshaft in accordance with British Standard MA 74.
Prevent the mainshaft from turning by fitting the reaction arm to the coupling (► page 9-57).
Fit the impeller nut and tighten to the recommended torque, Refer to drawing: HJ29201000 - Base Jet
Assembly
Apply Loctite 222 to the threads of the setscrew, fit and tighten to the recommended torque.
Working through the inspection hatch, slide the impeller seal and impeller fairing up against the nose of
the impeller.
It may be easier to access the impeller fairing through the jet intake if the screen
has been removed.
Tighten the impeller fairing ring set screws evenly to the recommended torque.
Remove the reaction arm from the coupling.
9-65
Overhaul HJ292 Product Manual
Tailpipe refitting
Tailpipe re-assembly
Wipe the bearing sleeve clean of any grease.
Dust the inside rubber of the marine bearing with French chalk or talcum powder Alternatively, use a
20:1 water and household detergent mix.
Clean and lightly grease the contact faces between the tailpipe and the intake.
Smear a new o-ring with grease and fit into the groove in the intake.
Lift the tailpipe over the bearing sleeve and slide up the mainshaft and over the studs in the intake.
Secure with nuts and washers using Loctite® 222.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
Make sure that the mainshaft assembly rotates freely.
Reconnect any water offtake hoses attached to the tailpipe.
9-66
HJ292 Product Manual Overhaul
The transom plate should only be removed if it is damaged or there is water leaking from
around the seal.
Before removing the transom plate, the following components must be removed:
Reverse duct
Reverse cylinder
Steering cylinder
Steering nozzle
Tailpipe
The reverse duct and tailpipe can be removed as a complete unit.
Refer to the relevant overhaul sections to remove the above equipment.
Transom plate
9-67
Overhaul HJ292 Product Manual
The transom plate has been fitted to the transom using marine sealant. Some effort may
be required to separate the transom plate from the transom.
Hatch extension
9-68
HJ292 Product Manual Overhaul
9-69
Overhaul HJ292 Product Manual
9-70
HJ292 Product Manual Overhaul
The vessel must be removed from the water before the screen and screen rake can be overhauled.
From beneath the vessel, support the screen using suitable lifting equipment.
Remove the nuts and washers and carefully lower the Screen.
Check that the studs are still secure, if necessary refit using Loctite® 263.
Check the screen for corrosion or damage, Replace or repair as necessary
Refit the screen to the intake block.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
9-71
Overhaul HJ292 Product Manual
Smear new o-rings with grease and fit to the screen rake bearings.
Smear the bore of the bearings with grease (A).
9-72
HJ292 Product Manual Overhaul
Fit the port bearing to the intake (make sure the grease nipple is at the top of the bearing).
From beneath the vessel, feed the screen rake pivot through the starboard bearing mounting hole in the
intake.
Raise the port side of the screen rake and slide the screen rake pivot fully home into the port bearing.
Fit the starboard bearing to the intake (make sure the grease nipple is at the top of the bearing).
Fit the screen rake actuator and cotter pin.
Tighten all fasteners to the specified torque. Find tightening torques for fasteners here (► page 10-26)
Connect the tension spring(s) to the actuator arm.
Grease the bearings via the nipples until grease just oozes from the inside ends of the bearings.
Refit the screen to the intake block
Operate the screen rake making sure that it does not foul on the intake screen.
9-73
Overhaul HJ292 Product Manual
Jet units that do not have a screen rake must have blanking plugs fitted to replace the screen rake bearings.
To fit the blanking plugs:
Smear the o-ring and shaft of the blanking plug with grease).
Fit the blanking plugs to the intake.
Tighten nuts to the specified torque. Find tightening torques for fasteners here (► page 10-26)
9-74
HJ292 Product Manual Appendix
10 - Appendix
In This Section
10-1
Appendix HJ292 Product Manual
Conversions
Torque Liquid Measure (Imperial)
1 pound foot = 1.3558 newton metres 1 Pint = 0.5506 litre
1 newton metre = 0.7375 pounds foot 1 gallon =4.546 litres
1(UK) gallon = 1.201 (US) gallon
Distance 1 litre = 0.2199 (UK) gallons
1 inch = 2.54 centimetres To Convert Fahrenheit to Celsius, subtract 32 then multiply by
1 foot = 0.3048 metre 5/9
1 mile = 1.609 kilometres To convert Celsius to Fahrenheit, multiply by 9/5 then add 32.
1 nautical mile = 1.8532 kilometres
1 millimetre = 0.03937 inches Liquid Measure (U.S.)
1 metre = 3.2808 feet 1 pint = 0.473 litre
1 kilometre = 0.6214 mile 1 gallon = 3.785 litres
1 kilometre = 0.539 nautical mile
Speed
Area 1 mile per hour = 0.8690 knots
1 inch² = 6.4516 centimetres² 1 kilometre per hour = 0.5396 knots
1 foot² = 929.03 centimetres² 1 knot = 1.8532 kilometres per hour
1 centimetre² = 0.1550 inch² 1mile per hour = 1.609 kilometres per hour
1 metre² = 10.76 feet² 1 kilometre per hour = 0.621 miles per hour
1 knot = 1.151 miles per hour
Power
1 horsepower = 0.7457 kilowatts Pressure
1 horsepower (Metric) = 0.7355 kilowatts 1 pound/inch² = 0.0689 bar
1 kilowatt = 1.341 horsepower 1 pound/foot² = 4.8824 kilogram/metre²
1 kilowatt = 1.3596 metric horsepower 1 pound/inch² = 6.895 kilopascal
1 Newton/millimetre² = 145.04 pounds/inch²
Force 1 bar = 14.5038 pounds/inch²
1 kilonewton = 224.86 pounds force 1 kilogram/metre² = 0.2048 pounds/foot²
1 pound force = 4.448 newtons 1 kilopascal = 0.145 pound/inch²
1 bar = 100 kilopascal
Weight
1 ounce = 28.35 grams
1 pound = 0.4536 kilograms
1 gram = 0.0353 ounce
1 kilogram = 2.205 pounds
1 tonne = 2205 pounds
Temperature
Fahrenheit Celsius
248 120
212 100
176 80
140 60
104 40
95 35
86 30
77 25
68 20
59 15
50 10
41 5
32 0
10-2
HJ292 Product Manual Appendix
General practice
No smoking in the presence of primer, activator or accelerator, as these products are highly
flammable. Never mix primer or activator and adhesive directly as liquids. For additional safe
handling procedures refer to the product material safety data sheets (MSDS) and technical data
sheets (TDS) available from www.loctite.com.
All parts must be free from oil and or grease. Do not use paint thinners for cleaning. Use solvent or
degreaser such as methylated spirits, trichlorethylene or acetone.
All painted bores must be fully cured before the application of Loctite.
Fixing and full cure times for all Loctite will be increased at reduced temperatures.
To prevent the product from clogging in the nozzle, do not allow the tip to touch metal surfaces during
application.
In general, nuts that secure anodes use Loctite 243 and a spring washer. Anodes in internal water
passages use nyloc nuts, external anodes use plain nuts.
10-3
Appendix HJ292 Product Manual
Equivalents
Loctite grade Equivalent
222 Purple Low strength threadlocker:
10-4
HJ292 Product Manual Appendix
Bushes, sleeves, composite bush assemblies (extra high strength retaining). Primer will be used
in all retaining applications.
1 - Apply primer to whole surface of bore and allow to dry before fitting.
2 - Apply Loctite to whole surface of bore and front of bush before fitting.
There are to be no dry areas between the bush and the bore.
Rotate bush when fitting to distribute the Loctite evenly.
For press fitted bushes, coat the entire bush and bore before pressing in the bush.
Bushes, sleeves, composite bush assemblies (extra high strength retaining). Primer will
be used in all retaining applications.
Do not apply primer to LG2 bushes.
1 - Apply primer to whole surface of bore and allow to dry before fitting.
2 - Apply Loctite to whole surface of bore and front of bush before fitting.
There are to be no dry areas between the bush and the bore.
Rotate bush when fitting to distribute the Loctite evenly.
For press fitted bushes, coat the entire bush and bore before pressing in the bush.
10-5
Appendix HJ292 Product Manual
Studs
Loctite Colour Primer, activator, accelerator Loctite® cure speed
Red Type Drying time Partial Full
263
Primer 7649 30-70 seconds With primer 10 minutes 2 hours
(optional) n/a Without primer 20 minutes 6 hours
10-6
HJ292 Product Manual Appendix
10-7
Appendix HJ292 Product Manual
10-8
HJ292 Product Manual Appendix
10-9
Appendix HJ292 Product Manual
10-10
HJ292 Product Manual Appendix
Dowel retention
Loctite Colour Primer, activator, accelerator Loctite® cure speed
Green Type Drying time Partial Full
680
Primer 7471 30-70 seconds 5 minutes 4-6 hours
10-11
Appendix HJ292 Product Manual
Installation checks
Jet unit mounting
Item Check Completed
1 Check the intake block is flush with the exterior of the hull bottom.
2 Check that there are no flow obstructions forward of the intake (refer to the hull details in jet
designers manual). Make a record of the size and position of any through hull penetrations or
strakes around the jet area, for use when commissioning the jet unit.
3 Inspect the intake base flange for obvious distortion or gaps between the intake base flange
and the hull.
4 Check the intake gasket (or silicon sealant) between the base and the mounting surface has
not squeezed out into the water passage. Trim off any excess gasket and sealant.
5 Check the transom plate seal is correctly located and secured (do not overtighten). If two
people are available and the boat is indoors, use a strong light to check the fit of the transom
cut out and seal.
6 For steel hulls make sure that the jet unit is insulated from the hull (refer to the drawings and
the "Corrosion" section of the product manual).
7 Check that engine exhaust outlets are above the expected waterline and well to the side of jet
units (refer to the Design Basics section in the jet unit product manual).
8 Check that the hull trim tabs (if fitted) will not interrupt the reverse flow (refer to the Design
Basics section in the product manual).
Notes:
10-12
HJ292 Product Manual Appendix
Notes:
10-13
Appendix HJ292 Product Manual
10-14
HJ292 Product Manual Appendix
Drive shaft
Item Check Completed
1 Ensure HamiltonJet have approved the driveline details
2 On universal joint driveshafts (refer to the design basics section in the
product manual) check:
Yoke offset angles are in the same plane, are equal and less than 5°.
Yokes are in the same plane (► page 3-10).
3 On bearing supported line shafts (refer to the design basics section in the
product manual) check:
Align support bearings with the engine flywheel.
Position outer support bearings close to the end couplings.
Notes:
10-15
Appendix HJ292 Product Manual
Commissioning checks
Pre-launch checks
Item Check Completed
1 Check that the plastic spiral wrap protective cover (where fitted) has been
removed from hydraulic shafts.
Check all hydraulic shafts for damage and contamination (weld splatter,
grinding dust, fibreglass resin, etc).
2 Check that all the jet unit inspection covers are correctly fitted and
secured.
3 Check that all the anodes have been fitted and that they have not been
painted over. Refer to anode location drawing.
4 If the steering assembly, tailpipe or reverse duct have been removed
during jet installation, check that all fasteners securing these items have
been torqued correctly.
Notes:
10-16
HJ292 Product Manual Appendix
3 For grease lubricated main bearings, add grease until grease comes out of
the front seal as shown in the "Initial Bearing Housing Re-Assembly"
section.
Make sure that all bearing housings and JHPU tanks are filled
with the correct quantity and grade of oil.
4 If a main bearing oil pump is fitted (HM-651 to HM-811) then check the
oil pump operation by loosening the oil pipe fitting on top of the bearing
housing and checking for oil flow.
5 Make sure the JHPU oil level is correct. Add oil as required (► page 10-
32)
6 If the vessel is fitted with shore power, then unplug the shore power and Measured
measure the electrical resistance between the hull and the earth pin of Resistance
the vessel shore power plug. A correctly wired isolation transformer or
galvanic isolator will result in high electrical resistance (greater than 1kΩ) _______Ω
between the hull and the earth conductor (refer to "Precautions Against
Corrosion" section of the product manual).
10-17
Appendix HJ292 Product Manual
2 Ensure the vessel is securely moored fore and aft and in deep clean
water.
3 With the reverse controls set to "zero speed", the engine(s) may be
started and the engine suppliers representatives can carry out engine
checks.
4 If the engine cooling water is taken from the jet unit offtake, confirm
that water is coming out of the engine exhaust outlets where
possible. Periodically check that the engine is running at the correct
operating temperature. Check that the cooling water hoses are
secure.
5 If the vessel is equipped with HSRC or HYRC and the pressure alarm
sounds, immediately shut the engine off and refer to the controls
product manual to check adjustments. Failure to immediately shut
down the engine may result in serious damage to the hydraulic pump
due to overheating.
6 Check for water leaks around the jet unit while the engine is running
particularly under the bearing housing (mainshaft water seal).
7 Check that the jet unit and driveshaft are running smoothly (no
vibration).
8 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.
9 Check that the reverse controls are working by monitoring the reverse
duct position while moving the reverse control lever(s).
10 Check that the steering controls are working by monitoring steering
nozzle position while moving the helm (check that port helm gives
port nozzle deflection, starboard helm gives starboard nozzle
deflection and that all nozzles are steering in the same direction).
12 After stopping the engine, check the main bearing and JHPU oil levels
and replenish if required.
10-18
HJ292 Product Manual Appendix
Notes:
10-19
Appendix HJ292 Product Manual
Vessel trial
Item Check Completed
1 Leave the mooring and check that the steering is operating correctly at
"Forward Speed", at "Zero Speed" and going "Astern".
2 Observe the jet stream when going "Dead Ahead" at speed to ensure
that it is relatively clean with an even shape.
3 Check the jet unit and driveshafts are running smoothly (no vibration)
over the entire engine operating speed range (i.e. from idle to full
ahead).
4 Periodically check the bearing housing temperature and record the
temperature once it reaches a steady value. Due to friction caused by
the seals, the bearing housing is likely to be warm. The temperature
should not exceed 80°C.
5 If practical check the driveshaft coupling joint temperatures (if fitted).
Increased joint temperature may indicate driveshaft misalignment.
6 Periodically check the hydraulic oil temperature at the oil tank. Record
the temperature reading after a sustained run at cruising speed and
after a period of vessel manoeuvring.
7 Record maximum speed (using GPS) and engine revolutions (strong
currents will result in inaccurate speed readings since the GPS provides
speed over ground). Verify the jet revolutions at maximum speed, using
a hand held tachometer at the jet unit coupling
8 Record vessel speed at varying engine revolutions if possible.
9 Record observations on vessel trim, loading, etc.
Notes
10-20
HJ292 Product Manual Appendix
3 Check for water leaks around the waterjet, especially at the transom at
the intake block and under the bearing housing (water seal leaks).
Notes
10-21
Appendix HJ292 Product Manual
Engine model
Temperature readings
Driveshaft joints, bearing housing, hydraulics
Temperature Location & comments
10-22
HJ292 Product Manual Appendix
Notes
10-23
Appendix HJ292 Product Manual
1 Welds
To be full penetration and conform to relevant classification society requirements (e.g. ABS, Lloyds
Register, DNV).
2 Welder qualifications
Properly qualified welder to relevant classification society requirements, in downhand or overhead as
required.
3 Inspection
Inspection to be done by a welding inspector qualified to relevant classification society requirements.
4 Site
The site must be:
Dry and free from steel dust or any other contaminates that could affect the finished weld condition.
Sheltered from draughts to prevent disturbance to shielding gas.
5 Welding process
M.I.G.
6 Welding wire
Plate (5086 or 5083) to plate (5086 or 5083), use 5356 filler wire.
Casting (EN AC 44100) to casting (EN AC 44100), use 4043 filler wire.
Casting (EN AC 44100) to plate (5086 or 5083), use 4043 filler wire.
5356 filler wire may be used if the local process/conditions show superior weld quality to 4043, however
adequate inspection shall be performed as per paragraph 15.
7 Shield gas
Argon or helium.
8 Weld position
Weld position options are:
Flat downhand. Turn hull over to do the other side flat downhand. Requires double vee prep.
Single vee prep. Use backing strip. Weld flat downhand one side only, then grind off backing strip.
Double vee prep. Flat downhand one side. Overhead other side.
10-24
HJ292 Product Manual Appendix
9 Weld prep
Double vee butt weld prep:
10 Cleanliness
Dress all surfaces to be welded just prior to welding to remove surface oxides.
Cast aluminium that has been submerged in salt water must be thoroughly rinsed in fresh water then
dried, prior to final dressing.
11 Preheat
Remove chill 50º - 60ºC (120º - 140ºF) to ensure weld prep area is dry.
12 Support
A rigid strong back should be clamped or tacked to the intake block during welding to prevent distortion.
13 Weld runs
Multipass runs may be necessary depending on plate and casting thickness.
Stitch 75mm with 75mm gaps for first 2 runs to minimize distortion.
Stitch sequence for the intake block to be a star sequence, rather than proceeding linearly around the
block circumference.
Grind stop starts before filling in. Subsequent runs may be full length runs.
14 Back gouging
Chipping, routing, milling, grinding or other suitable methods are to be employed at the root or under
side of the weld to obtain sound metal before applying subsequent beads.
Grind stop/start craters.
15 Visual inspection of welds acceptance level
No cracks, porosity, lack of fusion, cold laps or undercut.
Use dye penetrant to check outer surface of welds and intermediate weld passes, such as root passes,
and also to check back-chipped, ground or gouged joints prior to depositing subsequent passes,
Any dye penetrant used is to be thoroughly removed from area before rewelding.
Dye penetrant is not to be used where complete removal of the dye penetrant material cannot be
assured.
10-25
Appendix HJ292 Product Manual
Tightening torques
85113 Issue V
10-26
HJ292 Product Manual Appendix
The minimum thread length required in aluminium castings is twice the screw or bolt diameter.
10-27
Appendix HJ292 Product Manual
Stud installation
Rolled formed studs with nose
Size Torque
M20 48Nm (35lbf ft)
Thread stud into casting until thread bottoms. Confirm the stud
protrusion is equal to stud length minus thread length as per stud
description.
10-28
HJ292 Product Manual Appendix
Set screws
Set screw tightening torques (non aluminium)
Size Torque
M3 0.6Nm (0.4lbf ft)
M4 1.5Nm (1.1lbf ft)
M5 3Nm (2.2lbf ft)
M6 5Nm (3.7lbf ft)
M8 12Nm (9lbf ft)
M10 24Nm (18lbf ft)
M12 45Nm (33lbf ft)
A - Aluminium
10-29
Appendix HJ292 Product Manual
Hydraulic fittings
BSPP fittings in jet castings
Size Torque
1/8 4Nm (3lbf ft)
1/4 10Nm (7lbf ft)
3/8 20Nm (15lbf ft)
1/2 40Nm (30lbf·ft)
3/4 63Nm (46lbf ft)
1 105Nm (77lbf ft)
1-1/4 142Nm (105lbf ft)
1-1/2 320Nm (236lbf ft)
2 500Nm (369lbf ft)
Hoses
Size Torque
Imperial
1/4 20Nm (15lbf ft)
3/8 35Nm (26lbf ft)
1/2 60N m (44lbf ft)
3/4 115Nm (85lbf ft)
1 140Nm (103lbf ft)
1-1/4 210Nm (155lbf ft)
1-1/2 290Nm (214lbf ft)
2 400Nm (295lbf ft)
Metric
DN6 28Nm (21lbf ft)
DN10 38Nm (28lbf ft)
Refer to Label on hose for sizing
DN12 55Nm (40lbf ft)
DN19 100N·m (74 lbf·ft)
Hose clips
Part # Size Torque
201056 12-20 2.3Nm (1.7lbf ft)
201057 14-32 4Nm (3lbf ft)
201058 30-45 5Nm (3.7lbf ft)
201059 40-60 5Nm (3.7lbf ft)
205780 50-70 5Nm (3.7lbf ft)
201060 60-80 5Nm (3.7lbf ft)
206094 80-100 5Nm (3.7lbf ft)
064924 51-55 15Nm (11lbf ft)
209872 59-63 15Nm (11lbf ft)
10-30
HJ292 Product Manual Appendix
Thread lubricants
Thread type Description of lubricant where the thread lubricant or Loctite® is
not specified
Nuts on 316 stainless studs Multipurpose marine grade grease.
Nuts on high strength studs Multipurpose marine grade grease or marine grade anti-seize.
Anti-seize will reduce the risk of thread galling so is recommended, particularly on
larger or longer studs.
.
1/4" UNC - 1/8" UNC Multipurpose marine grade grease.
3/4" UNC Marine grade anti-seize.
Bronze impeller or coupling nuts Multipurpose marine grade grease.
Hydraulic fittings General purpose grease with PTFE base or hydraulic oil.
e.g. Accrolube® high efficiency grease with PTFE (grease must not contain graphite).
Fasteners inside sealed control modules No lubricant, fit dry.
Plastic male or female threads No lubricant, fit dry.
Other metric fasteners Multipurpose marine grade grease
Examples
Multipurpose marine grade Shell: Shell Alvania RL2
lithium based grease or Mobil: Mobilux 2, Mobilux EP 2
calcium sulphate based Castrol: Molub - Alloy 6040
grease. BP: Engergrease MP-MG 2
Anti-seize compounds
Do not use anti-seize compounds that contain graphite, nickel, copper or metal flake - these will
cause corrosion.
Anti-seize compounds, usually containing zinc flakes, are available for aluminium.
Only use Loctite® marine grade anti seize when using anti-seize on nuts fitted to high strength studs
to achieve the correct stud preload.
10-31
Appendix HJ292 Product Manual
Hydraulic fluids
Jastram manual hydraulic steering
Fluid: Jet model
ISO VG32 hydraulic oil HJ364
Examples:
Castrol: Hyspin AW32
Shell: Tellus 32
Esso/Exon/Mobil: Nuto H32/DTE Excel 32
Texaco/Chevron/Caltex: Rando HD32/AW32
Gulf: Harmony AW32
Oil volume (litres)
The oil volume in this system is dependent on several factors: the
number of stations, length of tubing etc. and are determined by the
configuration of the vessel.
10-32
HJ292 Product Manual Appendix
10-33
Appendix HJ292 Product Manual
BlueARROW/AVX:
HJ274 1.7
HJ292 1.8
HJ322 2.3
10-34
HJ292 Product Manual Appendix
Joint lubrication
Impeller and coupling taper joints
Grease:
Multipurpose marine grade grease
Apply a thin film of grease to the shaft taper (A).
10-35
Appendix HJ292 Product Manual
Barrier cord O-rings are natural rubber O-rings fitted to Inspection hatch covers. When lubricating barrier cord O-rings, use non-
petroleum based grease.
Petroleum based grease will react with the natural rubber in the barrier cord.
Identify barrier cord by its colour, either brown or white.
Ball joints
Grease:
Multipurpose marine grade grease.
Apply lubricant using a grease needle (A).
Threads
Refer to threaded fasteners tightening torques (► page 10-26).
10-36
HJ292 Product Manual Appendix
Impeller seal
Lubricant [A]
Use only
P80 IFC temporary rubber assembly lubricant (P/N 902021)
or
Methylated spirits (rubbing alcohol) on impeller seal surface to aid assembly
Do not use
Grease or oil
Apply lubricant to the mainshaft before fitting the impeller and marine bearing sleeve [A].
10-37
Appendix HJ292 Product Manual
Drivers guide
Starting up
Never stop the engine(s), or disengage the drive to the jet unit, when approaching a
mooring or at any time when control of the vessel may be required.
With jet or engine driven hydraulic pumps, it is not possible to move the reverse duct until
the pump is running.
Make sure that clutches and gearboxes, if fitted are in the neutral position.
After starting the engine(s):
Adjust the helm and reverse levers, to control vessel movement
10-38
HJ292 Product Manual Appendix
If in lightweight planing craft, the "astern" or "zero speed" positions are selected with the throttle
left open and the boat moving forward at speed, the resultant "braking effect" can be very severe.-
even more so than full braking with a motor vehicle.
Steering
The waterjet's mainshaft must always be rotating whenever steering thrust is required.
The steering nozzle deflects the jetstream to port or starboard causing the vessel to steer to port or
starboard respectively.
Note the following points when operating a waterjet powered vessel:
With the engine is stopped, there will be no jet of water to deflect. The vessel cannot then be steered or
stopped.
Never stop the engine or disengage the drive to the jet when approaching a mooring or at any time when
steering will be required.
The more the throttle is opened the greater the steering effect - i.e. the sharper the turn.
Steering is available at "zero speed" as well as all ahead and astern speeds.
It is important to note that there is no reversal of the steering while the vessel is moving
astern. When turning the helm to port, the bow of the vessel will also turn to port
whether the vessel is moving ahead or astern. This is the opposite of how steering works
in a motor vehicle.
It is recommended that new operators practice heading astern at low speeds until they
become familiar with this method of steering.
10-39
Appendix HJ292 Product Manual
Steering operation
Steering may only be possible at low RPM unless an emergency tiller extension is used.
10-40
HJ292 Product Manual Appendix
Emergency manoeuvring
Single jet unit
The vessel can be partially manoeuvred by raising and lowering the reverse duct with a rope The engine must
be kept at idle RPM.
Multiple jet units
Shut down the engine driving the jet without reverse and manoeuvre using the other jet(s).
Do not work the throttles - leave as set. With twin jets, manoeuvre using the helm with one
hand and both reverse levers with the other hand.
Use only low engine RPM - high RPM will give faster response but makes control more difficult.
If the bow is rotating to starboard, use port lock to stop the rotation (or vice versa) then centre
the helm to hold the heading.
If the vessel is moving ahead, then move the reverse lever(s) astern to bring the vessel to rest
(or vice versa) and then zero speed selected to hold the heading.
10-41
Appendix HJ292 Product Manual
Moving sideways
Moving sideways, twin waterjet
The following procedure moves the vessel to port. Transpose port and starboard to move to starboard.
Set both reverse control levers to zero speed and make sure the vessel is stationary.
Set both engine throttle levers to just above idle with slightly higher rpm on the port side.
Set steering to ahead.
Move the port reverse control lever to full astern and the starboard lever to full ahead. This will cause
the bow of the vessel to swing to port.
Turn the helm to starboard to counteract the bow's port rotation.
The vessel now moves sideways to port.
Adjust the port engine rpm or bring the starboard reverse control lever back towards the zero speed
position to prevent fore and aft movement (higher rpm moves the vessel aft).
With the vessel positioned correctly, move both reverse control levers back to zero speed and centre the
helm.
10-42
HJ292 Product Manual Appendix
10-43
Appendix HJ292 Product Manual
Cruising
Running at speed with a partially blocked inlet grill or debris on the impeller will result in cavitation
damage to the jet unit.
Take care to prevent cavitation damage to the jet units, as described below:
Acceleration should be gradual. Full power cannot be used at low vessel speeds such as when operating
on one engine only.
If there is a blockage of the jet unit, the engine will run at a higher than normal RPM, the vessel will
accelerate slowly and with reduced best speed. If such symptoms occur, immediately slow the vessel and
clear the blockage.
In conditions of severe weather or overload, reduce the engine speed accordingly.
If the steering becomes jammed, moving the helm quickly from side to side may free the steering nozzle.
The use of excessive force at the helm could damage steering components. Clear a severe jam-up of
the steering nozzle from the rear of the vessel.
Thoroughly check all steering components if a severe steering jam has occurred.
It is important to avoid pumping stones, sand, etc. through the jet unit as this will blunt and wear the
impeller.
The following diagrams illustrate good and bad practice:
10-44
HJ292 Product Manual Appendix
If it is not possible to pick a deep water area to start and stop in, then "idle" over the shallow area into deep
water before accelerating up to planing speed.
Momentarily stopping the engine will allow any debris picked up in the intake screen to drop away.
When leaving an area of shallow or debris filled water, ensure jets are well clear of the debris before
accelerating to high speed.
If debris accumulates in the jet unit, the engine will run at higher than normal RPM and the vessel will
accelerate slowly and may not reach full (planing) speed.
Prior to commencing operations, remove the inspection cover and check for debris around the impeller or
intake screen.
Make sure that the water level is below the level of the inspection cover before removing.
10-45
Appendix HJ292 Product Manual
Aerated water
Under certain conditions, some hulls may feed aerated water into the intake of the jet units.
When operating in areas where the water may be excessively aerated (e.g. fast flowing rapids or surf), note
the following:
There may be a loss in thrust due to the jet unit pumping a significant amount of air instead of water.
The impeller may unload suddenly causing the engine RPM to fluctuate wildly.
When these symptoms occur, reduce engine speed until the jet unit maintains a steady RPM and thrust.
Detecting blockages
In water with lots of debris, it may be necessary to clear the intake screens and impellers before each run.
In many cases debris can still accumulate with the vessel moored.
Any of the following can indicate a blocked jet unit:
Engine RPM increases.
Lack of jet thrust (vessel speed drops).
Abnormal noise and vibration from the jet unit.
Clearing blockages
To clear a blocked jet unit try the following:
Slowing or stopping the engine driving the blocked jet unit will often clear the blockage. This works best
when the vessel is still moving forward at speed.
Backflush the blocked jet unit (only possible if a reversible gearbox is fitted):
Stop or slow the vessel to displacement speed.
Move the reverse duct to the zero speed position.
Reverse the rotation of the blocked jet unit by engaging reverse gear and opening the throttle slightly.
It may be necessary to repeat the above procedure several times to clear the blockage.
To prevent damage to the hydraulic pump unit and the preload bearing, do not operate
backflush for more than 30 seconds. Keep the engine speed below 1000 rpm
Remove the inspection hatch cover (s) on the intake and manually clear the obstruction.
10-46
HJ292 Product Manual Appendix
10-47
HJ292 Product Manual Technical Drawings
11 - Technical Drawings
11-1
1 2 3 4 5 6 7 8
AB ITEM 43 FIT SHORT END
IN INTAKE
A 12 1 44 53 58 10 43 53 58 28 33 71 64
FIT FLUSH ITEM 64 WITH A
MACHINED FACE.
USE LOCTITE 325
B B
32
C C
30
22
AB
JET SUPPLIED WITH 63 AB
FIT SHORT END
ITEM 35 FITTED. 35 FIT ITEM 35 WITH 89 66 10 51 58 67 34 IN INTAKE 46 54 59 87
ITEM 63 SUPPLIED LOOSE LOCTITE 567
FIT ITEM 51 WITH FIT ITEM 67 WITH
LOCTITE 243 LOCTITE 263
NOTES:
45 48 54 59 50 57 62 47 55 60 65 25 1. ALL STUDS TO BE FITTED USING LOCTITE 263
D AB 2. REFER TO DRAWING 85144 FOR ADHESIVE SPECIFICATION AND D
APPLICATION
FIT ITEM 57 WITH 3. REFER TO DRAWING 85113 FOR FASTENER LUBRICATION AND TORQUE
LOCTITE 222 SPECIFICATION
4. REFER TO DRAWING No: 111178 FOR PAINT SPECIFICATION AND
APPLICATION.
16
E E
HamiltonJet
This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
TORQUE 480Nm DESIGN CHECK: N.T. 23/06/2016 SIGN.: ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED JET / CONTROL TYPE: HJ292
DRAWING REVISION: J.S.R. 23/06/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
DOCUMENT CHECK: N.T. 23/06/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:5 SHEET SIZE A3 Sheet1/5
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 13/12/1999 SIGN.: MACHINED SURFACE FINISH: Ra μm DWG No: HJ29201000 REV: AB
1 2 3 4 5 6 7 8
NOTES:
1. ALL STUDS TO BE FITTED USING LOCTITE 263
2. REFER TO DRAWING 85144 FOR ADHESIVE SPECIFICATION AND APPLICATION
3. REFER TO DRAWING 85113 FOR FASTENER LUBRICATION AND TORQUE SPECIFICATION
A 4. REFER TO DRAWING No: 111178 FOR PAINT SPECIFICATION AND APPLICATION. AB 76 77 78 79 80 A
74
SPARE FILTER ELEMENT
SUPPLIED LOOSE
75
B FIT ITEM 81 WITH
B
FIT ITEM 88 WITH DRY PRESS FIT LOCTITE 222
AB
AB
LOCTITE 680 ITEM 86 73
FIT ITEM 82 WITH
12 88 86 11 21 84 86 81 82 LOCTITE 263 SIDE VIEW ON
FILTER HOUSING
PRESS FIT
B 83 AB AB
FIT ITEM 56 WITH
LOCTITE 222
40
13 14 49 56 61 REF
C C
27
17
D D
E 52 19 B E
FIT ITEM 52 WITH 94
LOCTITE 222
HamiltonJet
This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
AB
REVISION: AB ECN: 22522 MATERIAL:
BASIC JET ASSEMBLY
ITEM 1 - 102185 REPLACED WITH 203123 STANDARD:
SCALE 1 : 1 DRAWING REVISION: J.S.R. 23/06/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
DOCUMENT CHECK: N.T. 23/06/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:3.5 SHEET SIZE A3 Sheet2/5
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 13/12/1999 SIGN.: MACHINED SURFACE FINISH: Ra μm DWG No: HJ29201000 REV: AB
1 2 3 4 5 6 7 8
NOTES:
1. ALL STUDS TO BE FITTED USING LOCTITE 263
2. REFER TO DRAWING 85144 FOR ADHESIVE SPECIFICATION AND APPLICATION
A 3. REFER TO DRAWING 85113 FOR FASTENER LUBRICATION AND TORQUE SPECIFICATION A
4. REFER TO DRAWING No: 111178 FOR PAINT SPECIFICATION AND APPLICATION.
B B
43 51 58
2 51 58
C AB AB AB C
SECTION B-B
SCALE 1 : 3
24.2 24.3
D 7 29 39 37 15 36 37 15 27 D
AB
USE LOCTITE 222 USE LOCTITE 222
APPLY TORQUE 12Nm (9lbs/ft) DETAIL A APPLY TORQUE 18Nm (13lbs/ft)
AB SCALE 1 : 1.5
AB
FIT ITEM 5 TO ITEM 4 FIT ITEM 93 WITH
WITH LOCTITE 680 LOCTITE 243
6 24.1 5 4 3 93 92
NOTE: POSITION OF GROOVE
E (NO GROOVE AT BOTTOM) E
24.4
DRY RUN ASSEMBLY OPTION
HamiltonJet
This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DETAIL C DRAWING REVISION: J.S.R. 23/06/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
SCALE 1 : 2 DOCUMENT CHECK: N.T. 23/06/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:5 SHEET SIZE A3 Sheet3/5
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 13/12/1999 SIGN.: MACHINED SURFACE FINISH: Ra μm DWG No: HJ29201000 REV: AB
1 2 3 4 5 6 7 8
A B C D E F G H Item Kit Part Number Product Description Drawing
A HJ29201001 BASIC JET STANDARD HJ29201000
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DRAWING REVISION: J.S.R. 23/06/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
DOCUMENT CHECK: N.T. 23/06/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:5 SHEET SIZE A3 Sheet4/5
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 13/12/1999 SIGN.: MACHINED SURFACE FINISH: Ra µm DWG No: HJ29201000 REV: AB
1 2 3 4 5 6 7 8
A B C D E F G H Item Kit Part Number Product Description Drawing
A16 B16 C16 D4 E4 43 201279 (STUDS) METRIC SS316 M8x40 (12/22) 30647
A2 B2 D2 E2 44 30661 (STUDS) METRIC SS316 M8x51 (16/16) 30647
A A
A8 B8 D8 E8 45 206680 (STUDS) METRIC SS316 M10x51 (22/22) 30637
A4 B4 C4 46 201281 (STUDS) METRIC SS316 M10x50 (15/26) 30637
A2 B2 C2 47 113343 (STUDS) METRIC SS316 M12x70 (24/24) 30639
A8 B8 D8 E8 48 201384 (WASHERS) (FLAT) METRIC SS316 M10x21x1.2 N/A
A3 B3 C3 49 106363 (STUDS) METRIC SAF2205 M16x160 (40/40) 30700
A4 B4 C4 50 111195 (STUDS) METRIC SAF2205 M20x188 (61/40) pr125 30692
A14 B14 C2 D12 E12 G12 51 201330 (NUTS) (NYLOC) METRIC SS316 M8 N/A AB
A2 B2 52 201245 (SCREWS) (SET SOCKET) METRIC SS316 M8x10 N/A
A14 B14 C12 D2 E2 53 201309 (NUTS) (HEX) METRIC SS316 M8 N/A
B B
A8 B8 D8 E8 F3 54 201310 (NUTS) (HEX) METRIC SS316 M10 N/A
A2 B2 C2 55 201311 (NUTS) (HEX) (METRIC) SS316 M12 N/A
A3 B3 C3 56 201312 (NUTS) (HEX) METRIC SS316 M16 N/A
A4 B4 C4 57 201313 (NUTS) (HEX) METRIC SS316 M20 N/A
A28 B28 C14 D14 E14 G12 58 201394 (WASHERS) (SPRING) METRIC SS316 M8 N/A AB
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DRAWING REVISION: J.S.R. 23/06/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
DOCUMENT CHECK: N.T. 23/06/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:5 SHEET SIZE A3 Sheet5/5
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 13/12/1999 SIGN.: MACHINED SURFACE FINISH: Ra µm DWG No: HJ29201000 REV: AB
1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
1 2 3 4 5 HJ29202002 F
Item PartNumber Qty ProductDescription DrawingNbr
1.1 105138 1 (JET) IMPELLERS TYPE (12.5) - (4 BLADE) As Cast 105138
1.2 104697 1 (JET) IMPELLERS TYPE (12) - (4 BLADE) Trimmed. 105138
1.3 105134 1 (JET) IMPELLERS TYPE (11) - (4 BLADE) Trimmed. 105138
1.4 104698 1 (JET) IMPELLERS TYPE (10) - (4 BLADE) Trimmed. 105138
15 16 22 20 23
B B
22 16 15
USE LOCTITE 243
18 BETWEEN 15 & 21
21
19
36 5
C C
ADJUST LIP SEAL (ITEM 29)
4 PER ADJUSTMENT
PROCEDURE SHOWN BELOW
29
17
D D
2 14 3 33 16 15
USE LOCTITE 325 BETWEEN USE LOCTITE 243 BETWEEN
ITEM 7 & ITEM 2 ITEM 15 & ITEM 14
32 31 30
E 11 E
USE LOCTITE 222 BETWEEN
ITEM 30 & ITEM 1 NOTES:
Q 10 1. ALL STUDS TO BE FITTED USING LOCTITE 263
2. REFER TO DRAWING 85144 FOR LOCTITE SPECIFICATION AND APPLICATION
3. REFER TO DRAWING 85113 FOR FASTENER LUBRICATION AND TORQUE SPECIFICATION
4. REFER TO DRAWING No: 111178 FOR PAINT SPECIFICATION AND APPLICATION.
12 13
HamiltonJet
This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
C C
D D
E E
34
DRY PRESS FIT
ITEM 34 INTO ITEM 7
HamiltonJet
This print is provided on a restricted basis and is not to be used
7 in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
NOTES - ADJUSTMENT OF END FLOAT: CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
1. FIT A 2.5mm THRUST WASHER (6) TO THE BOTTOM OF
EACH BUSH
REVISION: Q ECN: 24416 MATERIAL:
STEERING ASSEMBLY
2. FIT THE NOZZLE TO THE HOUSING WITH THE TAB ITEM 10 - 103359 (ZINC ANODE) REPLACED STANDARD:
TORQUE ITEM 8 TO FOR
WASHERS IN PLACE AND THE PIVOT PINS SCREWED IN WITH 203124 (ALUMINIUM ANODE) MAT CERT REQ: No TRACEABILITY REQ: No
200 Nm (150 ftlbs)
F THEN BEND ITEM 9
FIRMLY
[kg]
HJ292
3. ADJUST THE LOWER WASHER THICKNESS UNTIL THE FINISHED WEIGHT:
TO LOCK. NOZZLE SITS CENTRALLY IN THE HOUSING
8 DETAIL C 9 4. MEASURE THE VERTICAL END FLOAT AND ADJUST THE
DESIGN CHECK: S.K. 18/04/2016 SIGN.: ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED JET / CONTROL TYPE: 292
J.S.R. 7/04/2016
SCALE 2 : 3 TOP THRUST WASHER THICKNESS TO GIVE AN END DRAWING REVISION: SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
FLOAT OF BETWEEN 0.2mm AND 0.7mm DOCUMENT CHECK: S.K. 18/04/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:3 SHEET SIZE A3 Sheet2/3
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 8/10/1999 SIGN.: MACHINED SURFACE FINISH: Ra μm DWG No: HJ29206000 REV: Q
1 2 3 4 5 6 7 8
A B C D E F G Item Kit Part Number Product Description Drawing
B1 A HJ29206005 STEERING ASSEMBLY (PORT AND CENTER) HJ29206000
A B HJ29206025 STEERING ASSEMBLY (STARBOARD) HJ29206000 A
C 111522 NOZZLE PIVOT KIT 292 JT (FROM SERIAL NUMBER 001) HJ29206000
D 111512 NOZZLE KIT HJ29206000
E 111513 HOUSING KIT HJ29206000
F 111343 STEERING SHAFT BUSH KIT HJ32206000
G 111235 STEERING KIT FOR HJ292 HJ29206000
A1 D1 G1 1 110951 NOZZLE JT STEERING 110951
A1 E1 G1 2 109238 NOZZLE HOUSING (JT STEERING) 109238
A1 G1 3 109239 NOZZLE INSERT 109239
B A1 G1 4 109240 STEERING ARM 109240 B
A1 G1 5 109706 DEFLECTOR BUSH STST (JT STEERING) 102961
A2 C2 D2 E2 G2 6.1 111479-1 THRUST WASHER STEERING PIVOT (2.5mm) 111479
A2 C2 D2 E2 G2 6.2 111479-2 THRUST WASHER STEERING PIVOT (3.0mm) 111479
A2 C2 D2 E2 G2 6.3 111479-3 THRUST WASHER STEERING PIVOT (3.5mm) 111479
A2 C2 D2 E2 G2 6.4 111479-4 THRUST WASHER STEERING PIVOT (4.0mm) 111479
A2 C2 D2 G2 7 111483 SLEEVE FOR STEERING PIVOT BUSH 111483
A2 C2 G2 8 111481 PIVOT PIN JT STEERING 111481
A2 C2 E2 G2 9 105139 (WASHER) SPECIAL 54mm OD x30.5mm ID x1.2mm THICK SS316 105139
A1 D1 G1 10 203124 ANODE (ALUMINIUM) 203124 Q
A2 D2 G2 11 30661 (STUDS) METRIC SS316 M8x51 (16/16) 30647 STARBOARD JETS
C A2 D2 G2 12 201309 (NUTS) (HEX) METRIC SS316 M8 N/A
HJ292 06 025 C
A2 D2 G2 13 201394 (WASHERS) (SPRING) METRIC SS316 M8 N/A
A6 E6 G6 14 206680 (STUDS) METRIC SS316 M10x51 (22/22) 30637
A8 E6 G6 15 201310 (NUTS) (HEX) METRIC SS316 M10 N/A
A8 E6 G6 16 201395 (WASHERS) (SPRING) METRIC SS316 M10 N/A
A2 D2 G2 17 108188 (STUDS) METRIC SS316 M12x52 (17/24) 30639
A2 G2 18 201311 (NUTS) (HEX) (METRIC) SS316 M12 N/A
A2 G2 19 201396 (WASHERS) (SPRING) METRIC SS316 M12 N/A
A1 20 109241 STEERING CRANK 109241
A2 21 102834 COTTER 102834
A2 22 102993 (WASHERS) SPECIAL Ø25mm x 11mm ID x 3mm THICK 102993
D D
A1 23 111203 STEERING SHAFT (JT) 106973
A1 24 111344 TILLER 111277
A1 F1 25 61353 (SEAL) SCRAPER RING-WYCLIP N/A
A1 26 111123 STEERING BUSH & SEAL HOUSING 111123
A1 F1 27 61362 (OIL SEALS) 25x42x7 (#GACO DPSM 25427) C/W SS SPRING N/A
A1 28 111138 SLEEVE FOR STEERING SHAFT BUSH 111138
A2 D2 G2 29 111332 LIP SEAL 111332
A4 D4 G4 30 201214 (SCREWS) (M/C SCREWS) METRIC HEX HD SS316 M6x25 N/A
A4 D4 G4 31 201392 (WASHERS) (SPRING) (METRIC) SS316 M6 6.3x11.3x1.5 N/A
A4 D4 G4 32 201382 (WASHERS) (FLAT) (METRIC) 6.4x12.5x1 SS316 M6 N/A
E A6 E6 G6 33 201384 (WASHERS) (FLAT) METRIC SS316 M10x21x1.2 N/A
E
A2 C2 D2 G2 34 111480 PIVOT BUSH FOR STEERING 111480
PORT AND CENTRE JETS
A2 F2 35 111124 STEERING SHAFT BUSH 111124 HJ292 06 005
A2 G2 36 201385 (WASHERS) (FLAT) (METRIC) SS316 M12 N/A
A1 37 201246 (SCREWS) (SET SOCKET HD) METRIC SS316 M8x16 N/A
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DRAWING REVISION: J.S.R. 7/04/2016 SIGN.: REMOVE ALL SHARP EDGES & BURRS DRAWN TO HAMJET 085195 PROJECTION:
DOCUMENT CHECK: S.K. 18/04/2016 SIGN.: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:3 SHEET SIZE A3 Sheet3/3
GENERAL: +/- HOLES: ANGULAR:
1 2 3 4 ORIGINAL DESIGN: P.A.S 8/10/1999 SIGN.: MACHINED SURFACE FINISH: Ra µm DWG No: HJ29206000 REV: Q
This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
Q 24417
REVISION: ECN: MATERIAL:
REVERSE ASSEMBLY
ITEM 30 - 112657 (ZINC ANODE) REPLACED
WITH 203131 (ALUMINIUM ANODE)
STANDARD:
FOR
ADDITIONAL SHEET ADDED
MAT CERT REQ:
FINISHED WEIGHT:
TRACEABILITY REQ:
HJ292
DESIGN CHECK: S.K 18.04.16 SIGN. ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED JET / CONTROL TYPE HJ292
DRAWING REVISION: J.S.R 07.04.16 SIGN. REMOVE ALL SHARP EDGES AND BURRS DRAWN TO HAMJET 085195 PROJECTION:
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DRAWING REVISION: SIGN. REMOVE ALL SHARP EDGES AND BURRS DRAWN TO HAMJET 085195 PROJECTION:
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
DRAWING REVISION: SIGN. REMOVE ALL SHARP EDGES AND BURRS DRAWN TO HAMJET 085195 PROJECTION:
A A
B B
2 3
C C
D D
E E
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
A
A A
B B
1
3 4 5
B
C SECTION A-A C
SCALE 1 : 4
D D
E E
ISOMETRIC VIEW
ON DETAIL B
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
A
A Item Kit PartNumber ProductDescription DrawingNbr CHANGE HISTORY MANUFACTURING INFORMATION DRAWING INFORMATION
AMENDMENT REVIEW: S.K. 20/12/2010 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
A4 5 REF 201281 (STUDS) METRIC (316-STST) M10x50 (15/26) 30637 DESIGNED BY: P.A.S 18/10/1999 ECN: UNTOLERANCED DIMENSIONS & SURFACE FINISH SCALE: 1:5 SHEET SIZE A3 Sheet1/2
GENERAL: +/- 0.5 HOLES : +/- 0.2 ANGULAR: +/- 0.5
1 2 3 4 DESIGN REVIEW: P.A.S 18/10/1999 MACHINED SURFACE FINISH: Ra 6.3 μm DWG No.: HJ29209001 REV: A
1 2 3 4 5 6 7 8
A A
B B
2
C 3 4 C
1
3 4
D D
E 5 E
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
A
AMENDMENT REVIEW: S.K. 20/12/2010 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
1
10 4 11 13 15 16
C 6 13
3
D USE LOCTITE 243 ON 6 D
E 2 12 14 8 9 10 5
E
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
C
F B REDRAWN IN SOLIDWORKS
MAT. CERT REQ.: No TRACEABILITY REQ.: No
JET / CONTROL TYPE: 292
WEIGHT; CAST [kg]: MACHINED [kg]:
AMENDED BY: J.S.R. 15/02/2012 ECN: CL708
DRAWN TO HAMJET 085195 PROJECTION:
DWG No
AMENDMENT REVIEW: S.K. 15/02/2012 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
A A A
B B
C C
D D
SECTION AA
SCALE 1 : 4
E E
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
C
F B REDRAWN IN SOLIDWORKS
No No
DETAIL B MAT. CERT REQ.: TRACEABILITY REQ.:
JET / CONTROL TYPE: 292
SCALE 1 : 4
WEIGHT; CAST [kg]: MACHINED [kg]:
AMENDED BY: J.S.R. 15/02/2012 ECN: CL707
DRAWN TO HAMJET 085195 PROJECTION:
DWG No
AMENDMENT REVIEW: S.K. 15/02/2012 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
A A
1
5 5
18
4
B B
D
20
19
C C
D D
E E
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
F
TOOL KIT
HJ29211000
F 20
MAT. CERT REQ.: No TRACEABILITY REQ.: No
JET / CONTROL TYPE: 292
WEIGHT; CAST [kg]: MACHINED [kg]:
AMENDED BY: J.S.R. 6/12/2010 ECN: CL650
DRAWN TO HAMJET 085195 PROJECTION:
DWG No
AMENDMENT REVIEW: S.K. 6/12/2010 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
3.1 17.3
16
2.1 17.1
B B
9.3 11.2
14
3.3
9.4 11.3
C C
KIT C - 111028
7.2 11.3 8
KIT A - 104752 2.1
15
7.1 9.1 11.1
12
2.2 17.4
D D
9.2 16
9.3 11.2
17.2
3.3
13
E E
3.2
KIT D - 203277
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
F
AMENDMENT REVIEW: S.K. 6/12/2010 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
14
11.3 9.4 15
A A
2.3
3.2
A B C D E Item Kit PartNumber ProductDescription DrawingNbr
HJ29211000 MAINTENANCE TOOLS (GENERAL GROUPINGS) HJ29211000
A 104752 SERVICE TOOLS KIT (ELBE 0.115 & GWB) HJ29111000
B 111007 SERVICE TOOLS KIT (AQUADRIVE 20600 & CV42) HJ29111000
C 111028 SERVICE TOOLS KIT (AQUADRIVE 20400) HJ29111000
B 12 D 203277 SERVICE TOOLS KIT (AQUADRIVE 20300) HJ29111000 B
11.3 7.2 E 203286 SERVICE TOOLS KIT (HARDY SPICER 1600) HJ29111000
A1 B1 C1 D1 E1 1 104689 IMPELLER PULLER 104689
16 A1 D1 2.1 104917 TORQUE ARM (ELBE 0.115) 104917
B1 2.2 110795 TORQUE ARM (AQUADRIVE 20600-CV32-CV42 COUPLING) 110795
C1 E1 2.3 105797 TORQUE ARM 105797
A1 3.1 112456 MULTI SCREW COUPLING PULLER FOR VARIOUS JETS 112456
B1 E1 3.2 112407 MULTI SCREW COUPLING PULLER FOR VARIOUS JETS 112407
C1 D1 3.3 104918 COUPLING PULLER 104918
A1 B1 C1 D1 E1 4 201102 BOLT HEX M24x75 GR88 ZP N/A
A1 B1 C1 D1 E1 5 201412 (SOCKETS) TOOLS A/F 50mm 3/4" SQ. DRIVE (SOCKET) N/A
C A1 B1 C1 D1 E1 6 201448 (SKF) SPANNERS HN10 N/A
C
17.5 D2 7.1 201292 (NUTS) (IMPERIAL MILD STEEL) (ZP) 3/8"UNC N/A
A4 E4 7.2 201309 (NUTS) (METRIC ST ST 316) M8 N/A
C1 D1 8 201107 (BOLTS) (METRIC) MILD STEEL H/TENSILE GR88 (ZP) M20x60 N/A
KIT E - 203286 D2 9.1 201093 (BOLTS) (IMPERIAL) MILD STEEL 3/8"UNCx2.0" HT (ZP) N/A
B3 9.2 201162 (BOLTS) (METRIC) ST ST 316 M16x65 N/A
C3 D3 9.3 201103 (BOLTS) (METRIC) MILD STEEL H/TENSILE GR88 (ZP) M12x50 N/A
A4 E4 9.4 201225 (SCREWS) (M/C SCREWS) METRIC ST ST 316 HEX HD M8x70 N/A
A1 B1 C1 D1 E1 10 063625 (JET) PACKAGING CARTON 278x278x170 N/A
D2 11.1 201384 (WASHERS) (FLAT) METRIC ST ST 316 M10x21x1.2 N/A
D C3 D3 11.2 201385 (WASHERS) (FLAT) METRIC ST ST 316 M12x24x1.6 N/A D
A8 E8 11.3 201383 WASHER FLAT M8x16x1.2 SS316 N/A
A1 B1 E1 12 112408 FORCING BAR FOR MULTI SCREW COUPLING PULLER 112408
B1 13 112409 38mm FORCING BAR SPACER FOR AQUADRIVE COUPLING 112408
A1 E1 14 112410 15mm FORCING BAR SPACER FOR MULTI SCREW COUPLING 112408
A8 B8 E8 15 030855 (SCREWS) (CAPSCREWS) 10.9 ALLOY STEEL Socket Hd M12x55 N/A
A1 B1 E1 16 201262 (SCREWS) (CAPSCREWS) METRIC ST ST 316 Socket Hd M6x20 N/A
A1 17.1 REF 110585 COUPLING WITH MICRO-V PULLEY (ELBE 0.115) 110585
B1 17.2 REF 202785 COUPLING MICRO-V PULLEY (AQUADRIVE CV42) 202785
C1 17.3 REF 110931 COUPLING WITH MICRO-V PULLEY (AQUADRIVE 20400) 110931
E D1 17.4 REF 110927 COUPLING WITH MICRO-V PULLEY (AQUADRIVE 20300) 110927 E
E1 17.5 REF 110587 COUPLING WITH MICRO-V PULLEY (HARDY SPICER 1600) 110587
A1 B1 C1 D1 E1 18 REF 104619 COUPLING NUT AB2 104619
A1 B1 C1 D1 E1 19 REF 112291 IMPELLER NUT AB2 112291
A1 B1 C1 D1 E1 20 REF 063937 (SKF) NUTS SPECIAL KMT 10 063937
C. W. F. Hamilton & Co. Ltd This print is provided on a restricted basis and is not to be used
in any way detrimental to the interests of C. W. F. Hamilton and Co. Ltd
F
TOOL KIT
HJ29211000
AMENDMENT REVIEW: S.K. 6/12/2010 ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED
CHANGE SUMMARY - REFER TO E.C.N. FOR DETAILS MANUFACTURING INFORMATION DRAWING INFORMATION
A 24210
REVISION: ECN: MATERIAL:
ANODE LOCATION
NEW DRAWING STANDARD:
FOR
MAT CERT REQ:
FINISHED WEIGHT:
TRACEABILITY REQ:
HJ292 - ALUMINIUM
DESIGN CHECK: S.K 22.02.16 SIGN. ALL DIMENSIONS IN [mm] UNLESS OTHERWISE SPECIFIED JET / CONTROL TYPE HJ292
DRAWING REVISION: J.S.R 16.02.16 SIGN. REMOVE ALL SHARP EDGES AND BURRS DRAWN TO HAMJET 085195 PROJECTION:
B B
BLEND SMOOTHLY BACK TO
D2 REAR (PRESSURE) ORIGINAL BLADE SURFACE
OVER LENGTH `E' SUCH
THAT: E = 10 x R
DRESS REAR (PRESSURE) SIDE
DRESS THE SQUARE EDGE OF THE ONLY, TO WIDTH 'G'.
IMPELLER BLADE LEADING EDGE BACK,
'
`E
AND SHARPEN BLADE AS SHOWN,
TO RADIUS GIVEN BELOW IN TABLE 1.
C C
`R'
AT THE BLADE-HUB INTERFACE,
BLEND THE LE RADIUS INTO
THE BLADE-HUB RADIUS. ENSURE BURRS ARE REMOVED
BREAK SHARP EDGES
`G'
CHAMFER OR RADIUS 0.5 MAX
D T.E. WIDTH D
JET MODELS
`G' mm
2 212 213
2.5 241
TABLE 1: LEADING EDGE RADIUS 3 274 292 HTX30 322 362 364 M
`r'
`t'
M 29760
F 1.7 0.85 25 15 20 10 212-322 & HTX30 M
HTX30 ADDED TO SHEET 1 TABLES. HTX30 BALANCE LIMIT AND MAX TEST WEIGHT ADDED TO SHEET 2. NOTE
ADDED TO SHEET 2 TO CLARIFY THE BALANCE WEIGHT.
A3
2.0 1.0 35 20 25 12.5 364-403 B.DOA 13-11-2018
REVISED:
0.5 0.2 0.5
DOCUMENT REVIEW: I.HUN 13-11-2018 6.3 SCALE: N.T.S.
ENGINEERING REVIEW: I.HUN 13-11-2018 DRAWN TO HAMJET 085195 SHEET 1/5
1 2 3 4 5 82206 M
1 2 3 4 5 6 7 8
A A
B `x' B
ANY BALANCE WEIGHTS REQUIRED ARE TO BE
POSITIONED CLEAR OF MACHINED RECESS.
BALANCE LIMIT MAX TEST WEIGHT FOR IMPELLERS WITH NO MACHINED RECESS
JET MODEL
(g.cm)* @ OD (g) MINIMUM DIMENSION `X' IS 12mm.
213 22 2.0
C 241 TURBO 24 2.0 C
241 24 2.0
273 46 3.4
274 46 3.4
291 50 3.4
292 50 3.4
D HTX30 60 3.4 M D
322 96 6.0
362/364 110 6.0
391/403 220 11.0
BALANCE LIMIT TABLE BALANCE WEIGHT POSITION
M 29760
F ECCENTRICITY BALANCE CRITERION TO BE ACHIEVED M HTX30 ADDED TO SHEET 1 TABLES. HTX30 BALANCE LIMIT AND MAX TEST WEIGHT ADDED TO SHEET 2. NOTE
ADDED TO SHEET 2 TO CLARIFY THE BALANCE WEIGHT.
AND CAN BE USED IN DYNAMIC BALANCING. REVISED: B.DOA 13-11-2018
0.5 0.2 0.5
A3
ENGINEERING REVIEW:
I.HUN
I.HUN
13-11-2018
13-11-2018 DRAWN TO HAMJET 085195
6.3 SCALE:
SHEET 2/5
N.T.S.
1 2 3 4 5 82206 M
1 2 3 4 5 6 7 8
60°
A A
REPAIR OF SURFACE DEFECTS ON STAINLESS STEEL IMPELLERS.
R3
(B) BLADE THICKNESS MAY BE REDUCED LOCALLY BY UP TO 0.5mm
B B
FOR THE PURPOSE OF GRINDING OUT INCLUSIONS OR OTHER
SURFACE FLAWS.
(C) WHERE THE SURFACE DEFECT IS GREATER THAN 0.5mm DEEP, THE
DEFECT IS TO BE GROUND OUT TO CLEAN METAL, AS SHOWN,
REPAIRED BY WELDING AND GROUND BACK FLUSH TO ADJACENT
SURFACE.
E E
1 2 3 4 5 82206 M
1 2 3 4 5 6 7 8
A A
INCORRECT
DRESS BOTH SIDES
SMOOTHLY BACK.
FRONT
GRIND DENTS OUT OF
BLADE LEADING EDGE
SMOOTH RADIUS
C REFER TO TABLE 1 REAR C
INCORRECT
D D
E E
IMPELLER SHARPENING
THE LEADING EDGES OF THE IMPELLER MAY TEND TO BECOME "BLUNT" AFTER A PERIOD OF
TIME WITH THE ACTION OF SMALL SOLID PARTICLES IN THE WATER. THE PERFORMANCE OF THE
IMPELLER MAY DROP AS A RESULT.
ANY TIME THE INSPECTION COVER IS REMOVED, THE LEADING EDGE OF THE BLADES SHOULD
BE INSPECTED FOR WEAR. IF BADLY WORN, REMOVE THE IMPELLER (SEE MANUAL ON DOCUMENT TITLE HJ IMPELLER BLADE DRESSING INSTRUCTIONS & BALANCING INFO
DISMANTLING JET UNIT) AND SHARPEN AS SHOWN ABOVE. M 29760
F HTX30 ADDED TO SHEET 1 TABLES. HTX30 BALANCE LIMIT AND MAX TEST WEIGHT ADDED TO SHEET 2. NOTE
ADDED TO SHEET 2 TO CLARIFY THE BALANCE WEIGHT.
BOTH FRONT AND REAR SURFACES TO BE SMOOTH UNIFORM CURVES. ANY FLAT AREAS WILL REVISED: B.DOA 13-11-2018 A3
0.5 0.2 0.5
REDUCE EFFICIENCY AND CAUSE CAVITATION. DOCUMENT REVIEW: I.HUN 13-11-2018 6.3 SCALE: N.T.S.
ENGINEERING REVIEW: I.HUN 13-11-2018 DRAWN TO HAMJET 085195 SHEET 4/5
1 2 3 4 5 82206 M
1 2 3 4 5 6 7 8
A IDENTIFICATION PROCESS A
C C
D D
1 2 3 4 5 82206 M
Item No Item Description Task
1 Transom Pushrod Gland Grease every 3 months
2 Thrust Bearing Grease every 100 hours. It is preferable that mainshaft is turning when adding grease
3 Hydraulic Power Unit Filter Change Filter after first 5 hrs then every 1000 hrs of running
4 Hydraulic Power Unit Oil Level Check oil level Daily. Change after first 10 to 50 hrs then every 1000 hrs of running
5 HRSC Tie Rod Ends Grease every 3 months
6 Sreen Rake Grease every 3 months
Notes
Contact us
Access to HamiltonJet is unrestricted with the global headquarters and factory in New Zealand complemented by
company offices in both the United States of America, the United Kingdom and Singapore.
This network is further enhanced by authorised factory trained distributors in over 50 locations worldwide to pro-
vide comprehensive logistic support in the form of commissioning assistance, operation and maintenance training
programmes and spare parts supply. Additionally, factory-based field technicians are on permanent stand-by to
travel anywhere in the world at short notice.