Hamilton Jet HJ212 Manual

HJ212
Installation and Service Manual
R3A3
Jet unit Manual

Copyright © 2002. 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 or control type
HJ212
Part number
089212
Revision
R3
01/01/14
Amendment
A3
03/02/15

Contents
1 - Introduction _______________________________________________________1-1
Limited Warranty _________________________________________________________ 1-1
Warranty and Ownership Registration Form ___________________________________ 1-3
General Safety Notice _____________________________________________________ 1-4
2 - Product Description ______________________________________________2-1
Introduction _____________________________________________________________ 2-1
Equipment Description ____________________________________________________ 2-2
Main Components __________________________________________________ 2-3
3 - Design Basics ______________________________________________________3-1
Propulsion System Design __________________________________________________ 3-1
Hull Design ________________________________________________________ 3-1
Drive Lines ______________________________________________________________ 3-4
Requirements of the Driveline _________________________________________ 3-4
H-Bar Drive Lines____________________________________________________ 3-4
Engineering Checks__________________________________________________ 3-5
Driveline Options ___________________________________________________ 3-5
Universal Driveshaft Alignment ______________________________________________ 3-5
Jet Coupling Flange Details____________________________________________ 3-6
Drivelines for Diesel Engines __________________________________________ 3-6
Moments of Inertia__________________________________________________ 3-7
Mainshaft Dimensions _______________________________________________ 3-7
Critical Speed of Mainshaft ___________________________________________ 3-8
Jet Mainshaft Alignment ___________________________________________________ 3-8
Water Offtake____________________________________________________________ 3-9
Conventional Water Pickup ___________________________________________ 3-9
Engine Location and Mounting _____________________________________________ 3-10

Engine mounting___________________________________________________ 3-10
Engine systems ____________________________________________________ 3-10
Exhaust systems ___________________________________________________ 3-11
Governor settings __________________________________________________ 3-11
Dry run kit (optional extra) ________________________________________________ 3-12
Scope of use ______________________________________________________ 3-12
4 - Precautions Against Corrosion _________________________________4-1
General _________________________________________________________________ 4-1
Electrical Wiring System ______________________________________________ 4-1
D.C. Systems _______________________________________________________ 4-2
A.C. Systems _______________________________________________________ 4-2
Shore Connections ________________________________________________________ 4-2
Using an Isolating Transformer ________________________________________ 4-2
Using a Galvanic Isolator _____________________________________________ 4-3
Earth Bonding System _____________________________________________________ 4-3
Corrosion Monitor ________________________________________________________ 4-4
Trim Tabs and Other Submerged Fittings ______________________________________ 4-4
Earth Connections for Electronic Equipment ___________________________________ 4-4
Anodes _________________________________________________________________ 4-5
Jet Unit Anodes_____________________________________________________ 4-5
Hull Anodes ________________________________________________________ 4-5
Anti Fouling Paint _________________________________________________________ 4-5
Anti-Seize Compound______________________________________________________ 4-5
Impressed Current Protection _______________________________________________ 4-6
Steel Hulls and Carbon Fibre Reinforced F.R.P. Hulls _____________________________ 4-6
Earth Bonding System (Not Normally Current Conducting) __________________ 4-6
Checking the Insulation ______________________________________________ 4-6
5 - Installation_________________________________________________________5-1
GRP Hull intake block ________________________________________________ 5-1
Aluminium hull intake block___________________________________________ 5-1
Hull Preparation __________________________________________________________ 5-2

Fixing the Intake Block to the Hull ______________________________________ 5-2
Transom Preparation ________________________________________________ 5-2
Equipment Preparation ____________________________________________________ 5-3
Steering Components ________________________________________________ 5-3
Reverse Components ________________________________________________ 5-3
Mounting the Jet Unit _____________________________________________________ 5-3
Preparation ________________________________________________________ 5-3
Mounting the Jet Unit________________________________________________ 5-4
Fix the Transom Plate to the Hull_______________________________________ 5-4
Installation Checks for the Jet Unit _____________________________________ 5-4
Final Assembly _____________________________________________________ 5-6
Driveline and Engine Installation _______________________________________ 5-6
Engine Cooling ____________________________________________________ 5-10
Engine Systems ____________________________________________________ 5-10
Exhaust Systems ___________________________________________________ 5-10
Optional Impeller Installation_________________________________________ 5-10
Installation of Control Equipment ___________________________________________ 5-10
Reverse Latch Assembly _____________________________________________ 5-11
Reverse Cable _____________________________________________________ 5-11
Zero Speed Detent _________________________________________________ 5-12
Steering Installation ______________________________________________________ 5-13
Steering Wheel Number of Turns______________________________________ 5-13
Tiller Stop Fitting and Adjustment _____________________________________ 5-13
Cable Pulley System ________________________________________________ 5-14
Push-Pull Cable System______________________________________________ 5-14
Transom Preparation _______________________________________________ 5-14
6 - Commissioning____________________________________________________6-1
Pre-Launch Checks ________________________________________________________ 6-1
Post Launch Checks _______________________________________________________ 6-2
Engine Running Checks (Vessel Moored) ______________________________________ 6-2
Vessel Speed and Handling Trials ____________________________________________ 6-3
After Initial Trials (After Engine Shutdown) ____________________________________ 6-3

7 - Fault Finding_______________________________________________________7-1
System Faults ____________________________________________________________ 7-1
Jet Unit Faults____________________________________________________________ 7-1
Engine RPM increases suddenly________________________________________ 7-1
Engine RPM decreases _______________________________________________ 7-1
Water leaking from under the bearing housing ___________________________ 7-2
Loud high pitched rattling whine _______________________________________ 7-2
Excessive vibrations, gradually increasing ________________________________ 7-2
Engine RPM increases gradually over a period of time______________________ 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 ____________________________________________________ 7-3
Thrust bearing excessively hot _________________________________________ 7-3
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 _____________________________________________________ 7-4
Steering System Faults _____________________________________________________ 7-5
Steering nozzle slow to respond _______________________________________ 7-5
Steering jamming ___________________________________________________ 7-5
8 - Maintenance _______________________________________________________8-1
General _________________________________________________________________ 8-1
Salt Water Operation ________________________________________________ 8-2
Jet surface coating procedure _______________________________________________ 8-2
Introduction and scope_______________________________________________ 8-2
Application of Antifoul Coatings________________________________________ 8-2
Maintenance of Waterjet Coatings _____________________________________ 8-3
Preservation (Pre Installation) _______________________________________________ 8-7
Preservation (Post Installation) ______________________________________________ 8-8
Servicing Intervals ________________________________________________________ 8-8
HJ Jet Unit Service Intervals ___________________________________________ 8-9
Daily "pre use" servicing checks_______________________________________ 8-10

Jet Unit Servicing Details __________________________________________________ 8-10
Internal Water Path: ________________________________________________ 8-10
Thrust Bearing_____________________________________________________ 8-11
Water Seal: _______________________________________________________ 8-11
Anodes: __________________________________________________________ 8-11
Steering System ___________________________________________________ 8-12
Reverse Shaft and Bushes____________________________________________ 8-13
Reverse Linkages: __________________________________________________ 8-13
H Bar or Driveshaft Universal Joints____________________________________ 8-13
Engine Alignment:__________________________________________________ 8-13
Jet Unit ________________________________________________________________ 8-13
Impeller blades: ___________________________________________________ 8-13
Impeller check for wear and damage: __________________________________ 8-14
Marine bearing: ___________________________________________________ 8-14
Reverse duct ______________________________________________________ 8-14
Splash Guard ______________________________________________________ 8-14
Tailpipe, nozzle and nozzle housing ____________________________________ 8-14
Jet unit paintwork: _________________________________________________ 8-14
Excessive wear: ____________________________________________________ 8-15
Control System __________________________________________________________ 8-15
Checking the steering system_________________________________________ 8-15
Checking the Reverse Linkages _______________________________________ 8-17
Laying Up_________________________________________________________ 8-18
Tools __________________________________________________________________ 8-18
Threaded Fasteners ______________________________________________________ 8-19
Thread locking agents_______________________________________________ 8-19
Recommended Oils and Lubricants __________________________________________ 8-19
9 - Overhaul____________________________________________________________9-1
General Information_______________________________________________________ 9-2
Introduction _______________________________________________________ 9-3
Care of Jet Unit Paintwork ____________________________________________ 9-4
Torquing Sequence of Nuts ___________________________________________ 9-4
Anode Replacement _________________________________________________ 9-4
Refitting the Locating Dowels__________________________________________ 9-5

Reverse Assembly Overhaul ________________________________________________ 9-6
Reverse Duct Removal _______________________________________________ 9-6
Reverse Duct Overhaul _______________________________________________ 9-6
Reverse Link Removal and Inspection ___________________________________ 9-7
Bush and O-Ring Replacement _________________________________________ 9-7
Reverse Shaft Shouldered Bush Replacement_____________________________ 9-8
Latch System Removal and Overhaul____________________________________ 9-8
Latch System Checking for Wear _______________________________________ 9-9
Reverse Assembly Refitting ___________________________________________ 9-9
Steering Assembly Overhaul _______________________________________________ 9-12
Remove the Steering Shaft ___________________________________________ 9-12
Steering Nozzle Assembly Removal ____________________________________ 9-13
Steering Assembly Re-Fitting _________________________________________ 9-15
Bearing Housing Assembly overhaul _________________________________________ 9-18
Bearing Housing and Water Seal Assembly Dismantling____________________ 9-18
Inspect the Bearing Assembly and Water Seal ___________________________ 9-19
Reassemble the Bearing Housing and Water Seal_________________________ 9-20
Tailpipe Area Overhaul____________________________________________________ 9-22
Impeller - Checking for wear _________________________________________ 9-22
Marine water bearing - Checking for wear ______________________________ 9-22
Tailpipe Area Dismantling _________________________________________________ 9-23
Tailpipe, Marine Bearing and Wear Ring Inspection_____________________________ 9-23
Wear Ring Removal and Replacement _______________________________________ 9-23
Removal of the wear ring and insulator strip ____________________________ 9-24
Preparing a new wear ring for fitting ___________________________________ 9-24
Fitting a new insulator ______________________________________________ 9-25
Fitting a new wear ring ______________________________________________ 9-25
Impeller Overhaul________________________________________________________ 9-27
Inspection ________________________________________________________ 9-27
Blade leading edge repair procedure___________________________________ 9-27
Impeller outside diameter (O.D.) repair procedure _______________________ 9-28
Balancing _________________________________________________________ 9-28
Passivation _______________________________________________________ 9-29
Marine Bearing Replacement ______________________________________________ 9-29
Dry Run Bearing _________________________________________________________ 9-30
Dry Run Bearing Graphic ____________________________________________ 9-30
Tailpipe and Impeller Reassembly ___________________________________________ 9-31

Transom Plate Assembly Overhaul __________________________________________ 9-31
Transom Plate Removal _____________________________________________ 9-31
Transom Plate Refitting _____________________________________________ 9-32
Intake Screen ___________________________________________________________ 9-32
Intake Screen Removal ______________________________________________ 9-32
Intake Screen Refitting ______________________________________________ 9-32
Hatch Extension _________________________________________________________ 9-33
Hatch Extension Fitting______________________________________________ 9-33
Hatch Extension Removal ____________________________________________ 9-34
10 - Appendix _______________________________________________________ 10-1
Conversions ____________________________________________________________ 10-2
Loctite Application Guide__________________________________________________ 10-3
General Practice ___________________________________________________ 10-3
Primers, Activators and Accelerators___________________________________ 10-3
Equivalents _______________________________________________________ 10-4
KMT Nut Fitting and Removal _____________________________________________ 10-12
Installation Checks ______________________________________________________ 10-14
Jet Unit Mounting _________________________________________________ 10-14
Jet Unit General __________________________________________________ 10-15
Jet Systems Steering _______________________________________________ 10-16
Drive Shaft_______________________________________________________ 10-17
Commissioning Checks___________________________________________________ 10-18
Pre Launch Checks ________________________________________________ 10-18
Post Launch Checks________________________________________________ 10-19
Engine Checks (Vessel Moored) ______________________________________ 10-20
Vessel Trial ______________________________________________________ 10-22
After Initial Trials__________________________________________________ 10-23
Jet Unit Trials & Commissioning Data _________________________________ 10-24
Temperature Readings _____________________________________________ 10-24
Speed Trial Readings_______________________________________________ 10-24
Aluminium Weld Procedure_______________________________________________ 10-26
Tightening Torques _____________________________________________________ 10-28
Nut Tightening Torque _____________________________________________ 10-28
Screw Tightening Torques __________________________________________ 10-29

Stud Installation __________________________________________________ 10-30
Set Screws _______________________________________________________ 10-30
Hydraulic Cylinder Piston ___________________________________________ 10-31
Hydraulic Fittings _________________________________________________ 10-31
Thread Lubricants _________________________________________________ 10-33
Recommendations for Lubricants and Oils ___________________________________ 10-34
Hydraulic Fluids___________________________________________________ 10-34
Bearing Housing Lubrication ________________________________________ 10-36
Joint Lubrication __________________________________________________ 10-37
Drivers Guide __________________________________________________________ 10-38
Starting Up ______________________________________________________ 10-38
Ahead, Zero Speed and Astern Controls _______________________________ 10-39
Power Assisted Slowdown __________________________________________ 10-39
Steering _________________________________________________________ 10-40
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
11 - Technical Drawings ___________________________________________ 11-1