04b-Hamilton Jet-Hj-322 Jet Unit Product Manual

HJ-322 JET UNIT
Product Manual
HJ-322
Cover Page
MARINE PROPULSION UNITS
Product Manual
MODEL HJ-322
Jet Type HJ-322

Part Number 89322
Initial Issue 03/04/00
Amendment 18 04/10/04
AMENDMENT 18 04/10/04
INTRODUCTION
HJ-322
Copyright ©2002. CWF Hamilton & Co 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 CWF Hamilton & Co Ltd.
Due to our policy of continuous development, specifications in this manual are subject to change without
notice or obligation.
ii AMENDMENT 12 22/08/03
HJ-322 INTRODUCTION
CONTENTS
CONTENTS
Contents .....................................................................................iii
Introduction Amendment Record ................................................................ vii
Limited Warranty ....................................................................... ix
Warranty & Ownership Registration Form ................................ xi
Equipment Modification List .................................................... xiii
List of Tables ............................................................................. xv
List of Figures ...........................................................................xvii
List of Drawings .........................................................................xix
Warnings ...................................................................................xxi
Cautions ................................................................................. xxiii
PART A 1 Introduction & Product Description............................... 1.1
Operator Information 1.1 THE HAMILTON WATER JET SYSTEM....................................................... 1.1
1.1.1 Introduction .....................................................................................1.1
1.1.2 Main Components ............................................................................1.2
1.2 GENERAL ASSEMBLY DRAWINGS............................................................. 1.4
2 System Operation........................................................... 2.1

2.1 STARTING UP ........................................................................................... 2.1
2.2 “AHEAD” / “ZERO SPEED” / “ASTERN” CONTROLS ................................. 2.1
2.3 STEERING ................................................................................................. 2.2
2.3.1 Total Hydraulic Failure ....................................................................2.3
2.4 MANOEUVERING AND DOCKING............................................................. 2.3
2.4.1 Low Speed Manoeuvering and Docking ............................................2.3
2.4.2 Moving Sideways .............................................................................2.4
2.5 CRUISING ................................................................................................. 2.5
2.6 SHALLOW WATER OPERATION ................................................................ 2.6
2.7 ACCELERATION TO HIGH SPEED.............................................................. 2.6
2.8 AERATED WATER..................................................................................... 2.6
2.9 BLOCKAGES (DEBRIS IN THE JET UNIT) ................................................... 2.7
2.9.1 Avoiding Blockages ..........................................................................2.7
2.9.2 Detecting Blockages .........................................................................2.7
2.9.3 Clearing Blockages ...........................................................................2.7
2.9.4 Using the Inspection Cover ..............................................................2.7
2.10 OVERFLOW PREVENTER (OPTIONAL EXTRA) ........................................ 2.8
2.11 OPERATING WITH AN ENGINE AND JET UNIT OUT OF SERVICE........... 2.8
PART B 3 Design Basics .................................................................. 3.1
Design and Installation 3.1 PROPULSION SYSTEM DESIGN ................................................................. 3.1
Information 3.2 HULL DESIGN ........................................................................................... 3.1
3.2.1 Mono Hulled Vessel .........................................................................3.1
3.2.2 Multi Hulled Vessel ..........................................................................3.2
3.2.3 Trim Tabs ........................................................................................3.3
3.2.4 Engine Exhausts ...............................................................................3.4
3.3 DRIVELINES .............................................................................................. 3.4
3.3.1 Requirements of the Driveline ..........................................................3.4
3.3.2 Engineering Checks ..........................................................................3.4
3.3.3 Driveshaft Options ...........................................................................3.5
3.3.4 Universal Driveshaft Alignment ........................................................3.7
3.3.5 Jet Coupling Flange Details ...............................................................3.7
3.3.6 Moments of Inertia ...........................................................................3.8
3.3.7 Critical Speed of Mainshaft ..............................................................3.8
3.4 JET MAINSHAFT ALIGNMENT (FOR 5º OPTION ONLY) ............................ 3.9
3.5 WATER OFFTAKE ................................................................................... 3.10
3.6 ENGINE LOCATION & MOUNTING ......................................................... 3.11
3.6.1 General ..........................................................................................3.11
3.6.2 Mounting .......................................................................................3.11
3.6.3 Cooling ..........................................................................................3.11
3.6.4 Engine Systems ..............................................................................3.11
3.6.5 Governor Settings ...........................................................................3.11
AMENDMENT 18 04/10/04 iii

INTRODUCTION HJ-322
CONTENTS
3.7 DESCRIPTION OF THE DRY RUN SYSTEM (OPTIONAL EXTRA) ............. 3.12
3.7.1 Installation .................................................................................... 3.12
3.7.2 Corrosion ...................................................................................... 3.12
3.7.3 Scope of Use ................................................................................. 3.12
3.7.4 Fault Finding ................................................................................. 3.13
3.7.5 Maintenance ................................................................................. 3.13
3.7.6 Parts List ....................................................................................... 3.14
4 Precautions Against Corrosion ....................................... 4.1

4.1 GENERAL ................................................................................................. 4.1
4.1.1 Electrical Wiring System .................................................................. 4.1
4.1.2 Earth Bonding System ..................................................................... 4.2
4.1.3 Corrosion Monitor ........................................................................... 4.3
4.1.4 Earth Plate Connections for Electronic Transmitting Equipment ...... 4.3
4.1.5 Zinc Anodes .................................................................................... 4.3
4.1.6 In Service Checks ............................................................................ 4.4
4.1.7 Anti Fouling Paint ............................................................................ 4.4
4.1.8 Anti Seize Compound ...................................................................... 4.4
4.1.9 Impressed Current Protection .......................................................... 4.4
4.2 ALUMINIUM, G.R.P. AND WOOD HULLS (OTHER THAN STEEL).............. 4.5
4.2.1 Earth Bonding System - (Not Normally Current Conducting) ........... 4.5
4.3 STEEL HULLS AND CARBON FIBRE REINFORCED G.R.P. HULLS .............. 4.5
4.3.1 Earth Bonding System (Not Normally Current Conducting) .............. 4.5
4.3.2 Checking the Insulation ................................................................... 4.5
4.4 CORROSION DRAWINGS.......................................................................... 4.7
5 Installation ....................................................................... 5.1

5.1 BASIC INSTALLATION METHOD AND DRAWINGS REFERENCES ............. 5.1
5.2 HULL PREPARATION ................................................................................ 5.2
5.2.1 Fixing the Intake Block to the Hull ................................................... 5.2
5.2.2 Transom Preparation ...................................................................... 5.3
5.3 EQUIPMENT PREPARATION..................................................................... 5.4
5.3.1 Steering Components ...................................................................... 5.4
5.3.2 Reverse Components ....................................................................... 5.4
5.3.3 Removal of Other Parts ................................................................... 5.4
5.4 MOUNTING THE JET UNIT ...................................................................... 5.4
5.4.1 Mounting the Jet Unit to the Hull ..................................................... 5.5
5.4.2 Assembly of the Transom Plate to the Hull ...................................... 5.5
5.5 FINAL ASSEMBLY ..................................................................................... 5.7
5.5.1 Re-Fitting the Reverse Components ................................................. 5.7
5.5.2 Re-Fitting the Steering Components ................................................ 5.7
5.5.3 Assembling the Jet Steering Tillers ................................................... 5.7
5.5.4 Centreing the Jet(s) Steering ............................................................ 5.9
5.6 DRIVELINE AND ENGINE INSTALLATION ................................................ 5.9
5.6.1 Mounting the Engine ..................................................................... 5.10
5.6.2 Engine Cooling .............................................................................. 5.10
5.6.3 Engine Systems ............................................................................. 5.10
5.6.4 Exhaust Systems ........................................................................... 5.10
5.6.5 Governor Settings .......................................................................... 5.11
5.7 INSTALLATION CHECKS FOR THE JET UNIT .......................................... 5.11
5.8 INSTALLATION DRAWINGS .................................................................. 5.13
6 Commissioning ................................................................ 6.1

6.1 PRE-LAUNCH CHECKS ............................................................................. 6.1
6.2 POST LAUNCH CHECKS ........................................................................... 6.1
6.3 ENGINE RUNNING CHECKS (VESSEL MOORED) ...................................... 6.2
6.4 VESSEL SPEED AND HANDLING TRIALS .................................................. 6.2
6.5 AFTER INITIAL TRIALS (AFTER ENGINE SHUT DOWN)............................ 6.3
PART C 7 Fault Finding .................................................................... 7.1
Servicing Information 7.1 JET UNIT FAULTS..................................................................................... 7.1
7.2 REVERSE SYSTEM FAULTS....................................................................... 7.3
7.3 STEERING SYSTEM FAULTS ..................................................................... 7.5
iv AMENDMENT 18 04/10/04
HJ-322 INTRODUCTION
CONTENTS
8 Maintenance .................................................................. 8.1

8.1 GENERAL .................................................................................................. 8.1
8.2 PRESERVATION: (PRE-INSTALLATION) .................................................... 8.1
8.3 PRESERVATION: (POST INSTALLATION)................................................... 8.2
8.4 SERVICING INTERVALS............................................................................. 8.3
8.4.1 Daily "Pre Use" Servicing Checks .....................................................8.4
8.5 JET UNIT SERVICING DETAILS.................................................................. 8.5
8.6 TOOLS ...................................................................................................... 8.8
8.6.1 Standard Recommended Tools .........................................................8.8
8.6.2 Special Tools ....................................................................................8.8
8.7 THREADED FASTENERS............................................................................ 8.9
8.8 RECOMMENDED LUBRICANTS ................................................................. 8.9
9 Overhaul ......................................................................... 9.1

9.1 GENERAL INFORMATION ......................................................................... 9.2
9.2 REVERSE ASSEMBLY REMOVAL AND OVERHAUL .................................... 9.2
9.2.1 Reverse Duct Removal ......................................................................9.2
9.2.2 Reverse Duct Overhaul .....................................................................9.3
9.2.3 Reverse Cylinder Removal ................................................................9.3
9.2.4 Reverse Cylinder Overhaul ...............................................................9.4
9.3 REVERSE ASSEMBLY RE-FITTING ............................................................. 9.5
9.3.1 Reverse Cylinder: Refit to the Jet Unit ...............................................9.5
9.3.2 Reverse Duct: Refit to the Jet Unit ....................................................9.6
9.4 STEERING ASSEMBLY REMOVAL AND OVERHAUL................................... 9.7
9.4.1 Steering Cylinder Removal ...............................................................9.7
9.4.2 Steering Cylinder Overhaul ...............................................................9.7
9.4.3 Steering Shaft Removal .....................................................................9.7
9.4.4 Nozzle Assembly Removal ...............................................................9.8
9.4.5 Nozzle Assembly Overhaul ..............................................................9.9
9.5 STEERING ASSEMBLY RE-FITTING ......................................................... 9.13
9.5.1 Nozzle Assembly Re-Fitting ...........................................................9.13
9.5.2 Steering Bracket and Steering Shaft Re-Fitting ................................9.14
9.5.3 Steering Cylinder Re-Fitting ............................................................9.14
9.5.4 Steering Linkages Adjustment .........................................................9.14
9.6 BEARING HOUSING ASSEMBLY OVERHAUL ........................................... 9.15
9.6.1 Bearing Housing Dismantling .........................................................9.15
9.6.2 Water Seal Removal .......................................................................9.17
9.6.3 Water Seal Replacement and Re-Fitting .........................................9.18
9.6.4 Bearing Housing Re-Assembly .......................................................9.18
9.7 INTERNAL ANODE REPLACEMENT......................................................... 9.19
9.7.1 Intake Internal Anode .....................................................................9.19
9.8 TAILPIPE AREA - OVERHAUL .................................................................. 9.20
9.8.1 Impeller - Checking for Wear .........................................................9.20
9.8.2 Tailpipe Area - Dismantling ...........................................................9.20
9.8.3 Impeller Race - Overhaul ...............................................................9.20
9.8.4 Wear Ring - Removal and Replacement .........................................9.21
9.8.5 Impeller Area Overhaul ..................................................................9.22
9.8.6 Impeller Overhaul ..........................................................................9.23
9.8.7 Tailpipe Overhaul ..........................................................................9.24
9.8.8 Tailpipe Area Re-Assembly ............................................................9.25
9.9 TRANSOM PLATE ASSEMBLY OVERHAUL............................................... 9.26
9.9.1 Transom Plate Removal .................................................................9.26
9.9.2 Transom Plate Re-Fitting ................................................................9.27
9.10 OVERFLOW PREVENTER (OPTIONAL EXTRA) ...................................... 9.28
9.10.1 Overflow Preventer Fitting ............................................................9.28
9.10.2 Overflow Preventer Removal ........................................................9.29
9.11 SCREEN RAKE ASSEMBLY OVERHAUL (IF FITTED) ............................... 9.30
9.11.1 Screen Rake Removal ...................................................................9.30
9.11.2 Screen Rake Re-Fitting .................................................................9.30
9.11.3 Screen Rake Blanking Plugs ..........................................................9.31
9.11.4 Screen Removal ............................................................................9.32
9.11.5 Screen Re-Fitting ..........................................................................9.32
9.12 SERVICING DRAWINGS ........................................................................ 9.33
AMENDMENT 18 04/10/04 v
INTRODUCTION HJ-322
CONTENTS
Appendix APPENDIX-1: Conversion Chart ................................................. A.1

APPENDIX-2: Loctite Application Guide Chart - All Jets .......... A.3
APPENDIX-3: Installation Checks for Hamilton Water Jets ....... A.7
APPENDIX-4: Commissioning Checks for Hamilton Water Jets A.11
APPENDIX-5: KMT Nut: Fitting & Removal Instructions ............ A.19
vi AMENDMENT 18 04/10/04
INTRODUCTION
HJ-322
AMENDMENT RECORD
AMENDMENT RECORD
PART NO: 89322
JET MODEL: HJ-322
MANUAL: Product Manual
Amdt Incorporated By Date Amdt Incorporated By Date
1 C.W.F. Hamilton & Co Ltd 18/07/00 39
19 57
20 58
21 59
22 60
23 61
24 62
25 63
26 64
27 65
28 66
29 67
30 68
31 69
32 70
33 71
34 72
35 73
36 74
37 75
38 76
AMENDMENT 18 04/10/04 vii

INTRODUCTION
HJ-322
AMENDMENT RECORD
viii AMENDMENT 18 04/10/04

HJ-322 INTRODUCTION
LIMITED WARRANTY
LIMITED WARRANTY
TERMS OF COVERAGE
C.W.F. Hamilton & Co. Ltd. (Hamilton Jet) 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 Hamilton Jet within
the Warranty Period, Hamilton Jet's obligation is limited to, at its option, repairing or replacing the defective
Product, or component part at its factory or such other location as may be designated by Hamilton Jet.
Defective Products shall be returned to Hamilton Jet or its authorised service representative for inspection with
transportation charges prepaid by the purchaser to the location specified by Hamilton Jet. This Warranty only
applies where the Product is shown, to the satisfaction of Hamilton Jet, to be defective in material or
workmanship during the Warranty Period. Hamilton Jet 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 Hamilton Jet determines it is unable to repair or replace any component part(s) found to be defective in
materials and/or workmanship, Hamilton Jet's Warranty liability shall be limited to payment by Hamilton Jet
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
Hamilton Jet. All Warranty claims shall be lodged with Hamilton Jet or its authorised distributor.
WARRANTY PERIOD
The Warranty Period for Hamilton Jet Products is limited to a period of twenty-four (24) months from the date
of original shipment from the Hamilton Jet factory, or twelve (12) months from the vessel launch date,
whichever occurs first.
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 Hamilton Jet, 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. Hamilton Jet 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.
This Warranty does not extend to failures, damages or defects resulting from the following:
• What Hamilton Jet 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 Hamilton Jet.
• Incorrect installation, as per the applicable Hamilton Jet Product Manual and the applicable Hamilton
Jet 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 model manual, and a jet
mainshaft critical speed check carried out to Hamilton Jet's written satisfaction.
AMENDMENT 18 04/10/04 ix
INTRODUCTION
HJ-322
LIMITED WARRANTY
This Warranty does not cover or provide payment or reimbursement for the following:
• Any Product which may have been serviced, repaired or altered in any way by anyone other than
Hamilton Jet or a Hamilton Jet authorised facility.
• Any repairs or alterations carried out with the use of parts or accessories not manufactured by
Hamilton Jet or its authorised representatives.
• Items incorporated in any Hamilton Jet Product (other than by Hamilton Jet) when such items have
been manufactured by others or are warranted by their respective manufacturers in favour of the
purchaser.
• 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.
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 Hamilton Jet 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
Hamilton Jet 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. 1 January 2003
x AMENDMENT 18 04/10/04
HJ-322 INTRODUCTION
WARRANTY & OWNERSHIP REGISTRATION FORM
WARRANTY & OWNERSHIP

REGISTRATION FORM
C.W.F. Hamilton & Co. Ltd.
To allow Hamilton Jet to complete its records and in order to assist any claim under the attached Limited
Warranty, please complete this Warranty and Ownership Registration Form in full and return as soon as
possible by post or facsimile to:
The Marketing Department, C.W.F. Hamilton & Co Ltd., PO Box 709, Christchurch, New Zealand.
Fax +64 3 348 6969
Hamilton Jet encourages the Distributor to take responsibility for ensuring the Purchaser and the Distributor
complete this form at the time of sale and return it to Hamilton Jet. Please complete one form per vessel only.
Hamilton Jet
Model Serial Number(s)
Delivery date Commissioning /

In Service date
Vessel / Project
Purchaser
Address
Contact name Signed

Distributor
Address
Contact name Signed

Office Use Only Logged by: Proj. Code:
Date:
AMENDMENT 18 04/10/04 xi
INTRODUCTION
HJ-322
WARRANTY & OWNERSHIP REGISTRATION FORM
xii AMENDMENT 18 04/10/04

HJ-322 INTRODUCTION
EQUIPMENT MODIFICATION LIST

AMENDMENT JET SERIAL
DESCRIPTION OF CHANGES
NO NO.
Amendment 4 # 94 Onwards New Tailpipe Internal Anodes (Part No.111593) fitted. Quantity of
Internal Anodes increased to Qty. 6.
New Anode Plate attachment Studs (Part No. JCQHXAH) fitted.
New Internal Tailpipe Anode Mounting Plate (Part No. 111655) fitted.
Amendment 6 #98 Onwards. New Steering Arm (Part No.111684) fitted.
New Nozzle fitted (Part No.111669).
New Steering Arm Attachment Studs (Part No.111670) fitted. NOTE
these Studs are made from SAF2205 material.
Amendment 6 #101 Onwards New Eagle Water Seal (Part No.61529) fitted in place of Water Seal
(Part No.63880).
Amendment 8 #170 Onwards Grub Screw retaining added to the Forward Steering Bush and Seal
Housing.
Amendment 10 #243 Onwards Introduction of the AB2 Impeller Nut Part No. 112291.
Amendment 12 #278 Onwards Re-design of the Reverse Cylinder to Transom sealing. Reverse Cylin-
der Assembly (Part No. 111346) has been replaced by Reverse Cylin-
der (Part No. 112518).
Introduction of the following new components:-
Front Head Extension. (Part No. 112337).
Inner Resilient Mount. (Part No. 112339).
Outer Resilient Mount. (Part No. 112340).
Reverse Cylinder Gland. (Part No. 112341).
New Reverse Cylinder Gland Sleeve (Part No. 112338) added.
Product Bulletin PRB/07/2003 refers.
Amendment 15 #330 Onwards Impeller Nut torque increased from 400Nm (295 ft/lbs) to 600Nm
(440 ft/lbs). Product Bulletin PRB-02/04 refers.
AMENDMENT 18 04/10/04 xiii

INTRODUCTION
HJ-322
xiv AMENDMENT 18 04/10/04

HJ-322 INTRODUCTION
LIST OF TABLES
LIST OF TABLES
1 Introduction & Product Description ............................................................... 1.1
2 System Operation ........................................................................................... 2.1
3 Design Basics ................................................................................................... 3.1
Table 1: Mainshaft Angles (Relative to Keel Line in deg’s .................................................. 3.9
Table 2: Fault Finding ..................................................................................................... 3.13
4 Precautions Against Corrosion ....................................................................... 4.1
5 Installation ....................................................................................................... 5.1
6 Commissioning ................................................................................................ 6.1
7 Fault Finding .................................................................................................... 7.1
Table 3: Jet Unit Faults...................................................................................................... 7.1
Table 4: Reverse System Faults ......................................................................................... 7.3
Table 5: Steering System Faults......................................................................................... 7.5
8 Maintenance .................................................................................................. 8.1
Table 6: Servicing Intervals (Jet) ........................................................................................ 8.3
Table 7: Daily Servicing Checks (Jet) ................................................................................. 8.4
Table 8: Special Fasteners - HJ-322 Jet.............................................................................. 8.9
9 Overhaul .......................................................................................................... 9.1
AMENDMENT 18 04/10/04 xv
INTRODUCTION HJ-322
LIST OF TABLES
xvi AMENDMENT 18 04/10/04

HJ-322 INTRODUCTION
LIST OF FIGURES
LIST OF FIGURES
Figure 1: HJ-322 Jet Unit (0º Option Shown) ..................................................................... 1.4
Figure 2: Steering Operation.............................................................................................. 2.2
Figure 3: Moving to Port.................................................................................................... 2.4
Figure 4: Docking.............................................................................................................. 2.4
Figure 5: High Speed Planing in Shallow Water ................................................................. 2.6
Figure 6: Shallow Water Operation Slow Speed................................................................. 2.6
Figure 7: Shallow Water Operation Idle............................................................................. 2.6
3 Design Basics ................................................................................................... 3.1
Figure 8: Mono Hull Design Recommendations ................................................................. 3.1
Figure 9: Installation for Multiple Jets................................................................................ 3.2
Figure 10: Hull Design Recommendations for Multi Hull Vessels....................................... 3.2
Figure 11: Allowable Trim Tabs Location .......................................................................... 3.3
Figure 12: Drive Line Component Description ................................................................... 3.4
Figure 13: Double Universal Slip Jointed Driveshaft........................................................... 3.5
Figure 14: Torsionally Flexible Flywheel Coupling............................................................. 3.5
Figure 15: Double Element Torsionally Flexible Coupling .................................................. 3.5
Figure 16: Long Driveshafts............................................................................................... 3.6
Figure 17: “Z” Configuration Coupling .............................................................................. 3.7
Figure 18: “W” Configuration Coupling ............................................................................. 3.7
Figure 19: Drive Line Inertia Data Jet Mainshaft Dimensions ............................................. 3.8
Figure 20: Jet Mainshaft Alignment ................................................................................... 3.9
Figure 21: Water Offtake Pressure / Flow Graph............................................................. 3.10
Figure 22: Bearing Sleeve Inspection ............................................................................... 3.13
Figure 23: Dry Run Bearing Assembly ............................................................................. 3.14
5 Installation ....................................................................................................... 5.1
Figure 24: Jet Steering Tiller-Cotter Alignment with Modified Tiller ................................... 5.8
Figure 25: Tiller Position ................................................................................................... 5.8
Figure 26: Twin Jet Arrangement....................................................................................... 5.9
Figure 27: Exhaust System Layout................................................................................... 5.10
6 Commissioning ................................................................................................ 6.1
7 Fault Finding .................................................................................................... 7.1
8 Maintenance .................................................................................................. 8.1
9 Overhaul.......................................................................................................... 9.1
Figure 28: Bearing Assembly ........................................................................................... 9.15
Figure 29: View of KMT Nut............................................................................................ 9.16
Figure 30: Water Seal...................................................................................................... 9.17
Figure 31: Wear Ring Inspection & Removal Instructions ................................................ 9.21
Figure 32: Wear Ring Fitting Position .............................................................................. 9.22
Appendix
Figure 33: View of KMT Nut............................................................................................ A.20
AMENDMENT 18 04/10/04 xvii

INTRODUCTION HJ-322
LIST OF FIGURES
xviii AMENDMENT 18 04/10/04

HJ-322 INTRODUCTION
LIST OF DRAWINGS
LIST OF DRAWINGS
HJ-322-30-001 General Assembly Drawing with 0º Shaft Line .......................................... 1.5
HJ-322-30-002 General Assembly Drawing with 5º Shaft Line .......................................... 1.6
3 Design Basics ................................................................................................... 3.1

85114 Earth Bonding System Recommendations and Layout.............................................. 4.7
HJ-322-13-002 Anode Location Drawing ........................................................................... 4.8
5 Installation ....................................................................................................... 5.1
HJ-322-08-001 Installation Details GRP Hull with 5º Shaft Line. Sht 1............................. 5.13
HJ-322-08-002 Installation Details Aluminium Hull with 5º Shaft Line. Sht 1 .................. 5.17
HJ-322-08-003 Installation Details Steel Hull with 5º Shaft Line. Sht 1 ............................ 5.21
6 Commissioning ................................................................................................ 6.1
7 Fault Finding .................................................................................................... 7.1
8 Maintenance .................................................................................................. 8.1
9 Overhaul .......................................................................................................... 9.1

HJ-322-01-000 Basic Jet Assemblies Standard & Dry Run. Sht 1 ...................................... 9.33
HJ-322-01-000 Basic Jet Assemblies Standard & Dry Run. Sht 2 ...................................... 9.34
HJ-322-02-001 Couplings & Belts .................................................................................... 9.35
HJ-322-03-001 Impellers ................................................................................................. 9.36
HJ-322-06-000 Steering Assembly General Arrangement. Sht 1 ....................................... 9.37
HJ-322-06-000 Steering Assembly General Arrangement. Sht 2 ....................................... 9.38
HJ-322-07-001 Reverse Assembly. Sht 1.......................................................................... 9.39
HJ-322-07-001 Reverse Assembly. Sht 2.......................................................................... 9.40
HJ-322-07-002 Blanking Plugs for Reverse Cylinder......................................................... 9.41
HJ-322-09-000 Screen Rake Assembly & Blanking Plugs.................................................. 9.42
HJ-322-10-001 Overflow Preventer.................................................................................. 9.43
HJ-322-11-000 Tool Kits. Sht 1........................................................................................ 9.44
HJ-322-11-000 Tool Kits. Sht 2........................................................................................ 9.45
61529 Rotary Seal (Eagle) 2.5” Diameter Shaft................................................................. 9.46
82206 Impeller Blade Dressing Instructions & Balancing Information. Sht 1 ..................... 9.47
85018 Recommendation for Lubricants & Oils.................................................................. 9.51
85080 Weld Procedure for Welding Cast Intake Block into Aluminium Hulls .................... 9.52
AMENDMENT 18 04/10/04 xix

INTRODUCTION HJ-322
LIST OF DRAWINGS
85113 Recommendations for Fastener Locking, Torques and Thread Lubrication.............9.53

Appendix
xx AMENDMENT 18 04/10/04
INTRODUCTION
HJ-322
WARNINGS
GENERAL SAFETY
NOTICE
The specific Safety Warnings and Cautions summarised below appear in appropriate sections of this manual.
Each is referenced to the text by the Section on which it appears
WARNINGS
A WARNING is an operation or maintenance procedure, practice, condition or
statement which, if not strictly observed, could result in injury or death to
personnel.
This is a list of standard Warnings that will be found throughout this Manual. C.W.F. Hamilton & Co Ltd
advise that in the interests of safety, these Warnings be read and understood prior to commencement of any
maintenance or overhaul activities on the Jet Units / Controls Systems described within this Manual.
SELECTING ’ASTERN’ (CRASH STOP) ENSURE THAT THE VESSEL IS SECURELY

WHILE THE VESSEL IS MOVING AHEAD AT MOORED AS DURING COMMISSIONING
HIGH SPEED CAN PRODUCE A VERY RAPID THE JET UNIT MAY PRODUCE LARGE
DECELERATION. THRUST FORCES.
WARNING NEW OPERATORS SHOULD USE THE WARNING
"CRASH STOP" FEATURE VERY CARE- DO NOT PROCEED IF ANY OF THE CON-
FULLY. TROL SYSTEM FAULT ALARMS ARE STILL
DO NOT USE FULL HELM CONTROL UNTIL ACTIVATED
THE VESSEL HAS SLOWED.
Section 6.
Section 2.2.
EXERCISE EXTREME CARE IF WATER SEAL

EXTREME CARE IS REQUIRED WHENEVER REPLACEMENT IS TO BE CARRIED OUT IN
THE INSPECTION COVER IS REMOVED AS THE VESSEL AS WATER MAY ENTER THE
WATER MAY ENTER THE VESSEL VESSEL THROUGH THE INTAKE OPENING.
THROUGH THIS OPENING.
WARNING NEVER LEAVE THE INSPECTION COVER
WARNING REMOVED.
NEVER LEAVE THE INSPECTION COVER
Section 9.6.
REMOVED WITHOUT CONSTANT
MONITORING OF THE WATER LEVELS.
Section 2.9.3, Section 2.9.4, Section 8.5, Section 9.10 EXERCISE EXTREME CARE IF
and Section 9.10.2. OVERHAULING THE BEARING HOUSING
WITH THE VESSEL AFLOAT AS WATER MAY
ENTER THE VESSEL THROUGH THE
WARNING OPENING IN THE INTAKE.
Section 9.6.
AMENDMENT 18 04/10/04 xxi

INTRODUCTION
HJ-322
WARNINGS
APPROPRIATE SAFETY GLASSES, PROTEC-

TIVE GLOVES AND CLOTHING MUST BE
WORN TO PREVENT SKIN EXPOSURE TO
NITRIC ACID.
WARNING
Section 9.8.6.
xxii AMENDMENT 18 04/10/04

INTRODUCTION
HJ-322
CAUTIONS
CAUTIONS
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.
This is a list of standard Cautions that will be found throughout this Manual. C.W.F. Hamilton & Co Ltd advise
that these Cautions be read and understood prior to commencement of any maintenance on the Jet Units /
Controls Systems described within this Manual.
NEVER STOP THE ENGINE(S), OR ENSURE THAT THE WATER LEVEL IS

DISENGAGE THE DRIVE TO THE JET UNIT, BELOW THE INSPECTION COVER LEVEL
WHEN APPROACHING A MOORING OR AT BEFORE REMOVING THE INSPECTION
ANY TIME WHEN CONTROL OF THE COVER.
CAUTION CAUTION
VESSEL MAY BE REQUIRED.
Section 2.2. Section .
IF IN LIGHTWEIGHT PLANING CRAFT, THE BEFORE REMOVING THE INSPECTION

“ASTERN” OR “ZERO SPEED” POSITIONS COVER:-
ARE SELECTED WITH THE THROTTLE LEFT A) STOP ALL ENGINES.
OPEN AND THE BOAT MOVING FORWARD B) CHECK THAT THE STATIC WATER
CAUTION CAUTION
AT SPEED, THE RESULTANT “BRAKING LEVEL WILL BE BELOW THE INTAKE
EFFECT” CAN BE VERY SEVERE - EVEN INSPECTION COVER LIP.
MORE SO THAN FULL BRAKING WITH A C) IF THE STATIC WATER LEVEL IS TOO
MOTOR CAR. HIGH, BALLAST SHOULD BE PLACED
ON THE BOW TO RAISE THE STERN
Section 2.2. HIGH ENOUGH TO ALLOW THE
INTAKE INSPECTION COVER TO BE
REMOVED.
RUNNING AT SPEED WITH A PARTIALLY
D) ALTERNATIVELY, AN OPTIONAL
BLOCKED INLET GRILL OR DEBRIS ON THE
HATCH EXTENSION/OVERFLOW
IMPELLER WILL RESULT IN CAVITATION
PREVENTOR CAN BE FITTED TO
DAMAGE TO THE JET UNIT.
CAUTION THE INSPECTION HATCH OPENING
TO ALLOW INSPECTION OF THE
Section 2.5 and Section . INTAKE AT HIGHER WATER LEVELS.
Section 2.9.4.
DO NOT RUN THE JET UNIT IF THE
VESSEL HAS RUN AGROUND AS DAMAGE
NOT ALL HULL SHAPES ARE SUITABLE FOR
MAY OCCUR TO THE IMPELLERS AND
PROPULSION BY WATER JETS. GUIDELINES
STATOR.
CAUTION ON SUITABLE HULL SHAPES,
PERFORMANCE AND ENGINE MATCHING IS
CAUTION
Section 2.6. PROVIDED IN THE DESIGNERS MANUAL.
Section 3.2.
AMENDMENT 18 04/10/04 xxiii

INTRODUCTION
HJ-322
CAUTIONS
LOADS ON JET UNIT THRUST AN ISOLATION TRANSFORMER OR A

BEARING GALVANIC ISOLATOR MUST BE
CORRECTLY FITTED TO THE VESSEL’S
THE JET UNIT THRUST BEARING ACCEPTS ELECTRICAL SYSTEM IF THE VESSEL IS TO
CAUTION CAUTION
THRUST LOADS FROM THE JET UNIT TO BE CONNECTED TO AN EXTERNAL AC
PROPELL THE CRAFT. IT SHOULD NOT BE SHORE SUPPLY.
SUBJECTED TO EXCESSIVE LOADS FROM Section 4.1.1.
OTHER SOURCES AS DESCRIBED BELOW:
1.THE JET THRUST BEARING WILL NOT
STAND EXCESSIVE RADIAL LOADS
ANTI FOULING PAINTS
CAUSED BY ADAPTERS AND BELT PUL-
DO NOT USE COPPER OXIDE BASED
LEYS OVERHANGING THE JET COUPLING
ANTI-FOULING PAINTS. LEAVE ALL
FLANGE.
CAUTION STAINLESS STEEL PARTS POLISHED AND
2.THE JET THRUST BEARING WILL NOT
UNPAINTED. DO NOT PAINT OVER THE
WITHSTAND EXCESSIVE LOADS PRO-
ANODES.
DUCED BY RIGID DRIVELINES WHICH
DO NOT ACCOMODATE MISALIGNMENT Section 4.1.7, Section 8.5, and Section 9.1.
RESULTING FROM ENGINE MOVEMENT.
3.THERE IS A LIMIT TO THE DRIVESHAFT
WEIGHT THAT CAN BE SUPPORTED AT ANTI-SEIZE COMPOUNDS
THE JET UNIT. DO NOT USE ANTI-SEIZE COMPOUNDS
WHICH ARE BASED ON GRAPHITE, NICKEL
Section 3.3.
OR COPPER FLAKES - THESE WILL CAUSE
CAUTION
CORROSION. ANTI-SEIZE COMPOUNDS,
USUALLY CONTAINING ZINC FLAKES, ARE
IF A GEARBOX OR CLUTCH IS FITTED TO
AVAILABLE FOR ALUMINIUM.
THE ENGINE, A CONVENTIONAL HULL
WATER PICK-UP AND ENGINE RAW Section 4.1.8, Section 8.5, Section 8.8 and Section 9.1
WATER PUMP MUST BE USED.
CAUTION
FOR STEEL HULLS AND CARBON FIBRE
Section 3.5. and Section 5.6.2.
REINFORCED G.R.P HULLS, THE JET UNIT
MUST BE ELECTRICALLY INSULATED FROM
THE HULL.
PREVENTION OF CORROSION CAUTION
THE JET UNIT HAS BEEN DESIGNED TO
WITHSTAND THE CORROSIVE EFFECTS OF Section 4.3.
CAUTION OPERATION IN SALT WATER THROUGH
THE USE OF MATERIALS THAT ARE
RESISTANT TO SALT WATER CORROSION ENSURE THAT THE WATER PICK UP IS
AND BY THE PLACEMENT OF SACRIFICIAL NOT DIRECTLY AHEAD OF THE JET UNIT
ANODES IN SUITABLE LOCATIONS. INTAKE, BUT WELL TO THE SIDE TO
AVOID TURBULENT WATER FLOW INTO
CAUTION
VESSELS USING HAMILTON JET UNITS, THE JET.
MUST BE BONDED AND WIRED AS
Section 5.1 and Section 5.6.2.
DESCRIBED IN SECTION 4 "PRECAUTIONS
AGAINST CORROSION" SECTION OF THE
JET UNIT MANUAL
Section 4.1 and Section 5.
xxiv AMENDMENT 18 04/10/04

INTRODUCTION
HJ-322
CAUTIONS
IN MULTI JET UNIT INSTALLATIONS, TIGHTENING TORQUES:

EACH JET UNIT MAY BE CONFIGURED FOR ENSURE THAT ALL THREADED FASTENERS
PORT, STARBOARD OR CENTRE ARE TIGHTENED TO THE CORRECT
MOUNTING. CARE SHOULD BE TAKEN TO TORQUE AS DESCRIBED IN DRAWING
CAUTION CAUTION
ENSURE THAT EACH JET IS FITTED IN ITS 85113 OR THE RELEVANT ASSEMBLY
CORRECT POSITION. DRAWINGS.
Section 5.2. Section 8.7.
SWITCH OFF THE REVERSE CONTROL THE WATER SEAL SHOULD NOT BE
SYSTEM (IF OPERATIONAL) DURING REMOVED UNLESS IT IS BEING REPLACED.
STEERING ADJUSTMENT SO THAT THE
THE WATER SEAL WILL NOT PERFORM
REVERSE DUCT CANNOT BE
CAUTION CAUTION CORRECTLY IF IT IS REMOVED AND THEN
ACCIDENTALLY LOWERED.
REINSTALLED.
Section 5.5.4. THE WATER SEAL NEED ONLY BE
REPLACED IF IT IS LEAKING, OR THERE IS
INSUFFICIENT MATERIAL LEFT TO LAST TO
FAILURE TO CHECK COOLING WATER THE NEXT INSPECTION. REFER TO SEC-
HOSES MAY RESULT IN FLOODING OF THE TION 8 MAINTENANCE FOR DETAILS OF
VESSEL. THE INSPECTION REQUIRED.
CAUTION Section 9.6.

Section 6.3 and APPENDIX-4:
ALL WATER SEAL FACES MUST BE CLEAN

IF A PROBLEM IS DETECTED, RETURN TO AND FREE OF GREASE.
THE MOORING IMMEDIATELY, AT
REDUCED POWER. DO NOT OPERATE CAUTION
THE JET UNIT UNTIL THE FAULT HAS BEEN
CAUTION
REPAIRED. REFER TO SECTION 7 FAULT
Section 9.6.3.
FINDING.
Section 6.4.
AVOID USING EXCESSIVE HEAT DURING
WELDING.
DO NOT RUN THE JET UNIT OUT OF THE
WATER UNLESS IT IS FITTED WITH A DRY CAUTION
RUN KIT.
CAUTION Section 9.8.5.
Section 8.3.
BEFORE MOVING ANY CONTROLS, ENSURE

THAT ANY MARINE GROWTH IS REMOVED
FROM THE STEERING AND REVERSE LINK-
AGE RODS. THIS WILL PREVENT DAMAGE
CAUTION
TO THE SEALS THAT THESE CONTROL
RODS PASS THROUGH.
Section 8.3.
AMENDMENT 18 04/10/04 xxv

INTRODUCTION
HJ-322
CAUTIONS
xxvi AMENDMENT 18 04/10/04

PART A
Operator Information
• INTRODUCTION AND PRODUCT DESCRIPTION

• SYSTEM OPERATION
Section 1
INTRODUCTION & PRODUCT DESCRIPTION
1.1 THE HAMILTON WATER JET

SYSTEM
1.1.1 Introduction
In the modern world, waterjets have rapidly gained Hamilton Jet pioneered the commercial
acceptance as the leading means of propulsion for development of the modern waterjet system in the
all types of high speed marine craft including early 1950’s and today have over 30,000 units
ferries, work boats, patrol craft and pleasure boats. installed worldwide. With a complete range of
Recent advances in waterjet technology have put models suitable for power inputs of up to 3000 kW
them ahead of conventional propeller systems in per unit. Hamilton waterjets are ideally suited to the
both high speed performance and also reliability. efficient propulsion of a wide variety of high speed
Modern waterjet powered vessels offer many vessels, in either single or multiple configuration,
advantages, such as high efficiency, rapid typically from 5 to 50 meters in length.
acceleration, shallow draft, unrivaled Hamilton Jet is dedicated to the production of the
manoeuvrability and smooth, quiet operation. highest quality waterjets and controls systems
Whilst conventional propeller powered craft have designed and manufactured to meet the
several shortcomings, such as vibration, higher requirements of the worlds leading certifying
engine loading and susceptibility to damage from authorities. Full logistic support for projects is
water borne debris, waterjets generally offer lower provided by the global Hamilton Jet organisation
maintenance, longer engine life and simplified through factory support staff, regional offices and
installation. an extensive network of factory trained distributors
in over 50 locations worldwide.
Hamilton HJ 322 Jet Circa 2000 Hamilton Quinnat Jet Circa 1953
AMENDMENT 8 21/05/02 1.1

1 INTRODUCTION & PRODUCT DESCRIPTION
HJ-322
1.1 THE HAMILTON WATER JET SYSTEM
EQUIPMENT DESCRIPTION:—The Hamilton HJ 1.1.2 Main Components

Series is a range of highly efficient single stage
waterjets suitable for propelling craft typically up to
INTAKE AND INTAKE BLOCK:—The Intake
20 meters in length and 30 tonnes displacement, at
represents the main structural body of the Jet Unit
speeds up to 50 knots. HJ Series waterjets are
and is an integral part of the Hamilton Jet design.
generally directly driven by high speed diesel
The Intake is cast from high silicon aluminium alloy
engines. The HM Series are larger single stage
and is capable of transmitting the full net thrust
waterjets suitable for vessels typically up to 50m in
force of the Jet Unit to the hull bottom, and not to the
length and are generally driven by high speed diesel
transom or to the engine via the drive shaft. The
engines via a reduction gearbox.
Intake casting has a lower flange which mounts to
Mounted partly inboard at the stern of the vessel, an Intake Block, which is welded or bolted into the
the Hamilton waterjet consists of a totally integrated vessel hull. All Hamilton waterjets include an Intake
package with steering and reverse mechanisms and Screen that is carefully engineered into the waterjet
jet mounted control system hydraulic equipment. design so that operational parameters such as
Water is drawn into the waterjet through an intake cavitation resistance are unaffected by its presence.
screen at the base of the intake, which is mounted
flush with the hull bottom. The pumping unit
OIL COOLER:—The Intake has an integrated Oil
(impeller + stator) increases the pressure or "head"
Cooler for the hydraulic control system. This is
of the flow, which is then discharged at high velocity
connected to a Jet mounted Hydraulic Power Unit
at the nozzle. The reaction to this high velocity jet
(JHPU) via hoses.
stream provides the net thrust force, which is fully
transmitted through the intake to the hull bottom.
THRUST BEARING AND WATERSEAL:—The thrust
A single piece balanced steering nozzle precisely
force generated by the pressure differential across
directs the jet stream as commanded by the helm,
the waterjet Impeller is reacted on by a Thrust
providing high turning forces to either port or
Bearing inside a Bearing Housing attached to the
starboard. An independent split-duct type reverse
front of the Intake. No additional external thrust
deflector, usually hydraulically actuated, directs the
bearing is required. Aft of the Thrust Bearing on the
jet stream back underneath the hull to provide
waterjet Mainshaft is a mechanical face type
powerful astern thrust. The reverse deflector may
Waterseal which prevents water from entering the
be set to a "zero speed" position (where the ahead
vessel and Bearing Housing.
and astern thrusts are balanced) at which point full
steering is still available. Infinitely variable forward
and reverse thrust may be selected by varying the COUPLING & DRIVE SHAFT:—A Coupling is
position of the reverse duct and combined with the mounted on the Mainshaft forward of the Bearing
highly efficient steering, results in unparalleled Housing. A variety of Couplings are available to suit
vessel control and manoeuvrability. the type of driveshaft flange used. The driveshaft to
the waterjet must have axial and radial flexibility.
A vessel fitted with a Hamilton waterjet has the
minimum possible draft, with no protruding
underwater appendages. This allows operation in IMPELLER:—The Impeller design employed in all
shallow waters and in water with floating debris Hamilton waterjets is a highly refined mixed flow
that may foul or damage a typical propeller driven type capable of pumping large volumes of water at
vessel and also means increased safety for relatively low pressures, permitting high propulsive
personnel working in the water near the vessel. The coefficients to be achieved at fast vessel speeds with
waterjet unit is an ideal form of propulsion for outstanding resistance to cavitation. All Impellers
vessels working in a marine mammal environment. have been designed using sophisticated flow
analysis software. The cast stainless steel Impeller
runs within a replaceable stainless steel Wear Ring
located in the rear section of the Intake or within an
Impeller Housing attached to the rear face of the
Intake (on larger HM Series Jet Units).
1.2 AMENDMENT 8 21/05/02

HJ-322
1.1 THE HAMILTON WATER JET SYSTEM
TAILPIPE:—Aft of the Impeller is the Tailpipe SCREEN RAKE:—The HJ-213 to HJ-403 Jet Unit may
section containing a water lubricated marine be fitted with a Screen Rake as an accessory item.
bearing to support the rear of the Mainshaft. The The Screen Rake is a foot operated rake mounted in
Tailpipe contains a stator section that has vanes to the lower half of the Intake, designed to clear any
remove the rotational direction of the flow so that a debris that may be caught by the Intake Screen. The
uniform axial flow is presented to the Nozzle. spring return foot pedal for operating the Screen
Rake is mounted on the port side of the Intake
NOZZLE:—After the water flow passes the pump casing.
(Impeller + Stator), it is at a higher pressure and
relatively low velocity. At the Nozzle outlet, the DRY RUN KIT (OPTIONAL EXTRA ON HJ-212 TO
pressure is at atmospheric. This difference in flow HJ-362 JET UNITS):—Hamilton Jet Units are not
pressure is converted to flow velocity in the Nozzle. fitted with the Dry Run Kit as standard - this is an
The correct Nozzle sizing is critical to the correct optional extra.
operation of the pump in a given application. The Dry Run Kit is a simple solution to the problem
of starting the engine before putting the vessel in the
STEERING (JT TYPE STEERING NOZZLE):—The water, where there is no gearbox fitted. It is
Steering assembly is attached to the rear of the particularly useful for Man-Overboard boats and
Tailpipe. It consists of a Steering Housing, Nozzle Lifeboats where it is important to ensure that the
Insert and Steering Nozzle (which incorporates the engine will start before the vessel is in the water.
Nozzle described above). The Steering Nozzle is The Dry Run Kit consists of a special bearing which
mounted inside the Steering Housing on vertical can be run dry for short periods and run for long
pivot pins and is rotated to port or starboard by periods with water lubrication.
linkages attached to an inboard Steering Cylinder.
The Insert inside the Steering Housing ensures that OVERFLOW PREVENTER OR HATCH EXTENSION
the flow exiting the Stator section reaches the final (OPTIONAL EXTRA):—Hamilton Jet Units are not
Steering Nozzle outlet without being disturbed by fitted with Overflow Preventers as standard - this is
the steering mechanism, thus maximising steering an optional extra.
efficiency. The Overflow Preventer / Hatch Extension is used
where the static waterline (vessel fully laden) is
REVERSE DUCT:—The Reverse Duct is attached by above the level of the Inspection Cover. It is
horizontal pivot pins to the Tailpipe and can be attached to the top of the Intake outside the
positioned up or down by the inboard Reverse Inspection Hatch.
Cylinder. The ahead / astern function of the Reverse
Duct is an integral part of the Hamilton Jet package.
The split deflector type Reverse Duct is designed to
provide maximum astern thrust under all conditions
of vessel speed, water depth and throttle setting. A
splitter is incorporated to divide the flow and angle
the astern jet stream downwards and to the side, to
clear the vessel Transom and Intake opening. This
prevents recycling of flow through the Jet Unit
(which may be aerated or contain sediment) and
also excessive disturbance of the bottom of the
waterway. The result is very high reverse efficiency
that contributes to the excellent manoeuvrability
afforded by a Hamilton waterjet.
TRANSOM SEAL:—The Transom Seal serves to seal

the hole in the vessel Transom through which the
waterjet passes. It is bolted to the vessel Transom
and incorporates a flexible element which contacts
and seals around the Intake.
AMENDMENT 17 18/06/04 1.3

HJ-322
1.2 GENERAL ASSEMBLY DRAWINGS
STEERING CYLINDER INSPECTION COVER
OIL COOLER
TRANSOM PLATE
J.H.P.U.
REVERSE CYLINDER
COUPLING
REVERSE DUCT
(DOWN)
INTAKE BLOCK
STEERING NOZZLE TILLER REVERSE CYLINDER

IMPELLER RACE
TAIL PIPE BEARING HOUSING
INTAKE
INTAKE BLOCK
INTAKE SCREEN
(HIDDEN)
Figure 1: HJ-322 Jet Unit (0º Option Shown)
1.4 AMENDMENT 8 21/05/02

HJ-322 1 INTRODUCTION & PRODUCT DESCRIPTION
HJ-322-30-001 General Assembly Drawing with 0º Shaft Line
AMENDMENT 18 04/10/04 1.5
HJ-322
HJ-322-30-002 General Assembly Drawing with 5º Shaft Line
1.6 AMENDMENT 18 04/10/04
Section 2
SYSTEM OPERATION
2.1 STARTING UP 2.2 “AHEAD” / “ZERO SPEED” /

“ASTERN” CONTROLS
NEVER STOP THE ENGINE(S), OR
DISENGAGE THE DRIVE TO THE JET UNIT,
SELECTING ’ASTERN’ (CRASH STOP)
WHEN APPROACHING A MOORING OR AT
WHILE THE VESSEL IS MOVING AHEAD AT
ANY TIME WHEN CONTROL OF THE
CAUTION HIGH SPEED CAN PRODUCE A VERY RAPID
VESSEL MAY BE REQUIRED.
DECELERATION.
WARNING NEW OPERATORS SHOULD USE THE
NOTE: With HSRC Systems, the Control Lever "CRASH STOP" FEATURE VERY CARE-
cannot be moved until the engine and FULLY.
Hydraulic Pump (HPU) are running. DO NOT USE FULL HELM CONTROL UNTIL
1. Before starting engine(s), the following checks THE VESSEL HAS SLOWED.
should be carried out: "Astern" and "Zero Speed" are achieved by re-
a) Ensure that the vessel is securely tied up or directing the jetstream. If the Reverse Duct is
well clear of other objects. lowered fully, all of the jetstream is re-directed back
b) Ensure that the Helm is centred and the under the vessel giving "Full Astern Thrust". If the
Reverse Controls are at Zero Speed. Reverse Duct is lowered partially the jetstream is
c) Ensure that the Clutches and Gearboxes, if split giving some ahead and some astern thrust. At
fitted, are in neutral position. a certain Reverse Duct position the ahead and
2. After starting engine(s), adjust the Helm and astern thrusts will be equal so the vessel will not
Reverse Levers, to control vessel movement. move ahead or astern regardless of the throttle
opening. This position is given the technical term
"Zero Speed". (This term should not be confused
with the neutral position of a gearbox when the
driveline stops rotating).
When operating the Hamilton Reverse Control, the
Jet Unit is always rotating regardless of the position
of the Reverse Duct. Any intermediate position
between ahead and astern can be selected to give
infinitely variable speeds when manoeuvering.
"CRASH" OR "EMERGENCY STOP"

This Procedure Should Only Be Used In An
Emergency.
AMENDMENT 8 21/05/02 2.1

2 SYSTEM OPERATION
HJ-322
2.3 STEERING
2.3 STEERING
IF IN LIGHTWEIGHT PLANING CRAFT, THE The Steering Nozzle deflects the jet of water to port
“ASTERN” OR “ZERO SPEED” POSITIONS or starboard causing the vessel to steer to port or
ARE SELECTED WITH THE THROTTLE LEFT starboard respectively
OPEN AND THE BOAT MOVING FORWARD .
CAUTION
AT SPEED, THE RESULTANT “BRAKING
EFFECT” CAN BE VERY SEVERE - EVEN PORT CENTER STARBOARD
MORE SO THAN FULL BRAKING WITH A HELM HELM HELM
MOTOR CAR.
For normal operation to "Brake" the vessel's

forward motion :- AHEAD
1. Close the throttle.

2. Select "Zero Speed" or "Astern".
3. Open the throttle, gently at first until the desired
braking is achieved.
4. Close the throttle as soon as the vessel has ZERO SPEED
slowed to a standstill.
5. Do not use full steering until the vessel has
slowed.
ASTERN
Figure 2: Steering Operation
The following points should be remembered when

operating a Jet Vessel:-
1. If the engine is stopped there is no jet of water to
deflect and so the vessel cannot be steered or
stopped.
2. Never stop the engine or disengage the drive to
the Jet when approaching a mooring or at any
time when steering will be required.
3. The more the throttle is opened the greater the
steering effect - i.e. the sharper the turn.
4. Steering is available at "Zero Speed" as well as all
ahead and astern speeds - a feature which gives
the Hamilton Jet unrivalled manoeuvrability.
When moving ahead at "Zero Speed", or astern, the
bow of the vessel will always turn the way the
steering wheel is turned, i.e. move the steering to
port, the bow of the vessel will move to port and vice
versa.
This means that going astern the vessel has the
opposite steering to a motor car, a feature which
can be used to advantage when manoeuvring.
2.2 AMENDMENT 8 21/05/02

2 SYSTEM OPERATION
HJ-322
2.4 MANOEUVERING AND DOCKING
The following steering systems are suitable for this 2.4 MANOEUVERING AND
application:
a) A manual hydraulic steering system which DOCKING
gives approximately 1.3 turns of the helm
from full lock to full lock is recommended. (A 2.4.1 Low Speed Manoeuvering
greater number of turns will reduce the
sensitivity of the steering during low speed
and Docking
manoeuvring). The vessel is best manoeuvred as follows:-
b) A high quality rotary, or rack and pinion, 1. Move the Reverse Control Lever to the "Zero
cable system is an alternative but for single Speed" position.
jets only - the system must not allow more
2. Set the throttle to 1/3 open - approximately 1,000
than 1.5 turns of the helm from full lock to full
R.P.M. (In strong tide or wind conditions
lock.
increase the throttle opening to obtain greater
The Steering System is balanced so that power response as required to suit the conditions).
assisted controls are not necessary even for multiple
Jet Units. 3. A slight movement either way from the "Zero
Speed" position will be sufficient to move the
vessel ahead or astern until the manoeuvre is
2.3.1 Total Hydraulic Failure complete.
4. Steering will be very responsive at this throttle
EMERGENCY STEERING CONTROL:—In the case of opening. Full steering control is available at all
a complete manual hydraulic steering failure, the ahead/astern control lever positions and there is
Jet(s) may be steered by manually moving the Jet no change of steering "sense" at any time.
Tiller(s). Open the By-Pass Valve (or disconnect the
hydraulic hoses at the steering cylinder if there is no 5. Manoeuvre at a fixed throttle setting, working the
valve). The Nozzle position is indicated by the steering with one hand and the Ahead/Astern
gauge at the Helm. Steering may only be possible at Control Lever with the other hand.
low RPM unless an Emergency Tiller Extension is
NOTE:
used (not included in C.W.F Hamilton & Co Ltd
standard supply). 1. DO NOT WORK THE THROTTLES - Leave
as set. With TWIN JETS manoeuvering is
EMERGENCY MANUAL REVERSE DUCT best carried out using the Helm with one
CONTROL:—THIS MAY BE CARRIED OUT IN CASE OF FAIL- hand and both Reverse Levers with the other
URE OF THE REVERSE HYDRAULIC CONTROLS SYSTEM. hand.
2. USE ONLY LOW ENGINE RPM - High
TO RAISE THE REVERSE DUCT: RPM will give faster response but makes
control more difficult.
1. Attach a rope to the Reverse Duct.
3. If the bow is rotating to starboard, port lock
2. Take the weight of the Reverse Duct.
must be used to stop the rotation (or vice
3. Disconnect the front hydraulic hose from the versa) then the Helm is centred to hold the
Reverse Cylinder. heading.
4. Lift the Reverse Duct and tie off the rope so that 4. If the vessel is moving ahead then the
the Duct is raised out of the jet stream. Reverse Lever(s) must be moved astern to
This will enable the vessel to proceed at speed and bring the vessel to rest (or vice versa) and
return to base to have the fault checked and then Zero Speed selected to hold the
rectified. heading.
AMENDMENT 8 21/05/02 2.3

2 SYSTEM OPERATION
HJ-322
2.4 MANOEUVERING AND DOCKING
2.4.2 Moving Sideways
WITH TWIN JETS:— Use the following procedure to

move the vessel sideways away from the jetty.
Initially both controls are at "ZERO SPEED" and the
A.
vessel is stationary.
MOVING TO PORT
1. Set both engine RPMs to just above idle with JETTY
slightly higher RPM on the port side.

2. Set steering to ahead. B.
3. Move the port reverse lever to full astern and the

starboard lever to full ahead (A).
4. As the bow begins to swing to Port, turn the helm
to starboard to keep the vessel parallel to the
jetty (B).
5. The vessel will now move sideways to Port.
6. Adjust the port engine RPM to prevent fore and Figure 4: Docking
aft movement. (Higher RPM moves vessel aft).
This may also be done by bringing the starboard MOVING TO STARBOARD
reverse control back towards the Zero Speed
position. 7. Instructions 1 to 5 are the same but for Port read
Starboard and vice versa. When the Vessel is
safely clear move both controls back to zero
speed and centre the helm. Then move off in the
required direction.
DOCKING.
A.
Use the previous procedure when approaching or
moving away from a jetty or another vessel.
JETTY NOTE: If the vessel is moving sideways too fast the

controls should be set back to zero speed and
the Helm returned to the centre position.
Alternatively set the controls for sideways
movement in the opposite direction until the
vessel stops moving sideways. The required
control setting will vary according to wind
and tide conditions.
WITH TRIPLE JETS:—Using all three Jets to move

sideways gives best results.
Figure 3: Moving to Port
MOVING TO PORT
1. Set Steering to dead ahead, all three reverse
ducts to the "Zero Speed" position and RPM on
all Engines to the same value. (The RPM required
for manoeuvring will depend on the prevailing
sea conditions, higher RPM will improve
response).
2.4 AMENDMENT 9 24/01/03

2 SYSTEM OPERATION
HJ-322
2.5 CRUISING
2. For sideways motion to port, set the port Jet full 2.5 CRUISING
astern and the starboard Jet full ahead (this is
reversed for sideways motion to starboard).
3. Use the centre Jet Reverse Duct to control fore RUNNING AT SPEED WITH A PARTIALLY
and aft movement (Duct approximately 80% BLOCKED INLET GRILL OR DEBRIS ON THE
reversed). IMPELLER WILL RESULT IN CAVITATION
4. Use the Helm to control turning (rotation) DAMAGE TO THE JET UNIT.
CAUTION
moments, i.e. for sideways motion to port turn
the Helm to starboard to balance the turning Care must be taken to prevent cavitation damage to
moment of the port and starboard Jets. the Jet Units, as described below:
This method of sideways manoeuvring should result 1. Running at speed with a partially blocked Inlet
in 33% more side thrust than if only two Jets were Grill or debris on the Impeller will result in
used. Once set up, only the centre Jet Reverse cavitation damage to the Jet Unit. Therefore,
Control and the Helm need to be used for controlling before accelerating to full speed, all Jet Units
the sideways movement. should be cleared by BACKFLUSHING. Refer to
Section 2.9“Blockages (Debris in the Jet Unit)”.
MOVING TO STARBOARD: This should be done on every trip as soon as
Follow instructions 1 to 4 above, but for "Port" read clear water is reached.
"Starboard" and vice versa. 2. Acceleration should be carried out gradually.
Full power cannot be used at low vessel speeds
TO STOP SIDEWAYS MOVEMENT: such as when operating on one engine only.
1. Set the Helm to dead ahead, Throttle RPM to idle 3. If there is any blockage of the Jet Unit, the engine
and Reverse to Zero Speed before the vessel will run at a higher than normal RPM and the
reaches the required position. vessel will accelerate slowly and best speed will
2. Alternatively set Controls to start sideways be reduced. If such symptoms are noticed,
movement in the opposite direction until vessel immediately slow the vessel and clear the
stops sideways movement then set the Controls blockage. Refer to Section 2.9“Blockages (Debris
to :- in the Jet Unit)”.
• Steering Dead Ahead. 4. In conditions of severe weather or overload, the
• Throttle: Idle. engine speed should be reduced accordingly.
• Reverse: Zero Speed.
EMERGENCY MANOEUVERING:
1. With Multiple Jets. Shut down the engine
driving the Jet without reverse and manoeuvre
using the other Jet(s).
2. With a Single Jet. The vessel can be partially
manoeuvred by raising the Reverse Duct with a
rope and lowering it under its own weight. The
engine must be kept at idle RPM.
AMENDMENT 9 24/01/03 2.5

2 SYSTEM OPERATION
HJ-322
2.6 SHALLOW WATER OPERATION
2.6 SHALLOW WATER 2.7 ACCELERATION TO HIGH

OPERATION SPEED
If leaving an area of shallows, or with debris in the
water, ensure Jets are clear of debris before
DO NOT RUN THE JET UNIT IF THE accelerating to high speed. Refer to Section
VESSEL HAS RUN AGROUND AS DAMAGE 2.9.3“Clearing Blockages”. If there is any debris in
MAY OCCUR TO THE IMPELLERS AND the Jet the engine will run at higher than normal
STATOR. RPM and the vessel will only accelerate slowly and
CAUTION
may not reach full (planing) speed. Refer to Section
It is important to avoid pumping stones, sand, etc, 2.9.3“Clearing Blockages”.
through the Jet Unit as this will blunt and wear the Daily, prior to commencing operations, the
Impeller. The following diagrams illustrate good Inspection Cover should be removed and any debris
and bad practice: removed from around the Impeller or Intake Screen.
A: At high planing speeds, shallow water operation Refer to Section 8.4“Servicing Intervals”.
is not a problem until the vessel is nearly
grounded.
ENSURE THAT THE WATER LEVEL IS
BELOW THE INSPECTION COVER LEVEL
KNOTS
RPM BEFORE REMOVING THE INSPECTION
COVER.
CAUTION
RUNNING AT SPEED WITH A PARTIALLY

Figure 5: High Speed Planing in Shallow Water BLOCKED INLET GRILL OR DEBRIS ON THE
IMPELLER WILL RESULT IN CAVITATION
B: At slow displacement speeds avoid using high
DAMAGE TO THE JET UNIT.
RPM in shallow water. CAUTION
KNOTS RPM
2.8 AERATED WATER

It is possible that some Hulls may, under certain
conditions, feed aerated water into the intake of the
Jet Units.
Figure 6: Shallow Water Operation Slow Speed When operating in areas where the water may be
excessively aerated. (eg. fast flowing rapids or surf)
C: If it is not possible to pick a deep water area to the following points should be noted:
start off and stop in, then "idle" over the shallow
area into deep water before accelerating up to 1. There may be a loss in thrust due to the Unit
planing speed. If any debris has been picked up pumping a significant amount of air instead of
in the intake screen, momentarily stopping the water.
engine should allow the debris to drop away 2. The Impeller may unload suddenly causing the
from the screen. engine RPM to fluctuate wildly.
When these symptoms occur, reduce engine RPM
until the Jet Unit maintains a steady RPM and thrust.
KNOTS RPM
Figure 7: Shallow Water Operation Idle
2.6 AMENDMENT 12 22/08/03

2 SYSTEM OPERATION
HJ-322
2.9 BLOCKAGES (DEBRIS IN THE JET UNIT)
2.9 BLOCKAGES (DEBRIS IN THE blockage. If this fails to work, repeat actions
a) to c) several times.
JET UNIT) 3. Remove the Inspection Cover on the Intake and
manually clear the obstruction.
2.9.1 Avoiding Blockages Refer to Section 2.9.4“Using the Inspection Cover”.
Pieces of debris, water weed or sticks, etc will not
normally block or harm the Jet Unit. However, it is NOTE:
good practice to steer around such debris where 1. Check that the static water level will be safely
possible as any debris caught in the Intake Screen, below the lip of the Intake Inspection Cover.
Impeller or Tailpipe Stator Vanes can affect the Jet 2. If the static water level is too high, ballast
Unit's performance. should be placed on the bow of the vessel to
raise the stern high enough to allow the
2.9.2 Detecting Blockages Intake Inspection Cover to be removed.
In debris laden waters it may be necessary to clear 3. Alternatively, an optional extra Overflow
the Intake Screens and Impellers before each run. In Preventer can be fitted to the Inspection
many cases the debris is picked up while the Jet Unit Cover to allow inspection of the Intake
is moored, so it is advisable to clear the Intake Housing at higher water levels.
Screen in open or clear waters.
Blockages of the Jet Unit are usually noticed by the 2.9.4 Using the Inspection Cover
following symptoms:
1. Engine unloading (RPM increases).
2. Lack of Jet thrust (vessel speed drops). EXTREME CARE IS REQUIRED WHENEVER
THE INSPECTION COVER IS REMOVED AS
3. Abnormal noise and vibration from the Jet Unit. WATER MAY ENTER THE VESSEL
2.9.3 Clearing Blockages WARNING
EXTREME CARE IS REQUIRED WHENEVER MONITORING OF THE WATER LEVELS.
WATER MAY ENTER THE VESSEL
THROUGH THIS OPENING. BEFORE REMOVING THE INSPECTION
WARNING
COVER:-
NEVER LEAVE THE INSPECTION COVER A) STOP ALL ENGINES.
REMOVED WITHOUT CONSTANT B) CHECK THAT THE STATIC WATER
MONITORING OF THE WATER LEVELS. CAUTION
LEVEL WILL BE BELOW THE INTAKE
The following methods can be used to clear a INSPECTION COVER LIP.
blocked Jet Unit: C) IF THE STATIC WATER LEVEL IS TOO
HIGH, BALLAST SHOULD BE PLACED
1. Slow or stop the engine driving the blocked Jet
ON THE BOW TO RAISE THE STERN
Unit. The blockage will often clear itself. This
HIGH ENOUGH TO ALLOW THE
operation works best when the vessel is still
INTAKE INSPECTION COVER TO BE
moving forward at speed.
REMOVED.
2. BACKFLUSH the blocked Jet Unit (only possible if D) ALTERNATIVELY, AN OPTIONAL
a reversible gearbox is used) as shown below: HATCH EXTENSION/OVERFLOW
a) Stop or slow the Vessel to displacement PREVENTOR CAN BE FITTED TO
speed. THE INSPECTION HATCH OPENING
b) Move the Reverse Duct to the ZERO SPEED TO ALLOW INSPECTION OF THE
position. INTAKE AT HIGHER WATER LEVELS.
c) Reverse the rotation direction of the blocked
Jet Unit by engaging reverse gear and opening
the throttle slightly. This should clear the
AMENDMENT 12 22/08/03 2.7

2 SYSTEM OPERATION
HJ-322
2.10 OVERFLOW PREVENTER (OPTIONAL EXTRA)
2.10 OVERFLOW PREVENTER 2.11 OPERATING WITH AN

(OPTIONAL EXTRA) ENGINE AND JET UNIT OUT
NOTE: Refer to Drawing “HJ-322-10-001 Overflow
OF SERVICE
Preventer”. If the vessel is operated with an engine and Jet Unit
out of service, it is possible for the Jet Unit Mainshaft
The Overflow Preventer is an optional extra for use to rotate due to water flowing through the Jet Unit.
with Jet Units where the water level is above the This is undesirable as it can lead to damage of the
normal level of the Inspection Cover. gearbox.
1. It is attached to the top of the Intake Casing along
with the Inspection Cover. USE OF SHAFT BRAKE (IF FITTED) TO STOP
2. It provides an increase of approximately 150 mm MAINSHAFT ROTATION:—The Shaft Brake should
in allowable water level height. Refer to Section be fitted to the output shaft of the Gearbox. Apply
9.10“Overflow Preventer (Optional Extra)” for the Shaft Brake to stop the Jet Unit Mainshaft
fitting and removal instructions. rotation in Jet Units not in service.
USE OF ENGINE TO STOP MAINSHAFT

ROTATION:—If a Shaft Brake is not fitted, the Jet
Unit Mainshaft can be prevented from rotating by
engaging the Gearbox of the Engine which is out of
service.
NOTE: When using this method, it is possible for the

Jet Unit to rotate the Engine. If this occurs,
disengage the Gearbox and let the Jet Unit
Mainshaft rotate.
2.8 AMENDMENT 12 22/08/03

PART B
Design and Installation Information
• DESIGN BASICS
• PRECAUTIONS AGAINST CORROSION
• INSTALLATION
• COMMISSIONING
Section 3
DESIGN BASICS
3.1 PROPULSION SYSTEM

DESIGN
STRAKES INSIDE WIDTH OF
INTAKE SHOULD STOP 0.5 M AIR / WATER
JET UNIT SELECTION:—Jet Unit selection is a AFT OF DYNAMIC AIR / WATER INTERFACE
complex task and C.W.F. Hamilton should be INTERFACE
consulted for advice in all cases.
3.2 HULL DESIGN STRAKE
NOT ALL HULL SHAPES ARE SUITABLE FOR

PROPULSION BY WATER JETS. GUIDELINES
ON SUITABLE HULL SHAPES,
PERFORMANCE AND ENGINE MATCHING IS
CAUTION
PROVIDED IN THE DESIGNERS MANUAL.
JET UNIT
INLET
3.2.1 Mono Hulled Vessel

1. Aerated water generated by the vessel’s bow
wave must not pass directly aft to the Jet Unit
Intake(s).
0.1 M
a) A vee'd bow stem in conjunction with 10º
SHADED AREA SHOULD BE
minimum deadrise angle is recommended. KEPT FREE OF ANY APPENDAGES
b) Mount multiple Jet Units as close to the keel INCLUDING WATER PICKUPS
line as possible. ("staggered" engines can
allow closer centres). Figure 8: Mono Hull Design Recommendations
c) Planing strakes, keelsons, "plank keels" and
any other appendage that may create 2. For speeds over 30 knots, monohedron
turbulent flow into the Jet Unit(s) must be (constant deadrise) hulls are recommended for
removed from the hull bottom in front of and directional stability without appendages.
adjacent to the Jet Unit Intakes. Refer to Figure
8:“Mono Hull Design Recommendations”.
AMENDMENT 8 21/05/02 3.1

3 DESIGN BASICS
HJ-322
3.2 HULL DESIGN
3. Displacement speed and warped plane (reducing 5. Minimum distances between Jets for multiple
deadrise going aft) hulls may need additional installations. Refer Figure 9:“Installation for Mul-
directional stability. Twin “bilge keels” are tiple Jets”.
normally sufficient and these do not increase a) For dimensions A and B shown in Figure
draft or interfere with water flow into the Jet 9:“Installation for Multiple Jets” for Twin and
Intake. Triple Jet installations, refer to the
4. Immersion. The Jet Unit must be immersed with Installations Drawings shown in Section 5 of
the water line at least up to the underside of the this manual.
Mainshaft (at the Impeller) in order to prime the b) For applications using more than three Jets,
unit when the engine is started. consult C.W.F Hamilton & Co Ltd for
recommended distances between Jets.
"B"
"A" "A"
MINIMUM JET CENTERS

AT TRANSOM
JETS MOUNT FLAT TO HULL

AT ALL DEADRISE ANGLES
Figure 9: Installation for Multiple Jets
3.2.2 Multi Hulled Vessel following diagram. The Reverse Duct when in the
"up" (ahead) position must not project beyond the
Jet Units may be fitted in catamaran and some
sidewalls of a catamaran or trimaran hull or,
trimaran hulls. Air entrainment between the hulls
substantial drag may be caused.
occurs with these vessels and care must be taken to
ensure that this entrained air does not enter the Jet Consult with C.W.F. Hamilton in all cases if Jet Units
Unit intakes(s). This is alleviated if the hulls are are proposed in these types of hull.
deep in relation to the air tunnels so that the Jet
Units sit well down in the water, as indicated on the
Figure 10: Hull Design Recommendations for Multi Hull Vessels
3.2 AMENDMENT 8 21/05/02

3 DESIGN BASICS
HJ-322
3.2 HULL DESIGN
3.2.3 Trim Tabs located under the Jet Unit. Contact Hamilton Jet if
further details are required.
Trim Tabs cannot be mounted directly alongside the
Jet Unit, as when moving astern, the reverse jet The diagram shows the area within which the Trim
stream will hit them and reduce reverse thrust. Tab must lie. From the maximum width "W" at the
Transom, the area tapers inwards at 25º per side
It is possible to mount Trim Tabs under the Jet Unit
until it reaches the same width as the Reverse Duct
with any control equipment mounted on either side
bottom corners.
of the Jet Unit. The adjacent diagram serves as a
guide to the maximum size of trim tab that may be
Figure 11: Allowable Trim Tabs Location
AMENDMENT 13 25/11/03 3.3

3 DESIGN BASICS
HJ-322
3.3 DRIVELINES
3.2.4 Engine Exhausts 3.3.1 Requirements of the Driveline

Engine exhausts should not be located below the 1. The Driveline must accommodate parallel and
waterline near the Jet Units. angular misalignment plus allow axial
If engine exhausts are located in this area, water movement.
containing exhaust gases can be ingested by the Jet 2. The Driveline must transmit the torque input to
Unit when moving astern. This can cause loss of the Jet Unit with an acceptable life expectancy. It
thrust and control of the Jet Unit. does not have to transmit thrust loads as these
are absorbed by the Jet Unit.
3. Torsional flexibility will be required in the
3.3 DRIVELINES Driveline. A torsional vibration analysis must
always be carried out. The resultant torque on
the Jet Unit must always be in the same direction.
LOADS ON JET UNIT THRUST This should be carefully checked at engine idle
BEARING speed.
CAUTION THE JET UNIT THRUST BEARING ACCEPTS 3.3.2 Engineering Checks
THRUST LOADS FROM THE JET UNIT TO
PROPELL THE CRAFT. IT SHOULD NOT BE
All driveline component suppliers (including engine
SUBJECTED TO EXCESSIVE LOADS FROM
and jet suppliers) must be consulted with full
OTHER SOURCES AS DESCRIBED BELOW:
driveline details to ensure suitability and
1.THE JET THRUST BEARING WILL NOT compatibility of components.
STAND EXCESSIVE RADIAL LOADS
CAUSED BY ADAPTERS AND BELT PUL- CHECKS MUST INCLUDE:
LEYS OVERHANGING THE JET COU- 1. Critical speed check for whirling of the
PLING FLANGE. Mainshaft: consult C.W.F. Hamilton & Co. Ltd.
2.THE JET THRUST BEARING WILL NOT 2. Critical speed check for whirling of the
WITHSTAND EXCESSIVE LOADS PRO-
driveshaft: consult driveline supplier.
DUCED BY RIGID DRIVELINES WHICH
DO NOT ACCOMODATE MISALIGNMENT 3. Engine to Jet alignment: consult C.W.F. Hamilton
RESULTING FROM ENGINE MOVEMENT. & Co. Ltd.
3.THERE IS A LIMIT TO THE DRIVESHAFT 4. Torsional Vibration Analysis: consult engine or
WEIGHT THAT CAN BE SUPPORTED AT torsionally flexible coupling supplier.
THE JET UNIT.
NOTE: Critical speed checks should allow safe
operation up to the engine's "no load"
governor setting (or high idle).
TORSIONALLY FLEXIBLE COUPLING
FIXED LINESHAFT
(OPTIONAL)
MISALIGNMENT ABSORBING COUPLING
JET UNIT COUPLING MARINE

DIESEL
ENGINE
Figure 12: Drive Line Component Description
3.4 AMENDMENT 8 21/05/02

3 DESIGN BASICS
HJ-322
3.3 DRIVELINES
3.3.3 Driveshaft Options TORSIONALLY FLEXIBLE COUPLING (TFC):—The

torsional vibration analysis will determine how
The diagrams Figure 13:“Double Universal Slip
many TFCs are required and where they should be
Jointed Driveshaft” and Figure 14:“Torsionally Flexi-
located. At least one TFC should be fitted either:
ble Flywheel Coupling” show two common Driveline
• Between the engine and the gearbox.
components and their arrangements. These
• Immediately between the gearbox and any
diagrams are a guide only. Always contact C.W.F
shafting leading to the Jet Unit.
Hamilton & Co Ltd before designing the Driveline.
DOUBLE ELEMENT TORSIONALLY FLEXIBLE COU-

UNIVERSAL DRIVESHAFTS:
PLINGS
These are double universal slip-jointed Driveshafts,
Examples of such couplings are "Centaflex" and
also called Cardan shafts. They bolt directly to the
"Megaflex".
Jet Unit Coupling.
Use a double element torsionally flexible driveshaft
Lengths range from approximately 900 mm to 3,000
with support bearings such as the "Centaflex GZ"
mm. Lengths are limited by the weight which can be
type illustrated. The engine/gearbox is located In-
allowed at the Jet Unit Coupling. Refer to Section
line with the Jet Unit and can be flexibly mounted
3.3.7“Critical Speed of Mainshaft” and Section
with this type of coupling.
3.3.2“Engineering Checks”.
Length - From approximately 200 mm (8")
upwards, but limited by the weight which can be
DOUBLE UNIVERSAL SLIP JOINTED allowed at the Jet Unit coupling. Refer to Section
DRIVESHAFT
3.3.7“Critical Speed of Mainshaft”.
OFFSET ANGLES EQUAL

A° JET COUPLING
COUPLING ADAPTOR
TORSIONALLY FLEXIBLE
ELEMENTS
A°
YOKES IN SAME PLANE

JET COUPLING
FLYWHEEL ADAPTOR
ENGINE FLYWHEEL
Figure 13: Double Universal Slip Jointed Driveshaft

CENTAFLEX GZ ASSEMBLY
ENGINE FLYWHEEL
TORSIONALLY FLEXIBLE Figure 15: Double Element Torsionally Flexible Coupling

FLYWHEEL COUPLING
DOUBLE ELEMENT NON TORSIONALLY FLEXIBLE

COUPLINGS
An example of such a Coupling is "Centalink".
ENGINE FLYWHEEL
Figure 14: Torsionally Flexible Flywheel Coupling
AMENDMENT 8 21/05/02 3.5

3 DESIGN BASICS
HJ-322
3.3 DRIVELINES
GEAR COUPLING: NOTE: A double jointed coupling is required.

This Coupling is steel double jointed coupling which
is both flexible to allow for angular offset and also LONG DRIVESHAFTS:—Where the distance
rigid to absorb torsional twisting. between the gearbox flange and the Coupling flange
The Coupling is formed by two hubs which engage exceeds that possible with a MAC, then a fixed
into a flanged sleeve with internal straight parallel Lineshaft supported on pedestal bearings should be
teeth. Due to the design of the of the teeth used in conjunction with either universal driveshafts
curvature, if shaft misalignment occurs, the hub can or torsionally flexible couplings. Refer to Figure
oscillate in the flanged sleeve. 16:“Long Driveshafts”.
The curved face teeth couplings are flexible enough
NOTE: If a TFC is not required between the gearbox
to compensate for misalignments and axial
and the Lineshaft, then the Lineshaft can be
movements of coupled shafts. The same type of
directly attached to the gearbox flange using
coupling also allows for greater shaft offset.
normal propeller shafting criteria. The
Manufacturers recommendations regarding gearbox should be mounted rigidly to avoid
installation and alignment should be followed. misalignment.
TORSIONALLY FLEXIBLE FLYWHEEL

COUPLING WITHOUT SUPPORT BEARING
DOUBLE UNIVERSAL SLIP JOINT LINESHAFT WITH

DRIVE SHAFT SUPPORT BEARINGS
OFFSET ANGLES EQUAL

A°
A°
JET COUPLING
ENGINE FLYWHEEL
Figure 16: Long Driveshafts
3.6 AMENDMENT 8 21/05/02

3 DESIGN BASICS
HJ-322
3.3 DRIVELINES
3.3.4 Universal Driveshaft Alignment

1. There are only two allowable configurations
for location of centrelines for the Jet Unit and
Gearbox. These are the "Z" Configuration Common Deflection Plane
shown in Figure 17:““Z” Configuration ß1
Coupling” and “W” Configuration shown in
Figure 18:““W” Configuration Coupling” If
these requirements are not met, then
cavitation of the Jet Unit and machinery ß2
damage can result because the drive speed to
the Jet Unit is not constant.
2. The universal driveshafts must be assembled
with the yokes (forks) in the same plane.
3. Correct running length of the shaft is with the Figure 18: “W” Configuration Coupling
shaft extended to half the total spline
extension length. "W" CONFIGURATION COUPLING (For Constant
4. The splined end of the driveshaft is heavier Velocity B1 = B2.
and should be installed at the gearbox end of Input and Output Shaft intersect in one plane.
the Driveline. Requirement B1 = B2.
NOTE:
1. When the TFC couples directly to a
universal driveshaft, the TFC must provide
a bearing to support the universal
driveshaft.
ß
2. When the TFC couples directly to a Lineshaft
supported on bearings, a support bearing is
not required.
ß
3.3.5 Jet Coupling Flange
Details
Common Deflection Plane
Refer to Drawing “HJ-322-02-001 Couplings &
Figure 17: “Z” Configuration Coupling Belts” for all relevant Coupling details.
"Z" CONFIGURATION COUPLING (For Constant

Velocity) B1 = B2.
Input and Output Shaft are parallel to each other in
one plane. B1 = B2
AMENDMENT 8 21/05/02 3.7

3 DESIGN BASICS
HJ-322
3.3 DRIVELINES
3.3.6 Moments of Inertia responsibility of the vessel builder to see that this is
carried out by either the engine manufacturer or the
A Torsional Vibration Analysis must be carried out
flexible coupling manufacturer.
for the complete drive-train including Engine
Flexible Coupling, Gearbox, Driveshaft and Jet The Moment of Inertia Data for the Jet Unit is
rotational assembly, especially where a universal provided below, to enable a Torsional Vibration
driveshaft is used without a torsionally resilient Analysis to be carried out.
member or gearbox in the driveline. It is the
Figure 19: Drive Line Inertia Data Jet Mainshaft Dimensions
3.3.7 Critical Speed of Mainshaft

NOTE:
1. In all cases, for the calculation of the
"Critical Speed of the Jet Mainshaft" consult
C.W.F. Hamilton & Co Ltd.
2. The heavier splined end of the Universal
Driveshaft should be located towards the
engine.
If a heavy Driveline is used then a transverse
vibrational analysis of the Jet Mainshaft should be
carried out.
3.8 AMENDMENT 18 04/10/04

3 DESIGN BASICS
HJ-322
3.4 JET MAINSHAFT ALIGNMENT (FOR 5º OPTION ONLY)
3.4 JET MAINSHAFT ALIGNMENT

(FOR 5º OPTION ONLY) Table 1: Mainshaft Angles (Relative to Keel Line in deg’s
The HJ-322 Waterjet Mainshafts can be inclined at
HULL DEADRISE B1 B2
an angle of either 0º or 5º to the Intake base.
For 5º offset Jets, when the port and starboard Jets 0 0 5.0
are mounted at the Hull Deadrise angle, the Jet
Mainshafts are no longer parallel to the keel line in 5 0.4 5.0
plan. The following table lists the angle deviation of 10 0.9 4.9
the Jet Mainshaft when the Jet base is mounted
parallel to the keel line. 15 1.3 4.8
20 1.7 4.7
FOR INTAKE BASE PARALLEL TO KEEL LINE:
B1 =Shaft angle in Plan view. 25 2.1 4.5
B2 =Shaft slope in Elevation. 30 2.5 4.3
PORT INTAKE BASE LINE

B1
MAINSHA
FT
PLAN KEEL LINE
STARBOARD
FT
MAINSHA
B1
INTAKE BASE LINE
FT
MAINSHA
B2
ELEVATION
INTAKE BASE LINE
KEEL LINE
Figure 20: Jet Mainshaft Alignment
AMENDMENT 8 21/05/02 3.9

3 DESIGN BASICS
HJ-322
3.5 WATER OFFTAKE
3.5 WATER OFFTAKE The following graph of flow rates is for the Jet at
zero vessel speed. To determine RPM, refer to HP-
RPM curves in the Designers Manual or, to calculate
IF A GEARBOX OR CLUTCH IS FITTED TO the RPM from horse power use the following
formula:-
WATER PICK-UP AND ENGINE RAW
CAUTION hpx0.746 (1 ⁄ 3)
RPM = 1000X ----------------------------------------
ImpellerRating
The Jet Unit is fitted with a water offtake which may NOTE: Pressure increases with vessel speed.
be used as a supplementary water supply (e.g. for a Pressures in excess of 30psi are likely at
deck wash). If it is used as a part of the engine vessel speeds over 30kts.
cooling circuit, the designer / builder must satisfy
themselves that the available flow is sufficient for
the cooling requirements and the engine can
withstand the full pressure from the water offtake.
24
160
22
140
A = 226kW
20
B = 113kW
18 C = 37kW
120
D = 15kW
16
E = 7kW
100 F = 3.6kW
14
80 12
10
60
8
Pounds/inch² (psi)
Kilopascals (kPa)
40 6
A
4 B
20 C
2
D
E
0 0 F
U.S. Gallons/min.
0 10 20 30 40 50 60 70 80
0 50 100 150 200 250 300
Litres/min.
(1 Imperial Gallon = 1.2 U.S. Gallons)
Figure 21: Water Offtake Pressure / Flow Graph
3.10 AMENDMENT 8 21/05/02

3 DESIGN BASICS
HJ-322
3.6 ENGINE LOCATION & MOUNTING
3.6 ENGINE LOCATION & • The engine can withstand the maximum
pressure from the water offtake.
MOUNTING To be sure of correct flow for engine cooling a
conventional water pick up and the engine raw
3.6.1 General water pump should be used.
The engine(s) should be located in a position that
will give the craft the most suitable fore and aft trim
for the proposed boat speed. For semi-planing and
moderate planing speed craft it is likely that the en-
WATER PICK-UP AND ENGINE RAW
gine should be positioned well forward towards
amidships for best trim and thus speed. For very CAUTION
high speed vessels it is likely the engine should be
positioned aft, close to the Jet Unit, to obtain vest The Jet Unit water offtake can be used for a deck
trim and speed. Follow the recommendations of the cleaning hose but the pressure is not high enough
boat designer in this regard or consult C.W.F. Ham- for a fire hose.
ilton & Co Ltd.
CONVENTIONAL WATER PICK-UP.
3.6.2 Mounting
Mount the engine via mounting feet fixed to the
ENSURE THAT THE WATER PICK UP IS
engine bearers. The feet and bearers do not have to
NOT DIRECTLY AHEAD OF THE JET UNIT
withstand the propulsion thrust load as this is
INTAKE, BUT WELL TO THE SIDE TO
transmitted for the Jet unit directly to the hull.
AVOID TURBULENT WATER FLOW INTO
Flexible engine mounts will reduce vibration and CAUTION
THE JET.
noise but these must be used in conjunction with a
driveshaft system which does not cause a radial or Alternatively a cooling system separate from the Jet
side load at the Jet Unit Coupling as the engine Unit can be fitted to the engine maker’s
moves. specifications. The water pick up points must NOT
be directly ahead of the Jet Unit intakes and should
FOR STEEL HULLS:—Ensure the driveline be well to the side of the area forward and the same
electrically insulates the engine from the Jet Unit. width as the Intake opening.
3.6.3 Cooling 3.6.4 Engine Systems

Engine wiring, instrumentation and throttle systems
JET UNIT WATER OFFTAKE. are all conventional. Follow the manufacturers
The Jet Unit incorporates a 1¼” BSP water offtake recommendations.
point in the top of the Tailpipe outside the vessel.
This is fitted with a plug [80]. A 1¼” BSP to 1¼” BSP WITH STEEL HULLS.—Ensure the controls do not
(32mm) hosetail, part number JMNGAAO, can be electrically connect the Jet Unit to the hull.
fitted in place of the plug. This provides water at
pressures as follows: 3.6.5 Governor Settings
The “no load” governor setting (or “high idle”) on
TYPICAL MINIMUM PRESSURE:—10kPa (1.5 psi) at diesel engines should be set well clear of the full
600 RPM. throttle R.P.M. achieved when driving the Jet Unit so
that there is no chance of the governor reducing
TYPICAL MAXIMUM PRESSURE:—240 kPa (35 psi) power (and performance) at full throttle.
at 500 kW (670 hp) input power.
The water may be fed directly to the engine for
cooling without the need for a raw water pump,
provided that:
• The flow from the water offtake at idle is
sufficient to cool the engine.
AMENDMENT 8 21/05/02 3.11

3 DESIGN BASICS
HJ-322
3.7 DESCRIPTION OF THE DRY RUN SYSTEM (OPTIONAL EXTRA)
3.7 DESCRIPTION OF THE DRY THE FOLLOWING LIMITS MUST BE ADHERED TO,
TO ENSURE GOOD COMPONENT LIFE.
RUN SYSTEM (OPTIONAL
EXTRA) Maximum Dry Run Time 3 Minutes.
NOTE: Hamilton Jet Units are not fitted with the Dry Maximum Dry Run Engine 1000 RPM.
Run Kit as a standard fit. The Dry Run Kit Speed:
is an optional extra which can be fitted to the Minimum Time Between Dry 1 Hour.
Jet Unit at the customers request. Should the Runs:
customer require a Dry Run System fitted, it
can be purchased at additional cost and
The Dry Run Bearing is a compromise for use in
should be requested when the Initial Jet Order
both dry and wet running conditions. The best wet
is placed.
running design solution is the rubber Marine
This Dry Run System is a simple solution to the Bearing which cannot be run dry. The Dry Run
problem of starting a boat engine before putting the Bearing will wear out more rapidly than a standard
vessel in the water. It is particularly useful for Man- rubber Marine Bearing if the dry run system is used
Overboard boats and Lifeboats where it is important constantly in a dirty water environment. When
to ensure that the engine will start before the vessel used in silty water, life of the bearing and sleeve will
is in the water. be reduced, depending on the volume of grit in the
The Dry Run Kit consists of a specially formulated water. THIS SYSTEM SHOULD ONLY BE USED IN
Bearing which can be run dry for short periods and A CLEAN WATER ENVIRONMENT.
run for long periods with water lubrication. The If extended use in a dirty water environment is
standard rubber Marine Bearings are designed to expected, then regular monitoring of Marine Bearing
run in a water immersed environment where the wear is required.
water acts as a coolant and lubricant for the
Bearing and Water Seal. These cannot be run out
of water.
3.7.1 Installation
The Dry Run Bearing components are a direct
replacement for the standard Marine Bearing
components, therefore there is no requirement for a
special installation procedure for converting a Jet
Unit to the Dry Run System. The Dry Run Bearing
components can be fitted as shown for the normal
Marine Bearing replacement in the Jet Unit Manual.
3.7.2 Corrosion
All the components of the Dry Run Kit are made of
high quality corrosion resistant materials.
3.7.3 Scope of Use

Because there is no cooling for the Dry Run System
Waterseal and Marine Bearing, if a Jet Unit is run
without the vessel being immersed in water, the
Waterseal and the Marine Bearing will heat up
rapidly in the absence of water to act as a coolant.
3.12 AMENDMENT 8 21/05/02

3 DESIGN BASICS
HJ-322
3.7.4 Fault Finding
Table 2: Fault Finding
FAULT CAUSE REMEDY
Dry Run Bearing Jams up Excessive heat buildup. Run in water to cool.
when dry running. Leave overnight to cool.
May have grit in bearing. Flush out with clean water.
Clanging sound from the Impeller hitting the Wear Replace worn Dry Run Bearing and / or
Jet. Ring Nut due to worn Dry Sleeve.
Run Bearing. Check the Wear Ring and replace if dam-
aged.
Excessive scouring of Running in dirty water and Be careful not to suck sand or silt into Jet,
Shaft Sleeve. sucking sand or silt into do not use high RPM in water when starting
Jet. off.
3.7.5 Maintenance
INSPECTION:—Inspect every 100 hours, 50 dry DIAMETRICAL WEAR SHOULD

starts, or yearly, whichever is the soonest. BE LESS THAN 0.2mm
Remove the Tailpipe and inspect.

If the wear on the Bearing Sleeve is greater than
0.2mm, replace the Sleeve. Replace the plastic
Bearing when replacing the Sleeve.
NOTE: As the Dry Run Bearing runs on only one

half of the Bearing Sleeve, refer to Figure
23:“Dry Run Bearing Assembly”. The
Bearing Sleeve can be turned end for end
Figure 22: Bearing Sleeve Inspection
when it shows signs of wear.
ASSEMBLY NOTES
1. When changing The 'Dry Run Bearing Assembly',
dismantle and re-assemble the whole assembly
(plastic and metal shell) to the Tailpipe in the
same manner as removing or replacing a
standard rubber Marine Bearing. The plastic part
of the Bearing should be fitted so it sits closest to
the Impeller. The shell should sit flush with the
Tailpipe refer to Figure 23:“Dry Run Bearing As-
sembly”.
2. The Bearing Sleeve is the same as the Bearing
Sleeve for the rubber Marine Bearing. For fitting,
refer to Section 9“Overhaul” of this Manual.
AMENDMENT 8 21/05/02 3.13

3 DESIGN BASICS
HJ-322
3.7.6 Parts List

Refer to Drawings “HJ-322-01-000 Basic Jet As-
semblies Standard & Dry Run. Sht 1” and “HJ-322-
01-000 Basic Jet Assemblies Standard & Dry Run. Sht
2”.
DRY RUN BEARING

ASSEMBLY
BEARING SLEEVE
ROTARY SEAL
ASSEMBLY
Figure 23: Dry Run Bearing Assembly
3.14 AMENDMENT 8 21/05/02

Section 4
PRECAUTIONS AGAINST CORROSION
4.1 GENERAL 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,
PREVENTION OF CORROSION
starter solenoid, and alternator are single pole
THE JET UNIT HAS BEEN DESIGNED TO
devices using the engine block as the local return
WITHSTAND THE CORROSIVE EFFECTS OF
conductor. IN THIS SITUATION, IT IS
CAUTION OPERATION IN SALT WATER THROUGH
IMPORTANT TO CONNECT THE ENGINE BLOCK
THE USE OF MATERIALS THAT ARE
TO THE BATTERY NEGATIVE WITH A HEAVY
RESISTANT TO SALT WATER CORROSION
BATTERY CABLE.
AND BY THE PLACEMENT OF SACRIFICIAL
ANODES IN SUITABLE LOCATIONS. In installations with two engines and two battery
banks with cross-connect starting capability, there
VESSELS USING HAMILTON JET UNITS, must be two heavy conductors between the
MUST BE BONDED AND WIRED AS engines. Local standards’ if appropriate’ should be
DESCRIBED IN SECTION 4 "PRECAUTIONS complied with.
AGAINST CORROSION" SECTION OF THE
JET UNIT MANUAL A.C. SYSTEMS:—For a vessel with both AC and DC
circuits, it is essential for safety reasons that the AC
system has a separate earth wire.
Dock potentials can be as positive as +350mV
4.1.1 Electrical Wiring System relative to a silver / silver chloride reference
The guidance of the local inspecting authority rules electrode. If a vessel with bonded aluminium Jets is
should be sought, but in general note the following connected to such a dock potential through the
for: separate earth wire, without the protection of an
Isolation Transformer or a Galvanic Isolator, the
D.C. SYSTEMS:—Every part of the DC system corrosion rate of the aluminium would increase to
should use TWO insulated "normally conducting" a value far greater than the normal sea water
wires, a positive and a negative. The negative must corrosion rate. This would occur regardless of
not run through the frame of any unit, through the whether the aluminium was protected by anodes or
Hull of the boat, or through the bonding system. not.
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
the casing of the starter connected to the battery
AMENDMENT 8 21/05/02 4.1

4 PRECAUTIONS AGAINST CORROSION
HJ-322
4.1 GENERAL
A. USING AN ISOLATION TRANSFORMER corrosion will occur. The copper bonding strip
If using AC shore supply, the recommended method should be connected to the Jet Unit via a stainless
of preventing potentially serious galvanic or stray steel terminal connector.
current corrosion is to install an Isolation The bonding wire or strip which runs the length of
Transformer on board at the incoming line. the Hull, should be kept clear of bilge water.
When an Isolating Transformer is used, there must The main function of the bonding system is to
be no connection between the shore supply earth provide a path to battery negative, for stray
and the vessels earth bonding system. The primary currents.
winding shield is earthed to shore while the An exception exists for Steel and Fibre Reinforced
secondary winding should be grounded on board Plastic (FRP) Hulls whose reinforcement is carbon
the vessel. Only one side of the secondary winding fibre; the Jet Unit must be totally insulated from the
is grounded on the secondary side of the Hull and machinery thus relying totally on its own
transformer and the vessel’s grounding circuit is tied Anodes for protection.
in at this point. There must be no DC electrical When a bonding system is used, it is essential that
connection between the shore supply and the on cathodic protection is provided. This cathodic
board AC circuit. protection can be in the form of Sacrificial Anodes
or an Impressed Current System.
B. USING A GALVANIC ISOLATOR To minimise corrosion from stray current emanating
Alternatively with AC shore supply, a galvanic from within the vessel, all power sources (battery
isolator can be installed on the AC earth wire just and battery charger negatives, AC generator and the
after the shore power inlet. This isolator isolates the ship side of the shore supply earth) should be
vessel from low voltage D.C. galvanic currents, connected to the earth bonding system at a single
while allowing any short circuit to be safely common earth point. This will hold these circuits at
conducted back to shore. a common voltage. Any stray currents will then
Isolators with capacitors are to be preferred over have a direct path back to the battery negative or the
isolators with diodes only. The isolator should have AC source.
sufficient fault capacity to allow circuit breakers to Alternatively, this connection to the battery
trip under fault conditions. negative can be deleted PROVIDED that the
A correctly wired polarization transformer in following are carried out:
conjunction with a galvanic isolator is acceptable 1. There is a two wire normally current conducting
for connecting to an AC shore power system. electrical system which is isolated from the Hull,
Jet Unit and Engine,
AN ISOLATION TRANSFORMER OR A 2. There is an effective leakage monitoring system,
GALVANIC ISOLATOR MUST BE such as the "Test Light" system, which is used
CORRECTLY FITTED TO THE VESSEL’S regularly and the results are recorded.
ELECTRICAL SYSTEM IF THE VESSEL IS TO Without the bonding system to battery negative
CAUTION connection, stray current corrosion is possible and
BE CONNECTED TO AN EXTERNAL AC
SHORE SUPPLY. it is important to check for leakage:-
a) For every item of electrical equipment in
operation.
4.1.2 Earth Bonding System b) When there is any alteration to the electrical
In aluminium and GRP hulls, the Jet Unit, Hull (if system of the boat.
aluminium), all metal objects, electrical equipment c) When any electrical connection is made to
casings and Hull anodes should be connected with a shore.
low resistance bonding system (separate from
normally current conducting 2 wire electric system).
The bonding strip and connecting wires should be
aluminium or insulated copper of at least 14.5
sq.mm. cross section area (e.g. 5mm diameter.) to
give very low (e.g. 0.01ohm) electrical resistance.
If a copper bonding strip is used, it should not be
connected directly to the Jet Unit as galvanic
4.2 AMENDMENT 11 11/04/03

HJ-322
4.1 GENERAL
4.1.3 Corrosion Monitor 6. The earth plate should be connected by an

insulated wire to the vessels "Earth Bonding
It is recommended that a corrosion monitor be
System".
fitted.
The corrosion monitor should be a high impedance
device. There must be no possibility of an electrical 4.1.5 Zinc Anodes
connection between the Jet Units and the ships Anodes should not be painted over as they will not
batteries. function as intended. If the anodes are being eaten
If the Jet Units are isolated from the hull, corrosion away they are providing protection. They should be
monitoring of each Jet Unit external wetted surface inspected and replaced when half consumed
and internal Intake Duct should be carried out. because the material that remains will not provide
If the Jet Units are electrically connected to the hull, full protection. It is common for zinc anodes to be
corrosion monitoring of the hull only and each Jet partially covered with a very loose scale. The colour
Unit internal Intake Duct should be carried out. of the scale depends on local water conditions but
can typically be creamy white, light brown or green.
This scale, providing it is loose (i.e. easily scraped
4.1.4 Earth Plate Connections for off with a fingernail), is normal.
Electronic Transmitting If the anodes are not being eaten away, they are
Equipment not doing their job and the cause should be
Radios, radar’s and other transmitting equipment investigated. One reason could be that the anode
should NOT use the Jet Unit for an earth plate but does not have good electrical contact between the
must have a separate earth plate. component it is protecting and itself. The electrical
resistance should be less than 0.2 ohms.
Be guided by the installation instructions for the
radio; radar equipment etc, but in general these Poor quality zinc anodes may contain too much iron
systems should be electrically insulated from the Jet impurity. Such anodes tend to form a dense non-
Unit except that both the earth plate and the metal conducting oxide film (usually charcoal grey in
casings of the electrical transmitting equipment appearance). This condition usually occurs in fresh
should be connected to the earth bonding system. water. To confirm this condition, test for continuity
between the anode and the Jet Unit using a
1. An area of metal plate is required which is not multimeter set to ohms. If the anode has to be
painted and always immersed, even when at scraped with a knife to get a conductive reading, the
planing speeds. It is always in electrical contact anode is oxidized and must be replaced. Sanding
with the sea water. the anode surface provides a temporary solution,
2. The area of metal plate is typically but it will form the oxide again.
approximately 400 x 400 mm and should be
located close to the equipment radiating JET UNIT ANODES:—Refer to Drawing “HJ-322-
electrical waves but well forward of the Jet Units. 13-002 Anode Location Drawing”. The anodes fitted
3. For a metallic hull, the earth plate can be a to the Jet Unit are made from zinc alloy to US
thickened area of the hull, formed by welding military specification MIL-A-18001K. These anodes
additional plate inside the hull skin, up to 25 mm are fitted to the Reverse Duct, Steering Deflector,
thick. Reverse Cylinder and the main body of the Jet Unit.
Anodes are also fitted internally within the Tailpipe
4. For a non metallic hull a separate metal earth
and in most Jet models, within the Intake.
plate must be fixed externally to the hull. It
should be of material compatible with both the
"bonding strip" and hull (stainless steel is likely HULL ANODES:—Further anodes should be fitted on
to be the best option. It is not advisable to use the Hull, sufficient for Hull protection, as
copper as it can cause corrosion problems for determined using a portable reference electrode and
other metals). digital voltmeter and / or a corrosion monitor.
The Hull anodes should remain immersed at all
5. The "plate" should have a large stud welded to its
times.
centre and protruding inboard to which all the
zero voltage wires from equipment can be
connected to.
AMENDMENT 8 21/05/02 4.3

HJ-322
4.1 GENERAL
NOTE: Anodes fitted on the Transom of a planing 1. Remove any dirt, dust, grease etc. from the
speed craft will not be immersed when the external wetted paint surfaces using an
craft is at speed and therefore will not be appropriate solvent.
providing protection. 2. Apply an intermediate coat of International
Paints “Interprotect” to a nominal dry film
4.1.6 In Service Checks thickness of 50 microns (0.05mm / 0.002”).
In Service, the following three items should be 3. Apply anti-fouling to the appropriate thickness.
inspected regularly:
1. The Bonding System: For loose or corroded It is recommended that anti-fouling paint be re-
connections and test to ensure that electrical applied, both internally and externally, during the
resistance is still low. annual slipping of the vessel.
2. All Sacrificial Anodes: Replace when half
corroded / eroded. 4.1.8 Anti Seize Compound
3. Earth Leakage: There should be no current
leakage from any electrical item to the bonding
system. ANTI-SEIZE COMPOUNDS
DO NOT USE ANTI-SEIZE COMPOUNDS
WHICH ARE BASED ON GRAPHITE, NICKEL
4.1.7 Anti Fouling Paint OR COPPER FLAKES - THESE WILL CAUSE
CAUTION
ANTI FOULING PAINTS AVAILABLE FOR ALUMINIUM.
DO NOT USE COPPER OXIDE BASED
UNPAINTED. DO NOT PAINT OVER THE 4.1.9 Impressed Current Protection
ANODES. Impressed current protection may be used if
desired. Follow the suppliers instructions.
Impressed current systems should have a "fail safe"
The internal wetted surfaces of the Jet Unit,
feature which prevents the potential falling below -
excluding the Impeller, Wear Ring and Mainshaft,
1100mV referenced to a silver / silver chloride
are finished ex-factory, with a coating of
reference electrode.
International Paints (Akzo Nobel) “Interspeed
2000” type anti-fouling paint, in black.
The external wetted surfaces of the Jet Unit
including the inside passages of the Reverse Duct,
are finished with an International Paints epoxy
primer. This particular coating allows the
application of an anti-fouling paint system, after
an indefinite period of time, without special paint
surface preparation.
Our recommendation is to use any International
Paints anti-fouling that is suitable for an Aluminium
Hull. General guidelines for the application of the
recommended anti-fouling paint system are shown
following.
NOTE: These guidelines DO NOT apply to the

special International Paints “Intersleek”
system. Please contact a local paint
representative for detailed application
instructions for each type of anti-fouling
used.
4.4 AMENDMENT 8 21/05/02

HJ-322
4.2 ALUMINIUM, G.R.P. AND WOOD HULLS (OTHER THAN STEEL)
4.2 ALUMINIUM, G.R.P. AND 4.3.2 Checking the Insulation

WOOD HULLS (OTHER THAN 1. WITH THE VESSEL OUT OF THE WATER
STEEL) The resistance between the Jet Unit(s) and the
Hull should be 1000 ohms or greater. If the
reading is below 1000 ohms, the fault should be
4.2.1 Earth Bonding System - (Not investigated and rectified.
Normally Current Conducting) 2. WITH THE VESSEL IN THE WATER
Refer to Drawing “85114 Earth Bonding System For Steel Hulls:
Recommendations and Layout” which shows the a) Place a silver / silver chloride half cell in the
layout of the Earth Bonding System. seawater.
In the case of an aluminium Hull, an engine stringer b) With the silver / silver chloride half cell
or any other continuous longitudinal member may connected to the ‘common’ of a high
be used as the bonding strip. All junctions should impedance digital voltmeter (set to read 0 to
preferably be welded, but if bolted, should be clean, 2000 mV).
have a good contact and be regularly inspected and c) Connect the ‘positive’ terminal to the hull and
maintained. note the reading.
d) Repeat with the ‘positive’ terminal connected
to the Jet Unit(s) body.
4.3 STEEL HULLS AND CARBON e) Place a large zinc anode in the seawater and
electrically connect the hull to the anode.
FIBRE REINFORCED G.R.P. f) Repeat the digital voltmeter readings.
HULLS g) If Jet Unit(s) is insulated from the hull, the mV
readings for the Jet Unit(s) should not change.
h) The mV readings for the hull should be more
FOR STEEL HULLS AND CARBON FIBRE negative (eg: The reading could be -800mV
REINFORCED G.R.P HULLS, THE JET UNIT without the large zinc anode connected and -
MUST BE ELECTRICALLY INSULATED FROM 850mV with the large zinc anode connected to
THE HULL. the hull).
CAUTION i) This test can also be carried out with a
Corrosion Monitor, if fitted.
3. IN SERVICE
An insulating kit is supplied with the Jet Unit.
The insulation between the Jet Unit(s) and the
steel hull should be regularly checked.
4.3.1 Earth Bonding System (Not
Normally Current Conducting)
Refer to Drawing “85114 Earth Bonding System
Recommendations and Layout” for details of
insulating the Jet Unit from the Hull.
1. If a negative earth system is used on the vessel,
it MUST NOT be connected to the Jet Unit.
2. Every part of the vessel electrical system should
have TWO wires to it, a positive and a negative
wire.
3. With electrical auxiliary equipment installation
be guided by your electrician. Do not earth
electrical equipment to the Jet Unit, but to a
separate earth installed as far away from the Jet
Unit as possible.
AMENDMENT 8 21/05/02 4.5

HJ-322
4.3 STEEL HULLS AND CARBON FIBRE REINFORCED G.R.P. HULLS
4.6 AMENDMENT 8 21/05/02

HJ-322 4 PRECAUTIONS AGAINST CORROSION
4.4 CORROSION DRAWINGS
85114 Earth Bonding System Recommendations and Layout
AMENDMENT 18 04/10/04 4.7
HJ-322
HJ-322-13-002 Anode Location Drawing
4.8 AMENDMENT 18 04/10/04
Section 5
INSTALLATION
5.1 BASIC INSTALLATION Line. Sht 1” and “HJ-322-08-002 Installation De-

tails Aluminium Hull with 5º Shaft Line. Sht 2”.
METHOD AND DRAWINGS Refer to Installation Drawings “HJ-322-08-012
REFERENCES Installation Details Aluminium Hull with 0º Shaft
Line. Sht 1” and “HJ-322-08-012 Installation De-
tails Aluminium Hull with 0º Shaft Line. Sht 2”.
ENSURE THAT THE WATER PICK UP IS An Aluminium "Intake Block" is supplied ready to
NOT DIRECTLY AHEAD OF THE JET UNIT weld into a prepared opening in the Hull bottom.
INTAKE, BUT WELL TO THE SIDE TO "Intake Block" for 0º Shaft Line. (Part No. 107255).
AVOID TURBULENT WATER FLOW INTO "Intake Block" for 5º Shaft Line. (Part No. 111060).
CAUTION
THE JET.
It is assumed that the aluminium plating of the Hull
is one of the following types 5083, 5086, 6061,
FOR G.R.P. HULLS: 6063, 6101, 6202, 6151, or 6951. If not consult
Refer to Installation Drawings “HJ-322-08-001 In- C.W.F Hamilton & Co Ltd. The Intake Block is LM6
stallation Details GRP Hull with 5º Shaft Line. Sht 1” grade aluminium. Weld the Intake Block into the
and “HJ-322-08-001 Installation Details GRP Hull Hull using the weld procedure shown on Drawing
with 5º Shaft Line. Sht 2”. “85080 Weld Procedure for Welding Cast Intake
Block into Aluminium Hulls” Ensure the contours
between the Hull and the Intake Block at front and
Refer to Installation Drawings: “HJ-322-08-011
rear are smooth to within 1mm.
Installation Details GRP Hull with 0º Shaft Line. Sht
1” and “HJ-322-08-011 Installation Details GRP
Hull with 0º Shaft Line. Sht 2”. FOR STEEL HULLS:
An aluminium "Intake Block" is supplied with the Refer to Installation Drawings: “HJ-322-08-003
Installation Kit for fibre glassing into G.R.P Hulls. Installation Details Steel Hull with 5º Shaft Line. Sht
1” and “HJ-322-08-003 Installation Details Steel
"Intake Block" for 0º Shaft Line. (Part No. 107255).
Hull with 5º Shaft Line. Sht 2” and “HJ-322-08-013
"Intake Block" for 5º Shaft Line. (Part No. 111060). Installation Details Steel Hull with 0º Shaft Line. Sht
The Intake Block is best fitted into the Hull prior to 1”/“HJ-322-08-013 Installation Details Steel Hull
moulding. After moulding into the Hull the Intake with 0º Shaft Line. Sht 2”.
Block is also bolted to the Hull. For G.R.P Hulls, "Intake Block" for 0º Shaft Line. (Part No. 107255).
refer to the Installation Drawings which can be
"Intake Block" for 5º Shaft Line. (Part No. 111060).
found at the rear of this Section.
Special installation is required to ensure that the Jet
Unit is totally insulated from the Hull.
FOR ALUMINIUM HULLS:
An insulation kit is supplied to totally insulate the
Refer to Installation Drawing: “HJ-322-08-002
Jet Unit from the Hull.
Installation Details Aluminium Hull with 5º Shaft
AMENDMENT 9 24/01/03 5.1

5 INSTALLATION
HJ-322
5.2 HULL PREPARATION
5.2 HULL PREPARATION ALUMINIUM HULLS:

Refer to Installation Drawings: “HJ-322-08-002 In-
stallation Details Aluminium Hull with 5º Shaft Line.
IN MULTI JET UNIT INSTALLATIONS, Sht 1”/“HJ-322-08-002 Installation Details Alumin-
EACH JET UNIT MAY BE CONFIGURED FOR ium Hull with 5º Shaft Line. Sht 2” and “HJ-322-08-
PORT, STARBOARD OR CENTRE 012 Installation Details Aluminium Hull with 0º
MOUNTING. CARE SHOULD BE TAKEN TO Shaft Line. Sht 1”/“HJ-322-08-012 Installation De-
CAUTION tails Aluminium Hull with 0º Shaft Line. Sht 2”.
ENSURE THAT EACH JET IS FITTED IN ITS
CORRECT POSITION. It is assumed that the aluminium plating of the Hull
is of one of the following types: 5083, 5086, 6061,
6063, 6101, 6202, 6151 or 6951. If not consult
5.2.1 Fixing the Intake Block to the C.W.F. Hamilton & Co Ltd.
Hull The Intake Block is LM6 grade aluminium. Weld the
Intake block into the hull in accordance with the
NOTE: The 5o Intake Blocks are longer than the 0o information given in Drawing “85080 Weld Proce-
Intake Blocks. Ensure that the correct dure for Welding Cast Intake Block into Aluminium
Installation Drawings are referred to when Hulls”. Ensure that the contours between Hull and
cutting the Intake Block opening in the Hull. Intake Block, at front and rear, are smooth to within
1 mm. Grind flat where necessary, especially in
G.R.P. HULLS: front of the Intake.
Refer to Installation Drawings: “HJ-322-08-001 In-
stallation Details GRP Hull with 5º Shaft Line. Sht 1”/ STEEL HULLS:
“HJ-322-08-001 Installation Details GRP Hull with Refer to Installation Drawings: “HJ-322-08-003 In-
5º Shaft Line. Sht 2” and “HJ-322-08-011 Installa- stallation Details Steel Hull with 5º Shaft Line. Sht 1”/
tion Details GRP Hull with 0º Shaft Line. Sht 1”/“HJ- “HJ-322-08-003 Installation Details Steel Hull with
322-08-011 Installation Details GRP Hull with 0º 5º Shaft Line. Sht 2” and “HJ-322-08-013 Installa-
Shaft Line. Sht 2”. tion Details Steel Hull with 0º Shaft Line. Sht 1”/“HJ-
If possible, tape the Intake Block into the hull mould 322-08-013 Installation Details Steel Hull with 0º
prior to moulding the hull. For centre-mounted jets Shaft Line. Sht 2”.
an additional smooth surface will have to be taped
to the mould in front of the Intake Block to mould Electrical Isolation
over and form a fairing between the vee hull form The Intake Block, Jet Unit and Transom Plate must
and flat of Intake Block. For a wooden hull, or an be completely electrically isolated from the rest of
existing GRP hull, cut a hole in the hull larger than the Hull. This is achieved by the use of gaskets,
the Intake Block base flange to allow a scarfed joint bushes and studs, as shown on the Steel Hull
to be formed in GRP between the Intake Block and Installation Drawings.
the hull, as shown on the installation drawing.
After moulding, drill 36 x 11mm diameter holes at
the cast dimples in the bottom of the intake block up
through the Intake Block flange and hull.
Countersink the holes to accept the Countersunk
Head Machine Screw [12]. Liberally smear the
Screws [12] with RTV Silicon Sealant [18] provided.
Fit Screws [12] and secure with Flat Washers [11],
Spring Washers [10] and Nuts [9].
Torque load the Nuts [9] to the recommended
torque, refer to Drawing “85113 Recommendations
for Fastener Locking, Torques and Thread Lubrica-
tion”.
Ensure that the contours between Hull and Intake
Block at the front and rear are smooth to within 1
mm.
5.2 AMENDMENT 9 24/01/03

5 INSTALLATION
HJ-322
5.2 HULL PREPARATION
INSTALLING THE INTAKE BLOCK:—A steel recess any excess Sealant and trim off any protruding
must be built into the Hull to accept the Intake part of the Intake Block Gasket [27].
Block, as shown on the Installation Drawing.
NOTE: The prepared opening in the Hull has sloping

5.2.2 Transom Preparation
faces fore and aft to match the Intake Block. An area at either 90º (for 0º Shaft Line) or 95º (for
Use the following procedure to mount the 5º Shaft Line) to the Jet Intake base, has to be
Intake Block. prepared as shown on the appropriate Installation
Drawings. Ideally this area is flush with the
1. Once the prepared recess in the Hull is
Transom. For Steel Hulls cut, position and re-weld
completed, trial fit the Intake Block in place using
the required area if necessary.
3mm spacers instead of the Intake Block Gasket
[27]. For Oº Shaft Line: Transom Angle should be at
90º to the Intake Base.
2. With the Intake Block in place, drill through the
For 5ºShaft Line: Transom Angle should be at
36 countersunk points on the Intake Block from
95º to the Intake Base.
below, with an 11mm dia Drill. After piercing the
Intake Block make a small marking cut on the
steel hull with the drill. FOR GRP AND WOODEN HULLS:—If the Transom
is not close to the angle required, an insert can be
3. Remove the Intake Block and clean off all burrs. taped into the hull mould so the Transom area, can
4. Drill out the marked positions in the steel edges be moulded with the hull at the angle required.
of the prepared opening to 16mm to accept the Alternatively, the required area can be cut from the
Nylon Insulating Bushes [28]. Remove all burrs. Transom and re fibre glassed back at the correct
5. Fit the Insulating Bushes [28] and trim to the angle. One method to locate the cut-out Transom at
correct length. Remove the Insulating Bushes the correct angle is to install the Jet Unit, bolt the
from the Intake. Transom Plate assembly and Transom cut-out into
position on the Jet and then to fibreglass the cut-out
6. Liberally smear both sides of the Intake Block back into the Transom.
Gasket [27] with RTV Sealant [18] and fit the
Intake Block Gasket onto the Intake Block.
FOR METAL HULLS:—If the Transom is not close to
NOTE: The Gasket is designed to fold down around the angle required, cut out the required area,
the edges of the Intake Block. reposition at the required angle and re-weld back to
the Transom with any necessary inserts at the sides
7. Smear RTV Sealant [18] on top of the Gasket [27] and top.
and run a bead of RTV Sealant around the
internal corner of the prepared recess.
8. Ensure that all the Bolts [12] are liberally
smeared with RTV Sealant prior to fitting.
9. Install the Intake Block and secure in 3 positions
with Bolts [12], Nylon Insulating Bushes [28], Flat
Washers [11], Spring Washers [10] and Nuts [9].
Hand tighten.
10.Check for electrical isolation between the Intake
Block and the vessel hull before fitting the
remaining bolts.
11.Fit the remaining Bolts [12], Nylon Insulating
Bushes [28], Flat Washers [11], Spring Washers
[10] and Nuts [9].
12.Torque load all the Bolts and Nuts to the
recommended torque.
13.Once the Intake Block is installed, check again for
electrical isolation and then fill any gap at the
edges and corners with RTV Sealant. Clean off
AMENDMENT 8 21/05/02 5.3

5 INSTALLATION
HJ-322
5.3 EQUIPMENT PREPARATION
5.3 EQUIPMENT PREPARATION 5.4 MOUNTING THE JET UNIT

Do not unpack equipment until it is required for Refer to the following Installation Drawings at the
installation. This prevents mechanical damage and rear of this Section.
entry of foreign matter. Unpack carefully to prevent
damage and loss of small items. GRP HULLS:—“HJ-322-08-001 Installation Details
GRP Hull with 5º Shaft Line. Sht 1”/ “HJ-322-08-
5.3.1 Steering Components 001 Installation Details GRP Hull with 5º Shaft Line.
Sht 2” and “HJ-322-08-011 Installation Details GRP
Refer to Drawings “HJ-322-06-000 Steering Assem-
Hull with 0º Shaft Line. Sht 1”/“HJ-322-08-011 In-
bly General Arrangement. Sht 1” and “HJ-322-06-
stallation Details GRP Hull with 0º Shaft Line. Sht 2”.
000 Steering Assembly General Arrangement. Sht 2”.
The Jet Unit is shipped complete with the steering
ALUMINIUM HULLS.—“HJ-322-08-002 Installa-
components attached. It should not be necessary to
tion Details Aluminium Hull with 5º Shaft Line. Sht
remove any steering components prior to
1”/“HJ-322-08-002 Installation Details Aluminium
installation.
NOTE: For Hydraulic Steering options only, the Installation Details Aluminium Hull with 0º Shaft
Steering Cylinder will be supplied separate to Line. Sht 1”/“HJ-322-08-012 Installation Details
the Jet Unit. The boat builder will be Aluminium Hull with 0º Shaft Line. Sht 2”.
responsible for attaching the Steering
Cylinder to the vessel on completion of the Jet STEEL HULLS:—“HJ-322-08-003 Installation De-
installation. tails Steel Hull with 5º Shaft Line. Sht 1”/“HJ-322-
However, if problems with installation occur, refer 08-003 Installation Details Steel Hull with 5º Shaft
to Section 9.4“Steering Assembly Removal and Over- Line. Sht 2” and “HJ-322-08-013 Installation Details
haul” Section 9.5“Steering Assembly Re-Fitting” and Steel Hull with 0º Shaft Line. Sht 1”/“HJ-322-08-013
CT-SJK-04-010 shown in the Controls Manual, for Installation Details Steel Hull with 0º Shaft Line. Sht
removal and refitting instructions. 2”.
PREPARATION:—After mounting the Intake Block

5.3.2 Reverse Components
and making the Transom Hole in the Hull, carry out
the following actions:-
NOTE: The Jet Unit is shipped complete with the
Reverse Cylinder and Reverse Duct attached. 1. Ensure that the Reverse Duct and Tailpipe have
The Reverse Duct will require removal to been removed complete from the Jet Unit as
install the Transom Plate. shown in Section 5.3.2“Reverse Components”
To remove the Reverse Duct refer to Section and that the Transom Plate has been removed
9.2.1“Reverse Duct Removal”. from the Jet Unit as shown in Section 9.9“Tran-
som Plate Assembly Overhaul”.
5.3.3 Removal of Other Parts 2. Fit the Jet Unit complete with the Intake Screen
attached, into the hull. To carry out this
The Jet Unit is shipped with the Controls System operation, using approved lifting equipment, lift
fitted. Should it be necessary to remove the Controls the Jet Unit into the hull and position the Jet Unit
System, refer to the Controls Manual supplied, for so that the rear of the Jet Unit passes out through
details on the fitting and removal procedures. the Transom opening and the Intake Screen fits
centrally in the Intake block hole. Should the
Intake Screen require removal during
installation, refer to Section 9.11.4“Screen Re-
moval”.
3. Check that the Jet Unit is correctly located in
relation to the Transom hole, and that the Intake
Block mates neatly with the Intake casting.
Correct the hull preparation as necessary.
5.4 AMENDMENT 8 21/05/02

5 INSTALLATION
HJ-322
5.4 MOUNTING THE JET UNIT
4. Check that the contours between the hull and the 5.4.2 Assembly of the Transom Plate
Jet Unit Intake, at the front and rear are smooth
to within 1mm (1/32"). There should be no steps.
to the Hull
Ensure that the Reverse Duct has been removed
IF SATISFACTORY, PROCEED AS FOLLOWS:- from the Jet Unit.
1. Place the Transom Plate in over the rear of the Jet
5.4.1 Mounting the Jet Unit to the Unit and up against the Transom.
Hull 2. Centralize the Transom Plate in relation to the

Intake and rotate to position the Transom Plate's
1. Using approved lifting equipment, lift the Jet Unit vertical centerline square with the Jet Unit Intake
off the Hull and move it away from the Intake base. Ensure that the Transom Plate Anodes are
Block. located at the bottom of the Transom Plate.
2. Screw in and tighten the Studs provided into the
tapped holes in the Intake Block. A convenient G.R.P AND ALUMINIUM HULLS.
method of fitting the studs is to tighten two nuts
together on the top of the stud so that a spanner GRP HULL DRAWINGS.—Refer to Drawings“HJ-
can be engaged on the nuts to tighten the studs 322-08-001 Installation Details GRP Hull with 5º
into the base. The use of Loctite 262 [19] is Shaft Line. Sht 1”/ “HJ-322-08-001 Installation De-
recommended. Ensure threads are clean before tails GRP Hull with 5º Shaft Line. Sht 2” and “HJ-
applying Loctite. 322-08-011 Installation Details GRP Hull with 0º
3. Liberally apply neutral cure R.T.V. Silicone Shaft Line. Sht 1”/“HJ-322-08-011 Installation De-
Sealant [18] to the top of the Intake Block and the tails GRP Hull with 0º Shaft Line. Sht 2”.
underside of the Jet Unit Flange.
4. Carefully position the Jet Unit centrally over the ALUMINIUM HULL DRAWINGS.—Refer to Drawings
Intake Base and slowly lower the Jet Unit Flange “HJ-322-08-002 Installation Details Aluminium Hull
onto the Studs [8] on the Intake Block. with 5º Shaft Line. Sht 1”/“HJ-322-08-002 Installa-
5. Ensure that Studs fitted to the front of the Jet 2” and “HJ-322-08-012 Installation Details Alumin-
Intake, pass through the Intake Block. ium Hull with 0º Shaft Line. Sht 1”/“HJ-322-08-012
6. Secure the Jet Unit Intake to the Intake Block with Installation Details Aluminium Hull with 0º Shaft
Flat Washers [17], Spring Washers [16] and Nuts Line. Sht 2”.
[15]. Torque load to the recommended torque. 1. Place the Transom Plate over the Intake casting
7. Remove excess sealant from inside and outside and against the Transom.
the Jet Unit. 2. Rotate to position the Transom Plate on the
8. If not already connected, attach the Screen Rake vertical centreline square with the Intake Flange.
Spring [1] fitted to the underside of the Rake 3. Make small locating dimples in the Transom for
Actuator [8] to Bolt [6] attached to the starboard the 24 securing Screws [3], by using an 8.5mm
forward edge of the Intake Block, refer to diameter drill through the holes in the Transom
Drawing “HJ-322-09-000 Screen Rake Assembly Plate.
& Blanking Plugs”.
4. Slide the Transom Plate back off the Tailpipe.
5. Drill 8.5mm diameter holes through the Transom
using the dimples to locate. Remove all burrs.
6. Liberally apply neutral cure RTV Silicone Sealant
[18] (supplied) to the Transom Plate contact area
on the Hull and also the joint face of the Transom
Plate and the heads of the Screws [3].
7. Lubricate the Transom Plate O-Ring [2] with
vegetable oil and fit in place in the seal groove on
the Jet Unit Intake. Take care not to get any oil
on the Transom where RTV Sealant will be
applied.
AMENDMENT 9 24/01/03 5.5

5 INSTALLATION
HJ-322
5.4 MOUNTING THE JET UNIT
8. Slide the Transom Plate [1] over the O-Ring [2] 6. Lubricate the Transom Plate O-Ring [2] with
and line up the holes in the Transom Plate with vegetable oil. Fit in place in the seal groove on
the drilled holes in the Transom. the Jet Unit Intake. Take care not to get any oil
9. Fit the Transom Plate into place against the on the Transom where sealant will be applied.
Transom. 7. Liberally apply neutral cure RTV Silicone Sealant
10.Secure the Transom Plate to the Transom using [18] to the Transom Plate contact area on the
Screws [3], Nuts [4], Flat Washers [6] and Spring Hull and also the joint face of the Transom Plate
Washers [5] as shown in the installation and the heads of the Screws [3].
drawing. 8. Apply neutral cure RTV Silicone Sealant [18] to
the Transom Plate Gasket [26]. Fit to the
NOTE: Transom and align with the drilled holes.
1. Ensure that the screw heads are fitted to the 9. Slide the Transom Plate [1] over the O-Ring [2]
outside of the Transom as shown on the and line up the holes in the Transom Plate with
Installation Drawings. the drilled holes in the Transom.
2. Ensure that Flat Washers [6] are fitted to the 10.Install the Transom Plate in place against the
Screws [3] prior to fitting the screws through Transom Plate Gasket and Transom.
the Transom / Transom Plate.
11.With the Insulating Bushes [25] already fitted to
11.Tighten all 24, securing Screws to the the Transom Plate, fit and secure in 3 positions
recommended torque. with Screw [3], Nuts [4], Flat Washers [6] and
12.Wipe off any excess sealant. Spring Washers [5]. Hand tighten only.
NOTE:
STEEL HULLS
Refer to Drawings: “HJ-322-08-003 Installation 1. Ensure that the screw heads are fitted to the
Details Steel Hull with 5º Shaft Line. Sht 1”/“HJ-322- outside of the Transom as shown on the
08-003 Installation Details Steel Hull with 5º Shaft Installation Drawings.
Line. Sht 2” and “HJ-322-08-013 Installation Details 2. Ensure that Flat Washers [6] are fitted to the
Steel Hull with 0º Shaft Line. Sht 1”/“HJ-322-08-013 Screws [3] prior to fitting the screws through
Installation Details Steel Hull with 0º Shaft Line. Sht the Transom / Transom Plate.
2”. 12.The Transom Plate must be totally insulated
from the Hull by the Rubber Gasket [26] and
NOTE: The Transom Seal Assembly must be totally
Insulating Bushes [25] fitted to the Transom Plate
insulated from the hull by a Gasket [26] and
Mounting Screws.
Flanged Insulating Bushes [25] fitted around
the mounting Screws [3]. 13.Check the insulation between the Jet Unit and the
Transom. (The resistance between the Jet Unit
1. Fit the Insulating Bushes to the Transom Plate
and the Transom should be 1000 ohms or
and trim to the correct length. Note that these
greater. If the reading is below 1000 ohms, the
should be fitted from the outside of the
fault should be investigated and rectified before
Transom Plate.
continuing).
2. Place the Transom Plate over the Intake casing
14.Secure the Transom Plate and Gasket to the
and up against the Transom.
Transom with the remaining Screws [3], Nuts [4],
3. Rotate the Transom Plate to position it on the Flat Washers [6] and Spring Washers [5] as
vertical centreline square with the Intake Flange. shown in the Installation Drawing.
4. Make small locating dimples in the Transom for 15.Tighten all 24 securing Screws to the
the 24 securing Screws [3], by using an 8.5mm recommended torque.
diameter drill through the Insulating Bushes
16.Wipe off any excess sealant.
fitted to the Transom Plate, taking care not to
damage the Insulating Bushes. 17.Carry out a final check of the insulation between
the Jet Unit and the Transom. (Any fault should
5. Slide the Transom Plate back off the Tailpipe.
be investigated and rectified before continuing).
5.6 AMENDMENT 9 24/01/03

5 INSTALLATION
HJ-322
5.5 FINAL ASSEMBLY
5.5 FINAL ASSEMBLY REVERSE CYLINDER RE-FITTING:

Refer to Drawings “HJ-322-07-001 Reverse Assem-
bly. Sht 1” and “HJ-322-07-001 Reverse Assembly.
Sht 2”.
2”. The Reverse Cylinder may now be refitted to the Jet
Unit in accordance with the instructions at Section
The Reverse Duct and Tailpipe should have been
9.3.1“Reverse Cylinder: Refit to the Jet Unit”.
removed prior to the installation of the Jet Unit
through the Transom hole. Replace any position sensors and linkages that were
removed from the inboard end of the Reverse
The Reverse Duct, Tailpipe and Steering Assembly
Cylinder. Take care to correctly reconnect electrical
can now be refitted to the Jet Unit as shown in the
connections. Refer to the Overhaul Section of the
following procedures:-
Controls Manual for further information.
5.5.1 Re-Fitting the Reverse

5.5.2 Re-Fitting the Steering
Components
Components
STEERING BRACKET RE-FITTING:
2”. Refer to Section 9.5.2“Steering Bracket and Steering
Shaft Re-Fitting” for re-fitting details.
REVERSE DUCT AND TAILPIPE RE-FITTING (COM-
PLETE): STEERING CYLINDER RE-FITTING:
The Reverse Duct and Tailpipe should have been Refer to Section 9.5“Steering Assembly Re-Fitting”
removed prior to the installation of the Jet Unit for refitting details.
throught the Transom hole.
The Reverse Duct, Tailpipe and Steering Assembly STEERING SENSORS RE-FITTING:
may now be refitted to the Jet Unit as shown in the Refit any Sensors attached to the Tiller. Refer to the
following procedure:- Overhaul Section of the Controls Manual for details.
1. Using the appropriate approved Lifting
Equipment, lift the Reverse Duct complete with 5.5.3 Assembling the Jet Steering
Tailpipe and Steering Assembly attached and Tillers
locate onto Studs [50] fitted on the rear of the
The Jet Tiller as supplied, is pre drilled for the
Impeller Housing.
attachment of the tie rod bolts. The Tiller has been
2. Secure in position with Special Washer [61] and drilled with a series of holes in the surface of the
Nuts [56], using Loctite 222. Tiller. These holes are spaced at 6º intervals. The
3. Reconnect the Reverse Duct to the Reverse position for attaching the Tie Rods to the Tiller to
Cylinder (if fitted) as shown in paragraphs 10 to suit the different deadrise angles is at an angle from
12 of Section 9.3.2“Reverse Duct: Refit to the Jet the Jet centreline which is equal to the deadrise
Unit”. angle. Attach the Tie Rod to the Tiller at the nearest
appropriate drilled hole in the Tiller. Refer to
STEERING ASSEMBLY RE-FITTING: drawing CT-SJK-04-010 found in the Controls
Manual Drawings Package for correct fitting and
Refer to Section 9.5.2“Steering Bracket and Steering
positioning of the Jet Unit Tillers and Tie Rods for
Shaft Re-Fitting” to re-fit the Steering Shaft.
twin Jet applications.
REVERSE DUCT RE-FITTING: NOTE: Ensure that the Cotter Pins are fitted as
Using the appropriate lifting equipment, refit the shown in Figure 24:“Jet Steering Tiller-Cot-
Reverse Duct as shown in Section 9.3.2“Reverse ter Alignment with Modified Tiller” for all
Duct: Refit to the Jet Unit”. applications of Tiller orientation.
AMENDMENT 8 21/05/02 5.7

5 INSTALLATION
HJ-322
5.5 FINAL ASSEMBLY
SINGLE JET INSTALLATIONS:

Assemble the Cotter (taper) Pin in the Steering Tiller
from the opposite direction to the Cotter (taper) Pin
fitted in the Steering Crank.
WASHER
SPRING WASHER
COTTER
NUT
NUT
Figure 24: Jet Steering Tiller-Cotter Alignment with Modified Tiller
TWIN JET INSTALLATIONS: Tie Rod is supplied to facilitate accurate centreing of

Ganged control of steering in multiple Jet the Jets.
installations is achieved by swivel ended Tie Rod(s) The Jet Tiller can be fitted either to Port for centre
interconnecting the Jet Tillers. An adjustable length and port Jets or to Starboard for starboard Jets.
Figure 25: Tiller Position
5.8 AMENDMENT 8 21/05/02

5 INSTALLATION
HJ-322
5.6 DRIVELINE AND ENGINE INSTALLATION
THIS ANGLE TO BE THE

SAME AS DEADRISE ANGLE.
STARBOARD PORT
STE
ERI
NG
ACT
ION
DEADRISE ANGLE
JETS MOUNTS FLUSH WITH

HULL DEADRISE ANGLE
VIEW LOOKING AFT ON

TRANSOM
Figure 26: Twin Jet Arrangement
TRIPLE JET INSTALLATION: 5.6 DRIVELINE AND ENGINE

One Steering Cylinder only is required which should
mount on the Center Jet.
INSTALLATION
Two swivel ended Tie Rods are used to interconnect
the Jet Tillers, from starboard to center Jet and from GENERAL:
center to port Jet. The engine(s) should be located in a position that
will give the vessel the most suitable fore and aft
TIGHTENING COTTER (TAPER) PIN NUTS: trim for the proposed boat speed. For semi-planing
Ensure that all the Tillers are fitted the correct way and moderate planing speed craft it is likely that the
as shown for Single, Twin or Triple Jets. Torque load engine should be positioned well forward towards
all securing nuts to the recommended torque as amidships for best trim and thus speed. For very
shown in Drawing “85113 Recommendations for high speed craft it is likely the engine should be
Fastener Locking, Torques and Thread Lubrication”. positioned aft, close to the Jet Unit, to obtain best
trim and speed. Follow the recommendations of the
boat designer in this regard or consult C.W.F.
5.5.4 Centreing the Jet(s) Steering Hamilton & Co Ltd.
Before mounting the Cylinder or fitting the Steering
Tie Rod(s) ( for multiple Jet applications), ensure DRIVESHAFT INSTALLATION:
that all Nozzles are set to the "dead ahead" position Refer to Section 3.4“Jet Mainshaft Alignment (For 5º
and temporarily clamp the Nozzles so that the Option Only)” and Section 3“Design Basics” to get
Tillers will not move from the dead ahead position. the engine location and shaft line angle correct.
Consult C.W.F. Hamilton & Co. Ltd for an
Engineering check of driveline proposals.
SWITCH OFF THE REVERSE CONTROL
SYSTEM (IF OPERATIONAL) DURING
STEERING ADJUSTMENT SO THAT THE DRIVELINE COMPONENTS FOR DIESEL ENGINES:
REVERSE DUCT CANNOT BE The Driveline for a diesel engine installation will
CAUTION require a flexible Coupling normally mounted on the
ACCIDENTALLY LOWERED.
engine flywheel. It is essential that the Coupling is
sufficiently flexible to ensure that the slow speed
torsional vibration resonance point occurs below
engine idle RPM. The engine manufacturer will be
able to calculate the torsional coupling stiffness
required to achieve this.
AMENDMENT 8 21/05/02 5.9

5 INSTALLATION
HJ-322
5.6 DRIVELINE AND ENGINE INSTALLATION
5.6.1 Mounting the Engine hp) - refer to Section 3.5“Water OffTake”. The water
may be fed directly to the engine without the need
Mount the engine via mounting feet fixed to the
for a raw water pump, provided that:
engine bearers. The feet and bearers do not have to
a) The pressure from the water offtake at idle is
withstand the propulsion thrust load which is
sufficient to cool the engine.
transmitted from the Jet directly to the hull. Flexible
b) That the engine can withstand the full
engine mounts will reduce vibration and noise but
pressure from the water offtake.
these must be used in conjunction with a driveshaft
• To be sure of correct flow for engine cool-
system which does not cause a radial or side load at
ing, a conventional water pick up and the
the jet coupling as the engine moves. Refer to
engine raw water pump should be used.
Section 3.4“Jet Mainshaft Alignment (For 5º Option
• The Jet Unit water offtake can be used for
Only)” and also Section 3.3.3“Driveshaft Options”,
a deck cleaning hose but the pressure is
for recommended driveshaft and engine installation
not high enough for a fire hose. The Jet is
angles.
supplied with the water offtake plugged.
An 1¼ BSP to 1¼” (32mm) Hosetail, sup-
5.6.2 Engine Cooling plied loose, can be fitted in place of the
plug.

5.6.3 Engine Systems
WATER PICK-UP AND ENGINE RAW Engine wiring, instrumentation and throttle systems
WATER PUMP MUST BE USED. are all conventional - follow the manufacturers
CAUTION recommendations.
With the standard HSRC Reverse System, a two
lever (separate) throttle and reverse controls MUST
ENSURE THAT THE WATER PICK UP IS be used.
NOT DIRECTLY AHEAD OF THE JET UNIT
INTAKE, BUT WELL TO THE SIDE TO 5.6.4 Exhaust Systems
AVOID TURBULENT WATER FLOW INTO The exhaust system can be any conventional system
CAUTION
THE JET. approved by the engine manufacturer, except that
There is a 1¼" BSP outboard water offtake which for the efficient operation of the Jet Unit, in reverse,
provides water at approximately 10 kPa (11/2 psi) at exhaust outlets are best sited above the waterline.
600 RPM and up to 31kPa (45 psi) at - 260 Kw (350
EXHAUST OUTLETS
EXHAUST OUTLETS
WATER LINE
BOAT GOING BOAT GOING

ASTERN ASTERN
EXHAUST GASES
CHINE CHINE
WATER KEEL KEEL

ONLY WATER
FLOW
EXHAUST
GASES
Figure 27: Exhaust System Layout
5.10 AMENDMENT 8 21/05/02

5 INSTALLATION
HJ-322
5.7 INSTALLATION CHECKS FOR THE JET UNIT
5.6.5 Governor Settings 5.7 INSTALLATION CHECKS FOR

The "No Load" governor setting (or "High Idle") on THE JET UNIT
diesel engines, should be set well clear of the full
throttle R.P.M. achieved when driving the Jet Unit so
that there is no chance of the governor reducing JET UNIT: MOUNTING:
power (and performance) at full throttle. 1. Check that the Intake Block is faired to the hull
To check, select neutral if clutch or gearbox fitted bottom. Contours should be smooth with no
but without these unbolt the driveline at the engine steps or protrusions greater than 2mm.
flywheel and open the throttle fully. To accurately 2. Check that there are no flow obstructions
measure RPM, use a calibrated hand tachometer. forward of the Intake (Refer to Hull details in the
Jet Designers Manual and also Section 3.2“Hull
EXAMPLE: - IF THE MAXIMUM RPM FOR DRIVING THE JET Design”and Section 5.2“Hull Preparation” in this
UNIT IS 2800 RPM, THEN THE GOVERNOR SHOULD NOT manual).
BEGIN TO OPERATE UNTIL AT LEAST 2850 RPM. ON MOST 3. Inspect the Intake Block for obvious distortion or
DIESEL ENGINES THIS MEANS THE “NO LOAD GOVERNOR gaps between the Jet Unit Intake and the Intake
SETTING” (OR “HIGH IDLE”) SHOULD BE AT LEAST 3050 Block.
RPM. (I.E. 250 RPM HIGHER THAN THE LOADED MAXI-
4. GRP and Aluminium Hulls Only; Check that the
MUM RPM).
silicone sealant between the Intake Block and the
Ensure that the low idle RPM is set high enough to Jet Unit Intake has not squeezed out into the
avoid any vibration in the driveline. Extensive water passage. Trim off excess sealant if
idling with the driveline vibrating may damage the necessary.
Jet Unit. Refer to Section 3.3“Drivelines”.
5. Steel Hulls Only; Check that the sealant between
the Intake Block and the Jet Intake has not
squeezed out into the water passage. Check that
the Intake Block Gasket and sealant between the
Intake Block and the Hull Flange has not
squeezed out into the water passage. Check that
the Intake Block Gasket has been fitted properly,
reposition if required and trim off any excess
sealant if necessary.
6. Check the Transom Plate Seal is correctly located
and secured. (Do not over tighten). If two people
are available and the vessel is indoors, a strong
light may be used to check the fit of the Transom
cutout and Transom Seal.
7. Steel Hulls Only; Check that the Jet Unit is
insulated from the Hull (Refer to Section
4.3.2“Checking the Insulation” and the
Installation Drawings contained in this
manual).
8. Check that the engine exhausts are above the
expected waterline or well clear of the water jets.
Refer to Section 3.2.4“Engine Exhausts” in the
"Design Basics" Section and Section 5.6.4“Ex-
haust Systems” in the "Installation" Section of
this manual.
9. Check that the Hull Trim Tabs (if fitted) will not
interrupt reverse flow from the water jets. Refer
to Section 3.2.3“Trim Tabs” and Figure 11:“Al-
lowable Trim Tabs Location” in the "Design
Basics" Section of this manual.
AMENDMENT 18 04/10/04 5.11

5 INSTALLATION
HJ-322
5.7 INSTALLATION CHECKS FOR THE JET UNIT
JET UNIT: GENERAL:

1. Ensure that the Impeller is fitted to match the
engine rating. The Impeller part number
(Stamped on the Impeller Hub) can be viewed
through the Main Inspection Cover.
2. Check that the internal and external Anodes are
in place and have not been painted over. (Refer
to Drawing “HJ-322-13-002 Anode Location
Drawing”).
3. If antifouling has been applied to the Jet Unit
casing, ensure that it is compatible with
aluminium (i.e. Not copper based).
4. Check that the Main Inspection Cover O Ring is
correctly located and that the securing Nuts are
tightened to the recommended torque.
5. Check any water offtake connections (if fitted) for
correct fitting and security. Check that any
unused water offtakes are correctly plugged.
6. Check that the steering Linkages, Rod Ends and
Clevis are aligned in the same plane.
7. Ensure that the Bearing Housing is filled with an
approved grease prior to operating the Jet Unit
for the first time. Refer to Section 9.6.4“Bearing
Housing Re-Assembly” and Drawing “85018 Rec-
ommendation for Lubricants & Oils”.
DRIVE SHAFT:
1. Ensure that the Driveline details have been
checked and approved by CWF Hamilton & Co
Ltd.
2. On universal joint drive shafts (Refer to Section
3.3“Drivelines” in the "Design Basics" Section
of the Manual) check the following:-
• Yoke offset angles are in the same plane,
are equal and <5°.
• Yokes are in the same plane.
3. On Line Shafts supported by bearings (Refer to
Section 3.3“Drivelines” in the "Design Basics"
Section of the Manual) check the following:-
• Support bearings are aligned with the en-
gine flywheel.
• Outer support bearings are positioned
close to the end couplings.
5.12 AMENDMENT 18 04/10/04

5.8 INSTALLATION DRAWINGS
HJ-322

5 INSTALLATION
5.13
HJ-322-08-001 Installation Details GRP Hull with 5º Shaft Line. Sht 1

5 INSTALLATION
5.14
A B C Item Kit PartNumber Qty ProductDescription DrawingNbr

A 111324 INTAKE BLOCK & SCREEN KIT G.R.P. HULL. 5 deg SHAFT LINE HJ32208001
B 111321 INSTALLATION HARDWARE KIT HJ32208001
C 111330 TRANSOM PLATE KIT (ALUM & GRP HULL) HJ32208001
C 1 111322 1 TRANSOM PLATE HJ322 111322
C 2 107160 1 (JET) O RINGS SPECIAL TRANSOM SEAL 107160
C 3 HZQHXBK 24 (SCREWS) (M/C SCREWS) METRIC ST ST 316 HEX HD M8x70 N/A
C 4 JDQHXAC 26 (NUTS) (METRIC ST ST 316) M8 N/A
C 5 JEQKXAC 26 (WASHERS) (SPRING) METRIC ST ST 316 M8 N/A
C 6 JEOZXAF 48 (WASHERS) (FLAT) METRIC ST ST 316 M8x16x1.2 N/A
A 7 111060 1 INTAKE BLOCK 5deg SHAFT ANGLE 111060
B 8 30669 34 (STUDS) METRIC (316-STST) M12x59 30639
A 9 JDQHXAE 36 (NUTS) (METRIC ST ST 316) M10 N/A
A 10 JEQKXAE 36 (WASHERS) (SPRING) METRIC ST ST 316 M10 N/A
A 11 JEOZXAY 36 (WASHERS) (FLAT) METRIC ST ST 316 M10 (2mm THICK) N/A
A 12 HZPPXEE 36 (BOLTS) (M/C SCREWS) METRIC STST 316 M10x60 (CSK HD) N/A
A 13 111061 1 SCREEN 5deg SHAFT ANGLE 111061
B 15 JDQHXAH 34 (NUTS) (METRIC ST ST 316) M12 N/A
B 16 JEQKXAH 34 (WASHERS) (SPRING) METRIC ST ST 316 M12 N/A
B 17 JEOZXAK 34 (WASHERS) (FLAT) METRIC ST ST 316 M12x24x1.6 N/A
A1 B1 18 JMNGAAR 2 NEUT-CURE RTV SILICONE 310G N/A
B 19 MRINAAI 1 LOCTITE 262 10ML BOTTLE N/A
C 20 103359 1 ANODE MK3 103359
C 21 30667 2 (STUDS) METRIC (316-STST) M8x46 30647
A1 B1 C1 22 63595 1 (JET) PACKAGING BOLT BOX N/A
HJ-322
HJ-322 5 INSTALLATION
AMENDMENT 18 04/10/04 5.15
5 INSTALLATION
HJ-322
5.16 AMENDMENT 18 04/10/04
HJ-322

5 INSTALLATION
5.17
HJ-322-08-002 Installation Details Aluminium Hull with 5º Shaft Line. Sht 1

5 INSTALLATION
5.18
A B C Item Kit PartNumber Qty ProductDescription DrawingNbr

A 111325 INTAKE BLOCK & SCREEN KIT ALUMINIUL HULL. 5 deg SHAFT LINE HJ32208002
B 111321 INSTALLATION HARDWARE KIT HJ32208001
C 111330 TRANSOM PLATE KIT (ALUM & GRP HULL) HJ32208001
C 1 111322 1 TRANSOM PLATE HJ322 111322
C 2 107160 1 (JET) O RINGS SPECIAL TRANSOM SEAL 107160
C 3 HZQHXBK 24 (SCREWS) (M/C SCREWS) METRIC ST ST 316 HEX HD M8x70 N/A
C 4 JDQHXAC 26 (NUTS) (METRIC ST ST 316) M8 N/A
C 5 JEQKXAC 26 (WASHERS) (SPRING) METRIC ST ST 316 M8 N/A
C 6 JEOZXAF 48 (WASHERS) (FLAT) METRIC ST ST 316 M8x16x1.2 N/A
A 7 111060 1 INTAKE BLOCK 5deg SHAFT ANGLE 111060
B 8 30669 34 (STUDS) METRIC (316-STST) M12x59 30639
A 13 111061 1 SCREEN 5deg SHAFT ANGLE 111061
B 15 JDQHXAH 34 (NUTS) (METRIC ST ST 316) M12 N/A
B 16 JEQKXAH 34 (WASHERS) (SPRING) METRIC ST ST 316 M12 N/A
B 17 JEOZXAK 34 (WASHERS) (FLAT) METRIC ST ST 316 M12x24x1.6 N/A
B 18 JMNGAAR 1 NEUT-CURE RTV SILICONE 310G N/A
B 19 MRINAAI 1 LOCTITE 262 10ML BOTTLE N/A
C 20 103359 1 ANODE MK3 103359
C 21 30667 2 (STUDS) METRIC (316-STST) M8x46 30647
B1 C1 22 63595 1 (JET) PACKAGING BOLT BOX N/A
HJ-322
HJ-322

5 INSTALLATION
5.19

5 INSTALLATION
5.20
HJ-322
HJ-322

5 INSTALLATION
5.21
HJ-322-08-003 Installation Details Steel Hull with 5º Shaft Line. Sht 1

5 INSTALLATION
5.22
HJ-322
HJ-322

5 INSTALLATION
5.23

5 INSTALLATION
5.24
HJ-322
Section 6
COMMISSIONING
This information is intended for use by CWF 6.2 POST LAUNCH CHECKS
Hamilton representatives. Refer to the Controls
System manual for details of commissioning Perform the following procedures before the
checks specific to the controls system. engines are started.
1. Check that there are no water leaks:
a) At the Transom Seal.
ENSURE THAT THE VESSEL IS SECURELY b) At the Intake Base.
MOORED AS DURING COMMISSIONING c) From under the Bearing Housing (Water Seal
THE JET UNIT MAY PRODUCE LARGE leak).
THRUST FORCES. 2. Check the JHPU oil level.
WARNING
DO NOT PROCEED IF ANY OF THE CON- 3. Check the oil level in the Pump Reservoir and
TROL SYSTEM FAULT ALARMS ARE STILL
refill as required. Refer to the Controls Manual
ACTIVATED
supplied with this Jet Unit.
4. Ensure that the Bearing Housing is filled with an
approved grease prior to operating the Jet Unit
for the first time. Refer to Section 9.6.4“Bearing
6.1 PRE-LAUNCH CHECKS Housing Re-Assembly” and Drawing “85018 Rec-
1. Check all hydraulic shafts for damage and that ommendation for Lubricants & Oils”.
they are free from contamination (weld splatter, 5. Check that the waterline is up to at least the
grinding dust, fibreglass resin, etc). Mainshaft centreline so that the Jet Unit will
2. Check that all Inspection Covers on all Jet Units prime (pump water properly) when the engine is
are securely attached. started.
3. STEEL HULLS ONLY: Check that the insulation 6. Ensure that the vessel is securely moored fore
between the Jet Unit and the Hull of the vessel and aft and is located in deep clean water.
measures NOT LESS THAN 1000 Ohms. Refer to
Section 4.3.2“Checking the Insulation” for further
details.
AMENDMENT 18 04/10/04 6.1

6 COMMISSIONING
HJ-322
6.3 ENGINE RUNNING CHECKS (VESSEL MOORED)
6.3 ENGINE RUNNING CHECKS 6.4 VESSEL SPEED AND

(VESSEL MOORED) HANDLING TRIALS
1. The Water Bearing (Cutless Bearing) must
operate wet. Do Not operate the Jet Unit with the
vessel out of the water, or with the vessel ballasted IF A PROBLEM IS DETECTED, RETURN TO
THE MOORING IMMEDIATELY, AT
such that the Jet Unit does not prime (pump water
REDUCED POWER. DO NOT OPERATE
properly) when the engine is started.
THE JET UNIT UNTIL THE FAULT HAS BEEN
2. Ensure that the vessel is securely moored fore CAUTION
REPAIRED. REFER TO SECTION 7 FAULT
and aft, in deep water. FINDING.
3. With the Reverse Lever set to “Zero Speed”, the
engine(s) may be started and the engine
suppliers representatives can carry out engine 1. Leave the mooring and check that the steering is
checks. operating correctly at “Forward Speed”, at “Zero
Speed” and at “Astern”.
4. If the engine cooling water is taken from the Jet
Unit water offtake, confirm that water is passing 2. Observe the waterjet emerging from the Steering
out of the engine exhaust outlets, where possible. Nozzles when the vessel is going dead ahead at
Periodically check that the engine is running at speed. The waterjet should be a relatively clean
the correct operating temperature as this ensures with an even shape.
that the engine is receiving sufficient water from 3. Check that the Jet Unit and Driveshaft are
the Jet Unit water offtake. Check that the cooling running smoothly (no vibration) over the entire
water hoses are secure. engine operating speed range (i.e. from “Zero
Speed” to “Full Ahead”).
4. Periodically check the surface temperature of the
FAILURE TO CHECK COOLING WATER
Bearing Housing and record the temperatures
HOSES MAY RESULT IN FLOODING OF THE
once it reaches a steady value. Due to friction
VESSEL.
caused by the seals, the Bearing Housing is likely
CAUTION to be warm. The Bearing Housing operating
temperature should not exceed of 80º C. A faulty
5. Check for water leaks around the Jet Unit while bearing will be heard and felt as a vibration
the engine is running particularly under the through the Bearing Housing and is likely to
Bearing Housing (Mainshaft Water Seal). cause significant heat build-up in the Bearing
Housing.
6. Check that the Jet Unit and Driveshaft are
running smoothly (no vibrations). 5. If practical, check the Coupling joint
temperatures. Increased joint temperature may
7. Periodically check the Bearing Housing
indicate driveshaft misalignment.
temperature. The Bearing Housing operating
temperature should not exceed 80º C. 6. Periodically check the hydraulic oil temperature
at the JHPU oil reservoir. Record the temperature
8. Check that the Reverse Controls are working by
reading after a sustained run at cruising speed
monitoring the Reverse Duct position while
and also after a period of vessel manoeuvering.
moving the Control Lever.
7. Record maximum speed (using GPS) and engine
9. Check that the Steering Controls are working by
revolutions (Note that strong currents will result in
monitoring the Steering Nozzle position while
inaccurate speed readings since the GPS only
moving the Helm (check that port helm gives port
provides “speed over ground covered” readings).
nozzle deflection, and that all Nozzles are
At maximum speed the Jet Unit revolutions
steering in the same direction.
should be verified with a hand held tachometer at
10.Check that the steering travel is limited by the the Jet Unit Coupling.
Steering Cylinder and not the Steering Linkage.
8. Record Vessel speed at varying engine
11.After stopping the engines, check the hydraulic revolutions if possible.
systems oil levels and replenish if required.
9. Record observations on vessel trim, loading etc.
6.2 AMENDMENT 13 25/11/03

6 COMMISSIONING
HJ-322
6.5 AFTER INITIAL TRIALS (AFTER ENGINE SHUT DOWN)
6.5 AFTER INITIAL TRIALS (AFTER

ENGINE SHUT DOWN)
1. Refer to Section 8.4“Servicing Intervals” for any
after trials maintenance that may be required.
2. Ensure that all important information recorded
during trials is stored for later reference.
3. Check for water leaks around the Jet Unit
especially at the Transom Seal at the Intake Block
and under the Bearing Housing (Water Seal
leaks).
4. STEEL HULLS ONLY: Check that the insulation
between the Jet Unit and the Hull of the vessel
measures approximately 80 to 100 Ohms. Refer
to Section 4.3.2“Checking the Insulation” for
further details.
AMENDMENT 13 25/11/03 6.3

6 COMMISSIONING
HJ-322
6.5 AFTER INITIAL TRIALS (AFTER ENGINE SHUT DOWN)
6.4 AMENDMENT 13 25/11/03

PART C
Servicing Information
• FAULT FINDING
• MAINTENANCE
• OVERHAUL
Section 7
FAULT FINDING
HOW TO USE THIS FAULT FINDING TABLE: 3. Use the "REFER" column for more information
1. Look for a symptom on the table that is similar on each solution.
to the fault that has occurred. 4. Try the easiest (first) solution first.
2. Try each solution until the fault is found and
rectified.
7.1 JET UNIT FAULTS
Table 3: Jet Unit Faults
SYMPTOMS
NO POSSIBLE CAUSE SOLUTION REFER
1 The engine unloads (RPM increases).

There is some blockage of the Jet Unit. The blockage must be removed. Sect.“2.9
2 A lack of jet thrust (boat speed drops).
3 Excessive noise and vibration comes from the Jet Unit.
4 Water leaking from under the Bearing Housing.
Faulty Water Seal. Inspect and repair the Water Seal. Sect.“8.5
Sect.“9.6
5 Excessive high pitched rattling, whine.
Faulty Thrust Bearing. Inspect and repair the Thrust Bearing. Sect.“8.5 Item
No 2.
Sect.“9.6
AMENDMENT 8 21/05/02 7.1

7 FAULT FINDING
HJ-322
7.1 JET UNIT FAULTS
Table 3: Jet Unit Faults (Continued)
SYMPTOMS
6 Bad vibrations.
Worn Marine Bearing, or Marine Bear- Inspect and repair the Marine Bearing. Sect.“8.5 Item
ing water drain hole in the Tailpipe No 14/c).
Cone is blocked. Sect.“9.8.1
Worn Driveshaft universal joints. Inspect and repair the driveshaft in N/A.
accordance with the manufacturer’s
recommendation’s.
7 Engine revolutions gradually increasing over a period of time. Take off performance poor.
There is some blockage of the Jet Unit. The blockages must be removed. Sect.“2.9
Worn or blunt Impellers. Inspect and repair the Impeller as well Sect.“8.5 Item
as the Wear Ring. No14/a) & 14/
Excessive Impeller tip clearance. Inspect and repair the Impeller as well b).
as the Wear Ring. Sect.“9.8
8 Sudden increase in engine revolutions with not noticeable decrease in thrust.
Faulty tachometer. Repair tachometer. N/A.
9 Excessive engine revolutions, noisy Jet Unit with aerated water from Nozzle.
Screen blocked with wood or debris or The blockage must be removed. Sect.“2.9
rope through screen and wrapped
around the Mainshaft.
Object jammed in Stators and/or Impel- The object must be removed. Sect.“2.9
ler.
10 Low engine RPM.
Problem with engine. Investigate operation of engine. N/A
Incorrect Impeller and Nozzle selection. Contact C.W.F. Hamilton for a check N/A
to be made.
11 Thrust Bearing Housing excessively hot.
Thrust Bearing [36] or Seal [37] failure. Overhaul Thrust Bearing. Sect.“9.6
7.2 AMENDMENT 8 21/05/02

7 FAULT FINDING
HJ-322
7.2 REVERSE SYSTEM FAULTS

Table 4: Reverse System Faults
SYMPTOMS
1 Reverse Duct creeping down from the Up position

Reverse Cylinder Hose leaking. Replace the leaking hose. Refer to the Sect.“9.2.4
Controls Manual.
Reverse Cylinder Seal Failure. Overhaul the Reverse Cylinder. Drg “HJ-322-
Suspect Seals Are: 07-001 Reverse
Wiper Seals [14]. Assembly. Sht
Oil Seals [12]. 1”.
Piston Seal [13].
2 Reverse Cylinder: Oil Leaking from the Shaft outside the Transom.
Reverse Cylinder seal failure in the Overhaul the Reverse Cylinder. Sect.“9.2.4
Back Head [3]:
Suspect seals are: Drg “HJ-322-
Oil Seal [12]. 07-001 Reverse
Wiper Seal [14]. Assembly. Sht
1”.
3 Reverse Cylinder: Oil Leaking from the Shaft. Inside the vessel.
Reverse Cylinder seal failure in the Overhaul the Reverse Cylinder. Sect.“9.2.4
Front Head [3].
Suspect seals are: Drg“HJ-322-
Oil Seal [14]. 07-001 Reverse
Oil Seal [12]. Assembly. Sht
1”.
4 Reverse Cylinder: Oil Leaking around Cylinder Shaft Back Head / Front Head interface.
Reverse Cylinder seal failure. Overhaul Reverse Cylinder. Sect.“9.2.4
Suspect seals are: Drg“HJ-322-
O-Ring [11]. 07-001 Reverse
Assembly. Sht
1”.
5 Reverse Cylinder: Oil Leaking from Nipple [15].
Reverse Cylinder seal failure. Overhaul the Reverse Cylinder. Sect.“9.2.4
Suspect Seals are: Drg“HJ-322-
Bonded Seal [16]. 07-001 Reverse
Hose connections to Nipple. Assembly. Sht
1”.
AMENDMENT 8 21/05/02 7.3

7 FAULT FINDING
HJ-322
Table 4: Reverse System Faults (Continued)
SYMPTOMS
6 Reverse Cylinder: Water Leaking in by Back Head [3].

Reverse Cylinder seal failure: Overhaul Reverse Cylinder. Sect.“9.2.4
Suspect seals are. Drg“HJ-322-
Resilient Mount [8]. 07-001 Reverse
Resilient Mount [9]. Assembly. Sht
O-Ring [20]. 1”.
7 Poor Reverse Thrust.
Reverse Duct flow is being ingested into Determine reason for flow ingestion Refer to the
the Intake. into Intake and correct. HSRC Controls
Manual.
Reverse flow hitting the Trim Tabs. Check dimensions of Trim Tabs at Fig Sect.“3.2.3
Engine Exhaust is being ingested into 11 and reposition Trim Tabs. Sect.“3.2.4
the intake. Reposition engine exhausts to exhaust
above the water line.
8 Poor Forward Thrust.
Reverse Duct not travelling fully up. Determine reason for limited travel Sect.“9.2
and correct. Also refer to the
HSRC Controls
Manual.
9 Reverse Control Lever movement is stiff.
Reverse Control Lever or Cable is stiff. Disconnect the Reverse Control Cable Refer to the
at the Lever. HSRC Controls
Check Controller movement and cable Manual.
movement.
Lubricate as necessary.
Check for bent or loose linkages.
Check cable run from Control Lever to
the Reverse Cylinder Lever to ensure
that cable is not being accidentally
bent or crushed and restricting move-
ment.
Check cable type, length and route are
as specified.
10 No hydraulic pressure from the Jet Hydraulic Pump Unit (JHPU - Saginaw Pump).
Reverse cylinder is not functioning due Increase the Engine (Jet Unit) revolu- N/A
to little or no hydraulic pressure from tions in quick bursts to about
the JHPU. 1500RPM until the vanes in the JHPU
become free. (This may assist).
7.4 AMENDMENT 18 04/10/04

7 FAULT FINDING
HJ-322
7.3 STEERING SYSTEM FAULTS

Table 5: Steering System Faults
SYMPTOMS
1 Steering stiff at the Helm.

Grit jamming Nozzle. Move Nozzle from side to side to Sect.“9.4
release grit. Flush out.
Helm Wheel Stiff. Check, rectify and lubricate as neces- Refer to Con-
sary. trols Manual.
Steering Tiller Shaft stiff. Check movement of Steering Shaft and Sect.“9.4.2
clearance on Steering Bushes. Rectify
to a loose running fit.
Grit between Nozzle Bushes [34], and Remove Pivot Pins [8] Bushes [34] and Sect.“9.4.4
the Nozzle. Special Washers [6]. Check for wear. Drg“HJ-322-
Also check Lip Seals [29] for wear and 06-000 Steer-
damage. ing Assembly
Replace with new parts as necessary. General
Arrangement.
Steering Bush [5] or Steering Crank [20] Replace Steering Bush [5] and repair or Sht 1”.
worn or loose. or replace Steering Crank [20].
Corrosion build-up around the Steering Clean up Shaft. Remove Bushes, clean Sect.“9.4.
Shaft [23] or Steering Bush Seal Hous- out bores and refit using Loctite.
ing [26].
2 Steering Jamming.
Grit jamming the Steering Nozzle. Work Nozzle from side to side to Sect.“9.4.
release grit. Flush out. Drg“HJ-322-
06-000 Steer-
Steering Nozzle Pivot Bolts [8] loose or Remove, check and replace bolts to the ing Assembly
bent. torque specified on the drawing. General
Arrangement.
Steering Nozzle or Steering Housing Remove, rebuild or replace as neces- Sht 1”.
deformed by impact. sary.
AMENDMENT 8 21/05/02 7.5

7 FAULT FINDING
HJ-322
7.6 AMENDMENT 8 21/05/02

Section 8
MAINTENANCE
8.1 GENERAL 8.2 PRESERVATION: (PRE-

This Jet Unit has been designed to require the INSTALLATION)
absolute minimum of maintenance. However, it is
recommended that the Jet Unit be regularly
NEW JET PRESERVATION:—The following storage
examined for wear of Bearings, Seals and Bushes,
requirements must be provided to ensure that no
etc and checked for corrosion annually as a
damage or deterioration occurs to the Jet Unit :
minimum requirement.
1. Temperature must be between 10ºC and 40ºC
HYDRAULIC EQUIPMENT:—When servicing and above the "dew point" (i.e. no condensation
Hydraulic Equipment, use the following general is allowed to form).
rules to ensure effective and trouble free servicing: 2. It is desirable to keep Bearing Housing
1. Minimise the loss of oil to surrounding areas by components coated with grease; turn the Shaft
the liberal use of oil absorbent cloth. 180º once every month to achieve this.
2. If disconnecting hydraulic connections to 3. All exposed steel parts (except for stainless steel
components which are not going to be serviced parts) should be protected from corrosion. As a
immediately, plug the connection to prevent loss corrosion preventative treatment, coat all
of oil and entry of foreign particles. exposed steel parts with a thin layer of rust
preventative oil.
4. To protect hydraulic fittings, either:
a) Coat with oil impregnated corrosion
protection tape.
OR
b) Spray with a recognised corrosion protection
treatment.
PREPARATION FOR USE:—To prepare the Jet Unit

for use:
Ensure that the Bearing Housing is greased via the
Nipple on the top of the Bearing Housing. Refer to
Section 9.6.4“Bearing Housing Re-Assembly” Item
No 20.
AMENDMENT 8 21/05/02 8.1

8 MAINTENANCE
HJ-322
8.3 PRESERVATION: (POST INSTALLATION)
8.3 PRESERVATION: (POST

INSTALLATION) BEFORE MOVING ANY CONTROLS, ENSURE
THAT ANY MARINE GROWTH IS REMOVED
FROM THE STEERING AND REVERSE LINK-
DO NOT RUN THE JET UNIT OUT OF THE AGE RODS. THIS WILL PREVENT DAMAGE
CAUTION
WATER UNLESS IT IS FITTED WITH A DRY TO THE SEALS THAT THESE CONTROL
RUN KIT. RODS PASS THROUGH.
CAUTION
PERFORM THE FOLLOWING PROCEDURES AT AN
INTERVAL RANGING FROM 1 WEEK TO 1 MONTH,
When the vessel is not operational for an extended DEPENDING ON OPERATIONAL CONDITIONS.
period, the following procedures must be followed 1. Run the Jet Unit for a short time.
to prevent marine growth and corrosion problems. 2. Operate the Reverse Duct and Steering Nozzle
fully six times. Leave the Reverse Duct in the
IF THE JET UNIT IS TO BE LAID-UP, CARRY OUT raised position and the Steering Pushrod fully
THE FOLLOWING:- retracted.
1. Clean down the whole Jet Unit and wash inside 3. If the engine is not started, turn the Mainshaft by
and out with fresh water. 180º once per week. This can be done manually.
2. Hose the inside of the Jet through the Intake Grill
and the Nozzle. Allow to dry completely.
3. Spray with a suitable corrosion protection oil
such as Shell Ensis.
4. Oil and lubricate all moving parts.
5. Carry out the following on a monthly basis:-
a) If the engine cannot be run, turn the
Mainshaft by 180º. This can be done
manually.
b) Stroke the Reverse Duct fully six times and
leave in the raised position.
c) Operate the Steering from lock to lock fully six
times.
IF THE JET IS TO REMAIN MOORED, CARRY OUT

THE FOLLOWING:-
1. Actively prevent marine growth through the
following procedures:
a) Paint the inside and outside of the Jet Unit
with antifouling compound.
b) Keep light away from the Jet Unit. Moor the
vessel in deep water rather than shallow
water.
c) Place an opaque bag over the Steering Nozzle
to prevent light entering the inside of the Jet
Unit. In shallow water a similar cover should
be tied over the Intake Screen.
8.2 AMENDMENT 8 21/05/02

8 MAINTENANCE
HJ-322
8.4 SERVICING INTERVALS
8.4 SERVICING INTERVALS 2. The frequency of the following service items may
be varied to suit actual operating conditions.
Please note the following points: Refer to the appropriate Section for details.
1. Vessel usage is assumed to be 2000 operational • Jet Unit examination every 5000 hours refer
hours per year. Adjust your schedule as to Section 8.5“Jet Unit Servicing Details”. Item
necessary. 15.
Table 6: Servicing Intervals (Jet)
SERVICING INTERVALS (JET)

1ST
1ST 5 1 100 500 1 3 5000
ITEM WHAT TO DO REFER TO
HRS DAY HRS. HRS. MTH MTHS
2000
HRS.
HRS.
Internal Water Path Check for block-

ages and clear.
8.5/1 •
Thrust Bearing Lubricate. 8.5/2 • •
Water Seal Check for leaks. 8.5/4 • •
Anodes Check Condition. 8.5/5 •
Reverse Cylinder
Shaft
Lubrication 8.5/6 • •
Reverse Hydraulic
Cylinder & Hoses
Check for leaks
and condition
8.5/7 • •
Steering Hydraulic
Cylinder and Hoses
Check for leaks
and condition
8.5/8. • •
Steering Linkages Check Integrity. 8.5/9 •
Steering Pushrod Grease 8.5/10 • •
Steering Cotter Pins Check Integrity 8.5/11 •
Steering Crank Grease 8.5/12 • •
Driveshaft Universals Lubricate. 8.5/13 Every 500 Hrs or as recommended by the
manufacturer
Screen Rake and
Bearings
Check/Lubricate. 8.5/14 • •
Complete Jet Unit Examine / Repair. 8.5/15 • •
Steel Hull (Only) Insulation Check. 8.5/15h •
AMENDMENT 12 22/08/03 8.3

8 MAINTENANCE
HJ-322
8.4 SERVICING INTERVALS
8.4.1 Daily "Pre Use" Servicing

Checks
THE FOLLOWING AREAS SHOULD BE CHECKED ON

A DAILY BASIS IF THE VESSEL IS IN REGULAR USE.
Table 7: Daily Servicing Checks (Jet)
DAILY SERVICING CHECKS (JET)
AREA OPERATION
Intake Screen. Ensure that the water level is below the Inspection Cover or
Impeller. Overflow Preventer before removing the Inspection Cover.
Stator Blades. Check via the Inspection Cover that they are clear of debris.
Reverse Hydraulic Cylinder and Check for oil leaks, especially if oil has been added to the system.
Oil Lines.
Steering System. Check for oil leaks from the steering system, especially if oil has
been added to the system.
Check the freedom of movement of the Steering Linkages.
Check for security of attachment of the Hydraulic Oil Lines and
Linkages.
Position Indicator Senders Check for loose electrical connections, mountings and linkages if
(Transmitters). fitted on the system.
Thrust Bearing Housing. Check for signs of water leaking from under the Bearing Housing.
(Leaking Water Seal). If the Water Seal is leaking it should be
replaced as soon as possible otherwise water could contaminate
the Thrust Bearing causing corrosion and failure of the Thrust
Bearing.
8.4 AMENDMENT 8 21/05/02

8 MAINTENANCE
HJ-322
8.5 JET UNIT SERVICING DETAILS
EXTREME CARE IS REQUIRED WHENEVER

WARNING
ITEM NO ITEM OPERATION

1 Internal Water Path. Check for obstructions inside Intake daily.
Remove the Inspection Cover and check around the Impeller and
Intake Screen for obstructions and debris
Refer to Section 2.9“Blockages (Debris in the Jet Unit)”
2 Thrust Bearing. Grease with a good quality lithium-based ball bearing grease
every 100 hours or monthly in operation, whichever is soon-
est. Do not over grease. Normal operating temperature is 50 - 55
º C (120 - 130 º F) but the Bearing can operate up to 120 º F sat-
isfactorily, noting that most of the heat is generated by the Seals.
A faulty Bearing will be indicated by noise and vibration rather
than temperature.
3 Water Bearing. This is a water lubricated Bearing and requires no attention.
Do not run the Jet Unit out of water as this will damage the
Bearing and Water Seal.
4 Water Seal. Check daily for water leaks around the Bearing Housing drain
hole. Water Seal should also be checked for wear at 500 Hrs.
Visually check for water dripping from under the Bearing Hous-
ing. If water is found the Water Seal should be replaced.
5 Anodes. Check the condition of the Anodes every 3 months. Refer to
Drawing “HJ-322-13-002 Anode Location Drawing”.
a) All External Anodes. Replace any anode which is less than
half its original size. Refer to the various Sub-Sections in
Section 9“Overhaul” for information on Anode replacement.
b) Internal Intake Anodes. (Located on the internal flanks of the
Intake on either side of the Mainshaft). If the anodes are
more than half corroded they should be changed. Refer to
Section 9.7.1“Intake Internal Anode”.
c) Tailpipe Internal Anodes. Also change the Tailpipe internal
anodes at the same time as the Internal Intake Anode.
d) Ensure all fasteners are correctly tightened when fitting new
Anodes. Refer to Section 9.8.7“Tailpipe Overhaul” for infor-
mation on Anode replacement.
6 Reverse Cylinder Shaft Grease every 100 hours or monthly, whichever is soonest.
Grease with a water repellent grease. Refer to Section
9.3.1“Reverse Cylinder: Refit to the Jet Unit”.
AMENDMENT 18 04/10/04 8.5

8 MAINTENANCE
HJ-322

7 Reverse Hydraulic Check after the first 5 hours and then monthly.
Cylinder and Hoses. Check for leaks, damage or corrosion. Methodically check the
Reverse Cylinder and attached hoses for any signs of oil leaks,
damage or corrosion of the fittings. Repair as necessary. Refer to
the Controls Manual supplied with this Jet Unit for information on
hose replacement.
8 Steering Hydraulic Check after the first 5 hours and then monthly.
Cylinder and Hoses. check for leaks, damage or corrosion. Methodically check the
Steering Cylinder and attached hoses for any signs of oil leaks,
damage or corrosion of the fittings. Repair as necessary. Refer to
the Controls Manual supplied with this Jet Unit for information on
hose replacement.
9 Steering Linkages. Check integrity daily where possible.
Check that all linkages between the Steering Crank and the Steer-
ing Nozzle are secure and have a small amount of free play.
10 Steering Push Rod. Grease every 100 hours or monthly, whichever is soonest.
Grease with a water repellent grease.
11 Steering Cotter Pins. Check integrity daily where possible.
Check for security of attachment of the Steering Cotter Pins.
12 Steering Crank. Grease every 100 hours or monthly, whichever soonest.
Grease with a water repellent grease.
13 Driveshaft Universals. Lubricate every 500 hrs. or to suit the manufacturers recom-
mendations.
Follow the manufacturers recommendations for the type of Drive-
shaft used.
14 Screen Rake and Bear- Check every 100 hours or monthly, whichever is soonest for
ings (If fitted). free operation. Lubricate with a water repellent grease.
Stiffness or binding may be caused by debris caught in the screen
or seized Screen Rake Bearings. Grease bearings periodically with
water repellent grease.
15 Complete Jet Unit. Carry out an internal examination of the Jet Unit after the first
2000 hrs. operation and thereafter every 5000 hrs.
This examination should be carried out with the vessel out of the
water.
The following checks should be carried out:-
a) Impeller Blades - Check Clearance.
• Remove the Main Inspection Cover. Using Feeler Gauges,
check the clearance between the tips of the Impeller
Blades and the Wear Ring at each side of the Impeller not
top and bottom. Maximum recommended worn clear-
ance is 1.5mm (0.059ins) per side. New Clearance is Ap-
prox. 0.67mm (0.026ins).
b) Impeller - Check for Wear and Damage.
• Look for signs of corrosion and erosion damage on all
surfaces of the Impeller.
• Check the Impeller leading and trailing edges for damage.
8.6 AMENDMENT 12 22/08/03

8 MAINTENANCE
HJ-322

15(Cont’d) Jet Unit (Cont’d). c) Water Bearing - Inspect.
• Inspect the Water Bearing for scoring or localised wear.
• Replace if excessively worn. To check for wear, push the
Mainshaft hard from side to side. Check total sideways
movement at Impeller tips. Maximum recommended
worn movement is 0.6mm (0.024.ins). This indicates
the amount of wear in the Rubber Bearing and Shaft
Sleeve. These items are to be removed in accordance with
Section 9.8.2“Tailpipe Area - Dismantling” of this Manu-
al.
d) Reverse Duct - Removal.
• These items are to be removed in accordance with Section
9.2.1“Reverse Duct Removal”.
e) Steering Linkages - Disconnect.
9“Overhaul” and Steering Drawings shown in the Con-
trols Manual.
f) Tailpipe, Nozzle & Nozzle Housing - Removal
9“Overhaul” of this Manual.
g) Jet Unit Paintwork.
• The main body of the Jet Unit is constructed from silicon-
aluminium allow (LM6) which is resistant to corrosion
from salt water.
• The castings are finished in a polyurethane paint. Period-
ic cleaning down, wire-brushing and repainting may be
necessary depending on water conditions prevailing, and
extent of use.
• When the vessel is on a slip, preferably annually, the
complete Jet Unit should be inspected internally and ex-
ternally for faults, corrosion, or breakage’s. Clean down
and repaint the castings where necessary.
h) Refit Components.
• Refit components in accordance with the Overhaul Sec-
tion of this Manual. Follow the recommendations on
Drawing “85018 Recommendation for Lubricants & Oils”
for Bearing Housing lubricants and hydraulic fluids. Refer
to Drawing “85113 Recommendations for Fastener Lock-
ing, Torques and Thread Lubrication” for thread tighten-
ing torques, Joint lubrication, thread and joint locking.
i) Insulation Checks (Steel Hulls Only)
• Carry out Insulation Checks in accordance with Section
4.3.2“Checking the Insulation” monthly.
AMENDMENT 8 21/05/02 8.7

8 MAINTENANCE
HJ-322
8.6 TOOLS
8.6 TOOLS
ANTI FOULING PAINTS
DO NOT USE COPPER OXIDE BASED 8.6.1 Standard Recommended
ANTI-FOULING PAINTS. LEAVE ALL Tools
UNPAINTED. DO NOT PAINT OVER THE
THE FOLLOWING TOOLS ARE REQUIRED FOR
ANODES.
NORMAL MAINTENANCE ACTIVITIES:
1. Torque Wrench. ¾"sq/dr.
ANTI-SEIZE COMPOUNDS 2. Torque Wrench. ½" sq/dr.
DO NOT USE ANTI-SEIZE COMPOUNDS 3. Ratchet, Torque Bar And Short Extension ½" sq/
WHICH ARE BASED ON GRAPHITE, NICKEL dr.
OR COPPER FLAKES - THESE WILL CAUSE 4. Sockets A/F ½" sq/dr, 13 mm, 19 mm, 24 mm.
CAUTION
5. Spanners A/F. 1 x 9 mm, 2 x 17 mm, 1 x 24 mm.
AVAILABLE FOR ALUMINIUM. 6. Allen Keys 1 x 6 mm and 1 x 8 mm.
If excessive wear or damage has been found during 7. Pliers Long Nose.
the examination of the Jet Unit, then undertake the 8. Screw Driver Large, Flat Blade.
appropriate overhaul procedures as described in 9. Mallet, Rubber.
Section 9“Overhaul” Schedule the next
maintenance period to suit the conditions found
during this inspection, using the following
8.6.2 Special Tools
guidelines: Refer to Drawing “HJ-322-11-000 Tool Kits. Sht 1”.
1. Decrease the time between each maintenance
interval the if amount of dirt and sand in the
water increases.
2. Increase the time between each maintenance
interval if amount of dirt and sand in water
decreases.
3. Decrease interval if excessive wear was found in
the Jet Unit internal inspection refer to Section
8.5“Jet Unit Servicing Details”. Item 15.
4. Increase interval if minimal wear was found at
the Jet Unit internal inspection refer to Section
8.5“Jet Unit Servicing Details”. Item 15.
8.8 AMENDMENT 8 21/05/02

8 MAINTENANCE
HJ-322
8.7 THREADED FASTENERS
8.7 THREADED FASTENERS 1. Most applications are described on the Drawings

“Appendix-2: Loctite Application Guide Chart - All
Refer to Drawing “85113 Recommendations for Fas- Jets”.
tener Locking, Torques and Thread Lubrication”.
2. Special applications will be shown on the
relevant Assembly Drawings.
TIGHTENING TORQUES:
ENSURE THAT ALL THREADED FASTENERS
ARE TIGHTENED TO THE CORRECT 8.8 RECOMMENDED
CAUTION TORQUE AS DESCRIBED IN DRAWING LUBRICANTS
85113 OR THE RELEVANT ASSEMBLY
Recommended Oils and lubricants required are
DRAWINGS.
specified on Drawing “85018 Recommendation for
Lubricants & Oils” in this Manual.
TIGHTENING TORQUES FOR THREADED FASTEN-
ERS NOTE: Do not use brake fluid or heavier viscosity
oils.
1. The tightening torques for standard fasteners are
given on the drawing referenced at the start of
this section.
ANTI-SEIZE COMPOUNDS
2. The tightening torques for special fasteners are DO NOT USE ANTI-SEIZE COMPOUNDS
shown on the relevant drawings, and also in Ta- WHICH ARE BASED ON GRAPHITE, NICKEL
ble 8:“Special Fasteners - HJ-322 Jet”. OR COPPER FLAKES - THESE WILL CAUSE
CAUTION
3. Ensure that the recommended tightening torques CORROSION. ANTI-SEIZE COMPOUNDS,
are always used. USUALLY CONTAINING ZINC FLAKES, ARE
Table 8: Special Fasteners - HJ-322 Jet
TORQUE
ITEMS
NM LBS/FT
Reverse Duct Pivot Pins. 675 510
Nozzle Pivot Pins. 350 260
Impeller Nut. 600 440
Impeller Nut Set Screw 8 6
Coupling Nut. 250 185
Bearing Locknut KMT 11 270 200
KMT Locknut Set Screws 12 9
Reverse Cylinder Retaining 40 30
Nut.
All other Nuts to be torque loaded as per Draw-
ing “85113 Recommendations for Fastener Lock-
ing, Torques and Thread Lubrication”.
THREAD LOCKING AGENTS:—Most fasteners

require thread locking agents to prevent loosening.
AMENDMENT 15 31/03/04 8.9

8 MAINTENANCE
HJ-322
8.8 RECOMMENDED LUBRICANTS
8.10 AMENDMENT 8 21/05/02

Section 9
OVERHAUL
NOTE: The Maintenance operations detailed in this OVERHAUL PROCEDURE:—The following

Section should be carried out when the procedure describes the main activities when
Vessel is on a Slip or in Dry Dock. carrying out a complete overhaul, but can be
Overhaul of the Jet Unit should only be carried out used to plan any other type of overhaul.
after an examination indicates the need for an 1. Overhaul the Driveshaft (not described) (Refer to
overhaul. Refer to Section 8“Maintenance” for manufacturers manual).
details of how to examine the Jet Unit.
2. Overhaul the Reverse Assembly.
The Overhaul Section of the Controls Manual
contains additional information. 3. Overhaul the Steering Assembly.
The following overhaul procedures can be 4. Overhaul and refit the Bearing Housing area of
carried out on this Jet Unit: Jet Unit.
1. Reverse Assembly Removal and Overhaul. 5. Overhaul and refit the Tailpipe area of Jet Unit.
Sect.“9.2”. 6. Overhaul and refit the Transom Plate.
2. Reverse Cylinder Overhaul. Sect.“9.2.4”. 7. Refit the Steering Assembly.
3. Steering Assembly Removal and Overhaul. 8. Refit the Reverse Assembly.
Sect.“9.4”. 9. Refit the Driveshaft (not described).
4. Tailpipe Area Overhaul. Sect.“9.8”.
5. Bearing Housing Assembly ON COMPLETION OF OVERHAUL:—Perform the
Overhaul.Sect.“9.6”. appropriate commissioning of the Jet Unit as
described in this Jet Unit Manual Section 6“Com-
PRIOR TO COMMENCEMENT OF OVERHAUL:— missioning”.
Disconnect and remove all control equipment COMMISSIONING THE JET UNIT.
attached to components being overhauled. This
It is important that a commissioning of the vessel is
prevents damage to the less robust control
carried out on completion of an overhaul activity as
equipment.
adjustments and connections may have been
Take care to identify electrical or hydraulic altered during the overhaul operation.
connectors so they can be correctly replaced.
Cover all connectors to prevent entry of dirt or loss COMMISSIONING THE CONTROLS SYSTEM.
of hydraulic oil. Perform the appropriate commissioning of the
Controls System as described in the Controls
Manual supplied with this Jet Unit.
TOOLS:—All special tools required for the overhaul

of the Jet Unit are shown on Drawing “HJ-322-11-
000 Tool Kits. Sht 1”.
AMENDMENT 9 24/01/03 9.1

9 OVERHAUL
HJ-322
9.1 GENERAL INFORMATION
9.1 GENERAL INFORMATION 9.2 REVERSE ASSEMBLY

REMOVAL AND OVERHAUL
CARE OF JET UNIT PAINTWORK:—All castings on
the Jet Unit are of Silicon-Aluminium Alloy (LM6) NOTE:
which exhibits good resistance to salt water
1. The Maintenance operations detailed in this
corrosion.
Section should be carried out when the
Vessel is slipped.
ANTI FOULING PAINTS 2. For fault finding with the Reverse System,
DO NOT USE COPPER OXIDE BASED refer to the Controls Manual supplied with
this Jet Unit.
CAUTION STAINLESS STEEL PARTS POLISHED AND 3. For the overhaul of the Reverse Cylinder
UNPAINTED. DO NOT PAINT OVER THE refer to Section 9.2.4“Reverse Cylinder
ANODES. Overhaul” in this Manual.
9.2.1 Reverse Duct Removal

ANTI-SEIZE COMPOUNDS Refer to Drawing “HJ-322-07-001 Reverse Assem-
DO NOT USE ANTI-SEIZE COMPOUNDS bly. Sht 1” and “HJ-322-07-001 Reverse Assembly.
WHICH ARE BASED ON GRAPHITE, NICKEL Sht 2”.
OR COPPER FLAKES - THESE WILL CAUSE
CAUTION 1. Disconnect any Sensors attached to the Reverse
Cylinder. Refer to the Overhaul Section of the
Controls Manual supplied with this Jet Unit.
2. Whilst supporting the Reverse Duct with suitable
approved lifting equipment and a lifting sling
CARE OF STAINLESS STEEL PARTS:—Leave all attached to the Reverse Duct, disconnect the
stainless steel parts polished and unpainted. Reverse Cylinder from the Reverse Duct [25] by
removing the Split Pin [22] from the Hydraulic
ANODES:—Leave all Anodes unpainted. Cylinder Connecting Pin [21].
3. Take the weight of the Reverse Duct and
withdraw the Reverse Cylinder Connecting Pin
[21].
4. Move the Reverse Duct through its full range if
movement to check for stiffness or wear in the
Reverse Duct Cylinder Pin Bushes [24] located in
the inner faces of the Reverse Cylinder
attachment point on the Reverse Duct.
5. Lower the Reverse Duct.
6. While supporting the Reverse Duct arms, remove
the Reverse Duct Pivot Pins [28] and Special Poly
Washers [29].
7. Remove the Reverse Duct, taking care not to
damage the Reverse Duct Shouldered Bushes [27]
located in on the inner faces of the Reverse Duct
Arms.
9.2 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.2 REVERSE ASSEMBLY REMOVAL AND OVERHAUL
9.2.2 Reverse Duct Overhaul REPLACING THE REVERSE DUCT ANODES [30]:—
Refer to Drawing “HJ-322-07-001 Reverse Assem- Refer to Drawing “HJ-322-13-002 Anode Location
bly. Sht 1” and “HJ-322-07-001 Reverse Assembly. Drawing”. Visually check the Anodes [30] attached
Sht 2”. to the Reverse Duct Arms. If these Anodes are less
than half of their original size, they should be
If the Reverse Duct Shouldered Bushes [27] and
replaced. To replace these anodes carry out the
Special Poly Washers [29] fitted in the Reverse Duct
following actions :-
Arms, are worn or damaged, these should be
replaced. 1. Remove the Nuts [33] and Spring Washers [32]
from Studs [31] securing the Anodes [30] to the
REPLACING THE REVERSE DUCT SHOULDERED Reverse Duct Arm.
BUSHES [27]: 2. Remove Anode [30] from the Reverse Duct Arm.
1. Prior to re-fitting the Reverse Duct, the 3. The mating surfaces of the Anode / Reverse Duct
Shouldered Bushes [27] and Special Washers [29] Arm should be scraped clean to ensure a good
should be checked and replaced if required. electrical contact.
2. The Shouldered Bush [27] is normally a loose fit 4. Fit new Anode [30] and attach to the Studs [31]
over the Pivot Pins [28] and the inside diameter of with Nuts [33] and Spring Washers [32].
the bush should be round (not oval) to within 5. Torque load to the recommended torque.
approx 0.5 mm.
6. Carry out Items 1 to 5 above to replace the
3. Check that the threads on the Reverse Duct Pivot second Anode.
Pins [28] are free from burrs.
4. If replacing the Shouldered Bushes [27], carry out 9.2.3 Reverse Cylinder Removal
a) The bore in the Reverse Duct Arms must be Refer to Drawing “HJ-322-07-001 Reverse Assem-
cleaned of paint and corrosion deposits and bly. Sht 1” and “HJ-322-07-001 Reverse Assembly.
painted with a Zinc Chromate Etch Primer. Sht 2”.
b) When the paint is dry, coat the bore of the The Reverse Cylinder need only be dismantled if it
Reverse Duct Arms and the outer surfaces of is suspected that a seal has failed and hydraulic
the Bushes [27] with a smear of grease. oil is found leaking along the Piston Shaft
c) Press the new Bushes into the Reverse Duct Assembly from either end of the cylinder. This
Arms. Wipe off any surplus grease. indicates that the Piston Shaft Seals are defective
and must be replaced.
5. Should the Reverse Duct Threaded Bush [26],
fitted to the Tailpipe, require replacement, refer Also refer to the Controls Manual Overhaul Section
to Section 9.8.2“Tailpipe Area - Dismantling”. for information on the Reverse Assembly.
1. With the Reverse Duct disconnected from the
REPLACING THE REVERSE CYLINDER ATTACH- Reverse Cylinder, disconnect and fit blanking
MENT PIN BUSHES [24]: plugs to the hydraulic hoses attached to the
Reverse Cylinder.
1. If replacing the Shouldered Bushes [24], carry out
the following actions:- 2. From outside the vessel, remove the Reverse
a) The bore in the Reverse Duct Attachment Cylinder Retaining Nut [17], Reverse Cylinder
Point must be cleaned of old Loctite, paint and Mount Washer [18] and the Resilient Mount [9]
corrosion deposits and painted with a Zinc from the Reverse Cylinder Front Head Extension
Chromate Etch Primer. [7] / Transom Plate Interface.
b) Coat the outer surfaces of Bushes [24] and the 3. From inside the vessel, withdraw the Reverse
Reverse Duct attachment point bore with Cylinder from the Transom ensuring that the
Loctite 325. Resilient Mount [8] and O Ring [20] are also
c) Press the new Bushes into the Reverse Duct removed.
attachment point, ensuring that the shoulder 4. Refit the Reverse Cylinder Retaining Nut [17] and
of the Bush is fitted on the inside of the Reverse Cylinder Mount Washer [18] to the
attachment point. Rotate the Bushes twice to Reverse Cylinder to prevent loss.
distribute the Loctite evenly over the surfaces.
Wipe off any surplus Loctite. 5. The Reverse Cylinder can now be removed from
the vessel for further in-depth maintenance.
AMENDMENT 8 21/05/02 9.3

9 OVERHAUL
HJ-322
9.2 REVERSE ASSEMBLY REMOVAL AND OVERHAUL
9.2.4 Reverse Cylinder Overhaul NOTE: The Reverse Cylinder Shaft Piston Assembly
is not to be dismantled further and should
Refer to Drawing “HJ-322-07-001 Reverse Assem-
only be replaced as a complete item.
Sht 2”. 11.Thoroughly clean and inspect all components for
wear and damage and replace as required.
DISMANTLING:
RE-ASSEMBLY:
NOTE: This operation should be carried out in a Refer to Drawing “HJ-322-07-001 Reverse Assem-
clean workshop environment where the bly. Sht 1” and “HJ-322-07-001 Reverse Assembly.
cleanliness of components can be Sht 2”.
maintained. Recommended Oils and Greases are to be used for
1. With the Reverse Cylinder removed from the assembly of the Reverse Assembly.
vessel and taken to a clean workshop 1. Grease and fit new 'O' Ring Seals [11], Shaft Seals
environment. [12] and Wiper Seals [14] to the Front and Back
2. Remove Nuts [6] and Spring Washers [5] from the Heads using BP Energrease MM EP 2 or
Studs [4] retaining the Back Head [3] to the equivalent. Ensure that the Shaft and Wiper Seals
Cylinder [2]. are correctly fitted as shown in the referenced
3. Remove the Back Head, Cylinder, Shaft / Piston drawing above.
Assembly [1] and the Front Head off Studs [4] 2. Fit the Resilient Mount [8] to the Front Head
attached to the Front Head Extension [7]. Extension [7] ensuring that the Resilient Mount is
4. The Nipples [15] fitted to the Reverse Cylinder correctly fitted as shown in the referenced
Front Head and Back Head can be left fitted drawing above.
unless they are leaking or require replacing. 3. Grease and fit a new 'O' Ring [20] to the seal
5. If the Nipples [15] are removed, replace the groove in the tail of the Front Head Extension [7]
Bonded Seals [16] before refitting the Nipples [15] using BP Energrease MM EP 2 or equivalent.
to the Reverse Cylinder. 4. Grease and fit a new 'O' Ring [10] to the recess at
6. The Grease Nipple [34] fitted to the Front Head the front of the Front Head Extension using BP
Extension [7] can be left fitted unless it requires Energrease MM EP 2 or equivalent.
replacing. 5. Grease and fit a new Piston Seal [13] to the
7. Remove and discard the following O Rings and Piston/Shaft Assembly [1].
Seals from the Front / Back Head [3]:- 6. Fit a new Bush [19] to the Reverse Cylinder
• Shaft Seal [12]. Retaining Nut [17].
• Wiper Seal [14]. 7. Fit a new Wiper Seal [14] to the Reverse Cylinder
• ‘O’ Ring [11]. Retaining Nut [17], using BP Energrease MM EP
8. Remove and discard the following O Rings from 2 or equivalent, ensuring that the Wiper Seal is
the Front Head Extension [7]:- correctly fitted as shown in the referenced
• ‘O’ Ring [20]. drawing above.
• ‘O’ Ring [10]. 8. Ensure that Studs [4] are still fitted to the Front
9. Remove and discard the following Bushes and Head Extension [7]. If the 4 x threaded Reverse
Seals from the Reverse Cylinder Retaining Nut Cylinder Studs [4] require refitting to the Front
[17]:- Head Extension [7], refit using Loctite 262 to one
• Wiper Seal [14]. end of the Stud and tighten into the Front Head.
• Bush [19]. 9. Fit the Front Head over the Studs [4] ensuring
10.Remove and discard the following Seal from the that the Nipple [15] on Cylinder Port ‘A’ fitted to
Shaft / Piston Assembly [1]:- the Front Head, is aligned with the Grease Nipple
• Piston Seal [13]. [34] fitted to the Front Head Extension.
10.Grease both outside ends of the Cylinder [2]
using BP Energrease MM EP 2 or equivalent and
push fit one end of the Cylinder into the Front
Head [3].
9.4 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.3 REVERSE ASSEMBLY RE-FITTING
11.Lubricate the Shaft/Piston Assembly [1] using a 9.3 REVERSE ASSEMBLY RE-
mineral based oil such as the recommended
hydraulic oils shown in Drawing “85018 Recom- FITTING
mendation for Lubricants & Oils”.
12.Fit the Shaft/Piston Assembly [1] into the 9.3.1 Reverse Cylinder: Refit to the
Cylinder ensuring that the Piston Shaft end with Jet Unit
the Reverse Duct attachment point is passed
through the Front Head. Take care not to
dislodge the Seals [12] and [14] fitted in the Front
Sht 2”.
Head and Piston Seal [13] fitted to the Piston.
Push the Piston into the Cylinder. Also refer to the Controls Manual Overhaul
Section for additional information on the Reverse
13.Fit the Back Head over the Studs [4] and over the System.
end of the Cylinder [2] ensuring that the Seal [11]
and Seals [12] and [14] are not displaced. 1. Remove the Retaining Nut [17], Reverse Cylinder
Mount Washer [18] and Resilient Mount [9] from
14.Ensure that the Nipple [15] on Cylinder Port ‘B’ the Reverse Cylinder Front Head Extension [17].
fitted to the Back Head is in alignment with the
Nipple fitted to the Front Head at Cylinder Port
FROM INSIDE THE VESSEL:
‘A’ and the Grease Nipple [34] fitted to the Front
Head Extension. 2. Ensure that the Resilient Mount [8] has been
correctly fitted to the Front Head Extension.
15.Secure the Front Head, Cylinder and Back Head
in position with Spring Washers [5] and Nuts [6]. 3. Ensure that a new "O" Seal [20] has been fitted to
Torque load to the recommended torque. the Front Head Extension.
16.Fit the Resilient Mount [9] and Reverse Cylinder 4. Lightly smear the Front Head, from the "O" Ring
Mount Washer [18] onto the rear of the Front [15] to the start of the threaded portion of the
Head Extension [7] and ensure that they are Front Head Extension with a marine grease. Do
secured loosely in position with the Reverse not grease the threads of the Front Head
Cylinder Retaining Nut [17]. Extension.
17.Take care not to dislodge Seal [14] and Bush [19] 5. Ensure that Reverse Cylinder locating Capscrew
fitted to the Retaining Nut when fitting the [23] and Spring Washer [32] are fitted to the
Retaining Nut over the Piston Shaft [1]. inside of the Transom Plate. If these are not
fitted, refit using Loctite 262 and torque load to
18.If possible workshop test the Reverse Cylinder
the correct torque.
before reinstalling into the vessel. The workshop
Test Pressure for the Cylinder is 2500 psi (173 6. Pass the Front Head Extension part of the
Bar). Reverse Cylinder through the Transom Plate until
the shoulder with the Resilient Mount [8] is firmly
19.The Reverse Cylinder can now be refitted to the
pushed up against the Transom Plate and the
Jet Unit.
cutout in the Front Head Extension is correctly
located with the locating Capscrew [23] fitted to
the inside of the Transom. Port ‘A and Port ‘B’ on
the Reverse Cylinder should be facing
uppermost.
FROM OUTSIDE THE VESSEL:

7. Correctly fit the Resilient Mount [9] and the
Reverse Cylinder Mount Washer [18] over the
Reverse Cylinder Shaft as shown in drawing “HJ-
322-07-001 Reverse Assembly. Sht 1”.
8. Pass the Resilient Mount [9] and Reverse Cylinder
Mount Washer [18] up the Cylinder Shaft and
into the recess in the Transom Plate.
AMENDMENT 9 24/01/03 9.5

9 OVERHAUL
HJ-322
9.3 REVERSE ASSEMBLY RE-FITTING
9. Lightly smear the Cylinder Shaft with grease and 8. Insert the Pivot Pins ensuring that the Bushes [27]
fit the Reverse Cylinder Retaining Nut [17] down and Special Washers [29] are correctly located.
the Shaft taking care not to dislodge Seal [14] and 9. Tighten the Reverse Duct Pivot Pins [28] to the
Bush [19] fitted in the Retaining Nut [17]. recommended torque. Torque load to 675 Nm
10.Screw the Retaining Nut [17] onto the Front Head (510 lbs/ft). Section 8.7“Threaded Fasteners”
Extension by a few threads to retain the Reverse refers.
Cylinder in position until the Reverse Cylinder is 10.Raise and support the Reverse Duct and align the
connected to the Reverse Duct. Reverse Cylinder Piston Shaft Assembly [1] with
11.Ensure that the Resilient Mounts are correctly the attachment point on the Reverse Duct.
positioned in the Transom. 11.Fit Connecting Pin [21] through the Reverse Duct
attachment point and through the attachment
FROM INSIDE THE VESSEL: hole in the end of the Reverse Shaft, ensuring that
12.Connect Hose connections to the Reverse the Bushes [24] in the Reverse Duct attachment
Cylinder in accordance with the Controls Manual point are secure and in their correct position.
Hose Connection Drawings. 12.Secure Connecting Pin [21] in position with Split
13.Grease the Reverse Cylinder Piston Shaft Pin [22].
Assembly via the Grease Nipple [34] located on 13.Slacken off the Reverse Cylinder Retaining Nut
the Front Head Extension. Lubricate until grease [17] and remove from the threaded portion of the
is seen escaping around Seal [14] at the rear of Front Head Extension [7].
the Reverse Cylinder Retaining Nut [17] located
14.Clean off the threads and apply Loctite 569 to the
on the outside of the Transom.
threads. Tighten the Reverse Cylinder Retaining
Nut [17] onto the Front Head Extension [7]
9.3.2 Reverse Duct: Refit to the Jet ensuring that the Resilient Mounts remain in
Unit position and that the Cylinder is located in the
correct position by the Capscrew [23] fitted to the
inside of the Jet Unit Intake Flange.
Sht 2”. 15.Torque load the Reverse Cylinder Retaining
Nut [17] to 40 Nm (30 ft/lbs).
REVERSE DUCT: 16.Carry out a full functional check of the Reverse
1. Examine the Shouldered Pivot Bushes [27] and System to ensure correct operation and that the
the Special Washers [29] for wear and damage full range of movement is possible.
and replace if required. Refer to Section
9.2.2“Reverse Duct Overhaul”.
2. Examine the Threaded Bushes [26] fitted to the
Tailpipe, for wear and damage and replace if
required. Refer to Section 9.8.2“Tailpipe Area -
Dismantling”.
3. Ensure that the thread and surfaces of the Pivot
Pins [28] and the Bushes [26] and [27] are clean.
4. Coat threads, Bushes, and Special Washers [29]
with a recommended marine grease.
5. Ensure that the Shouldered Pivot Pin Bushes [27]
are fitted into the Reverse Duct Arms with the
shoulder on the inside of the Reverse Duct Arm.
6. Position the Reverse Duct so that the Pivot Pin
Bushes are aligned with the threaded holes in the
Tailpipe.
7. Fit Special Washers [29] to each of the Pivot Pins
[28] prior to fitting the pins to the Reverse Duct
Arms.
9.6 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.4 STEERING ASSEMBLY REMOVAL AND OVERHAUL
9.4 STEERING ASSEMBLY 9.4.2 Steering Cylinder Overhaul

REMOVAL AND OVERHAUL The Steering Assembly uses a Seastar Hydraulic
Cylinder to operate the Steering Tiller, refer to the
The Steering Assembly uses a Seastar Hydraulic Seastar Maintenance Manual for any maintenance
Cylinder to operate the Steering Tiller, refer to the required on the Steering Cylinder.
Seastar Maintenance Manual for any maintenance
required on the Steering Cylinder.
9.4.3 Steering Shaft Removal
9.4.1 Steering Cylinder Removal Refer to Drawing “HJ-322-06-000 Steering Assem-
Refer to Drawing “HJ-322-06-000 Steering Assem- 000 Steering Assembly General Arrangement. Sht 2”.
000 Steering Assembly General Arrangement. Sht 2”.
INSPECTING THE STEERING SHAFT AND BUSHES:
The Steering Cylinder need only be dismantled if
Ensure that the Steering Tiller [24] has been
it is suspected that a seal has failed and hydraulic
disconnected from the Steering Cylinder.
oil is found leaking along the Piston Rod
Assembly from either end of the cylinder. This 1. Check the Steering Shaft [23] for:-
indicates that the Piston Rod Seals are defective a) Freedom of movement.
and must be replaced. Refer to the Seastar b) Excessive wear in the front, centre and rear
Manual for information on Seal replacement. Steering Shaft Bushes [35].
c) Security of the front and rear Steering Shaft
STEERING CYLINDER REMOVAL: Bush Sleeves [28].
d) Security of the Steering Bush and Seal Housing
1. Disconnect any Sensors attached to the Tiller [26].
[24]. Refer to the Overhaul Section of the e) Worn or damaged Scraper [25] and Seal [27].
Controls Manual. f) Excessive wear in the ball end of the Steering
2. Disconnect the Steering Cylinder hose Crank [20] and the Nozzle Crank Bush [5].
connections from the Seastar Steering Cylinder, 2. Replace the Steering Bushes and Seals if
ensuring that all connections are fitted with damaged or worn.
blanking plugs to prevent the ingress of moisture
and dirt and the leaking of hydraulic oil.
REMOVING THE STEERING SHAFT:
3. Disconnect the Steering Cylinder Rod End from
1. To remove the Steering Crank [20] from the
the Tiller [24].
Steering Shaft [23] remove Nut [15], Spring
4. To remove the Steering Cylinder from the vessel. Washer [16] and Special Washer [22] securing
Refer to Drawing CT-SJK-02-004 in the the Cotter [21] to the Steering Crank.
Controls Manual.
2. Push the Steering Shaft [23] forwards into the
5. Remove Nuts [6] and Spring Washers [7] from vessel and slide the Steering Crank off the end of
Studs [5] securing the Steering Cylinder to the the Steering Shaft.
Steering Bracket .
3. Remove the Steering Crank [20] from the Nozzle
6. Remove the Steering Cylinder from the Steering Crank Bush [5].
Bracket.
STEERING BRACKET REMOVAL:

7. Remove the Nuts [8] and Spring Washers [3] from
the Studs [2] securing the Steering Cylinder
Bracket to the top of the Intake.
8. Remove the Steering Cylinder Bracket from the
Studs [2].
9. Check all components for signs of corrosion,
wear and damage and replace as required. Refer
to the Seastar Manual for information on Seal
replacement.
AMENDMENT 8 21/05/02 9.7

9 OVERHAUL
HJ-322
9.4.4 Nozzle Assembly Removal NOTE: When removing the lower Pivot Pin, take
care not to lose the Thrust Washer [6] fitted
Refer to Drawing “HJ-322-06-000 Steering Assem-
inside the Steering Pivot Bush [34].
000 Steering Assembly General Arrangement. Sht 2”. 5. Hook out the Thrust Washer [6] fitted inside the
upper Steering Pivot Bush [34].
1. Check the Steering Crank Bush [5] for security
and wear. Replace if loose or worn. 6. Push the top of the Nozzle upwards to release the
lower Nozzle Bush from the Nozzle Housing.
2. Rotate the Nozzle [1] through its full arc of travel
to check for stiffness or wear in the Steering Pivot 7. Pull the Nozzle rearwards to remove the Nozzle
Bushes [34] and Thrust Washers [6]. from the Nozzle Housing.
8. Clean all parts thoroughly and examine for wear
NOZZLE / NOZZLE HOUSING REMOVAL COM- and damage and replace as necessary.
PLETE:
INSPECTING THE STEERING NOZZLE [1] AND
NOTE: The Nozzle, Nozzle Housing and Nozzle NOZZLE COMPONENTS:—Examine the following
Insert should be removed as a complete components for wear or damage and repair or
assembly. To remove, carry out the following replace as necessary:-
actions:-
1. Steering Pivot Bush Sleeve [7]. Replace if worn
1. To remove the Nozzle, Nozzle Housing and or damaged.
Nozzle Insert complete, remove the Nuts [54],
Spring Washers [59] and Flat Washers [48] from 2. Pivot Pins [8]. Replace if worn or damaged.
the Studs [45] securing the Nozzle Housing and 3. Nozzle Crank Bush [5]. Check for wear or
Nozzle Insert to the Tailpipe. Drawings “HJ- damage and replace as required.
322-01-000 Basic Jet Assemblies Standard & Dry 4. Nozzle Insert [3]. Examine for damage and
Run. Sht 1” and “HJ-322-01-000 Basic Jet As- corrosion. Repair or replace as required.
semblies Standard & Dry Run. Sht 2” refer.
5. Steering Pivot Pin Bush [34]. Check for wear
2. Hit the Nozzle Housing sideways with a Soft and damage. Replace.
Hammer and remove the Nozzle Housing
6. Steering Arm [4]. Check for wear and damage.
complete with Nozzle and Nozzle Insert [3] off
Examine to ensure that the Steering Arm has not
the Tailpipe.
been bent or distorted from impact damage.
3. Remove the Nozzle Insert from the rear of the Replace if excessively damaged or worn.
Nozzle Housing and examine for wear, corrosion
7. Steering Crank [20]. Check the condition of the
or damage and repair or replace as necessary.
Steering Crank Ball, replace if excessively worn.
REMOVING THE NOZZLE FROM THE NOZZLE 8. Thrust Washers [6]. Check for wear or damage.
HOUSING:—To remove the Nozzle from the Nozzle Replace if worn.
Housing, carry out the following actions:- 9. Lock Washers [9]. Discard and replace once
1. Remove the JT Steering Lip Seals [29] as shown removed. Do not re-use.
previously in this section. 10.Cotter [21]. Check the condition. Replace if
2. Remove Nuts [18] and Spring Washers [19] from damaged.
Studs [17] securing the Steering Arm [4] to the 11.JT Steering Lip Seals [29]. Check the condition
Nozzle and remove the Steering Arm. and security of the Lip Seals. Replace if damaged
3. Using a flat bladed screwdriver, flatten off the tab or worn.
on the Tab Washer [9] retaining the Pivot Pins [8] 12.Anode [10]. Check the condition. Replace if
at the top and bottom of the Nozzle [1]. more than 2/3 rds corroded.
4. Whilst supporting the Nozzle, unscrew and
remove the upper and lower Pivot Pins [8] and
Tab Washers [9].
9.8 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.4.5 Nozzle Assembly Overhaul REPLACING THE STEERING PIVOT PIN BUSHES
[34] AND SLEEVES [7]:
bly General Arrangement. Sht 1” and “HJ-322-06- The Nozzle is fitted with two Pivot Pin Bushes [34]
000 Steering Assembly General Arrangement. Sht 2”. and Sleeves [7] to accommodate the Steering Nozzle
Pivot Pins [8].
REPLACING THE JT STEERING LIP SEALS [29]: NOTE: The Sleeves [7] need only be replaced if the
The JT Steering Lip Seals can be replaced without spherical surface shows signs of wear.
separating the Nozzle from the Nozzle Housing. Inspect the Steering Pivot Bushes [34] and Sleeves
The Nozzle / Nozzle Housing must be removed [7] in the Nozzle. These should be replaced if any
from the Tailpipe to carry out Lip Seal signs of wear or damage is found.
replacement.
1. The Nozzle should be taken to a workshop
To replace the JT Steering Lip Seals [29], carry out
facility and removed from the Nozzle Housing as
shown at the start of this Section.
1. With the JT Steering Nozzle [1] and the Nozzle
2. The Steering Pivot Bushes [34] are a press fit into
Housing [2] removed complete from the Jet Unit
the Sleeves [7]. These may need to be split and
Tailpipe and with the Nozzle and Nozzle
peeled out to remove from the Steering Pivot
Housing placed face down on a work bench,
Bush Sleeves [7].
unscrew and remove the 4 Cap Screws [30] and
Spring Washers [31] at the rear of the Nozzle 3. If the Sleeves [7] require replacement, using a
securing the 2 Lip Seals [29] to the rear face of the suitable Press, carefully press out the old Sleeves,
Nozzle. It may be necessary to apply light heat to the
Nozzle in the area of the Sleeves to break the
2. Carefully remove the 2 Lip Seals [29] and discard.
Loctite Seal.
3. Replace with 2 new Lip Seals, ensuring that the
4. Ensure that the Pivot Bush bores are cleaned of
JT Steering Lip Seals [29] are fitted with the
old loctite and paint.
overhang of the Seal facing outwards when the
Seal is fitted to the JT Steering Nozzle [1]. (The 5. Repaint the bore using a zinc chromate etch
lip on the seal will be facing towards the front of primer and repaint.
the Jet Unit when completely assembled to the 6. Apply a thin coat of Loctite 7075 to the outside of
Nozzle Housing [2]). the Flanged Sleeve [7] and allow to dry.
4. Refit the 2 new Lip Seals [29] in position.
NOTE: Activator 7075 must be used otherwise
NOTE: There is some movement in the Lip Seals [29] Loctite 325 will not cure. Do Not apply
when loosely secured with Cap Screws [30], Activator 7075 to the painted Nozzle
this is to allow the Lip Seals to be adjusted to Housing bore.
fit the inside of the Nozzle Housing [2]. 7. Apply Loctite 325 to the Flanged Sleeve [7],
5. Thoroughly clean the threads of the Cap Screws 8. Press the new Flanged Sleeve [7] fully home into
[30] and apply Loctite 222. the Nozzle, ensuring that the Sleeves are pressed
6. Secure the JT Steering Lip Seals [29] in position in evenly and are fully home in the Nozzle.
using Cap Screws [30] and Spring Washers [31]. 9. Clean off any surplus Loctite from around the
7. Adjust the Lip Seal [29] to provide a 0.4mm to replacement Sleeves.
0.6mm gap to the spherical inner surface of the 10.Fit new Steering Pivot Bushes [34] and push fully
Nozzle Housing [2]. Tightened to the home into the Sleeves [7] already fitted to the
recommended torque. Steering Nozzle [1].
8. Refit the JT Steering Nozzle [1] complete with the
Nozzle Housing [2] to the Tailpipe as shown in
Section “Nozzle Refit to the Nozzle Housing:”.
AMENDMENT 8 21/05/02 9.9

9 OVERHAUL
HJ-322
REPLACING THE REAR STEERING SHAFT BUSH 14.Refit a new Steering Shaft Bush [35] from the rear
[35] AND STEERING SHAFT BUSH SLEEVE [28] FIT- of the jet and press into the Steering Shaft Bush
TED TO THE NOZZLE HOUSING: Sleeve.
1. Examine the Steering Shaft Bush [35] and the
Steering Shaft Bush Sleeve [28] located on the REPLACING THE FORWARD STEERING SHAFT
Nozzle Housing. BUSH [35] AND STEERING SHAFT BUSH SLEEVE
[28] FITTED TO THE STEERING BRACKET AT-
2. To replace the Steering Shaft Bush [35], push out
TACHED TO THE JET UNIT INTAKE:
the Bush [35] rearwards from the Sleeve [28].
Refer to the Controls Manual supplied with this Jet
3. Refit a new Steering Shaft Bush [35] from the Unit for the correct Steering Mounting Bracket
rear. Drawing “HJ-322-06-000 Steering Assem- details.
bly General Arrangement. Sht 1” refers.
1. Examine the Steering Shaft Bush [35] and the
4. The Steering Shaft Bush Sleeve [28] should not Steering Shaft Bush Sleeve [28] located on the
require replacement. Should it be necessary to Nozzle Housing.
replace the Sleeve [28], the Steering Shaft should
be removed from the Jet Unit as shown in Section 2. The Steering Shaft Bush Sleeve [28] should not
9.4.3“Steering Shaft Removal”. require replacement. Should it be necessary to
replace the Sleeve [28], the Steering Shaft should
5. To replace the Steering Shaft Bush Sleeve [28], be removed from the Jet Unit as shown in Section
ensure that the Steering Shaft Bush [35] has been 9.4.3“Steering Shaft Removal”.
removed as shown above.
3. To replace the Steering Shaft Bush Sleeve [28],
6. Press out the Steering Shaft Bush Sleeve ensure that the Steering Shaft Bush [35] has been
rearwards from the boss on the Nozzle Housing. removed as shown above.
7. Clean out the bore of old loctite and activator. 4. Press out the Steering Shaft Bush Sleeve from the
8. Remove all evidence of paint from inside the boss on the Steering Bracket.
bore. 5. Clean out the bore of old loctite and activator.
NOTE: The bore in the Steering Housing boss is 6. Remove all evidence of paint from inside the
NOT to be painted. bore.
9. Apply Loctite Activator 7075 to the outside of the NOTE: The bore in the Steering Bracket boss is NOT
Steering Shaft Bush Sleeve [28] and allow to dry. to be painted.
Ensure that the outside of the Steering Shaft Bush
Sleeve is completely covered in activator. Do 7. Apply Loctite Activator 7075 to the outside of the
NOT apply activator to the bore of the Nozzle Steering Shaft Bush Sleeve [28] and allow to dry.
Housing. Ensure that the outside of the Steering Shaft Bush
Sleeve is completely covered in activator. Do
NOTE: Loctite Activator 7075 must be used to refit NOT apply activator to the bore of the Steering
the Steering Shaft Bush Sleeve otherwise the Bracket boss.
Loctite 325 will not cure and retain the
Steering Shaft Bush Sleeve in position. NOTE: Loctite Activator 7075 must be used to refit
the Steering Shaft Bush Sleeve otherwise the
10.Apply Loctite 325 to the outside of the of the Loctite 325 will not cure and retain the
Steering Shaft Bush Sleeve [28] and press the Steering Shaft Bush Sleeve in position.
Steering Shaft Bush Sleeve into the bore on the
Nozzle Housing boss. 8. Apply Loctite 325 to the outside of the of the
Steering Shaft Bush Sleeve [28] and press the
11.Rotate the Steering Shaft Bush Sleeve when Steering Shaft Bush Sleeve into the bore on the
fitting to evenly distribute the loctite around the Steering Bracket boss.
bore.
9. Rotate the Steering Shaft Bush Sleeve when fitting
12.Press in the Bush Sleeve ensuring that it is fully to evenly distribute the loctite around the bore.
home in the bore.
10.Press in the Bush Sleeve ensuring that it is fully
13.Wipe off any excess loctite from around the Bush home in the bore and sits flush with the end of
Sleeve. the boss.
9.10 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
11.Wipe off any excess loctite from around the Bush 10.Apply Loctite 262 to the threads of the Set Screw
Sleeve and the bore of the boss. [38] and tighten to retain Steering Bush and Seal
12.Press fit a new Steering Shaft Bush [35] into the Housing [26] in the boss on the Jet Unit Intake.
Steering Shaft Bush Sleeve ensuring that it is fully 11.Smear the the Seal [27] with grease and refit to
home in the bore and sits flush with the end of the recess in the forward end of the Seal Housing
the boss. [26], ensuring that the Seal is fitted correctly.
12.Smear the the Steering Shaft Bush [35] with
REPLACING THE STEERING BUSH AND SEAL grease. Refit the Steering Shaft Bush [35] from
HOUSING [26] AND STEERING SHAFT BUSH [35], the rear, pushing the Bush up against the rear of
SCRAPER SEAL [25] AND SEAL [27] FITTED TO THE the Seal [27] already fitted.
JET UNIT INTAKE:
13.Smear the the Scraper Seal [25] with grease and
The Steering Bush and Seal Housing [26] should refit to the recess in the rear of the Steering Bush
not require replacement: However, should it be and Seal Housing [26], ensuring that the Seal is
necessary to replace the Steering Bush and Seal fitted correctly with the lip facing rearwards.
Housing, the Steering Shaft should be removed from Refer to Drawing “HJ-322-06-000 Steering As-
the Jet Unit as shown in the Jet Unit Product Manual sembly General Arrangement. Sht 1” and “HJ-
at Section 9.4.2“Steering Cylinder Overhaul”. The 322-06-000 Steering Assembly General Arrange-
Steering Bush and Seal Housing should be pressed ment. Sht 2” for correct seal positioning.
out forwards and a new Steering Bush and Seal
Housing fitted. 14.Refit the Steering Shaft as shown in Section
9.5.2“Steering Bracket and Steering Shaft Re-Fit-
1. To replace the Steering Bush and Seal Housing ting”.
[26], remove the Seal [27] from the forward end
of the Seal Housing [26]. NOTE: Ensure that the Seal [27] and the Scraper
2. Remove the Scraper Seal [25] from the rear end of Seal [25] are fitted correctly. Refer to
the Bush & Seal Housing. Drawing “HJ-322-06-000 Steering Assem-
bly General Arrangement. Sht 1”.
3. Push the Steering Shaft Bush [35] forwards out of
the Seal Housing.
REPLACING THE NOZZLE CRANK BUSH [5]:—To
4. Slacken off the Set Screw [38] securing the replace the Nozzle Crank Bush [5], carry out the
Steering Bush and Seal Housing [26] to the Jet following operation:-
Unit Intake.
1. With the Nozzle removed from the Nozzle
5. Press the Steering Bush and Seal Housing [26] Housing and taken to a workshop facility.
forwards out from the Jet Unit Intake.
2. Remove the Steering Arm from the Nozzle as
6. Clean out the bush bores of old loctite and loctite shown in Sub-Section “Removing the Nozzle from
activator. the Nozzle Housing” shown previously in this
7. Apply Loctite Activator 7075 to the outside of the Section.
Steering Bush and Seal Housing [26] and allow to 3. Using a suitable drift or press, carefully push out
dry. the old Nozzle Crank Bush [5] from the Steering
Arm Boss ensuring that the bore is not scored or
NOTE: Loctite Activator 7075 must be used to refit
damaged. It may be necessary to apply light heat
the Steering Bush and Seal Housing
to the Steering Arm Boss in the area of the Nozzle
otherwise the Loctite 680 will not cure and
Crank Bush to break the Loctite Seal.
retain the Steering Bush and Seal Housing
[26] in position. 4. Clean out the bore of the Steering Arm Boss of old
loctite and ensure that the bore is NOT PAINTED.
8. Apply Loctite 680 to the Steering Bush and Seal
Housing bore and press in the Steering Bush and 5. Apply a thin coat of Loctite 7471 to the outside
Seal Housing [26] ensuring that it is fully home in surface of the Bush [5] and allow to dry. Do NOT
the bore. apply Activator to the bore of the Steering Arm
boss.
9. Wipe of and excess Loctite from around the
Steering Bush and Seal Housing.
AMENDMENT 8 21/05/02 9.11

9 OVERHAUL
HJ-322
NOTE: Loctite Activator 7471 must be used to refit REPLACING THE ANODE [10] FITTED TO THE
the Nozzle Crank Bush otherwise the Loctite NOZZLE HOUSING [2]:
680 will not cure and retain the Bush in Refer to Drawing “HJ-322-13-002 Anode Location
position. Drawing”.
6. Apply Loctite 680 to the bore of the Steering Arm 1. Check the Nozzle Anode [10] attached to the
Boss . underside of the Nozzle Housing [2]. Should it be
less than 2/3rds of its original size, it should be
NOTE: There are to be NO dry areas between the replaced.
Crank Bush and the bore of the Steering Arm
Boss once the Crank Bush is fitted. 2. To replace the Nozzle Anode [10], carry out the
following operation:-
7. Carefully press the Crank Bush [5] into the a) Remove Nuts [12] and Spring Washers [13]
Steering Arm boss, ensuring that the Bush is from Studs [11] securing the Anode [10] to the
pressed in evenly and does not protrude above underside of Nozzle Housing [2].
the sides of the Steering Arm. b) Remove the Anode [10] from the underside of
8. Ensure that the Crank Bush [5] is pushed fully the Nozzle Housing.
into the Steering Arm Boss until the Crank Bush c) The mating surfaces of the Anode / Nozzle
is flush with the base of the Steering Arm Boss. Housing should be scraped clean to ensure a
9. Clean off any surplus Loctite from around the good electrical contact.
replacement Bush. d) Fit a new Anode [10] and attach to the Studs
[11] on the underside of the Nozzle Housing
with Nuts [12] and Spring Washers [13].
REPLACING THE ANODE [10] FITTED TO THE
e) Torque load to the recommended torque.
NOZZLE:
Refer to Drawing “HJ-322-13-002 Anode Location 3. If the Anode is still in good condition, ensure that
Drawing”. the Anode is not painted over.
1. Check the Nozzle Anode [10] attached to the 4. Scrub the Anode with a wire brush if a coating of
underside of the Nozzle [1]. Should it be less than corrosion has built up on the Anode.
2/3rds of its original size, it should be replaced.
2. To replace the Nozzle Anode [10], carry out the
following operation:-
a) Remove Nuts [12] and Spring Washers [13]
from Studs [11] securing the Anode [10] to the
underside of Nozzle [1].
b) Remove the Anode [10] from the underside of
the Nozzle.
c) The mating surfaces of the Anode / Nozzle
should be scraped clean to ensure a good
electrical contact.
d) Fit a new Anode [10] and attach to the Studs
[11] on the underside of the Nozzle with Nuts
[12] and Spring Washers [13].
e) Torque load to the recommended torque.
3. If the Anode is still in good condition, ensure that
the Anode is not painted over.
4. Scrub the Anode with a wire brush if a coating of
corrosion has built up on the Anode.
9.12 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.5 STEERING ASSEMBLY RE-FITTING
9.5 STEERING ASSEMBLY RE- 2. Thrust Washers 6 are available in sizes

from 2.5mm to 4.0mm in 0.5mm size
FITTING increase.
9.5.1 Nozzle Assembly Re-Fitting NOZZLE ‘VERTICAL END FLOAT’ ADJUSTMENT:

“HJ-322-06-000 Steering Assembly General Ar- 1. Check to ensure that the Nozzle is centrally
rangement. Sht 1” and “HJ-322-06-000 Steering As- positioned in the Nozzle Housing.
sembly General Arrangement. Sht 2”. 2. Adjust the position of the Nozzle by replacing the
lower Thrust Washer [6] with a larger or smaller
NOZZLE REFIT TO THE NOZZLE HOUSING: Washer until the Nozzle is located centrally
Refer to Drawing “HJ-322-06-000 Steering Assem- within the Steering Housing.
bly General Arrangement. Sht 1” and “HJ-322-06- 3. With the Nozzle located centrally in the Nozzle
000 Steering Assembly General Arrangement. Sht 2”. Housing, check the “Vertical End Float” between
With the Nozzle / Nozzle Housing removed from the the Nozzle and the Nozzle Housing. This should
Jet Unit and placed on a suitable workbench. be “Between 0.2 to 0.7mm”.
1. Ensure that the Nozzle Insert has been refitted to 4. Adjust the “Vertical End Float”, by replacing the
the rear of the Nozzle Housing as shown in upper Thrust Washer [6] with a larger or smaller
Section 9.5.1“Nozzle Assembly Re-Fitting”. Washer until the Nozzle “Vertical End Float” is
2. With the Steering Arm attachment point between 0.2 to 0.7mm.
uppermost, tilt the nose of the Nozzle slightly 5. Once the Nozzle “Vertical End Float” has been
upwards, feed the upper nozzle mounting point checked and adjusted, tighten both Pivot Pins [8]
into the Nozzle Housing. and torque load to 350 Nm (260 lbs/ft).
3. Push down on the nose of the Nozzle ensuring
that the lower nozzle mounting point passes into NOTE: If the JT Steering Lip Seals are to be changed,
the Nozzle Housing. they should be refitted at this point. Refer to
"Replacing the JT Steering Lip Seals [29]" in
4. Align the upper and lower Bushes [34] in the Section 9.4.4“Nozzle Assembly Removal”.
Nozzle with the upper and lower openings in the
Nozzle Housing. 6. Rotate the Nozzle through its full arc of travel to
ensure no stiffness or binding of the Nozzle.
5. Smear the Pivot Pins [8], threads with grease.
7. Bend over the locking tabs on the Tab Washers
6. Refit the lower Thrust Washer [6] into the lower [9] to secure the Pivot Pins in position.
Steering Pivot Bush [34] and retain in position
with marine grease. NOTE: The Nozzle Insert must locate onto the small
7. Fit the lower Pivot Pin [8] fitted with a new Tab Nozzle Insert Location Pin located at the top,
Washer [9] and tighten firmly to retain the rear of the Nozzle Housing when fitting the
Nozzle in position. Do not secure the Tab Washer Nozzle Insert onto the rear of the Nozzle
[9] in position. Housing.
8. Fit the upper Thrust Washer [6] into the upper
Steering Pivot Bush [34] and retain in position NOZZLE AND NOZZLE HOUSING RE-FITTING:
with marine grease. Before re-fitting the Nozzle and Nozzle Housing
to the Tailpipe of the Jet Unit, the Nozzle Insert
9. Fit the upper Pivot Pin [8] fitted with a new Tab
must be refitted to the rear of the Nozzle Housing.
Washer [9] and tighten firmly to retain the
Carry out the following:-
Nozzle in position. Do not secure the Tab Washer
[9] in position. 1. Smear a new O Ring [36] with grease and fit to
the seal groove located at the rear of the Nozzle
NOTE: Insert.
1. The Nozzle “Vertical End Float Adjustment” 2. Offer the Nozzle Insert up to the rear of the
now has to be checked to achieve an end Nozzle Housing, ensuring that the Nozzle Insert
float of 0.2 to 0.7mm between the Steering is correctly orientated as shown in drawings
Nozzle and the Steering Housing. referenced above.
AMENDMENT 16 02/05/04 9.13

9 OVERHAUL
HJ-322
9.5 STEERING ASSEMBLY RE-FITTING
3. Refit the Nozzle complete with Nozzle Housing 4. Reconnect the Steering Cylinder Hose
to the Studs [45] fitted to the rear of the Tailpipe connections to the Steering Cylinder. Refer to
and secure to Studs [45] with Flat Washers [48], the Controls Manual Drawing Package for
Spring Washers [59] and Nuts [54] using Loctite correct Hose connection layout.
243 on the threads of Studs [45]. Torque load 5. Re-connect any Sensors that were previously
Nuts [54] to the recommended torque. disconnected from the Steering Crank. Refer to
the Overhaul Section of the Controls Manual.
9.5.2 Steering Bracket and Steering
Shaft Re-Fitting 9.5.4 Steering Linkages Adjustment
bly General Arrangement. Sht 1” and “HJ-322-06- NOTE: It is important that the Steering Nozzle and
000 Steering Assembly General Arrangement. Sht 2”. the Steering Cylinder are correctly linked so
that at full lock in both directions there are a
1. Refit the Steering Bracket [4] to Studs [17] at the few millimetres clearance between the
top of the Nozzle, secure with Spring Washers Steering Nozzle and the Steering Nozzle
[19] and Nuts [18]. Torque to the correct torque. Housing. Should any foul occur, check for
2. Refit the Nozzle complete with Nozzle Housing worn Bushes in the Steering Nozzle.
and Nozzle Insert, to the Tailpipe of the Jet Unit
and secure to Studs [45] with Spring Washers FOR MULTI JET APPLICATIONS ONLY. If
[59], Flat Washers [48] and Nuts [54]. Torque the Steering Tie Rods have been removed or
load to the recommended torque. replaced, refer to Section 5.5.3”Assembling
3. Smear the ball of the Steering Crank [20] with the Jet Steering Tillers”, 5.5.4”Centreing the
grease and refit into the Steering Crank Bush [5], Jet(s) Steering” and Figure 26:”Twin Jet
ensuring that the Steering Crank is orientated as Arrangement” for information on
shown in the drawings referenced above. installation of the Tie Rods for Multi Jet
applications.
4. Pull the Steering Shaft [23] rearwards. Fit the
Steering Crank onto the end of the Steering Shaft.
5. Refit the Cotter [21] through the Steering Crank
[20] to secure the Crank to the Steering Shaft.
Secure with Special Washer [22], Spring Washer
[16], and Nut [15]. Torque load to the
recommended torque.
6. Reconnect the Steering Tiller [24] to the Steering
Cylinder.
9.5.3 Steering Cylinder Re-Fitting

Refit the Steering Bracket to the Jet Unit Intake. Refer
to Drawing CT-SJK-02-004 in the Controls Manual
supplied with this Jet Unit and the following
information:-
1. Refit the Steering Bracket to Studs [2] located on
the top of the Jet Unit Intake and secure with
Spring Washers [3] and Nuts [8]. Torque load to
the correct torque.
2. Fit the Steering Cylinder to the Steering Bracket
and secure to Studs [5] with Spring Washers [7]
and Nuts [6]. Torque load to the correct torque.
3. Reconnect the Cylinder Rod End to the Tiller [24]
and secure with Bolt, Washer and Nut supplied
with the cylinder. Torque load to the
recommended torque.
9.14 AMENDMENT 16 02/05/04

9 OVERHAUL
HJ-322
9.6 BEARING HOUSING ASSEMBLY OVERHAUL
9.6 BEARING HOUSING

ASSEMBLY OVERHAUL EXERCISE EXTREME CARE IF
OVERHAULING THE BEARING HOUSING
WITH THE VESSEL AFLOAT AS WATER MAY
EXERCISE EXTREME CARE IF WATER SEAL ENTER THE VESSEL THROUGH THE
WARNING OPENING IN THE INTAKE.
REPLACEMENT IS TO BE CARRIED OUT IN
THE VESSEL AS WATER MAY ENTER THE
VESSEL THROUGH THE INTAKE OPENING.
WARNING NEVER LEAVE THE INSPECTION COVER
REMOVED.
7 29 39 15 37 13 36 14 37 15 27 8 17
18 52
Figure 28: Bearing Assembly
9.6.1 Bearing Housing Dismantling INITIAL WORK:

Refer to Drawings “HJ-322-01-000 Basic Jet As- To dismantle the Bearing Housing, carry out the
semblies Standard & Dry Run. Sht 1” and “HJ-322- following operations:-
01-000 Basic Jet Assemblies Standard & Dry Run. Sht 1. Uncouple the Driveshaft from the Jet Unit.
2”. 2. Remove the JHPU from its mounting on the
Bearing Housing. Refer to the Controls Manual
supplied with this Jet Unit for JHPU removal
THE WATER SEAL SHOULD NOT BE information.
REMOVED UNLESS IT IS BEING REPLACED.
THE WATER SEAL WILL NOT PERFORM 3. Remove the Inspection Cover [25] and fit the
CORRECTLY IF IT IS REMOVED AND THEN Mainshaft Support Tool [13] to support the
CAUTION Mainshaft during the dismantling of the Bearing
REINSTALLED.
THE WATER SEAL NEED ONLY BE Housing. Refer to Drawing “HJ-322-11-000 Tool
REPLACED IF IT IS LEAKING, OR THERE IS Kits. Sht 1”.
INSUFFICIENT MATERIAL LEFT TO LAST TO 4. Remove the Coupling Grub Screw [52].
THE NEXT INSPECTION. REFER TO SEC- 5. Fit the Torque Arm [2] to prevent the Coupling
TION 8 MAINTENANCE FOR DETAILS OF from turning refer to Drawing “HJ-322-11-000
THE INSPECTION REQUIRED. Tool Kits. Sht 1”.
6. Unscrew and remove the Coupling Nut [17] from
the Mainshaft.
AMENDMENT 8 21/05/02 9.15

9 OVERHAUL
HJ-322
7. Use a Coupling Puller [3] to draw the Coupling release from the threads. The brass locking pins
free of the Mainshaft refer to Drawing “HJ-322- have to be released by light tapping in the vicinity
11-000 Tool Kits. Sht 1” of the locking screws, with a suitable hammer.
8. Remove the Coupling Key [8] from the Mainshaft. 3. In some applications, the KMT Nut is shrouded
9. Unscrew the 3 Bearing Housing retaining Nuts by the Bearing Housing and so access to the KMT
[56] from the Studs [49] and remove with the Nut is restricted. To overcome this problem, a
Special Washers [61]. long bar may be used by placing one end of the
bar against the surface of the KMT Lock Nut, in
10.Slide the Bearing Cap [14] complete with Outer the vicinity of the Locking Screw and lightly
Oil Seal [37], off the Mainshaft. striking the opposite end of the bar with a
suitable hammer until the Locking Pins are
REMOVING THE KMT BEARING RETAINING NUT released. Refer to Figure 29:“View of KMT Nut”.
[27]:
4. Temporarily refit the Coupling Key [8], the
1. To remove the KMT Bearing Retaining Nut [27], Coupling with the Coupling Puller and Reaction
slacken the three Bearing Nut Lockscrews and Arm attached and the Coupling Nut [17], to the
tap the edges of the nut with a soft hammer to Mainshaft to prevent the Mainshaft from turning.
release the locking pins located under the
5. Unscrew the KMT Bearing Retaining Nut [27].
lockscrews.
2. The brass locking pins inside the KMT Nut are a
force fit onto the mainshaft and do not easily
TAP HERE TO RELEASE

THE LOCKING PINS
ROUND BAR
LOCKING SCREW &

LOCKING PINS
KMT NUT
Figure 29: View of KMT Nut
6. Unscrew and remove the Coupling Nut [17] and Inner Oil Seal [37] and the Water Seal fixed
withdraw the Coupling off the Mainshaft, components).
complete with the Coupling Puller and Reaction
Arm attached. NOTE: The Bearing Housing can now be removed to
a workshop facility and dismantled on a
7. Remove Coupling Key [8] off the Mainshaft [20].
workbench.
8. Remove the KMT Bearing Retaining Nut [27] off
11.Remove the Bearing Carrier [18] from the Bearing
the Mainshaft.
Housing.
9. Remove the Outer Seal Sleeve [15] off the
12.Remove the Bearing [36] from inside the Bearing
Mainshaft.
Housing.
10.Slide the Bearing Housing [13] off the Mainshaft
(The Bearing Housing will still contain Bearing
[36], Bearing Carrier [18], Inner Seal Sleeve [15],
9.16 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
NOTE: If the Bearing is difficult to remove, hot water 14.Press out the Inner Oil Seal [37] from the Bearing
poured over the Bearing Housing will help to Housing.
remove the Bearing. 15.Remove O Ring [39] from the recess in the Intake.
13.Remove the Inner Seal Sleeve [15] from the
Bearing Housing.
Figure 30: Water Seal
9.6.2 Water Seal Removal c) Bearing Carrier [18]. Check for wear or damage.
d) Water Seal [29] and Stationary Face Assembly.
Refer to Drawing “61529 Rotary Seal (Eagle) 2.5” Di-
Check to see if mating faces are scored or
ameter Shaft”.
chipped. Always replace both Seal and Seal Insert
1. With the Bearing Housing removed, unscrew the even if one or other appears unworn.
Setscrews [S], retaining the Waterseal to the e) 'O' Ring [39]. Check for cuts or deformation.
Mainshaft. Figure 30:“Water Seal” refers. f) Circlip [L] located on the Mainshaft. Figure
2. Slide the Water Seal forwards off the Mainshaft. 30:“Water Seal” refers. Remove and discard.
3. Remove Circlip [L] from the recess in the Always replace with a new Circlip [L], when
Mainshaft and remove off the Mainshaft. Figure replacing the Water Seal.
30:“Water Seal” refers. g) Thoroughly clean and examine all parts.
CHECKING FOR WEAR:—Check the following parts

for wear and replace where necessary:-
a) Oil Seals [37] and Seal Sleeves [15]. Check for
cuts, wear and deformation. Replace as
required.
b) Bearing [36]. Check for wear or damage.
AMENDMENT 8 21/05/02 9.17

9 OVERHAUL
HJ-322
9.6.3 Water Seal Replacement and sic Jet Assemblies Standard & Dry Run. Sht 1” and
“HJ-322-01-000 Basic Jet Assemblies Standard &
Re-Fitting Dry Run. Sht 2”.
Refer to Drawing “HJ-322-01-000 Basic Jet Assem-
5. Lubricate the inner face of the Inner Oil Seal [37].
blies Standard & Dry Run. Sht 1” and “HJ-322-01-
000 Basic Jet Assemblies Standard & Dry Run. Sht 2”. 6. Fit the Bearing Housing to the Mainshaft, taking
care not to damage the carbon face of the Water
Seal [29].
ALL WATER SEAL FACES MUST BE CLEAN 7. Grease the outside surface of the Inner Seal
AND FREE OF GREASE. Sleeve [15].
8. Slide the Inner Seal Sleeve [15] over the
CAUTION Mainshaft and push it through the inner Oil Seal
[37] until the Seal Sleeve [15] rests firmly against
the shoulder on the Mainshaft [20].
1. Fit a new Waterseal Retaining Circlip [L] and 9. Refit the inner half of the Bearing Carrier into the
ensure that it is correctly positioned in the circlip Bearing Housing until the Bearing Carrier is
groove on the Mainshaft. pushed up against the inner Seal Sleeve [15].
2. To allow the Water Seal to slide onto the 10.Pre-pack the Bearing [36] with grease then press
Mainshaft, lubricate the Mainshaft with a 20:1 the Bearing into the Bearing Housing [13].
water and household detergent mix. 11.Fit the outer half of the Bearing Carrier [18] down
3. Carefully replace the Waterseal parts in the the Mainshaft and between the Bearing and the
following order :- Drive Collar [K], Spring [H], O- Mainshaft.
Ring [G], Seal Ring Shell [A] and Seal Ring [F] as 12.Using a Soft Hammer, gently tap the inside of the
shown in Figure 30:“Water Seal”. Bearing Carrier until it is level with the outside
4. Slide the Waterseal Assembly down the face of the Bearing [36].
Mainshaft, through the hole in the Intake until 13.Slide the Outer Seal Sleeve [15] over the
the Drive Collar [K] rests against the Circlip [L] Mainshaft and push it up against the outer face
previously fitted to the Mainshaft. of the Bearing [36].
5. Whilst holding the Water Seal pressed against
the Circlip [L], tighten up the Grub Screws [J] FITTING THE KMT BEARING RETAINING NUT:
around the circumference of the Drive Collar [K]
1. Prior to fitting the KMT Bearing Locknut [27],
and torque load to 12 Nm (9 lbs/ft).
ensure that the Locking Screws in the Locknut are
partially withdrawn and that the Locking Pins are
9.6.4 Bearing Housing Re-Assembly not protruding into the thread path of the KMT
Refer to“HJ-322-01-000 Basic Jet Assemblies Stand- Locknut.
ard & Dry Run. Sht 1” and “HJ-322-01-000 Basic Jet 2. Lubricate the KMT Bearing Locknut [27] and
Assemblies Standard & Dry Run. Sht 2” and Figure assemble onto the Mainshaft hand tight only.
28:“Bearing Assembly” and Figure 30:“Water Seal”.
3. Temporary refit the Coupling Key [8] and
1. Lubricate the Bearing Housing recess at the rear Coupling to the Mainshaft.
of the Bearing Housing and the Nitrile Boot [D]
4. Lightly tighten the Coupling Nut [17] to secure
with a 20:1 water and household detergent mix.
the Coupling in position.
2. Press in the Insert Nitrile Boot [D] and Seal Ring
5. Fit the Reaction Arm to the Coupling and torque
Insert [E] into the recess in the rear of the Bearing
the KMT Bearing Locknut to the recommended
Housing. Figure 30:“Water Seal” refers.
torque. (270 Nm / 200 lb/ft). Refer to drawings
3. Smear the "O" Ring [39] with marine grease and “HJ-322-01-000 Basic Jet Assemblies Standard &
fit into the recess in the rear of the Bearing Dry Run. Sht 1”.
Housing. Figure 28:“Bearing Assembly” refers.
6. Tighten the 3 KMT Bearing Locknut Set Screws to
4. Smear the inner Oil Seal [37] with marine grease the recommended torque.
and press into the Bearing Housing [13]. Ensure
7. Remove the Coupling Nut, Coupling and
that the seal lip faces towards the Coupling
Coupling Key from the Mainshaft.
Flange. Refer to Drawings “HJ-322-01-000 Ba-
9.18 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
9.7 INTERNAL ANODE REPLACEMENT
8. Lubricate the Outer Oil Seal [37] and press into 9.7 INTERNAL ANODE
the Bearing Cap [14] until the Outer Oil Seal is
pressed firmly up against the shoulder in the REPLACEMENT
Bearing Cap. Ensure that the Seal lip faces Refer to Drawing “HJ-322-13-002 Anode Location
towards the Coupling Flange. Refer to Drawing Drawing”.
Dry Run. Sht 1”. 9.7.1 Intake Internal Anode
9. Lightly grease the contact faces between the The replacement of the Intake Internal Anode should
Bearing Housing and the Bearing Cap be carried out when the vessel is in dry dock.
10.Lightly grease the inner face of the Outer Oil Seal To carry out this operation, refer to Drawings “HJ-
[37] with marine grease and fit the Bearing Cap 322-01-000 Basic Jet Assemblies Standard & Dry
[14] onto Studs [49] fitted on the forward face of Run. Sht 1” and “HJ-322-01-000 Basic Jet Assem-
the Bearing Housing. blies Standard & Dry Run. Sht 2”.
11.Fit Special Washers [61] and Nuts [56], using The Internal Anode [66] can be removed through the
Loctite 222 to secure. Torque load to the Inspection Cover [25] on the Jet Intake.
recommended torque. 1. Remove the Inspection Cover [25] and O Ring [40]
12.Remove the Mainshaft Support Tool [13], from the Inspection Cover opening.
(Drawing “HJ-322-11-000 Tool Kits. Sht 1” 2. Inspect the Anode [66] located on the starboard
refers). fitted to the mainshaft and refit the side of the Intake. Replace the Anode if it is more
Inspection Cover [25]. than half corroded, otherwise clean with a wire
13.Lightly grease the keyway and threaded area of brush.
the Mainshaft, the bore and keyway of the 3. Should the Anode require replacement, remove
Coupling Flange and the face of the Coupling Nut the securing Nuts [53] , Spring Washers [58] and
[17]. the Anode [66].
14.Fit the Coupling Key [8] and the Coupling to the 4. The Screws [67] do not have to be removed from
Mainshaft. the Intake.
15.Fit the Coupling Nut [17] to the Mainshaft, 5. If the Screws [67] have been removed and need to
ensuring that the Set Screw [52] has been backed be replaced, fit Flat Washer [10] to each of the
off. screws and apply Loctite 262 to the threads near
16.Fit the Torque Arm to the Coupling to prevent the the head of the screws.
Coupling from turning and torque load the 6. Screw the two bolts fully home through the
Coupling Nut [17] to the recommended torque. location holes on the starboard side of the Jet
250Nm. (185lbs/ft). Unit Intake.
17.Whilst slowly rotating the Mainshaft, lightly 7. Fit a new Anode [66] through the Inspection
grease the Bearing via the Grease Nipple [34] on Hatch and onto the Screws [67] protruding into
the top of the Bearing Housing. Continue the Intake. Ensure that the Anode is fitted with
greasing until grease is seen escaping between curved side into the recess.
the Seal [37] and the Seal Sleeve [15] at the front
of the Bearing Housing. 8. Add Loctite 243 to the threads of the two Screws
[62].
18.Turn the Mainshaft by hand to ensure that it
rotates freely before connecting the Coupling to 9. Fit Spring Washers [58] and Nuts [53] to the two
the Driveshaft. screws and tighten to the recommended torque.
10.Smear the Inspection Cover O Ring [40] with
grease and fit to the groove on the underside of
the Inspection Cover.
11.Refit the Inspection Cover and secure in position
on Studs [47] with Flat Washers [65], Spring
Washers [60] and Nuts [55].
AMENDMENT 9 24/01/03 9.19

9 OVERHAUL
HJ-322
9.8 TAILPIPE AREA - OVERHAUL
9.8 TAILPIPE AREA - OVERHAUL to Section 9.4.4“Nozzle Assembly Removal”. and

Drawings “HJ-322-01-000 Basic Jet Assemblies
NOTE: The Maintenance operations detailed in this Standard & Dry Run. Sht 1” and “HJ-322-01-000
Section should be carried out when the vessel Basic Jet Assemblies Standard & Dry Run. Sht 2”.
is in dry dock. 1. To remove the Tailpipe from the Intake, ensure
If The Reverse Duct has not already been removed, that any hoses connected to the Hose Tail [63]
it must be removed before proceeding. Refer to have been disconnected.
Section 9.2.1“Reverse Duct Removal”. 2. Remove Nuts [56] and Special Washers [61] from
If the Steering Linkages have not already been Studs [50] securing the Tailpipe to the Intake.
disconnected, they must be disconnected before 3. Hit the Tailpipe sideways with a rubber hammer
proceeding. Refer to Section 9.4.2“Steering Cylin- to free the joint. Remove the Tailpipe from the Jet.
der Overhaul”.
IMPELLER REMOVAL:
9.8.1 Impeller - Checking for Wear Refer to Drawings “HJ-322-01-000 Basic Jet Assem-
CHECKING FOR WEAR:—Refer to Drawings.“HJ- 000 Basic Jet Assemblies Standard & Dry Run. Sht 2”.
322-01-000 Basic Jet Assemblies Standard & Dry 1. With the Coupling fitted to the Mainshaft, fit the
Run. Sht 1” / “HJ-322-01-000 Basic Jet Assemblies Torque Arm to the Coupling to prevent the
Standard & Dry Run. Sht 2” and drawings shown in Mainshaft from turning.
Section 5“Installation”.
2. Unscrew the Impeller Nut [19] securing Setscrew
Before dismantling the Tailpipe end of the Jet Unit,
[52] a few turns.
remove the Inspection Cover [25] (or Intake Screen
[13] if in dry dock) and carry out the following 3. Unscrew and remove the Impeller Nut from the
checks. Mainshaft.
1. Impeller Tip Wear Check: Using feeler gauges, NOTE: If the Impeller Nut is stiff to remove, apply
check the clearance between the tips of the gentle heat on the Nut.
Impeller Blades and the Wear Ring [11] at each
side of the Jet Unit (i.e. Not top and bottom). 4. Withdraw the Water Bearing Sleeve [6] from
Maximum recommended worn clearance is 1.5 between the Impeller and the Mainshaft.
mm (0.059") per side. 5. Withdraw the Impeller off the Mainshaft.
2. Marine Bearing Wear Check: Push the 6. Remove the Impeller Key [4] from the Mainshaft
Mainshaft [20] hard from side to side. Check ensuring that the securing Dowel [5] remains
total sideways movement at the Impeller Blade fitted to the Mainshaft.
tips. Maximum New Clearance is 0.67mm
(0.026ins). This indicates the amount of wear in 9.8.3 Impeller Race - Overhaul
the Marine Water Bearing [24] and Water
Bearing Sleeve [6].
IMPELLER RACE REMOVAL:
The Impeller Race need not be removed unless it is
9.8.2 Tailpipe Area - Dismantling badly worn or corroded or the Wear Ring / Insulator
Refer to Drawings “HJ-322-01-000 Basic Jet As- require replacement. Minor corrosion damage such
semblies Standard & Dry Run. Sht 1” and “HJ-322- as pitting on the Impeller Race may be repaired by
01-000 Basic Jet Assemblies Standard & Dry Run. Sht welding. Grind the welded surface flush with the
2”. original surface. If the surface wear is more than
1mm deep, a new Impeller Race should be fitted.
DISMANTLING:—Refer to Drawing “HJ-322-06-
000 Steering Assembly General Arrangement. Sht 1” NOTE: The Impeller Race may be removed to a
and “HJ-322-06-000 Steering Assembly General Ar- workshop facility for the replacement of the
rangement. Sht 2”. Wear Ring and Insulator . (Refer to Section
Ensure that the Steering Nozzle, Nozzle Insert and 9.8.4“Wear Ring - Removal and Replace-
Nozzle Housing have been removed prior to ment” for details).
commencing the Tailpipe Area dismantling. Refer To remove the Impeller Race, proceed as follows:-
9.20 AMENDMENT 11 11/04/03

9 OVERHAUL
HJ-322
With the Reverse and Steering Assemblies removed, 9.8.4 Wear Ring - Removal and
refer to Section 9.2“Reverse Assembly Removal and
Overhaul” and Section 9.4“Steering Assembly Re-
Replacement
moval and Overhaul” for removal details.
REMOVING THE OLD WEAR RING AND
1. Remove Nuts [56] and Special Washers [61] from
INSULATOR:—Refer to Drawings “HJ-322-01-000
Studs [69] securing the Impeller Race to the
Basic Jet Assemblies Standard & Dry Run. Sht 1” and
Intake.
2. Hit the Impeller Race sideways with a rubber or Dry Run. Sht 2”.
wooden mallet to free the joint and remove the
Impeller Race off the Intake and withdraw off the STEP 1:
Mainshaft.
1. Find the joint in the Wear Ring [11] and force a
3. Remove and discard O Ring [38] from the long thin screw driver between the Wear Ring
Impeller Race / Intake flange. and the Insulator [21], adjacent to the Wear Ring
4. Examine the Wear Ring [11] for wear, pitting and joint, until the end of the Wear Ring is free. Refer
score damage. In the event of this being very to Step 1, Figure 31:“Wear Ring Inspection & Re-
badly scored, or if the Wear Ring has swollen moval Instructions”.
inwards, it should be replaced. If possible,
request your local agent to carry out the STEP 2:
replacement of the Wear Ring.
2. Pull the free end of the Wear Ring inwards and
5. Examine the Impeller Race Anode [1] located on remove it from the Intake.
the underside of the Impeller Race. if this anode
3. Remove the Wear Ring Insulator [21] and
is less than half of its original size, it should be
thoroughly clean and degrease the Intake Bore.
replaced.
Refer to Step 2, Figure 31:“Wear Ring Inspection &
Removal Instructions”.
IMPELLER RACE EXTERNAL ANODE [1], REPLACE-
MENT:
Drawings “HJ-322-01-000 Basic Jet Assemblies
Standard & Dry Run. Sht 1” and “HJ-322-01-000 START
Basic Jet Assemblies Standard & Dry Run. Sht 2”
refer. Refer to Drawing “HJ-322-13-002 Anode Lo-
cation Drawing”.
1. Check the Impeller Race Anode [1] attached to
the underside of the Impeller Race, if this is less STEP 1
than half of its original size, it should be
replaced.
2. To replace the Impeller Race Anode, carry out the
following operation:- STEP 2
a) Remove the Nuts [53] and Spring Washers REMOVAL
[58] from Studs [44].
b) Remove the External Anode [1].
c) Ensure that the mating surfaces are scraped
clean for a good electrical contact.
d) Fit a new External Anode [1].
e) Attach with Nuts [53] and Spring Washers
[58]. Torque load to the recommended
torque. INSERTION 1 2 3
3. If the Anode is still in good condition, ensure that
it has not been painted over.
4. Scrub down with a wire brush if a coating has Figure 31: Wear Ring Inspection & Removal Instructions
built up on the Anode.
AMENDMENT 9 24/01/03 9.21

9 OVERHAUL
HJ-322
PREPARING A NEW WEAR RING FOR FITTING: 5. Continue driving the Wear Ring into the Impeller
1. Before fitting a new Wear Ring, it should be trial Race until the Wear Ring sits approximately 0.8
fitted into the Impeller Race with no Insulator mm (1/32") from the end of the recess in the
fitted. There should be a gap of approximately Impeller Race.
1mm between the mating ends of the Wear Ring 6. The Wear Ring must not touch any part of the Jet
with the Wear Ring completely fitted into the Unit except the Insulator.
Impeller Race bore. 7. The Wear Ring is correctly fitted when it sits
2. The Wear Ring may not fit without some “dress” flush with the inner end of the Impeller Race
filing of the mating ends to reduce the Flange. Refer to Figure 32:“Wear Ring Fitting Po-
circumference slightly. DO NOT REMOVE TOO sition”.
MUCH METAL FROM THE WEAR RING as the 8. On completion of the fitting of the Wear Ring,
Wear Ring must be a tight fit in the Impeller Race electrical insulation between the Wear Ring and
once the Insulator is fitted. This ensures that the the Impeller Race Casting should be checked
Wear Ring remains in the correct position during using a multimeter. The resistance reading
operation. should be over 1000 ohms.
.
FITTING A NEW INSULATOR:
IMPELLER RACE
1. Paint the Impeller Race Bore with a thin layer of
FORWARD
two pot vinyl etch primer suitable for aluminium TAILPIPE
O RING
and allow to dry. INTAKE
2. Apply a coat of zinc phosphate epoxy primer

suitable for aluminium (such as International
Paints Intercure 200 HS) and allow to dry.
3. Apply a second coat of zinc phosphate epoxy WEAR RING
primer. While the primer is still wet, fit a new INSULATOR Wear Ring should sit flush with
inner recess of Intake Flange
Insulator [21] to the Impeller Race, ensuring that Wear Ring sits approx. 0.8mm (1/32")
from the end of the Impeller Race
the Insulator is in contact with the primer over
the whole surface of the Impeller Race bore. Figure 32: Wear Ring Fitting Position
4. Smear the whole Insulator surface with a thin
layer of grease or oil. NOTE: The Wear Ring is in the correct position
when it is located approximately 0.8 mm (1/
FITTING A NEW WEAR RING: 32") from the end of the recess in the
Impeller Race. Refer to Figure 32:“Wear
STEP 1: Ring Fitting Position” and the Wear Ring
sits flush with the inner recess of the Impeller
1. Take a new Wear Ring [11] and with the chamfer Race Flange. This gap must be maintained to
end leading, butt the strip at the chamfers by prevent electrical contact between the Wear
twisting slightly (this reduces the lead in Ring and the Tailpipe / Intake of the Jet Unit.
diameter) and gradually feed it inside the
Insulator [21] fitted in the Impeller Race until the
Wear Ring butts fully. 9.8.5 Impeller Area Overhaul
2. Slide the Wear Ring evenly into the Impeller Race Minor corrosion damage around the Wear Ring /
as far as possible by hand. Impeller position such as pitting may be repaired by
welding. Grind the welded surface flush with the
original surface.
STEP 2:
If the surface wear is more than 1mm deep, a new
3. Place a heavy steel plate over the edge of the Impeller Race should be fitted.
Wear Ring (The plate is used to prevent damage
to the end of the Wear Ring and should cover
whole diameter of the Wear Ring).
4. Drive the Wear Ring evenly into the Impeller
Race by hitting the plate with a large hammer.
9.22 AMENDMENT 9 24/01/03

9 OVERHAUL
HJ-322
9.8.6 Impeller Overhaul Balancing Information. Sht 1” to ”82206 Impeller

Blade Dressing Instructions & Balancing Informa-
tion. Sht 3”.
AVOID USING EXCESSIVE HEAT DURING 4. Blend well back into the original blade surface.
WELDING.
5. Both front and rear surfaces are to be a smooth
uniform curve with no sudden bumps or change
CAUTION in direction.
6. Grind or file a smooth radius along the leading
edge as shown in Drawings ”82206 Impeller
NOTE: All welds must be passivated to prevent
Blade Dressing Instructions & Balancing Informa-
corrosion.
tion. Sht 1” to ”82206 Impeller Blade Dressing In-
Impellers are stainless steel type CF8M conforming structions & Balancing Information. Sht 3”.
to ASTM A 743 or 316 to BS 3100. Filler metal
should have a chemical analysis similar to AISI 316L
IMPELLER OUTSIDE DIAMETER (O.D.) REPAIR
(Carbon content less than 0.03%). Post weld heat
PROCEDURE:
treatment is not required. Passivation is required
after welding is completed. 1. If the Impeller O.D. is excessively worn it may be
built up by welding. After welding turn on a
INSPECTION: mandrel to the correct O.D. Use light cuts to
avoid blade distortion. Dress the faces back flush
1. Inspect all surfaces of the Impeller for any sign of with the original surfaces.
corrosion or erosion damage. Damaged areas
should be weld repaired and dressed back to a 2. Turn the outside diameter to 319.2 - 319.0 mm
smooth surface again. making sure that it is concentric with the bore.
(Light cuts should be taken when turning the
2. Check the Impeller leading and trailing edges for outside diameter to avoid deformation of the
damage. In particular the outer corners of a Impeller Blades).
blade may be bent if the Impeller is dropped or
mishandled. Bent or dented blades may be 3. File and polish.
straightened using a large adjustable spanner or
other suitable tool. Bring the blade back to its BALANCING:
original smooth profile checking against other 1. The Impeller must be balanced if welding or
undamaged blades. grinding has been carried out on the Impeller.
3. Inspect the leading edges, excessively worn or 2. Balance the Impeller statically, preferably on the
blunt leading edges may be built up by welding. Mainshaft with the Coupling and all keys in
Blunt Impellers cause loss of performance and place. If this is not possible then balance the
sometimes cavitation. Impeller statically on a suitable mandrel set on
4. Check the Impeller O.D. horizontal knife edges or bars to within the
maximum out of balance specified.
BLADE LEADING EDGE REPAIR PROCEDURE: 3. Balance to within 100 gm-cm (0.72 oz/ins).
Drawing “HJ-322-03-001 Impellers” and Drawings Balance weights of 316 SS may be welded to the
”82206 Impeller Blade Dressing Instructions & Bal- inside of the hub and grinding is permitted.
ancing Information. Sht 1” to ”82206 Impeller Blade
Dressing Instructions & Balancing Information. Sht
3” show the desired blade profile. The following
information should also be referred to:
1. Dress the edge back to a smooth curve removing
the minimum amount of metal.
2. Weld repair damaged edges if required.
3. Dress both faces of the blade taking slightly more
metal off the rear side until the leading edge is the
correct thickness all along. Refer to Drawings
”82206 Impeller Blade Dressing Instructions &
AMENDMENT 13 25/11/03 9.23

9 OVERHAUL
HJ-322
PASSIVATION: 9. Refit the Tailpipe to the Tailpipe Studs [50] and

secure with Special Washers [61] and Nuts [56]
using Loctite 222.
APPROPRIATE SAFETY GLASSES, PROTEC-
TIVE GLOVES AND CLOTHING MUST BE NOTE: The Studs [50] are SAF Stainless Steel Studs.
WORN TO PREVENT SKIN EXPOSURE TO Attaching Nuts [56] should be torque loaded
NITRIC ACID. to 130 Nm (95 lbs/ft) refer to “85113 Rec-
WARNING ommendations for Fastener Locking, Torques
and Thread Lubrication”.
1. If the Impeller has been welded, passivation is 10.Torque load to the correct torque.
required.
11. Turn the Mainshaft to ensure that the assembly
2. Immerse the Impeller in hot 30% Nitric Acid for will rotate.
at least 2 hours.
3. Rinse in clean water. REPLACING THE REVERSE DUCT PIVOT BUSHES
4. If nitric acid immersion is not possible, a "brush [26]:
on" pickling / passivation gel may be used on To replace the Threaded Reverse Duct Pivot Bushes
weld and heat affected areas. [26] carry out the following actions. Refer to
Drawing “HJ-322-07-001 Reverse Assembly. Sht 1”
and “HJ-322-07-001 Reverse Assembly. Sht 2”.
9.8.7 Tailpipe Overhaul
1. With the Tailpipe removed from the Jet Unit
Refer to Drawings “HJ-322-01-000 Basic Jet Assem-
Intake, remove the threaded Bush [26]. It may be
necessary to apply light heat to the Tailpipe in
000 Basic Jet Assemblies Standard & Dry Run. Sht 2”.
the area of the Bush to break the Loctite Seal.
1. Check the Marine Water Bearing [24] and Water
2. Clean out the Bush bores in the Tailpipe,
Bearing Sleeve [6] for wear or excessive scoring
ensuring that all old Loctite is removed.
and if necessary replace. Refer to Section 8.5“Jet
Unit Servicing Details”. Item 13/3. Also 3. Apply a thin coat of Loctite 747 or T Primer to the
9.8.1“Impeller - Checking for Wear”. Replace mating surfaces of the Bush and the bores in the
automatically if the Impeller has just been built Tailpipe. Allow to dry.
up and the Wear Ring has been replaced. 4. Coat the surfaces of the Bushes and the Tailpipe
2. Use either an internal extractor to pull the Water bores with Loctite 262.
Bearing [24] from the Tailpipe, or place the 5. Screw the Bushes [26] fully into the Tailpipe.
Tailpipe under a press and push out the Water Wipe off any excess Loctite.
Bearing [24] and Tailpipe Fairing [16] together.
3. When refitting the Tailpipe Fairing, use "Loctite EXTERNAL TAILPIPE ANODES [1], REPLACEMENT:
680" or equivalent. Refer to Drawing “HJ-322-13-002 Anode Location
4. Apply grease to the Tailpipe bore before inserting Drawing”, Drawings “HJ-322-01-000 Basic Jet As-
a new Water Bearing but ensure that the grease semblies Standard & Dry Run. Sht 1” and “HJ-322-
is kept away from the rubber bearing surfaces 01-000 Basic Jet Assemblies Standard & Dry Run. Sht
of the Water Bearing. 2” refer.
5. When pressing in the new Water Bearing, use a 1. Check the external Tailpipe Anodes [1] attached
wooden block under the nose of the Tailpipe to the outside rear face of the Tailpipe, if these
Fairing to take the load. are less than half of their original size, they
should be replaced.
6. Dust the Marine Water Bearing [24] with Talcum
Powder or French Chalk. 2. To replace the External Tailpipe Anodes, carry
out the following operation:-
7. Clean and grease the Tailpipe / Intake contact
a) Remove the Nuts [53] and Spring Washers
faces.
[58] from Studs [44].
8. Smear the Intake / Tailpipe O Ring [38] with b) Remove the External Anode [1].
marine grease and refit the to the recess in the c) Ensure that the mating surfaces are scraped
Intake. clean for a good electrical contact.
d) Fit a new External Anode [1].
9.24 AMENDMENT 12 22/08/03

9 OVERHAUL
HJ-322
e) Attach with Nuts [53] and Spring Washers 9.8.8 Tailpipe Area Re-Assembly
[58]. Torque load to the recommended
torque.
f) Repeat for the second external Anode.
3. If the Anode is still in good condition, ensure that 2”.
it has not been painted over. Refer to the specified minimum torque values shown
4. Scrub down with a wire brush if a coating has in Section 8.7“Threaded Fasteners” and on Drawing
built up on the Anode. “85113 Recommendations for Fastener Locking, Tor-
ques and Thread Lubrication” when tightening all
INTERNAL TAILPIPE ANODES [2] REPLACEMENT: nuts.
Refer to Drawing “HJ-322-13-002 Anode Location
Drawing”, Drawings “HJ-322-01-000 Basic Jet As- IMPELLER RE-ASSEMBLY:
semblies Standard & Dry Run. Sht 1” and “HJ-322- 1. Smear a light coating of grease over the
01-000 Basic Jet Assemblies Standard & Dry Run. Sht Mainshaft from the Impeller keyway rearwards
2” refer. to the start of the Impeller Nut threads. Do not
1. Check the 6 x Internal Tailpipe Anodes [2] grease the threads.
attached to the Anode Mounting Plate [26] which 2. Insert the Impeller Key [4] with chamfers facing
is fitted to the forward face of the Tailpipe. down into the Mainshaft keyway and locate onto
Should these be less than 2/3rds their original Dowel [5] in the bottom of the keyway.
size, they should be replaced.
3. Slide the Impeller onto the Mainshaft [20]
2. To replace the 6 x Internal Tailpipe Anodes [2], followed by the Water Bearing Sleeve [6].
carry out the following operation:-
a) With the Tailpipe removed from the Intake [9], NOTE: When fitting a new Impeller onto a Jet Unit,
remove the Nyloc Nuts [51] and Spring the Impeller taper must be lapped to the
Washers [58] from the Studs [43] attaching Mainshaft in accordance with British
the Anode Mounting Plate [26] to the Tailpipe. Standard MA 74.
b) Remove the Nyloc Nuts [51] and Spring 4. Prevent the Mainshaft from rotating by fitting the
Washers [58] attaching each Anode to the the Torque Arm to the Coupling.
Anode Mount Plate.
c) Remove the 6 x Internal Tailpipe Anodes [2]. 5. Fit the Impeller Nut [19], ensuring that the Set
d) Ensure that the mating surfaces between the Screw [52] is backed off. Torque load the
Anode and the Anode Mounting Plate are Impeller Nut to 600 Nm (440 lbs/ft).
scraped clean for a good electrical contact. 6. Tighten the Impeller Nut Set Screw [52] to 8 Nm
e) Coat the threads of the Anodes [2] with Loctite (6 lbs/ft).
243. 7. Remove the Torque Arm from the Coupling.
f) Fit new Internal Tailpipe Anodes [2] to the
Anode Mounting Plate [26] and secure with IMPELLER RACE RE-FITTING:
Nyloc Nuts [51] and Spring Washer [58],
If the Impeller Race has been removed from the rear
g) Torque load to the recommended torque.
face of the Intake, this can now be re-fitted to the Jet
h) Coat the threads of Studs [43] fitted to the
Unit.
Tailpipe, with Loctite 243 and refit the Anode
Mounting Plate [26] to the Studs [43]. Secure With the Impeller re-fitted to the Mainshaft as
with Nyloc Nuts [51] and Spring Washers [58] shown previously, carry out the following actions:-
and torque load to the recommended torque. 1. Smear a new Seal [38] with marine grease and fit
3. If the Anodes are still in good condition, ensure to the seal recess in the forward face of the
that the Anodes are not painted over. Impeller Race.
4. Scrub the Anodes with a wire brush if a coating 2. Fit the Impeller Race to the Intake ensuring that
of corrosion has built up on the Anodes. the Anode is on the underside of the Impeller
Race. Secure the Impeller Race to Studs [69] with
Special Washer [61] and Nut [56].
3. Torque load to the recommended torque.
AMENDMENT 15 31/03/04 9.25

9 OVERHAUL
HJ-322
9.9 TRANSOM PLATE ASSEMBLY OVERHAUL
NOTE: The Studs [69] are SAF Stainless Steel Studs. 9.9 TRANSOM PLATE ASSEMBLY
The attaching Nuts [56] should be torque
loaded to 130 Nm (95 lbs/ft) refer to OVERHAUL
“85113 Recommendations for Fastener
Locking, Torques and Thread Lubrication”. NOTE: The Transom Plate O-Ring [2] and Transom
Plate [1] should not be removed unless they
TAILPIPE RE-ASSEMBLY: are suspected of leaking or unless the
Transom Plate [1] is corroded or damaged.
1. Wipe the Water Bearing Sleeve [6] clean to
Should it be necessary to remove the Transom Seal
ensure that the Marine Bearing [24] remains free
Assembly from the Transom, for repair or
of grease.
replacement of damaged or worn components,
2. Dust the rubber of the Marine Bearing [24] with carry out the following operation.
talc or french chalk. To replace the Transom Plate O-Ring [2] or Transom
3. Clean and grease the Tailpipe to Intake contact Plate [1], the Reverse Duct must be removed to allow
faces. access to the Transom Plate.
4. Smear the O-Ring [38] with grease to retain in
position and fit to the Tailpipe Spigot. 9.9.1 Transom Plate Removal
5. Refit the Tailpipe over the Studs [50] fitted to the
rear of the Impeller Race. NOTE: The Reverse Duct should be removed
complete to allow access to remove the
6. Apply Loctite 222 to the Studs [50] and secure the Transom Plate.
Tailpipe to the Impeller Race with Special
To remove the Reverse Duct components complete,
Washers [61] and Nuts [56]. Tighten the Nuts
refer to Section 9.2.1“Reverse Duct Removal”.
[56] to the recommended torque.
7. Using the Special Tool "Reaction Arm", fitted to G.R.P AND ALUMINIUM HULLS:
the Coupling, as a handle, turn the Mainshaft to
For GRP Hulls refer to Drawings “HJ-322-08-001
ensure that the Mainshaft and Impeller rotates
freely.
1”/“HJ-322-08-001 Installation Details GRP Hull
8. Reconnect any hoses that were previously fitted with 5º Shaft Line. Sht 2” and “HJ-322-08-011 In-
to the Hosetail [63] on the port side of the stallation Details GRP Hull with 0º Shaft Line. Sht 1”/
Tailpipe. “HJ-322-08-011 Installation Details GRP Hull with
0º Shaft Line. Sht 2”.
NOZZLE BUSHES - REPLACEMENT:
Ensure that all worn or damaged Steering and For Aluminium Hulls refer to Drawings “HJ-322-
Reverse System Bushes, Scrapers and Seals have 08-002 Installation Details Aluminium Hull with 5º
been replaced prior to re assembly of the Tailpipe Shaft Line. Sht 1”/“HJ-322-08-002 Installation De-
and Nozzle. Refer to Section 9.4.2“Steering Cylinder tails Aluminium Hull with 5º Shaft Line. Sht 2” and
Overhaul” and Section 9.4.4“Nozzle Assembly Re- “HJ-322-08-012 Installation Details Aluminium Hull
moval”. with 0º Shaft Line. Sht 1”/“HJ-322-08-012 Installa-
2”.
To remove the Transom Plate [1] and replace the
O-Ring [2], carry out the following operation:
1. Slacken and remove the Screws [3], Flat Washers
[6], Spring Washers [5] and Nuts [4] securing the
Transom Plate to the Transom.
NOTE: There are 2 Flat Washers [6] fitted to either

side of the Transom / Transom Plate.
2. Remove the Transom Plate off the Jet Unit Intake
and remove off the rear of the Jet Unit.
9.26 AMENDMENT 16 02/05/04

9 OVERHAUL
HJ-322
9.9 TRANSOM PLATE ASSEMBLY OVERHAUL
3. Remove the Transom Plate O-Ring [2] from 2. Liberally apply neutral cure RTV Silicone Sealant
around the Jet Unit and discard. [18] (supplied) to the Transom Plate contact area
4. Clean off any old RTV Sealant from the Transom on the Hull and also the joint face of the Transom
Plate [1] and the Transom and examine for Plate and the heads of the Screws [3].
damage and corrosion. Replace or repair as 3. Slide the Transom Plate [1] over the O-Ring [2]
required. and line up the holes in the Transom Plate with
the drilled holes in the Transom.
STEEL HULLS: 4. Fit the Transom Plate into place against the
Refer to Drawings “HJ-322-08-003 Installation De- Transom.
tails Steel Hull with 5º Shaft Line. Sht 1” / “HJ-322- 5. Secure the Transom Plate to the Transom using
08-003 Installation Details Steel Hull with 5º Shaft Screws [3], Nuts [4], Flat Washers [6] and Spring
Line. Sht 2” and “HJ-322-08-001 Installation Details Washers [5] as shown in the installation
GRP Hull with 5º Shaft Line. Sht 1” / “HJ-322-08- drawing.
001 Installation Details GRP Hull with 5º Shaft Line.
Sht 1”. NOTE:
To remove the Transom Plate [1] and replace the 1. Ensure that the screw heads are fitted to the
Transom Plate O-Ring [2], carry out the following outside of the Transom as shown on the
operation: Installation Drawings.
1. Slacken and remove the Screws [3], Flat Washers 2. Ensure that Flat Washers [6] are fitted to the
[6], Spring Washers [5] and Nuts [4] securing the Screws [3] prior to fitting through the
Transom Plate to the Transom. Transom / Transom Plate.
NOTE: There are 2 Flat Washers [6] fitted to either 6. Tighten all 24, securing Screws to the
side of the Transom / Transom Plate. recommended torque.
2. Remove the Nylon Insulating Bushes [25] from 7. Wipe off any excess sealant.
around the Transom Plate.
3. Remove the Transom Plate off the Jet Unit Intake. STEEL HULLS:
4. Remove the Transom Gasket [26] from the NOTE: The Transom Seal Assembly must be totally
Transom Plate / Transom interface and discard. insulated from the hull by Gasket [26] and
5. Remove the Transom Plate O-Ring [2] from Flanged Insulating Bushes [25] fitted around
around the Jet Unit and discard. the mounting Screws [3].
6. Clean off any old RTV Sealant from the Transom 1. Fit the Insulating Bushes to the Transom Plate
Plate [1] and the Transom and examine for and trim to the correct length. These should be
damage and corrosion. Replace or repair as fitted from the outside of the Transom Plate.
required. 2. Place the Transom Plate over the Intake casing
and up against the Transom.
9.9.2 Transom Plate Re-Fitting 3. Lubricate the Transom Plate O-Ring [2] with
If a new Transom Plate is being fitted, refer to vegetable oil. Fit in place in the seal groove on
Section 5.4.2“Assembly of the Transom Plate to the the Jet Unit Intake. Take care not to get any oil
Hull” for information on how to fit the Transom on the Transom where sealant will be applied.
Plate. 4. Liberally apply neutral cure RTV Silicone Sealant
If the Transom plate is being refitted, follow the [18] to the Transom Plate contact area on the
instructions below:- Hull and also the joint face of the Transom Plate
and the heads of the Screws [3].
G.R.P AND ALUMINIUM HULLS: 5. Apply neutral cure RTV Silicone Sealant [18] to
1. Lubricate the Transom Plate O-Ring [2] with the Transom Plate Gasket [26]. Fit the Transom
vegetable oil. Fit in place in the seal groove on Plate Gasket [26] to the Transom and align with
the Jet Unit Intake. Take care not to get any oil the drilled holes.
on the Transom where RTV Sealant will be
applied.
AMENDMENT 8 21/05/02 9.27

9 OVERHAUL
HJ-322
6. Slide the Transom Plate [1] over the O-Ring [2] 9.10 OVERFLOW PREVENTER
and line up the holes in the Transom Plate with
the drilled holes in the Transom. (OPTIONAL EXTRA)
7. Install the Transom Plate in place against the Refer to Drawing “HJ-322-10-001 Overflow Prevent-
Transom Plate Gasket and Transom. er”.
8. With the Insulating Bushes [25] already fitted to C.W.F. Hamilton & Co Ltd can supply an Overflow
the Transom Plate, fit and secure in 3 positions Preventer [1] as an optional extra. This item enables
with Screw [3], Nuts [4], Flat Washers [6] and work to be carried out on the Jet Unit where
Spring Washers [5]. Hand tighten only. normally, by removing the Inspection Cover, this
may allow water to enter the vessel. The Overflow
NOTE: Preventer raises the height of the Inspection Cover
by approximately 150mm.
1.Ensure that the screw heads are fitted to the
outside of the Transom as shown on the
Installation Drawings. EXTREME CARE IS REQUIRED WHENEVER
2.Ensure that Flat Washers [6] are fitted to the THE INSPECTION COVER IS REMOVED AS
Screws [3] prior to fitting through the WATER MAY ENTER THE VESSEL
Transom / Transom Plate. THROUGH THIS OPENING.
WARNING
9. The Transom Plate must be totally insulated from
the Hull by Rubber Gasket [26] and Insulating NEVER LEAVE THE INSPECTION COVER
Bushes [25] fitted to the Transom Plate Mounting REMOVED WITHOUT CONSTANT
Screws. MONITORING OF THE WATER LEVELS.
10.Check the insulation between the Jet Unit and the

Transom. (The resistance between the Jet Unit 9.10.1 Overflow Preventer Fitting
and the Transom should be 1000 ohms or The following Drawings refer:“HJ-322-01-000 Basic
greater. If the reading is below 1000 ohms, the Jet Assemblies Standard & Dry Run. Sht 1” / “HJ-
fault should be investigated and rectified 322-01-000 Basic Jet Assemblies Standard & Dry
before continuing). Run. Sht 2” and Drawing “HJ-322-10-001 Overflow
11.Secure the Transom Plate and Gasket to the Preventer”.
Transom with the remaining Screws [3], Nuts [4], To fit the Overflow Preventer [1] carry out the
Flat Washers [6] and Spring Washers [5] as following operation:-
shown in the Installation Drawing.
1. Ensure that the water level is below the level of
12.Tighten all 24 securing Screws to the the Inspection Cover.
recommended torque and wipe off any excess
2. Ballast the bow end of the vessel to ensure that
sealant.
water does not enter the vessel through the
13.Carry out a final check of the insulation between Inspection opening when the Inspection Cover is
the Jet Unit and the Transom. (Any fault should removed.
be investigated and rectified before
3. Remove Nuts [55], Flat Washers [65] and Spring
continuing).
Washers [60] from the three Studs [47] retaining
the Inspection Cover [25].
4. Remove the Inspection Cover [25] and O Ring
[40].
5. Smear the underside of the Overflow Preventer
[1] with RTV Silicone Sealant [8]. Refer Drawing
“HJ-322-10-001 Overflow Preventer”.
6. Fit the Overflow Preventer over the Inspection
Cover opening and secure in position with Flat
Washers [3] and Screws [2] and tighten to the
recommended torque.
7. Remove any excess RTV Sealant.
9.28 AMENDMENT 8 21/05/02

9 OVERHAUL
HJ-322
8. With the Overflow Preventer securely fitted in 4. Remove the Inspection Cover [25] and O Ring
position, ensure that the Drain Bung [7] is [40].
securely closed. 5. Ensure that the O Ring [40] fitted to the
9. Check the Seal [40] fitted to the Inspection Cover Inspection Cover [25] is not perished or
[25] for wear or damage and replace as required. damaged, replace if required.
10.Smear the Seal [40] with marine grease and refit 6. Smear O Ring [40] with grease and refit to the O
to the seal groove on the underside of the Ring groove in the Inspection Cover [25].
Inspection Cover. 7. Remove the attaching Screws [2] and Flat
11.Refit the Inspection Cover [25] to the three Studs Washers [3] securing the Overflow Preventer to
[47] fitted around the Inspection Cover opening the Inspection Cover Intake opening and remove
and secure in position with Nuts [55], Flat the Overflow Preventer. Refer to Drawing “HJ-
Washers [65] and Spring Washers [60]. 322-10-001 Overflow Preventer”.
12.To drain any surplus water from inside the
NOTE: The Overflow Preventer has been attached
Overflow Preventer, slacken the Drain Bung [3]
using RTV Silicone Sealant and may require
fitted to the base of the Overflow Preventer.
some effort to remove.
NOTE: A ½ ID hose may be fitted to the Drain 8. Clean off any excess Silicone Sealant from
Connector [4] to carry water to the vessel around the Inspection Cover.
bilge. 9. Refit the Inspection Cover [25] to the Inspection
13.Ensure that the Overflow Preventer is not leaking opening in the top of the Intake and secure onto
water from around the base and from the Drain Studs [47] with Spring Washers [60] and Nuts
Connector [4]. [55]. Tighten to the recommended torque.
Visually check that the Inspection Cover is not
9.10.2 Overflow Preventer Removal leaking.
To remove the Overflow Preventer carry out the
following operations:-
EXTREME CARE IS REQUIRED WHENEVER

WARNING
The following Drawings refer:“HJ-322-01-000 Basic

Jet Assemblies Standard & Dry Run. Sht 1” / “HJ-
322-01-000 Basic Jet Assemblies Standard & Dry
Run. Sht 2” and Drawing “HJ-322-10-001 Overflow
Preventer”.
1. Ensure that the water level is below the level of
the Inspection Cover.
2. Ballast the bow end of the vessel to ensure that
water does not enter the vessel through the
Inspection opening when the Inspection Cover is
removed.
3. Remove Nuts [55], Flat Washers [65] and Spring
Washers [60] from the three Studs [47] retaining
the Inspection Cover [25] to the top of the Intake.
AMENDMENT 8 21/05/02 9.29

9 OVERHAUL
HJ-322
9.11 SCREEN RAKE ASSEMBLY OVERHAUL (IF FITTED)
9.11 SCREEN RAKE ASSEMBLY Rake pivot point to clear the starboard Screen
Rake Bearing housing in the Intake.
OVERHAUL (IF FITTED) 9. Carefully lower the Screen Rake [7] from the
Refer to Drawing “HJ-322-09-000 Screen Rake As- underside of the Intake.
sembly & Blanking Plugs”.
10.Check the Screen Rake for distortion, damage
Before removing the Screen Rake, ensure that the and excessive wear at the Screen Rake Bearing
Screen has been removed, refer to Section attachment points. Repair or replace as
9.11.4“Screen Removal”. required.
The Screen Rake need only be dismantled if it is
11.Remove the Screen Rake Bearing Attachment
suspected of being defective for the following
Nuts [14], Spring Washers [16] and Flat Washers
reasons:-
[18] from the Port Screen Rake Bearing [4] and
a) The Port [4] and Starboard [5] Screen Rake
withdraw the Port Screen Rake Bearing from the
Bearings are worn.
Intake.
b) The "O" Rings [11] and [12] are leaking.
c) The Screen Rake [7] is damaged or bent. 12.Check the "O" Rings [11] and [12] on the
Starboard Screen Rake Bearing and replace if cut,
damaged or distorted.
9.11.1 Screen Rake Removal
13.Check the Starboard Screen Rake Bearing for
Refer to Drawing “HJ-322-09-000 Screen Rake As-
wear and damage. Replace as required.
To remove the Screen Rake Assembly, the vessel 14.Remove the Grease Nipple [10] from the
should be removed from the water to allow access Starboard Screen Rake Bearing [5] and ensure
to the underside of the vessel. To remove the Screen that the grease channels are not blocked.
Rake, carry out the following:- 15.Refit the Grease Nipple [10].
1. Support the Screen Rake beneath the vessel. 16.Check the "O" Ring [12] on the Port Screen Rake
2. From inside the vessel, disconnect and remove Bearing and replace if cut, damaged or distorted.
the Tension Spring [1] from the Rake Actuator [9] 17.Remove the Grease Nipple [10] from the Port
and Spring Attachment Bolt [17] on the starboard Screen Rake Bearing [5] and ensure that the
side of the Intake, in the vicinity of the Coupling grease channels are not blocked.
Flange. 18.Refit the Grease Nipple [10].
3. Remove Nut [13], Spring Washer [15], Special 19.Thoroughly clean all components and examine
Washer [2] and the Cotter [8] securing the Rake for wear, damage and distortion.
Actuator [9] to the Screen Rake [7].
4. Remove the Rake Actuator [9]. 9.11.2 Screen Rake Re-Fitting
5. With the Screen Rake supported beneath the Refer to Drawing “HJ-322-09-000 Screen Rake As-
vessel, from inside the vessel, remove the Screen sembly & Blanking Plugs”.
Rake Bearing Attachment Nuts [14], Spring
Washers [16] and Flat Washers [18] from the 1. Smear a new "O" Ring [12] with grease and fit on
Starboard Screen Rake Bearing [5]. the Port Screen Rake Bearing. Smear the shaft of
the port Screen Rake Bearing with marine grease.
6. Whilst ensuring that the Screen Rake is
supported, withdraw the Starboard Screen Rake 2. Smear the bore of the Port Screen Rake Bearing
Bearing [5]. The starboard Screen Rake pivot [4] with marine grease and fit to the Studs [46] on
point will now rest on the Screen Rake Bearing the port side of the Intake. Refer to Drawing “HJ-
housing in the Intake. 322-01-000 Basic Jet Assemblies Standard & Dry
Run. Sht 1” and “HJ-322-01-000 Basic Jet As-
7. From beneath the vessel, whilst supporting the semblies Standard & Dry Run. Sht 2”.
Screen Rake move the Screen Rake fully to
starboard to allow the port Screen Rake pivot 3. Secure with Spring Washer [16], Flat Washer [18]
point to clear the Port Screen Rake Bearing [4]. and Nuts [14], ensuring that the Grease Nipple
[10] is positioned at the top of the bearing.
8. With the port Screen Rake pivot point clear of the
Port Screen Rake Bearing [4], move the Screen 4. Torque load to the recommended torque.
Rake to starboard to allow the Starboard Screen
9.30 AMENDMENT 18 04/10/04

9 OVERHAUL
HJ-322
5. From beneath the vessel, whilst supporting the 9.11.3 Screen Rake Blanking Plugs
Screen Rake and before fitting the Starboard
Refer to Drawing “HJ-322-09-000 Screen Rake As-
Screen Rake Bearing, feed the starboard Screen
Rake pivot point through the starboard Screen
Rake mounting point in the Intake. Should it be necessary to run the Jet Unit without a
Screen Rake, Blanking Plugs [19] can be fitted in
6. Raise the port side of the Screen Rake and align place of the Port and Starboard Screen Rake
the pivot point of the Screen Rake with the Port Bearings.
Screen Rake Bearing [4].
To fit the Blanking Plugs, carry out the following
7. Push the Screen Rake fully to port and into the procedure:
Port Screen Rake Bearing [4].
1. Remove the Screen Rake as shown in Section
8. Inside the vessel, smear new "O" Rings [11] and 9.11.1“Screen Rake Removal”.
[12] with marine grease and fit to the Starboard
2. Ensure that "O" Ring [12] fitted to the Screen
Screen Rake Bearing [5]. Smear the shaft and
Rake Blanking Plug [19] is not damaged, cut or
bore of the Starboard Screen Rake Bearing with
distorted.
marine grease.
3. Liberally coat the shaft of the Blanking Plug with
9. Fit the Starboard Screen Rake Bearing [5] over the
grease and fit onto Studs [46], refer to Drawings
Starboard Screen Rake pivot point which is
protruding through the Intake.
Dry Run. Sht 1” and “HJ-322-01-000 Basic Jet
10.Align the Screen Rake Bearing [5] with the Studs Assemblies Standard & Dry Run. Sht 2”.
[46] on the Intake, Refer to Drawing “HJ-322-
4. Secure with Spring Washer [16], Flat Washers
01-000 Basic Jet Assemblies Standard & Dry Run.
18] and Nut [14]. Torque load to the
Sht 1” and “HJ-322-01-000 Basic Jet Assemblies
recommended torque.
Standard & Dry Run. Sht 2”.
5. Repeat Items 2 to 4 above to fit the second
11.Ensure that the Grease Nipple [10] is positioned
Blanking Plug.
at the top of the Starboard Screen Rake Bearing.
12.Secure with Spring Washer [16], Flat Washers
[18] and Nuts [14]. Torque load to the
recommended torque.
13.Fit the Screen Rake Actuator [9] to the Starboard
Screen Rake pivot point and Fit Cotter Pin [8].
Secure with Special Washer [2], Spring Washer
[15] and Nut [13]. Torque load to the
recommended torque.
14.Connect one end of the Spring [1] to the Spring
Anchor Point Bolt [17] and connect the other end
of the Spring [1] to the Screen Rake Actuator [9].
15.Grease the port and starboard Screen Rake
Bearings through the Grease Nipples [10] on the
top of the Screen Rake Bearings until grease is
seen to ooze from the inboard ends of the Screen
Rake Bearings.
16.Remove the support from the Screen Rake
beneath the vessel.
17.Carry out a functional check of the Screen Rake
Assembly. Have someone positioned beneath
the vessel to observe that the Screen Rake
operates without fouling on the Intake Screen.
AMENDMENT 18 04/10/04 9.31

9 OVERHAUL
HJ-322
9.11.4 Screen Removal

To remove the Screen from the Intake, carry out
GRP HULLS (0º AND 5º):—Refer to “HJ-322-08-

001 Installation Details GRP Hull with 5º Shaft Line.
Sht 1”/“HJ-322-08-001 Installation Details GRP
1”/“HJ-322-08-011 Installation Details GRP Hull
with 0º Shaft Line. Sht 2”.
ALUMINIUM HULLS (0º AND 5º):—Refer to “HJ-

322-08-002 Installation Details Aluminium Hull with
5º Shaft Line. Sht 1”/“HJ-322-08-002 Installation
Details Aluminium Hull with 5º Shaft Line. Sht 2”
and “HJ-322-08-012 Installation Details Aluminium
Hull with 0º Shaft Line. Sht 1”/“HJ-322-08-012 In-
stallation Details Aluminium Hull with 0º Shaft Line.
Sht 2”.
STEEL HULLS (0º AND 5º):—“HJ-322-08-003 In-

stallation Details Steel Hull with 5º Shaft Line. Sht 1”
/ “HJ-322-08-002 Installation Details Aluminium
Hull with 5º Shaft Line. Sht 2”, and “HJ-322-08-001
1” / “HJ-322-08-001 Installation Details GRP Hull
with 5º Shaft Line. Sht 2”.
1. Whilst supporting the Screen [13], remove the 4
Nuts [15], Spring Washers [16], Flat Washers
[17] off the Studs [8] securing the front of the
Screen to the underside of the Intake Block.
2. Remove the 4 Nuts [15], Spring Washers [16],
Flat Washers [17] off the Studs [8] securing the
rear of the Screen to the underside of the Intake
Block.
3. Lower the Screen off the Studs [8] and remove
from the vessel for repair, refurbishment.
9.11.5 Screen Re-Fitting

Ensure that the Screen Rake has been re-fitted. Refer
to Section 9.11.2“Screen Rake Re-Fitting”.
1. Ensure that the 8 Studs [8] that support the front
and rear of the Screen are securely fitted to the
Intake. If the Studs are loose, refit using Loctite
262 [19].
2. Offer the Screen up to the 8 Studs [8] on the front
and rear of the underside of the Intake and secure
in position with Flat Washers [17], Spring
Washers [16] and Nuts [15].
3. Tighten to the recommended torque.
9.32 AMENDMENT 9 24/01/03

9.12 SERVICING DRAWINGS
HJ-322

9 OVERHAUL
9.33
HJ-322-01-000 Basic Jet Assemblies Standard & Dry Run. Sht 1

9 OVERHAUL
9.34
A B C D E F G H I Ite m Kit PartNumbe r M ov exAlias Qty ProductDe scription DrawingNbr A B C D E F G H I Item Kit PartNumber M ove xAlias Qty ProductDe scription DrawingNbr
A HJ32201001 BASIC JET STANDARD HJ32201000 A B C 28 107108 1 OIL COOLER COVER 107108
B HJ32201004 BASIC JET C/W DRY RUN SHAFT HJ32201000 A B 29 61529 061529 1 (JET) ROTARY SEALS 2.5" (SS8-H1309CSN-X40) 61529
C 111338 INTAKE KIT HJ32201000 A B C 30 63097 063097 1 (LABELS) (MODEL & SERIAL No PLATE) 63097
D 107204 TAILPIPE KIT STD HJ32201000 A B C 31 63135 063135 1 (LABELS) (PATENT PLATE) 63135
E 111340 TAILPIPE KIT DRY RUN HJ32201000 A B C 32 63610 063610 1 (LABELS) ( W ARNING PLATE) 63610
F 107205 IMPELLER RACE KIT HJ32201000 A B C 33 65234 065234 2 3/8" BSPP PUSHLOCK FITTING, MALE (3D982-6-6C) N/A
G 111339 BEARING HOUSING KIT HJ32201000 A B G 34 HEIDAAA 200917 1 (GREASE) NIPPLES 1/8"BSP 304 stst N/A
H 111654 ANODE KIT:- TAILPIPE INTERNAL HJ32201000 A B D E 35 HIQUAAG 200937 1 (PLUGS) B.S.P.P. PLUG 1-1/4" BSP SQ HD 316 S.S. N/A
B E I 106627 DRY RUN BEARING ASSEMBLY HJ29201000 A B G 36 63878 063878 1 (SKF) BEARINGS ALL TYPES (SKF QJ317 OR QJ317NZ) N/A
D E REF 104867 2 THREADED BUSH 104867 A B G 37 JW KZADF 201499 2 (OIL SEALS) NAK SCW 10-85*110*12 N/A
C REF 61362 061362 1 (OIL SEALS) 25x42x7 (Gaco DPSM 25427) C/W SS SPRING N/A A B C1 D1 E1 F 38 107167 2 (JET) O RINGS SPECIAL CORD DIA. 0.103x1069 108975
C REF 111138 1 SLEEVE for STEERING SHAFT BUSH 111138 A B G 39 HMHRADK 200988 1 (O RINGS) IMPERIAL 0.13x6.50x6.75 (260N70) N/A
C REF 111124 1 STEERING SHAFT BUSH (Orkot TL) 111124 A B C 40 HMHRADQ 200991 1 (O RINGS) IMPERIAL 0.25x5.25x5.75 (431N70) N/A
C REF 111123 1 STEERING BUSH & SEAL HOUSING 111123 A B C 41 107168 1 (JET) O RINGS SPECIAL CORD DIA. 0.13x1130 107168
C REF JAJYXCD 201246 1 (SCREW S) (SET SCREW S) METRIC 316 ST ST Socket M8x16 N/A A B C18 D4 E4 43 JCQHXAH 201279 22 (STUDS) METRIC (316-STST) M8x40 (12/22) 30647
C REF 61353 061353 1 (SEAL) SCRAPER RING-W YCLIP 61332 A B D2 E2 F1 44 30661 030661 3 (STUDS) METRIC (316-STST) M8x51 (16/16) 30647
A B D2 E2 F1 1 102185 3 ANODE 102185 A B D E 45 110431 8 (STUDS) METRIC (316-STST) M10x55 (20/20) 30637
A B D E H 2 111593 6 ANODE (INTERNAL) TAILPIPE 111593 A B C 46 JCQHXAO 201281 4 (STUDS) METRIC (316-STST) M10x50 (15/26) 30637
A B 4 107124 1 IMPELLER KEY 107124 A B C 47 103916 3 (STUDS) METRIC (316-STST) M12x64 (24/24) 30639
A B 5 104192 1 PIN 5 dia x 9 108250 A B D E 48 JEOZXAI 201384 8 (W ASHERS) (FLAT) METRIC ST ST 316 M10x21x1.2 N/A
A B 6 111202 1 W ATER BEARING SLEEVE 111202 A B C 49 30723 030723 3 (STUDS) METRIC (316-STST) M16x180 (35/35) 30634
A B 7 109964 1 CIRCLIP (ROTARY SEAL RETAINER) 109964 A B F 50 107268 8 (STUDS) METRIC (SAF-2205) M16x135 (40/40) 30700
A B 8 109432 1 COUPLING KEY 109432 A B D E H 51 JDQSXAC 201330 10 (NUTS) (METRIC NYLOC ST ST 316) M8 N/A
A B C 9 111057 1 INTAKE 111057 A B 52 JAJYXCB 201245 2 (SCREW S) (SET SCREW S) METRIC 316 ST ST Socket M8x10 N/A
A B C 10 JEOZXAF 201383 20 (W ASHERS) (FLAT) METRIC ST ST 316 M8x16x1.2 N/A A B C20 D2 E2 F1 53 JDQHXAC 201309 23 (NUTS) (METRIC ST ST 316) M8 N/A
A B F 11 107266 1 W EAR RING 107266 A B D E 54 JDQHXAE 201310 8 (NUTS) (METRIC ST ST 316) M10 N/A
A B D E 12 107102 1 TAILPIPE 107102 A B C 55 JDQHXAH 201311 3 (NUTS) (METRIC ST ST 316) M12 N/A
A B G 13 111062 1 BEARING HOUSING (with saginaw pump mount) 111062 A B C11 F16 56 JDQHXAL 201312 19 (NUTS) (METRIC ST ST 316) M16 N/A
A B G 14 111064 1 BEARING CAP (with saginaw pump mount) 111064 A B C20 D12 E12 F1 H10 58 JEQKXAC 201394 33 (W ASHERS) (SPRING) METRIC ST ST 316 M8 N/A
A B G 15 109965 2 SEAL SLEEVE 109965 A B D E 59 JEQKXAE 201395 8 (W ASHERS) (SPRING) METRIC ST ST 316 M10 N/A
A B D E 16 104618 1 TAILPIPE FAIRING 104618 A B C 60 JEQKXAH 201396 3 (W ASHERS) (SPRING) METRIC ST ST 316 M12 N/A
A B 17 104619 1 COUPLING NUT AB2 104619 A B C11 F16 61 103451 19 (W ASHER) SPECIAL M16 316 STST 103451
A B G 18 107122 2 BEARING CARRIER 107122 A B D E 63 JMNGAAO 201411 1 (HOSE) TAILS 1-1/4" BSP (#BSP-6-HT-032) 316 STST N/A
A B 19 112291 1 AB2 IMPELLER NUT 112291 A B G 64 110806 1 SLEEVE FOR SAGINAW PUMP MOUNT 110806
A B 20 111063 1 MAINSHAFT 111063 A B C 65 JEOZXAK 201385 3 (W ASHERS) (FLAT) METRIC ST ST 316 M12x24x1.6 N/A
A B F 21 107267 1 INSULATOR (W EAR RING) 107267 A B C 66 111059 1 ANODE INTERNAL 111059
A B 23 107285 1 (Jet) W ood Transport Crate HJ 322 107285 A B C 67 HZQHXBF 201223 2 (SCREW S) (M/C SCREW S) METRIC ST ST 316 HEX HD M8x55 N/A
A D 24.1 106265 1 MARINE W ATER BEARING 80x60x180 106264 A B F 68 107254 1 IMPELLER RACE 107254
B E I 24.2 106627-1 1 BEARING SHELL 106627-1 A B C 69 107165 8 (STUDS) METRIC (SAF-2205) M16x95 (35/35) 30700
B E I 24.3 106627-2 1 BEARING INNER 106627-2 A B 70 111428 1 322 LABELS KIT 111420
B E I 24.4 111126 1 (GENERAL) ROUND CIRCLIP (DRY RUN BEARING) 104201 71 111336 REF PAINT APPLICATION 322 JET (STD) Gloss Finish. 111178
A B 25 106972 1 INSPECTION COVER (S/No 2506 on) 106972 72 111335 REF PAINT APPLICATION 322 JET (OPTIONAL) Antifoul Preparation 111178
A B D E 26 111655 1 ANODE MOUNTING PLATE HJ292 & 322 111655 A B C 73 W AQUDAC 201767 2 BONDED SEAL 3/8" BSP (400-823-4490-74) N/A
A B G 27 63879 063879 1 (SKF) NUTS SPECIAL Lock Nut KMT 11 63879
TORQUE CHART Nm ft/lb

IMPELLER NUT (19) 600 440
COUPLING NUT (17) 250 184
BEARING LOCK NUT (27) 270 200
IMPELLER NUT SET SCREW (52) 8 6
COUPLING NUT SET SCREW (52) 8 6
BEARING LOCK NUT SET SCREW 8 6

ALL OTHER NUTS AS PER DRAWING 85113
HJ-322
HJ-322-01-000 Basic Jet Assemblies Standard & Dry Run. Sht 2
HJ-322 9 OVERHAUL
HJ-322-02-001 Couplings & Belts
AMENDMENT 18 04/10/04 9.35
9 OVERHAUL
9.36
Code Item Kit PartNumber Qty ProductDescription DrawingNbr

3 1 107120 1 (JET) IMPELLERS TYPE (26) - (6 BLADE) 107117
3 1 108849 1 (JET) IMPELLERS TYPE (36) - (6 BLADE) (PITCHED) 107117
3 1 110667 1 (JET) IMPELLERS TYPE (33) - (6 BLADE) (PITCHED) 107117
3 1 107117 1 (JET) IMPELLERS TYPE (32) - (6 BLADE) As Cast 107117


HJ-322
HJ-322-03-001 Impellers
HJ-322 9 OVERHAUL
HJ-322-06-000 Steering Assembly General Arrangement. Sht 1
AMENDMENT 18 04/10/04 9.37
9 OVERHAUL
HJ-322
HJ-322-06-000 Steering Assembly General Arrangement. Sht 2
9.38 AMENDMENT 18 04/10/04
HJ-322 9 OVERHAUL
HJ-322-07-001 Reverse Assembly. Sht 1
AMENDMENT 18 04/10/04 9.39
9 OVERHAUL
HJ-322
HJ-322-07-001 Reverse Assembly. Sht 2
9.40 AMENDMENT 18 04/10/04
HJ-322
Item PartNumber Qty ProductDescription DrawingNbr

1 111315 2 BLANKING PLUG FOR REVERSE CYLINDER HJ292 &322 111315
2 HYQHXDY 1 (BOLTS) (METRIC) ST ST 316 M10x50 N/A
3 JDQSXAE 1 (NUTS) (METRIC NYLOC ST ST 316) M10 N/A
4 JMNGAAS 1 NEUT-CURE RTV SILICONE 75G N/A

9 OVERHAUL
9.41
HJ-322-07-002 Blanking Plugs for Reverse Cylinder

9 OVERHAUL
HJ-322
HJ-322-09-000 Screen Rake Assembly & Blanking Plugs
9.42 AMENDMENT 18 04/10/04
HJ-322
ITEM PART No QTY DESCRIPTION DWG No

1 107221 1 OVERFLOW PREVENTER 107221
2 30728 4 M6 x 12 PAN HEAD M/C SCREW (316 S.S.)
3 JEOZXAD 4 M6 WASHER (316 S.S.)
4 107298 1 DRAIN CONNECTION 107298
5 JDQKXAJ 1 M16 THIN NUT (316 S.S.)
6 JEOZXAM 2 M16 WASHER (316 S.S.)
7 63825 1 DRAIN BUNG-NATRA
8 JMNGAAS 1 RTV SILICONE SEALANT (NEUTRAL CURE)

9 OVERHAUL
9.43
HJ-322-10-001 Overflow Preventer

9 OVERHAUL
HJ-322
HJ-322-11-000 Tool Kits. Sht 1
9.44 AMENDMENT 18 04/10/04
HJ-322
A B C D Item Kit PartNumber MovexAlias Qty ProductDescription DrawingNbr

A 110348 SERVICE TOOLS KIT for 150x8xM12 & ELBE 0.115. HJ32111000
B 110349 SERVICE TOOLS KIT HARDY SPICER 1650-1710-1810 HJ32111000
C 110350 SERVICE TOOLS KIT for 180x10xM16, 180x8xM14 & ELBE 0.119, 0.120. HJ32111000
D 110796 SERVICE TOOLS KIT for AQUADRIVE 20600, CV32 & CV42. HJ32111000
A B C D 1 104689 1 IMPELLER PULLER 104689

A 2.1 104917 1 TORQUE ARM (ELBE 0.115) 104917
B 2.2 106080 1 TORQUE ARM (HARDY SPICER COUPLING) 106080
C 2.3 104938 1 TORQUE ARM (ELBE 0.119 & GWB 587.42 COUPLINGS) 104938
D 2.4 110795 1 TORQUE ARM (AQUADRIVE 20600-20400) 110795
A C 3.1 112456 MULTI SCREW COUPLING PULLER FOR VARIOUS JETS 112456
B D 3.2 112407 1 MULTI SCREW COUPLING PULLER FOR VARIOUS JETS 112407
A B C D 5 JMNGAAP 201412 1 (SOCKETS) TOOLS A/F 50mm 3/4" SQ. DRIVE (SOCKET) N/A
A B C D 6 112499 1 BEARING NUT SPANNER (SKF KMT11) 112499
B 7.1 HYQHXCE 201136 8 (BOLTS) (METRIC) ST ST 316 M8x60 N/A
A B 7.2 HYQHXEA 201145 8 (BOLTS) (METRIC) ST ST 316 M10x60 N/A
A C 7.3 HYQHXFV 201154 8 (BOLTS) (METRIC) ST ST 316 M12x60 N/A
C D 7.4 HYQHXIP 201162 8 (BOLTS) (METRIC) ST ST 316 M16x65 N/A
B 8.1 JDQHXAC 201309 8 (NUTS) (METRIC ST ST 316) M8 N/A
A B 8.2 JDQHXAE 201310 8 (NUTS) (METRIC ST ST 316) M10 N/A
A C 8.3 JDPVYAH 201305 8 (NUTS) (METRIC MILD STEEL) M12 (GR88) (ZP) N/A
B 9.1 JEOZXAF 201383 8 (WASHERS) (FLAT) METRIC ST ST 316 M8x16x1.2 N/A
A B 9.2 JEOZXAI 201384 8 (WASHERS) (FLAT) METRIC ST ST 316 M10x21x1.2 N/A
A C 9.3 JEOZXAK 201385 8 (WASHERS) (FLAT) METRIC ST ST 316 M12x24x1.6 N/A
A1 B1 C D 9.4 JEOZXAM 201386 9 (WASHERS) (FLAT) METRIC ST ST 316 M16 N/A
A B C D 10 HYIXXHP 201102 1 (BOLTS) (METRIC) MILD STEEL H/TENSILE GR88 (ZP) M24x75 N/A
A B C D 11 112408 1 FORCING BAR FOR MULTI SCREW COUPLING PULLER 112408
A B C D 12 107191 1 ROTARY SEAL FITTING SLEEVE (Acetal) 107191
A B C D 13 109966-1 1 MAINSHAFT SUPPORT TOOL: SUPPORT HOOK 109966
A B C D 14 63625 063625 1 (JET) PACKAGING CARTON 278x278x170 N/A
A B C 15 112410 1 15mm FORCING BAR SPACER FOR MULTI SCREW COUPLING PULLER 112408
D 16 112409 1 38mm FORCING BAR SPACER FOR AQUADRIVE COUPLING 112408
A B C D 17 30855 030855 8 (SCREWS) (CAPSCREWS) 10.9 ALLOY STEEL Socket Hd M12x55 N/A
A B C D 18 JBJYXAJ 201262 1 (SCREWS) (CAPSCREWS) METRIC ST ST 316 Socket Hd M6x20 N/A
A B C D 19 109966-2 1 MAINSHAFT SUPPORT TOOL: SUPPORT BAR 109966
A1 B1 C D 20 JDPVYAL 201306 9 (NUTS) (METRIC MILD STEEL) M16 (GR88) (ZP) N/A
B 21.1 HYQHXCA 201132 2 (BOLTS) (METRIC) ST ST 316 M8x40 N/A
A B 21.2 HYQHXDW 201142 2 (BOLTS) (METRIC) ST ST 316 M10x40 N/A
A C 21.3 30828 030828 2 (BOLTS) (METRIC) ST ST 316 M12x40 N/A
C D 21.4 HYIXYDS 201106 2 (BOLTS) (METRIC) MILD STEEL H/TENSILE GR88 (ZP) M16x45 N/A

9 OVERHAUL
9.45
HJ-322-11-000 Tool Kits. Sht 2

9 OVERHAUL
9.46
DO NOT SCALE THIS DRAWING REMOVE ALL SHARP CORNERS ALL DIMENSIONS IN mm. UNLESS OTHERWISE SHOWN
10 2 3 4 5 6 7 8 9
v
HJ-322
61529 Rotary Seal (Eagle) 2.5” Diameter Shaft
HJ-322
DO NOT SCALE THIS DRAWING REMOVE ALL SHARP EDGES ALL DIMENSIONS IN mm UNLESS OTHERWISE STATED PROJECTION

C. W. F. Hamilton & Co. Ltd Christchurch, New Zealand
F
AMENDMENT MATERIAL Certified Weight (kg) = N9 EXCEPT AS STATED

F - Sht.2 - BALANCE WEIGHTS ADDED & 212 TURBO
Cast UNLIMITED DIMENSIONS TO BE ±0.5 Scale 1:1
JET ADDED.
M/C DESCRIPTION
9 OVERHAUL
Standard IMPELLER BLADE DRESSING
82206
Approvals
INSTRUCTIONS & BALANCING
ECN CL324 BY R.J.L DATE 17.05.04 INFORMATION
Name Date
SHEET 1 OF 4 SHEETS
DWG No
JET ALL
Designed M.J.H. 26.06.03
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 Ltd Reviewed DWG No 82206 F
9.47
82206 Impeller Blade Dressing Instructions & Balancing Information. Sht 1

9 OVERHAUL
9.48

F

REFER TO SHEET 1 FOR CHANGES
M/C DESCRIPTION
IMPELLER BLADE DRESSING
HJ-322
Standard
82206
Approvals INSTRUCTIONS & BALANCING

ECN BY DATE
Name Date INFORMATION.
SHEET 2 OF 4 SHEETS
DWG No
JET ALL
HJ-322

F

REFER TO SHEET 1 FOR CHANGES
9 OVERHAUL
M/C DESCRIPTION
IMPELLER BLADE DRESSING

82206
Standard
Approvals INSTRUCTIONS & BALANCING

ECN BY DATE
Name Date INFORMATION.
SHEET 3 OF 4 SHEETS
DWG No
JET ALL
9.49

9 OVERHAUL
9.50

F

REFER TO SHEET 1 FOR CHANGES.
M/C DESCRIPTION
Standard IMPELLER BLADE DRESSING

82206
HJ-322
Approvals
INSTRUCTIONS.
ECN BY DATE
Name Date PRESSURE EDGE RADIUS
SHEET 4 OF 4 SHEETS
DWG No
JET ALL
Designed M.J.H. 09-09-03

HJ-322 9 OVERHAUL
85018 Recommendation for Lubricants & Oils
AMENDMENT 18 04/10/04 9.51
9 OVERHAUL
9.52
HJ-322
85080 Weld Procedure for Welding Cast Intake Block into Aluminium Hulls
HJ-322

9 OVERHAUL
9.53
85113 Recommendations for Fastener Locking, Torques and Thread Lubrication

9 OVERHAUL
HJ-322
9.54 AMENDMENT 18 04/10/04
Appendix
• SUPPLEMENTARY TECHNICAL INFORMATION

HJ-322 APPENDIX
APPENDIX-1: CONVERSION CHART

TORQUE
1 pound foot = 1.3558 newton metres 1 newton metre = 0.7375 pounds foot.
DISTANCE
1 inch = 2.54 centimetres 1 millimetre = 0.03937 inches
1 foot = 0.3048 metre 1 metre = 3.2808 feet
1 mile =1.609 kilometres
1 nautical mile = 1.8532 kilometre 1 kilometre = 0.6214 mile
1 kilometre = 0.539 nautical mile
SURFACE or AREA
1 square inch = 6.4516 square centimetres 1 square centimetre = 0.1550 square inch
1 square foot = 929.03 square centimetres 1 square metre = 10 .76 square feet
POWER
Horsepower Kilowatts
1 Horsepower = 0.7457 Kilowatts 1 Kilowatt = 1.341 Horsepower
1 Horsepower (Metric) = 0.7355 Kilowatts 1 Kilowatt = 1.3596 Metric Horsepower
FORCE
I kilonewton = 224.86 pounds force 1 pound force = 4.448 newtons
WEIGHT
1 ounce = 28.35 grams 1 gram = 0.0353 ounce
1 pound = 0.4536 Kilograms 1 kilogram = 2.205 pounds
1 Tonne = 2205 pounds
TEMPERATURE LIQUID MEASURE (IMPERIAL)

Farenheit Celsius 1 pint = 0.5506 litre
1 gallon = 4.546 litres
248 °F 120 °C 1 (UK) gallon = 1.201 (US) gallon
212 100 1 litre = 0.2199 (UK) gallons
176 80
140 60
104 40 LIQUID MEASURE (U.S.)
95 35 1 pint = 0.473 litre
86 30 1 gallon = 3.785 litres
77 25
68 20
59 15
50 10
41 5
32 0
Fahrenheit to Celsius: Celsius to Fahrenheit:
Subtract 32, then multiply by 5/9. Multiply by 9/5, then add 32
SPEED
1 mile per hour = 0.8690 knots 1 mile per hour = 1.609 kilometres per hour
1 kilometre per hour = 0.5396 knots 1 kilometre per hour = 0.621 miles per hour
1 knot = 1.8532 kilometres per hour 1 knot = 1.151 miles per hour
PRESSURE
1 pound /inch 2 = 0.0689 bar 1 bar = 14.5038 pound / inch 2
1 pound / foot 2 = 4.8824 kilogram / metre 2 1 kilogram / metre 2 = 0.2048 pound / foot2
1 pound /inch 2 = 6.895 Kilopascal 1 Kilopascal = 0.145 pound /inch 2
1 Newton/millimetre2 = 145.04 pounds/square inch 1 bar = 100 kilopascal
AMENDMENT 12 22/08/03 A.1

APPENDIX HJ-322
A.2 AMENDMENT 12 22/08/03

HJ-322 APPENDIX
APPENDIX-2: LOCTITE APPLICATION GUIDE CHART - ALL JETS
WARNINGS
NO SMOKING IN THE PRESENCE OF PRIMER, ACTIVATOR OR ACCELERATOR.
PRIMER 7471, ACTIVATOR 7075 AND ACCELERATOR 7649, ARE ALL HIGHLY FLAMMABLE.
NEVER MIX PRIMER OR ACTIVATOR AND ADHESIVE DIRECTLY AS LIQUIDS.
FOR ADDITIONAL SAFE HANDLING PROCEDURES REFER TO THE PRODUCT DESCRIPTION

SHEETS.
EQUIVALENTS:
638 LOCTITE IS THE EQUIVALENT OF 680 AND IS USED WITH 7471 PRIMER.
317 LOCTITE IS THE EQUIVALENT OF 325 AND IS USED WITH 736 ACTIVATOR.
LOCTITE APPLICATION: GENERAL PRACTICE

1. All parts must be free from oil and or grease.
DO NOT USE PAINT THINNERS for cleaning.
Use solvents such as Methylated Spirits, Trichlorethylene or Acetone.
2. Primers, Activators or Accelerators should not be applied to ‘Active Surfaces’, such as Bronzes
and Steel.
3. Primers, Activators or Accelerators are not to be applied to any painted surface.
4. Allow sufficient time for Primers, Activators or Accelerators, where applied, to dry.
5. All painted Bores must be fully cured before the application of Loctite.
6. Fixing and full cure times for all Loctite will be increased at reduced temperatures.
7. Refer to relevant Product Data Sheets or Guidelines for safe use and Practice of all Loctite
Products.

APPENDIX HJ-322

HJ-322 APPENDIX

APPENDIX HJ-322

HJ-322 APPENDIX
APPENDIX-3: INSTALLATION CHECKS FOR HAMILTON WATER JETS

1. JET UNIT: MOUNTING:
ITEM
CHECK TO BE CARRIED OUT COMPLETED
NO .
1.1 Check the Intake Mounting Block is faired to the Hull bottom.
1.2 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.
1.3 Inspect the Intake Base Flange for obvious distortion or gaps between the
Mounting Block and the Intake base Flange.
1.4 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 gas-
ket and sealant.
1.5 Check the Transom Plate Seal is correctly located and secured. (Do not over-
tighten). If two people are available and the boat is indoors, a strong light may
be used to check the fit of the Transom cut out and Seal.
1.6 For Steel Hulls check that the Jet Unit is insulated from the Hull (Refer to the
drawings and the "Corrosion" Section of the Product Manual).
1.7 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).
1.8 Check that the Hull Trim Tabs (if fitted) will not interrupt the reverse flow
(Refer to the Design Basics Section in the PInstallation and Service manual).
REMARKS:

APPENDIX HJ-322
2. JET UNIT: GENERAL:
ITEM
NO.
2.1 Ensure that the correct Impeller is fitted to match engine duty. Impeller part
number (stamped on hub) can be seen through the Jet Unit Inspection Cover.
2.2 Check that all Anodes are in place and have not been painted over. (Refer to
the Anode Location drawings shown in the Product Manual).
2.3 If antifouling has been applied to the Jet casing ensure it is compatible with alu-
minium (i.e. not copper based).
2.4 Check that the Inspection Hatch Seal is correctly located in the seal groove and
that the Inspection Hatch securing bolts are tightened to the correct torque.
2.5 Check that the Bearing Housing has been filled with grease as shown in Section
9.6.4"Bearing Housing Re-Assembly", Item 17.
2.6 Check that the Water Offtake Hoses (when fitted) are appropriately and
securely fitted.
2.7 Check that any unused Water Offtakes are plugged.
REMARKS:

HJ-322 APPENDIX
3. JET SYSTEMS: STEERING:
ITEM
NO .
3.1 For Jet Units with Tiller type Steering (e.g. HM-422) check that the Cotter Pins
(Tapered Pins which locate the Tiller Arms on the Steering Shaft) are facing the
correct direction for the deadrise angle and the number of Jets (Refer to the
Steering Drawings in the Product Manual).
3.2 For manual hydraulic helms ensure that:-
• Correct steering ratio (1 to 2 turns of Helm from lock to lock).
• Full lock travel is limited by the cylinder, not the steering linkage.
• Steering sense is correct (i.e. port Helm provides port Nozzle movement).
• Ensure that all air has been bled from the Steering system (feel at the Wheel
will be soft and spongy if there is still air in the Steering system).
REMARKS:

APPENDIX HJ-322
4. DRIVE SHAFT:
ITEM
NO.
4.1 Ensure driveline details have been approved by CWF Hamilton & Co Ltd.
4.2 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 are <5º.
• Yokes are in the same plane.
4.3 On Bearing supported Line Shafts (Refer to the Design Basics Section in the
Product Manual) check:
• The Support Bearings are aligned with the Engine Flywheel.
• Outer Support Bearings are close to the end of the Couplings.
REMARKS:
A.10 AMENDMENT 12 22/08/03

HJ-322 APPENDIX
APPENDIX-4: COMMISSIONING CHECKS FOR HAMILTON WATER JETS
APPENDIX-4:

Refer to the relevant Controls Product Manual for commissioning of the Controls System.
1. PRE LAUNCH CHECKS:
ITEM
CHECKS TO BE CARRIED OUT COMPLETED
NO .
1.1 Check that the plastic spiral wrap protective cover (where fitted) has been
removed from hydraulic shafts (HM-Models only). Check all hydraulic shafts
for damage and that they are free from contamination (weld splatter, grinding
dust, fiberglass resin, etc).
1.2 Check that all the Jet Unit inspection covers are correctly fitted and secured.
1.3 Check that all the Anodes have been fitted and that they have not been painted
over. Refer to Drawing “HJ-322-13-002 Anode Location Drawing”.
REMARKS:
AMENDMENT 15 31/03/04 A.11

APPENDIX HJ-322
2. POST LAUNCH CHECKS:
ITEM
NO.
2.1 Check for water leaks at the Transom Seal, Intake base, and from under the
Bearing Housing (Water Seal leaking).
2.2 For oil lubricated Main Bearings (HJ-362 and above), check that the correct
Dipstick is fitted and that oil level is correct (Dipstick length is dependent on
the deadrise angle of the Jet Unit). For HM-651 to HM-811, check that the Dip-
sticks are on the correct side (Refer to the Dipstick drawings in the Product
Manual).
2.3 For grease lubricated Main Bearings (HJ-212 to HJ-322), whilst slowly rotating
the Mainshaft, lightly grease the Bearing via the Grease Nipple on the top of the
Bearing Housing. Continue greasing until grease is seen escaping between the
Seal and the Seal Sleeve at the front of the Bearing Housing.
ENSURE THAT ALL BEARING HOUSINGS

ARE CORRECTLY FILLED WITH THE COR-
RECT AMOUNT AND GRADE OF OIL. IF
THIS IS NOT DONE, THEN DAMAGE WILL
CAUTION
OCCUR TO THE JET UNIT.
2.4 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.
2.5 Check the JHPU oil level and replenish as required.
REMARKS:
A.12 AMENDMENT 18 04/10/04

HJ-322 APPENDIX
3. ENGINE RUNNING CHECKS (VESSEL MOORED):
ITEM
NO .
3.1 The Water Bearing (Cutless Bearing) must operate wet unless the optional Dry
Run Kit has been fitted (Dry Run Kit available for HJ-212 to HJ-322 Jet Units
only).
For a Jet Unit fitted with a Dry Run Kit, the following applies:-
Maximum Dry Run Time of 3 minutes with engine speed not exceeding 1000 RPM.
Minimum time between Dry Runs of 1 hour.
Do not operate the standard Jet Unit with the vessel out of the water, or with
the vessel ballasted such that the Jet Unit does not prime (pump water prop-
erly) when the engine is started.
3.2 Ensure the vessel is securely moored fore and aft and in deep clean water.
3.3 With the Reverse Controls set to "Zero Speed", the engine(s) may be started
and the engine suppliers representatives can carry out engine checks.
3.4 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.
FAILURE TO CHECK COOLING WATER

HOSES MAY RESULT IN FLOODING OF THE
VESSEL.
CAUTION
3.5 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.
3.6 Check for water leaks around the Jet Unit while the engine is running particu-
larly under the Bearing Housing (Mainshaft Water Seal).
3.7 Check that the Jet Unit and Driveshaft are running smoothly (no vibration).
3.8 Periodically check the Bearing Housing temperature. The temperature should
not exceed 80ºC.
3.9 Check that the Reverse Controls are working by monitoring the Reverse Duct
position while moving the Reverse Control Lever(s).
AMENDMENT 12 22/08/03 A.13

APPENDIX HJ-322
ITEM
NO.
3.10 Check that the Steering Controls are working by monitoring Steering Nozzle
position while moving the Helm. (Check that port helm gives port Nozzle deflec-
tion, starboard helm gives starboard Nozzle deflection and that all Nozzles are
steering in the same direction).
3.11 Check that steering travel is limited by the hydraulic Steering Cylinder and not
the Steering Linkage. (For Jet Units fitted with Steering Cylinders and Linkages).
3.12 After stopping the engine, check that the Main Bearing and JHPU oil levels and
replenish if required.
REMARKS:
A.14 AMENDMENT 12 22/08/03

HJ-322 APPENDIX
4. VESSEL TRIAL:
ITEM
NO .
4.1 Leave the mooring and check that the steering is operating correctly at "For-
ward Speed", at "Zero Speed" and going "Astern".
4.2 Observe the jet stream when going "Dead Ahead" at speed to ensure that it is
relatively clean with an even shape.
4.3 Check that the Jet Unit and Driveshaft are running smoothly (no vibration) over
the entire engine operating speed range (i.e. from "Zero Speed" to "Full
Ahead").
4.4 Periodically check the Bearing Housing temperature and record the tempera-
ture 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 80ºC.
4.5 If practical check the Coupling joint temperatures (if fitted). Increased joint
temperature may indicate Driveshaft misalignment.
4.6 Periodically check the hydraulic oil temperature at the oil. Record the tempera-
ture reading after a sustained run at cruising speed and after a period of vessel
maneuvering.
4.7 Record maximum speed (using GPS) and engine revolutions (strong currents
will result in inaccurate speed readings since the GPS provides speed over
ground). At maximum speed the jet revolutions should be verified with a hand
held tachometer at the Jet Unit Coupling.
4.8 Record vessel speed at varying engine revolutions if possible.
4.9 Record observations on vessel trim, loading, etc.
REMARKS:
AMENDMENT 12 22/08/03 A.15

APPENDIX HJ-322
5. AFTER INITIAL TRIALS:
ITEM
NO.
5.1 Refer to the Maintenance Section of the Product Manual for any servicing that
may be required on completion of trials.
5.2 For Steel Hulls check that the Jet Unit is insulated from the Hull. The resist-
ance should be approximately 100 ohms but will vary depending on water
salinity and hull characteristics. Refer to the Precautions Against Corrosion
Section of the Product Manual.
5.3 Check for water leaks at the Transom Seal, Intake Base, and from under the
Bearing Housing (Water Seal leaking).
REMARKS:
A.16 AMENDMENT 12 22/08/03

HJ-322 APPENDIX
6 JET UNIT TRIALS & COMMISSIONING DATA:
COMMISSIONING COMMISSIONING
ENGINEER: DATE:
HAMILTON JET
VESSEL DESCRIPTION:
PROJECT NUMBER:
JET UNITS
VESSEL DISPLACEMENT:
SERIAL NUMBER(S):
JET MODEL(S): GEARBOX RATIO:
ENGINE POWER &

IMPELLER RATING:
RPM:
ENGINE MODEL:
6.1. TEMPERATURE READINGS (DRIVESHAFT JOINTS, BEARING HOUSING, HYDRAULICS (IF FITTED)
TEMPERATURE: LOCATION AND COMMENTS:
6.2. SPEED TRIAL READINGS:

ENGINE SPEED: VESSEL SPEED: COMMENTS (LOADING, SEA CONDITIONS ETC):
AMENDMENT 12 22/08/03 A.17

APPENDIX HJ-322
COMMENTS:
A.18 AMENDMENT 12 22/08/03

HJ-322 APPENDIX
APPENDIX-5: KMT NUT: FITTING & REMOVAL INSTRUCTIONS
APPENDIX-5: KMT NUT: FITTING & REMOVAL

INSTRUCTIONS
Technical Data:
MATERIAL: High Strength Steel.
FINISH: Phosphated and Saturated with Oil.
LOCKING SCREWS: P6SS ISO/DIN 913, Grade 12.9.
LOCKING PINS: Hard Drawn Brass.
THREAD TOLERANCE: 5H, ISO 965/3
Recommended Shaft Thread Tolerance: 6g.
GENERAL:
The KMT Nut is quite simple to fit, as each Nus is provided with 4 cut-outs and 2 Spanner Flats on its outer
surface. The KMT Nut also has a number of radial and axial holes which can be used for tightening the Nut.
A Hook or Impact Spanner is recommended for the fitting and removal of the Nut but Open Ended or
Adjustable Spanners may be used.
The KMT Nut can be locked in position by means of the 3 Locking Screws are tightened to the recommended
torque, using a Socket / Allen Key or a Torque Wrench..
FITTING THE KMT NUT:
Prior to fitting the KMT Nut, ensure that the Locking Screws are partially withdrawn and that the Locking Pins
are not protruding into the thread path of the KMT Nut.
Fit the Nut to the Shaft and torque load to the recommended torque.
Screw down the Locking Screws evenly so that the brass Locking Pins contact the screw threads of the Shaft.
Torque load the Locking Screws evenly to the recommended torque. Do not over tighten.
KMT Bearing M6 Locknut Screws - 5 Nm (4ft/lbs).
REMOVING THE KMT NUT:
To remove the KMT Nut, partially withdraw the 3 Locking Screws located around the circumference of the
Nut.
Because the brass Locking pins are a force fit onto the Shaft and do not easily release from the threads of the
Shaft, they have to be released by lightly tapping in the vicinity of the Locking Screws, with a suitable hammer.
In some applications, the KMT Nut is shrouded by the Bearing Housing and so access to the nut is restricted.
To overcome this problem, a long bar may be used by placing the one end of the bar in the vicinity of the
Locking Screw and lightly striking the opposite end of the bar with a suitable hammer until the locking Pins
are released. Refer Figure “View of KMT Nut.” on page A20" If this fails to release the pins, tighten the KMT
Nut slightly to remove any residual torque and tap the nut again using slightly heavier blos. Unscrew the KMT
Nut and remove from the Shaft.
AMENDMENT 12 22/08/03 A.19

APPENDIX HJ-322
APPENDIX-5: KMT NUT: FITTING & REMOVAL INSTRUCTIONS
TAP HERE TO RELEASE

THE LOCKING PINS
ROUND BAR
LOCKING SCREW &

LOCKING PINS
KMT NUT
Figure 33: View of KMT Nut.
A.20 AMENDMENT 12 22/08/03

NOTES
Hamilton Jet is an international company committed to meeting their customer’s needs through the
production of waterjet propulsion systems of the highest standards. Dedicated to waterjet propulsion.
Hamilton Jet is globally represented by an extensive support network.
World Headquarters European Office American Office

C.W.F. Hamilton & Co Ltd Hamilton Jet (U.K.) Ltd Hamilton Jet Inc.
P.O. Box 709 Christchurch Unit 4a 1111 N.W. Ballard Way
New Zealand The Birches Industrial Estate Seattle, WA 98107
Phone: +64 3 962 0530 East Grinstead West Sussex Phone: +1 206 784 8400
Fax +64 3 348 6969 RH19.1XZ United Kingdom Fax: +1 206 783 7323
E-Mail: marketing@hamjet.co.nz Phone +44 1342 313 437 E-Mail: marketing@hamiltonjet.com
Web: www.hamiltonjet.co.nz Fax +44 1342 313 438 Web: www.hamiltonjet.com
E-Mail: info@hamjetuk.com
MEMBER OF THE C.W.F. HAMILTON GROUP

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HJ-322 JET UNIT

MARINE PROPULSION UNITS

Jet Type HJ-322

Copyright ©2002. CWF Hamilton & Co Ltd

2 System Operation........................................................... 2.1

AMENDMENT 18 04/10/04 iii

4 Precautions Against Corrosion ....................................... 4.1

5 Installation ....................................................................... 5.1

6 Commissioning ................................................................ 6.1

8 Maintenance .................................................................. 8.1

9 Overhaul ......................................................................... 9.1

Appendix APPENDIX-1: Conversion Chart ................................................. A.1

AMENDMENT 18 04/10/04 vii

viii AMENDMENT 18 04/10/04

NO REPRESENTATIONS OR EXPRESS OR IMPLIED WARRANTY EXCEPT AS HEREIN STATED

C.W.F. Hamilton & Co. Ltd. 1 January 2003

WARRANTY & OWNERSHIP

Delivery date Commissioning /

Contact name Signed

Contact name Signed

xii AMENDMENT 18 04/10/04

EQUIPMENT MODIFICATION LIST

AMENDMENT 18 04/10/04 xiii

xiv AMENDMENT 18 04/10/04

xvi AMENDMENT 18 04/10/04

7 Fault Finding .................................................................................................... 7.1

8 Maintenance .................................................................................................. 8.1

AMENDMENT 18 04/10/04 xvii

xviii AMENDMENT 18 04/10/04

3 Design Basics ................................................................................................... 3.1

4 Precautions Against Corrosion ....................................................................... 4.1

7 Fault Finding .................................................................................................... 7.1

8 Maintenance .................................................................................................. 8.1

9 Overhaul .......................................................................................................... 9.1

AMENDMENT 18 04/10/04 xix

85113 Recommendations for Fastener Locking, Torques and Thread Lubrication.............9.53

SELECTING ’ASTERN’ (CRASH STOP) ENSURE THAT THE VESSEL IS SECURELY

EXERCISE EXTREME CARE IF WATER SEAL

AMENDMENT 18 04/10/04 xxi

APPROPRIATE SAFETY GLASSES, PROTEC-

xxii AMENDMENT 18 04/10/04

NEVER STOP THE ENGINE(S), OR ENSURE THAT THE WATER LEVEL IS

Section 2.2. Section .

IF IN LIGHTWEIGHT PLANING CRAFT, THE BEFORE REMOVING THE INSPECTION

AMENDMENT 18 04/10/04 xxiii

LOADS ON JET UNIT THRUST AN ISOLATION TRANSFORMER OR A

Section 4.1 and Section 5.

xxiv AMENDMENT 18 04/10/04

IN MULTI JET UNIT INSTALLATIONS, TIGHTENING TORQUES:

Section 5.2. Section 8.7.

CAUTION Section 9.6.

ALL WATER SEAL FACES MUST BE CLEAN

BEFORE MOVING ANY CONTROLS, ENSURE

AMENDMENT 18 04/10/04 xxv

xxvi AMENDMENT 18 04/10/04

• INTRODUCTION AND PRODUCT DESCRIPTION

1.1 THE HAMILTON WATER JET

AMENDMENT 8 21/05/02 1.1

EQUIPMENT DESCRIPTION:—The Hamilton HJ 1.1.2 Main Components

1.2 AMENDMENT 8 21/05/02

TRANSOM SEAL:—The Transom Seal serves to seal

AMENDMENT 17 18/06/04 1.3

STEERING CYLINDER INSPECTION COVER