Hamilton HJ213 Product Manual PN 89213 Rev R2 A52 2014-08-04.pdf

Product Manual Change Summary

Manual Type HJ213

Part Number 89213

Revision R2 30/11/03

Amendment A52 04/08/2014

Refer to ECN 23235 for amendments.

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www.hamiltonjet.co.nz

Installation and Service Manual

HJ213

Jet Unit Manual

R2A52

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

Manual Type HJ213

Part Number 89213

Revision R2 30/11/03

Amendment A52 09/09/2014

HJ213

Contents

Introduction Contents .......................................................................................v

Introduction Warnings & Cautions ..................................................................ix Limited Warranty .............................................................................xi

Part A Operator Information

Section 1 Introduction & Product Description............................................................... 1.1

1.1 The Hamilton Water Jet System................................................................ 1.1

1.1.1 Introduction .................................................................................... 1.1

1.1.2 Main Components .......................................................................... 1.3

1.2 The Hamilton HSRX Reverse System........................................................ 1.6

1.3 General Assembly Drawings .................................................................... 1.6

Section 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 Manoeuvring and Docking ...................................................................... 2.4

2.4.1 Low Speed Manoeuvring and Docking ........................................... 2.4

2.4.2 Moving Sideways ............................................................................ 2.5

2.5 Cruising ................................................................................................... 2.7

2.6 Shallow Water Operation ........................................................................ 2.8

2.7 Acceleration to High Speed ..................................................................... 2.9

2.8 Aerated Water.......................................................................................... 2.9

2.9 Blockages (Debris in the jet unit).............................................................. 2.9

2.9.1 Avoiding Blockages ........................................................................ 2.9

2.9.2 Detecting Blockages ....................................................................... 2.9

2.9.3 Clearing Blockages ....................................................................... 2.10

2.9.4 Using the inspection cover ............................................................ 2.10

2.10 Inspection Hatch Extension. (Optional Extra) ....................................... 2.11

2.11 Operating with an Engine and jet unit Out of Service........................... 2.11

2.12 HSRX Reverse System .......................................................................... 2.12

Part B Design and Installation

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

3.1 Propulsion System Design........................................................................ 3.1

3.2 Hull Design ............................................................................................. 3.1

3.2.1 Hull Loads ...................................................................................... 3.1

3.2.2 Mono Hulled Vessel ....................................................................... 3.4

3.2.3 Multi Hulled Vessel ........................................................................ 3.5

3.2.4 Trim Tabs ........................................................................................ 3.6

3.3 Drivelines ................................................................................................ 3.7

3.3.1 Requirements of the Driveline ......................................................... 3.7

3.3.2 Engineering Checks ......................................................................... 3.7

3.3.3 Drive Shaft Options ........................................................................ 3.8

3.3.4 Universal Driveshaft Alignment .................................................... 3.10

3.3.5 Jet Coupling Flange Details ........................................................... 3.12 v

Introduction HJ213

3.3.6 Drivelines for Diesel Engines ......................................................... 3.12

3.3.7 Moments of Inertia ........................................................................ 3.12

3.3.8 Critical Speed of Mainshaft ........................................................... 3.12

3.4 Jet Mainshaft Alignment ......................................................................... 3.13

3.5 Water Off-Take ...................................................................................... 3.14

3.6 HSRX Reverse System Description ......................................................... 3.15

3.6.1 Basic Hydraulic Circuit ................................................................. 3.15

3.6.2 Layout of Components .................................................................. 3.16

3.6.3 Scope of Supply ............................................................................ 3.16

3.7 Engine Location & Mounting.................................................................. 3.17

3.7.1 General ......................................................................................... 3.17

3.7.2 Mounting ...................................................................................... 3.17

3.7.3 Cooling ......................................................................................... 3.17

3.7.4 Engine Systems .............................................................................. 3.18

3.7.5 Engine Exhausts ............................................................................. 3.18

3.7.6 Governor Settings .......................................................................... 3.18

3.8 Description of the Dry Run System (Optional Extra) ............................... 3.19

3.8.1 Installation .................................................................................... 3.19

3.8.2 Corrosion ...................................................................................... 3.19

3.8.3 Scope of Use ................................................................................. 3.19

3.8.4 Fault Finding ................................................................................. 3.20

3.8.5 Maintenance ................................................................................. 3.20

3.8.6 Parts List ........................................................................................ 3.20

Section 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 Trim Tabs and Other Submerged Fittings ......................................... 4.3

4.1.5 Earth Plate Connections for Electronic Transmitting Equipment ....... 4.4

4.1.6 Anodes ............................................................................................ 4.4

4.1.7 Anti Fouling Paint ........................................................................... 4.5

4.1.8 Anti Seize Compound ..................................................................... 4.5

4.1.9 Impressed Current Protection .......................................................... 4.5

4.2 Aluminium, G.R.P. and Wood Hulls (Other Than Steel or Carbon Fibre).. 4.5

4.2.1 Earth Bonding System - (Not Normally Current Conducting) ........... 4.5

4.3 Steel Hulls and Carbon Fibre Reinforced F.R.P. Hulls............................... 4.5

4.3.1 Earth Bonding System (Not Normally Current Conducting) .............. 4.6

4.3.2 Checking the Insulation ................................................................... 4.6

4.4 The HSRX Reverse System........................................................................ 4.6

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

5.1 Basic Installation Method and Drawing References (jet unit) .................... 5.1

5.2 Hull Preparation....................................................................................... 5.2

5.2.1 Fixing intake Block to Hull .............................................................. 5.2

5.2.2 Transom Preparation ....................................................................... 5.4

5.3 Equipment Preparation............................................................................. 5.4

5.3.1 Steering Components ...................................................................... 5.4

5.3.2 Reverse Components ....................................................................... 5.4 vi

5.3.3 Removal of Other Parts ................................................................... 5.4

5.4 Mounting The jet unit .............................................................................. 5.5

5.4.1 Mounting the jet unit ...................................................................... 5.5

5.4.2 Assembly of the Transom Plate to the Hull ...................................... 5.6

5.5 Steering Installation.................................................................................. 5.7

5.5.1 Re-Fitting the Steering Components ................................................ 5.7

5.5.2 Steering Wheel, Number of Turns ................................................... 5.8

5.5.3 Tiller Stop Fitting and Adjusting ...................................................... 5.8

5.5.4 Assembly of the Jet Steering Tillers .................................................. 5.9

5.5.5 Centering the Jet(s) Steering ............................................................. 5.9

5.6 Final Assembly......................................................................................... 5.9

5.6.1 Reverse Cylinder Fitting .................................................................. 5.9

5.6.2 Reverse Duct Re-Fitting ................................................................... 5.9

5.6.3 Reverse Cable ............................................................................... 5.10

5.7 Engine Installation.................................................................................. 5.10

5.7.1 Mounting the Engine ..................................................................... 5.10

5.7.2 Engine Cooling ............................................................................. 5.11

5.7.3 Engine Systems ............................................................................. 5.11

5.7.4 Exhaust Systems ............................................................................ 5.11

5.7.5 Governor Settings ......................................................................... 5.11

5.8 Installation Checks for the jet unit .......................................................... 5.13

5.9 Installing the HSRX Reverse System ....................................................... 5.14

5.9.1 Remote Operating Systems ........................................................... 5.15

5.9.2 Cable Installation .......................................................................... 5.15

5.9.3 Reverse Control Lever Adjustment ................................................ 5.15

5.9.4 Alternative Remote Operating Systems .......................................... 5.15

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

6.1 Pre-Launch Checks .................................................................................. 6.1

6.2 Post Launch Checks ................................................................................. 6.2

6.3 Engine Running Checks (Vessel Moored) ................................................. 6.2

6.4 Vessel Speed and Handling Trials ............................................................ 6.4

6.5 After Initial Trials (After Engine Shut Down) ............................................. 6.4

Part C Servicing Information

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

7.1 Jet Unit Faults .......................................................................................... 7.1

7.2 Reverse System Faults .............................................................................. 7.4

7.3 Steering System Faults .............................................................................. 7.7

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

8.1 General.................................................................................................... 8.1

8.2 Jet Surface Coating Procedure. ................................................................. 8.1

8.2.1 Introduction and Scope. .................................................................. 8.1

8.2.2 Application of Antifoul Coatings ..................................................... 8.1

8.2.3 Maintenance of Jet Unit paint. ........................................................ 8.3

8.3 ................................................................................................................ 8.6

8.4 Preservation: (Pre-Installation).................................................................. 8.6

8.5 Servicing Intervals.................................................................................... 8.7

8.5.1 Servicing Intervals (Jet) .................................................................... 8.8 vii

8.5.2 Servicing Intervals (Hydraulic Reverse System) ................................ 8.9

8.5.3 Daily "Pre Use" Servicing Checks .................................................. 8.10

8.6 Servicing Details .................................................................................... 8.11

8.6.1 jet unit Servicing Details ............................................................... 8.11

8.6.2 HSRX Controls Servicing Details ................................................... 8.18

8.7 Tools...................................................................................................... 8.22

8.7.1 Standard Recommended Tools ...................................................... 8.22

8.7.2 Special Tools ................................................................................. 8.22

8.8 Threaded Fasteners ................................................................................ 8.22

8.9 Recommended Oils and Lubricants........................................................ 8.23

Section 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 .................................................................... 9.3

9.2.2 Reverse Duct Overhaul ................................................................... 9.3

9.2.3 Reverse Cylinder Removal .............................................................. 9.4

9.2.4 Reverse Cylinder Overhaul ............................................................. 9.5

9.3 Reverse Assembly Re-Fitting..................................................................... 9.8

9.3.1 Reverse Cylinder - Refit to the jet unit ............................................. 9.8

9.3.2 Reverse Duct - Refit To jet unit ........................................................ 9.8

9.4 Steering Assembly Removal and Overhaul ............................................. 9.10

9.4.1 Steering Cylinder Removal ............................................................ 9.10

9.4.2 Steering Cylinder Overhaul ........................................................... 9.10

9.4.3 Steering Shaft Removal .................................................................. 9.10

9.4.4 Nozzle Assembly Removal ............................................................ 9.11

9.4.5 Nozzle Assembly Overhaul ........................................................... 9.12

9.5 Steering Assembly Re-Fitting .................................................................. 9.14

9.5.1 Nozzle Assemby Re-Fitting ........................................................... 9.14

9.5.2 Re-Assemble the Nozzle/ Nozzle Housing to the Tailpipe ............. 9.15

9.5.3 Steering Shaft Re-Fitting ................................................................ 9.15

9.5.4 Steering Cylinder Re-Fitting ........................................................... 9.16

9.5.5 Steering Cylinder / Steering Control Cable Connect ....................... 9.16

9.6 Bearing Housing Assembly Overhaul ..................................................... 9.16

9.6.1 Bearing Housing Dismantling ........................................................ 9.17

9.6.2 Water Seal Removal ...................................................................... 9.18

9.6.3 Water Seal Replacement and Re-Fitting ......................................... 9.20

9.6.4 Re-Assembly of the Bearing Housing ............................................. 9.21

9.7 Tailpipe Area - Overhaul........................................................................ 9.22

9.7.1 Impeller - Checking For Wear ....................................................... 9.22

9.7.2 Tailpipe Area - Dismantling .......................................................... 9.22

9.7.3 Impeller Area Overhaul ................................................................. 9.22

9.7.4 Impeller Overhaul ......................................................................... 9.23

9.7.5 Inspection of the Tailpipe, Marine Bearing and Wear Ring ............ 9.24

9.7.6 Wear Ring - Removal and Replacement ........................................ 9.25

9.7.7 Tailpipe Overhaul ......................................................................... 9.28

9.7.8 Tailpipe Area Re-Assembly ........................................................... 9.29

9.8 transom plate Assembly Overhaul .......................................................... 9.29

9.8.1 transom plate Removal .................................................................. 9.29

9.8.2 transom plate Re-Fitting ................................................................ 9.30 viii

9.9 Screen Rake Assembly Overhaul (If fitted) .............................................. 9.31

9.9.1 Screen Rake Removal ................................................................... 9.31

9.9.2 Screen Rake Re-Fitting .................................................................. 9.32

9.9.3 Screen Rake Blanking Plugs .......................................................... 9.33

9.9.4 Screen Removal ............................................................................ 9.33

9.9.5 Screen Re-Fitting ........................................................................... 9.33

9.10 hatch extension.................................................................................... 9.34

9.10.1 hatch extension Fitting ................................................................ 9.34

9.10.2 hatch extension Removal ............................................................ 9.35

9.11 HSRX Hydraulic Reverse System.......................................................... 9.36

9.11.1 Removal of the Pump Assembly from the jet unit ........................ 9.36

9.11.2 Re-Fitting the Pump Assembly to the jet unit ............................... 9.37

Appendix A-1 Conversions ............................................................................................ A.1 A-2 Loctite Application Guide ....................................................................... A.2 A-3 Installation Checks ................................................................................ A.11 A-4 Commissioning Checks ......................................................................... A.15

Drawings ix x ix

IntroductionHJ213HJ213 Warnings & Cautions

General Safety Notice

Warnings & Cautions A Warning: is an operation or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in injury or death to personnel.

This is indicated throughout the manual as below.

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 .

This is indicated throughout the manual as below.

WARNING

CAUTION

x

IntroductionHJ213HJ 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.

xi

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.

Vessel-to-shore electrical connections that change the corrosion potential of the vessel. For vessels equipped with shore power this warranty will not extend to the product unless an isolating transformer or galvanic isolator is fitted as described in the applicable HamiltonJet Product Manual.

Incorrect installation, as per the applicable 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 Hamilton Jet Product Manual, and a Jet Mainshaft critical speed check carried out to Hamilton Jet's written satisfaction.

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. July 2005 [Rev H] xii

IntroductionHJ213HJ 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:

xiii xiv

• Introduction and Product Description

• System Operation Part A Operator Information

Section 1 Introduction & Product Description

1.1 The Hamilton Water Jet System

HJ213

Section 1 Introduction & Product Description

1.1 The Hamilton Water Jet System

1.1.1 Introduction

In the modern world, waterjets have rapidly gained acceptance as the leading means of propulsion for all types of high speed marine craft including ferries, work boats, patrol craft and pleasure boats. Recent advances in waterjet technology have put them ahead of conventional propeller systems in both high speed performance and also reliability. Modern waterjet powered vessels offer many advantages, such as high efficiency, rapid acceleration, shallow draft, unrivaled manoeuvrability and smooth, quiet operation. Whilst conventional propeller powered craft have several shortcomings, such as vibration, higher engine loading and susceptibility to damage from water borne debris, waterjets generally offer lower maintenance, longer engine life and simplified installation.

Hamilton Jet pioneered the commercial development of the modern waterjet system in the early 1950’s and today have over 30,000 units installed worldwide. With a complete range of models suitable for power inputs of up to 3000kW per unit. Hamilton waterjets are ideally suited to the efficient propulsion of a wide variety of high speed vessels, in either single or multiple configuration, typically from 5 to 50 meters in length.

Modern Hamilton Jet Circa 2000 1.1

HJ213

Hamilton Jet is dedicated to the production of the highest quality waterjets and controls systems designed and manufactured to meet the requirements of the worlds leading certifying authorities. Full logistic support for projects is provided by the global Hamilton Jet organisation through factory support staff, regional offices and an extensive network of factory trained distributors in over 50 locations worldwide.

Equipment description:

The Hamilton HJ series is a range of highly efficient single stage waterjets suitable for propelling craft typically up to 20 meters in length and 30 tonnes displacement, at speeds up to 50 knots. HJ Series waterjets are generally directly driven by high speed diesel engines. The HM series are larger single stage waterjets suitable for vessels typically up to 50m in length and are generally driven by high speed diesel engines via a reduction gearbox.

Mounted partly inboard at the stern of the vessel, the Hamilton waterjet consists of a totally integrated package with steering and reverse mechanisms and jet mounted control system hydraulic equipment. Water is drawn into the waterjet through an intake screen at the base of the intake, which is mounted flush with the hull bottom. The pumping unit (impeller + stator) increases the pressure or "head" of the flow, which is then discharged at high velocity at the nozzle. The reaction to this high velocity jet stream provides the net thrust force, which is fully transmitted through the intake to the hull bottom.

A single piece balanced steering nozzle precisely directs the jet stream as commanded by the helm, providing high turning forces to either port or starboard. An independent split-duct type reverse deflector, usually hydraulically actuated, directs the jet stream back underneath the hull to provide powerful astern thrust. The reverse deflector may be set to a "zero speed" position (where the ahead 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 position of the reverse duct and combined with the highly efficient steering, results in unparalleled vessel control and manoeuvrability.

A vessel fitted with a Hamilton waterjet has the minimum possible draft, with no protruding underwater appendages. This allows operation in shallow waters and in water with floating debris that may foul or damage a typical propeller driven vessel and also means increased safety for personnel working in the water near the vessel. The waterjet unit is an ideal form of propulsion for vessels working in a marine mammal environment.

Hamilton Quinnat Jet Circa 1953 1.2

HJ213

1.1.2 Main Components

Intake and intake block The intake represents the main structural body of the jet unit and is an integral part of the Hamilton Jet design.

The intake is cast from high silicon aluminium alloy and is capable of transmitting the full net thrust force of the jet unit to the hull bottom, and not to the transom or to the engine via the drive shaft. The intake casting has a lower flange which mounts to an intake block, which is welded or bolted into the vessel hull. All Hamilton waterjets include an intake screen that is carefully engineered into the waterjet design so that operational parameters such as cavitation resistance are unaffected by its presence.

Oil cooler The intake has an integrated oil cooler for the hydraulic control system. This is connected to a jet mounted hydraulic power unit (JHPU) via hoses.

Thrust bearing and waterseal The thrust force generated by the pressure differential across the waterjet Impeller is reacted on by a thrust bearing inside a bearing housing attached to the front of the intake. No additional external thrust bearing is required. Aft of the thrust bearing on the waterjet mainshaft is a mechanical face type waterseal which prevents water from entering the vessel and bearing housing.

Coupling and drive shaft A coupling is mounted on the mainshaft forward of the bearing housing. A variety of couplings are available to suit the type of driveshaft flange used. The driveshaft to the waterjet must have axial and radial flexibility.

Impeller The impeller design employed in all Hamilton waterjets is a highly refined mixed flow type capable of pumping large volumes of water at relatively low pressures, permitting high propulsive coefficients to be achieved at fast vessel speeds with outstanding resistance to cavitation. All impellers 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).

Tailpipe Aft of the impeller is the tailpipe section containing a water lubricated marine bearing to support the rear of the mainshaft. The tailpipe contains a stator section that has vanes to remove the rotational direction of the flow so that a uniform axial flow is presented to the nozzle.

Nozzle After the water flow passes the pump (impeller + stator), it is at a higher pressure and relatively low velocity.

At the nozzle outlet, the pressure is at atmospheric. This difference in flow pressure is converted to flow velocity in the nozzle. The correct nozzle sizing is critical to the correct operation of the pump in a given application.

Steering (JT type steering nozzle) The steering assembly is attached to the rear of the tailpipe. It consists of a steering housing, nozzle insert and steering nozzle (which incorporates the nozzle described above). The steering nozzle is mounted inside the steering housing on vertical pivot pins and is rotated to port or starboard by linkages attached to an inboard steering cylinder. The insert inside the steering housing ensures that the flow exiting the stator section reaches the final steering nozzle outlet without being disturbed by the steering mechanism, thus maximising steering efficiency.

1.3

HJ213

Reverse duct The reverse duct is attached by horizontal pivot pins to the tailpipe and can be positioned up or down by the inboard reverse 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.

Screen rake The HJ-213 to HJ-403 jet unit may be fitted with a screen rake as an accessory item. The screen rake is a foot operated rake mounted in the lower half of the intake, designed to clear any debris that may be caught by the intake screen. The spring return foot pedal for operating the screen rake is mounted on the port side of the intake casing.

Dry run kit (optional extra on HJ-212 to HJ-362 jet units) Hamilton jet units are not fitted with the dry run kit as standard - this is an optional extra.

The dry run kit is a simple solution to the problem of starting the engine before putting the vessel in the water, where there is no gearbox fitted. It is particularly useful for man-overboard boats and lifeboats where it is important to ensure that the engine will start before the vessel is in the water. The dry run kit consists of a special bearing which can be run dry for short periods and run for long periods with water lubrication.

Overflow preventor or hatch extension (optional extra) Hamilton jet units are not fitted with overflow preventers as standard - this is an optional extra.

The overflow preventer / hatch extension is used where the static waterline (vessel fully laden) is above the level of the inspection cover. It is attached to the top of the intake outside the inspection hatch.

1.4

HJ213

Figure 1: HJ-213 jet unit

TRANSITION DUCT

INSPECTION HATCH

REVERSE CYLINDER

STEERING SHAFT

REVERSE DUCT (DOWN)

REVERSE DUCT UP

OIL COOLERCOUPLING

INTAKE

TRANSOM PLATE

TILLER

OIL COOLER

INTAKE SCREEN (HIDDEN)

TRANSITION DUCT

INTAKE

STEERING

NOZZLE

TAIL PIPE

ANODES

BEARING HOUSING

1.5

1.2 The Hamilton HSRX Reverse System

HJ213

1.2 The Hamilton HSRX Reverse System

The Hamilton HSRX reverse system is a self contained hydraulic reverse actuation system.

The actuation is provided by a compact hydraulic reverse cylinder that uses a rotary valve inside the cylinder to give proportional positioning control. This allows fast control response where accurate posistioning is not required (from the fully up position to just prior to the reverse duct entering the waterjet) and fine control of the reverse cylinder position where it is needed (around the zero speed / reverse position).

With the piston restriction (A) fully open, equal pressure acts on both the rod end and cap end of the HSRX cylinder. As the cap end area is larger than the rod end area, the cylinder extends.

With the piston restriction (A) closed, the cylinder retracts. At full retraction, the bypass valve (B) opens, reducing the system pressure and power consumption of the pump.

The back pressure valve (3) Is factory preset at 3.45 MPa (500psi).

The pump assembly (1) is belt driven directly from the jet unit.

The pump assembly comprises, pump, an integral tank, flow control and pressure relief valves.

1.3 General Assembly Drawings

Figure 2: Basic Hydraulic Circuit Diagram 1.6

Section 2 System Operation

2.1 Starting Up

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Section 2 System Operation

2.1 Starting Up

Note: With HSRX reverse control, the reverse duct may slowly drop to a full reverse position when the engine is not running.

At start-up, the reverse duct may be in full reverse position, but will move to correspond with the control lever position as soon as the JHPU (Hydraulic pump unit) is running.

1. Before starting engine(s), the following checks should be carried out.

a) The vessel is securely tied up or well clear of other objects.

b) The helm is centred and the reverse controls are at zero speed.

c) Clutches and gearboxes, if fitted, are in neutral position.

2. After starting the engine(s) move the helm and reverse lever, to control vessel movement.

2.2 “Ahead” / “Zero Speed” / Astern” Controls

"Astern" and "zero speed" are achieved by re-directing the jetstream. If the reverse duct is lowered fully, all of the jetstream is re-directed back under the vessel giving "full astern thrust". If the reverse duct is lowered partially the jetstream is split giving some ahead and some astern thrust. At a certain reverse duct position the ahead and astern thrusts will be equal so the vessel will not 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.

CAUTION

Never stop the engine(s), or disengage the drive to the jet unit, when approaching a mooring or at any time when control of the vessel may be required.

WARNING

Selecting ’astern’ (crash stop) while the vessel is moving ahead at high speed can produce very rapid deceleration. and should only be used in an emergency situation.

New operators should use the "crash stop" feature very carefully.

Do not use full helm control until the vessel has slowed.

2.1

2.3 Steering

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“Crash” or “emergency stop” This procedure should only be used in an emergency.

To "brake" the vessel's forward motion :-

1. Close the throttle.

2. Select "astern".

3. Open the throttle, gently at first until the desired braking is achieved.

4. Close the throttle as soon as the vessel has slowed to a standstill.

5. Do not use full steering until the vessel has slowed.

2.3 Steering

The steering nozzle deflects the Jet of water to port or starboard causing the vessel to steer to port or starboard respectively.

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.

CAUTION

If in lightweight planing craft, the “astern” or “zero speed” positions are selected with the throttle left open and the boat moving forward at speed, the resultant “braking effect” can be very severe - even more so than full braking with a motor car.

Figure 3: Steering Operation

ASTERN

ZERO SPEED

AHEAD

HELM

PORT CENTER

HELM HELM

STARBOARD

2.2

2.3 Steering

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The following steering systems are suitable for this application:

a) A manual hydraulic steering system which gives approximately 1.3 turns of the helm from full lock to full lock is recommended. (A greater number of turns will reduce the sensitivity of the steering during low speed manoeuvring).

b) A high quality rotary, or rack and pinion, cable system is an alternative but for single Jets only - the system must not allow more than 1.5 turns of the helm from full lock to full lock.

The steering system is balanced so that power assisted controls are not necessary even for multiple jet units.

2.3.1 Total Hydraulic Failure

Emergency steering control:

In the case of a complete manual hydraulic steering failure, the Jet(s) may be steered by manually moving the jet tiller(s). Open the by-pass valve (or disconnect the hydraulic hoses at the steering cylinder if there is no valve). (or disconnect the cable from the steering arm [17]). Refer to Drawing “HJ-213-06-000 Steering Assembly General Arrangement”.

The nozzle position is indicated by the gauge at the helm. Steering may only be possible at low RPM unless an emergency tiller extension is used (not included in CWF Hamilton standard supply).

Emergency manual reverse duct control This may be carried out in case of failure of the reverse hydraulic control system.

To raise the reverse duct:

1. Attach a rope to the reverse duct.

2. Take the weight of the reverse duct.

3. Disconnect the front hydraulic hoses from the reverse cylinder.

4. Lift the reverse duct and tie off the rope so that the reverse duct is in the raised position and out of the jet stream.

This will enable the vessel to proceed at speed and return to base to have the fault checked and rectified.

2.3

2.4 Manoeuvring and Docking

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2.4 Manoeuvring and Docking

2.4.1 Low Speed Manoeuvring and Docking

The vessel is best manoeuvred as follows:-

1. Move the reverse control lever to the "zero speed" position.

2. Set the throttle to 1/3 open - approximately 1,200 R.P.M. (In strong tide or wind conditions, increase the throttle opening to obtain greater response as required to suit the conditions).

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 complete.

4. Steering will be very responsive at this throttle opening. Full steering control is available at all ahead/astern control lever positions and there is no change of steering "sense" at any time.

5. Manoeuvre at a fixed throttle setting, working the steering with one hand and the ahead / astern control lever with the other hand.

Note:

1.DO NOT WORK THE THROTTLES - Leave as set. With TWIN JETS, manoeuvering is best carried out using the helm with one hand and both Reverse Levers with the other hand.

2. USE ONLY LOW ENGINE RPM - High RPM will give faster response but will make control of the vessel more difficult.

3.If the bow is rotating to starboard, port lock must be used to stop the rotation (or vice versa) then the helm is centred to hold the heading.

4.If the vessel is moving ahead then the reverse lever(s) must be moved astern to bring the vessel to rest (or vice versa) and then zero speed selected to hold the heading.

2.4

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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 vessel is stationary.

Moving to port

1. Set both engine RPMs to just above idle with slightly higher RPM on the port side.

2. Set steering to ahead.

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 aft movement. (higher RPM moves vessel aft). This may also be done by bringing the starboard reverse control back towards the zero speed position.

Figure 4: Moving to Port

JETTY

A.

2.5

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Docking.

Use the above procedure when approaching or moving away from a jetty or another vessel.

Note: If the vessel is moving sideways too fast the controls should be set back to zero speed and the helm returned to 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 will give the best results.

1. Set the 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 manoeuvering will depend on the prevailing sea conditions, higher RPM will improve response).

2. For sideways movement to port, set the port jet to full astern and the starboard jet to full ahead (this is reversed for sideways movement to starboard).

3. Use the centre jet reverse duct to control fore and aft movement (duct should be approximately 80% reversed).

4. Use the helm to control turning (rotation) moments, i.e. for sideways movement to port, turn the helm to starboard to balance the turning moment of the port and starboard Jets.

This method of sideways manoeuvering should result in 33% more side thrust than if only two jets were used.

Once set up, only the centre jet reverse control and the…