MANUAL FOR WATERJET FF410

Instruction manual Kamewa water jets

Kamewa FF410

FF410 Instruction manual Kamewa water jets

Table of Contents Preface

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About the instruction manual

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1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Driving the boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 8

1. Safety instructions

2. Introduction to the FF-series 2.1 Water jet unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2 The control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Operating the boat 3.1 3.2 3.3 3.4 3.5 3.6

Maneuvering the vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating in shallow water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating through flotsam and seaweed . . . . . . . . . . . . . . . . . . . Operating in heavy seas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control system calibration with LCD display . . . . . . . . . . . . . . . .

19 43 45 46 47 50

4. Starting and stopping 4.1 4.2 4.3 4.4

Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the engine and the water jet unit . . . . . . . . . . . . . . . . . . After starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the engine and water jet unit . . . . . . . . . . . . . . . . . . . . .

53 53 54 55

5. Maintenance instructions 5.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.2 Laying up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.3 Fault-tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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6. Removing and installing 6.1 6.2 6.3 6.4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools for removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . Removal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 72 74 91

7. Technical information 7.1 7.2 7.3 7.4

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended lubricants and sealants . . . . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117 117 118 119

8. Spare parts 8.1 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 8.2 Spare part series 1, 1–2 seasons or a maximum of 1500 hours of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.3 Other spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Glossary

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Preface

Preface Thank you for choosing us as the supplier of the water jet unit for your boat. It is the responsibility of the operator to ensure that the water jet unit is handled and cared for in a safe and correct manner. Therefore you should read the instruction manual thoroughly so that you learn how to operate the controls and other equipment safely before casting off for the first time. In particular pay special attention to the safety information. To obtain trouble-free operation with low wear the water jet unit must be maintained and stored in accordance with these instructions. To avoid personal injury and damage to the equipment, follow the instruction manual when operating, servicing and maintaining the water jet unit. Rolls-Royce accepts no responsibility for any damage that occurs as a consequence of work carried out by non-authorized personnel. Please feel free to contact Rolls-Royce if you have any queries regarding this equipment. We wish you success with the new water jet unit. © 1998-2007 Rolls-Royce Oy Ab. We reserve the right to make changes.

About the instruction manual In the instruction manual you will find safety information, a general introduction of the water jet unit, the basic theory for maneuvering a boat with a water jet unit, the main maintenance instructions, technical data and a spare parts catalogue. Finally there is also a glossary containing the most common terms. You will find enclosed drawings and documents in section “DRAWINGS”. Always have the instruction manual close to hand. Store it in a safe place and do not forget to hand it over to the new owner if you sell your boat.

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Preface

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Safety instructions

1. Safety instructions 1.1 General Read this chapter very carefully. It concerns your personal safety. This chapter describes how the safety information in the manual is presented. There is also an overview of basic boating safety for boating and care of the water jet unit.

Warning!

If these instructions are not followed, there is a risk of personal injury, serious damage to the product or property or major operating faults.

Caution!

Draws attention to factors that may cause damage to the product or property, or operational faults.

NOTE! Draws attention to important information that facilitates maintenance or operation.

1.2 Driving the boat The new boat

Caution!

Carefully read the instruction manual and other information supplied with the boat. Learn how to safely handle and operate the engine, controls and other equipment. If this is your first boat or you are inexperienced with this type of boat, we recommend that you practice maneuvering the boat in a quiet and calm area. Make sure you learn the handling characteristics of the boat at different speeds, water and load conditions before casting off on your first “real” trip. Remember that according to the law, anyone in charge of a boat is required to know and follow all traffic and safety rules and regulations at sea. Check which regulations apply to you and the waters in which you will be sailing by contacting the relevant authorities or marine safety organisation. It is a good idea to take a mate’s course. We recommend that you contact a regional boating or marine safety organisation for information about suitable courses.

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Safety instructions

Accidents and near misses

Caution!

Statistical evidence clearly demonstrates that insufficient maintenance of boats and engines, and a lack of safety equipment are the major cause of accidents and near misses on the water. Ensure that your boat, engine and water jet unit are maintained according to the instructions in the relevant instruction manual and that all essential safety equipment is on board and functional.

Safety switch

Caution!

We recommend that you install and use a safety switch, especially if your boat is capable of high speed. The safety switch stops the engine if the pilot falls and/or loses control of the boat.

Daily check

Caution!

Make a habit of carrying out visual inspections prior to operation (before starting the engine) and after operation (after the engine has been stopped). This will help you to quickly identify potential leaks or other abnormalities.

Caution!

Check that the impeller shaft rotates freely.

Caution!

Check the oil level in the bearing housing.

Caution!

Check the oil level in the hydraulic tank.

Before starting for the first time

Caution!

Check that there are no foreign objects in the inlet duct or impeller housing.

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Safety instructions

Maneuvering

Warning!

The braking effect is extremely powerful if the reversing bucket control is shifted to full reverse when driving ahead at high speed. Avoid heavy and sudden steering and ahead/astern maneuvers. There is a risk of those on board falling down or overboard. If full steering lock is applied at high speed the boat will turn sharply. This produces high side forces and may cause personal injury and equipment damage. Never drive close to bathers or in areas where it is reasonable to expect that there may be people in the water. Take care when maneuvering in harbours for example. Because of the power of the water expelled by the water jet, injury can be caused even when maneuvering at low speeds. The suction in the inlet duct presents a risk to people and objects in the water under the boat and close to the inlet opening. There is a danger that these may be adhered to the inlet duct and cause major damage or suffer serious injury. It is the responsibility of the captain/operator to ensure that the area around the inlet opening is clear of people or objects.

While driving

Warning!

Never open the anode hatch or the inspection hatch when the engine is operating.

Warning!

If the water jet unit disengages or the engine stalls while driving, there is no steering or drive force and the boat cannot be maneuvered.

After driving

Caution!

When the boat is not in use, the reversing bucket of the water jet unit must be in the “full ahead” position and the steering nozzle turned so that the piston rod is inside the steering cylinder. This is to protect the piston rods from corrosion and fouling.

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Safety instructions

1.3 Maintenance work Prior to maintenance

Caution!

There are directions for safe and correct maintenance and service procedures in the instruction manual. Read through them carefully before beginning work. Never attempt an operation if you are not completely confident of how to do it. Contact Rolls-Royce if necessary. Undertaking any work envisaged by this document may either directly or indirectly create risks to (1) the safety and health of the person undertaking the work or (2) the water jet unit and/or its components whilst the work is being undertaken. It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to the work envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health and safety of the persons undertaking the work. It is also the user’s responsibility to ensure that appropriate controls and precautions are identified and applied in relation to work envisaged by this document to protect against risks to the water jet unit and/or its components whilst the work is being undertaken. Neither this document, nor its use, in any way absolves the user from their responsibility to ensure that the controls and precautions referred to above are implemented. If, whilst undertaking any work envisaged by this document, you become aware of any Rolls-Royce product design related feature which could create risk to a person undertaking work or to the water jet unit and/or its components please contact After Sales department at Rolls-Royce Oy Ab immediately. It is the user’s responsibility to make all relevant hazard identifications and risk assessments of all the activities associated with the use of this document. It is the user’s responsibility to design and implement safe systems of work and to supply safe equipment (including, without limitation, safety equipment) and training (including, without limitation, health and safety training) to anyone using this document to work on products to which it relates.

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Safety instructions

A user without the relevant experience of working in accordance with this document or with products, or similar products, to which it relates should seek appropriate advice to enable them to identify the appropriate health and safety controls and precautions and controls and precautions to protect against risks to the water jet unit and/or its components whilst work is being undertaken. Technical assistance can be sought from Rolls-Royce and will be subject to Rolls-Royce’s terms and conditions.

While carrying out maintenance work

Warning!

Never work alone when removing or installing heavy components, even when using the safe lifting equipment such as lockable pulleys. In most cases two people are required when working with lifting equipment; one to operate the lifting equipment and the other to ensure that all components have sufficient space to move freely so that they are not damaged during the lift.

Warning!

Make it impossible to start the engine by disconnecting the electrical system. Secure a warning sign on the instrument panel - “Maintenance work in progress!”

Warning!

The intermediate shaft should only be adjusted with the engine stationary.

Warning!

Never open the inner inspection hatch and the anode hatch before checking that the water level is lower than the hatch openings. The boat may sink if water can enter the boat through the opening. Never leave the hatches open when the boat is in the water.

Warning!

The water jet unit hydraulic system operates under extremely high pressure. This pressure may be high even when the engine is not operating. Always take great care when opening nipples. Carelessness can result in injury. In addition, the oil may be hot and cause scalding.

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Safety instructions

Warning!

The chemicals used (for example sealant and thread sealant) can cause skin irritation. Follow the safety instructions on the product packaging.

Warning!

Use only components manufactured or approved by Rolls-Royce. Remember that components that appear identical to approved components may not fulfil the requirements.

Warning!

Ensure clean conditions and take great care when installing.

After maintenance

Caution!

The oil in the bearing housing must be topped up before the water jet unit is operated.

Caution!

The water jet unit must not be operated dry, since the rubber bearing and the mechanical sealing require water lubrication.

Caution!

The tightness of the bearing tensioner nut should be checked after approximately 30 hours of operation and should be re-tightened if necessary.

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Introduction to the FF-series

2. Introduction to the FF-series 2.1 Water jet unit Main components of the water jet unit

Kamewa Rolls-Royce Oy Ab, Finland

Type:

-

Unit number: Date (month / year):

/

12 11

13

14

10

9 8 7

6 5 4 3

2 1

1. Reversing bucket 2. Steering nozzle 3. Guide vane chamber 4. Impeller 5. Impeller housing 6. Steering shaft 7. Inlet duct 8. Anode hatch

9. Bearing housing 10. Inspection hatch 11. Reversing cylinder 12. Serial number plate 13. Oil dip stick 14. Shaft flange

Figure 2-1. Main components of the water jet unit.

NOTE! Refer to the enclosed “assembly drawing” for more information about the water jet unit components.

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Description of function Water enters through the inlet duct. The base plate of the inlet duct is positioned flat against the hull of the boat. Water enters both as a result of the movement of the boat and due to the action of the impeller, which sucks it in. At low speeds, most of the water is sucked in, while at higher speed most of the water is pressed in. The pump is said to be operating at heavy or light load. Inside the inlet duct the speed of the water slows, causing the pressure to increase. There is a further increase in pressure above the impeller until the guide vanes in the guide vane chamber eliminate the rotation of the water flow. This maintains the energy generated by the rotation. The flow of water then accelerates via the guide vane chamber and the trim nozzle (which is located on the end of the guide vane chamber) and out in to the air. It is the difference between the ingoing and outgoing speeds which generates thrust. This can be explained using the impulse law:

where T thrust (N) ρwater density (kg/m3) Q volumetric flow (m3/s) Vout average speed out (m/s) Vin average speed in (m/s)

Function of the reversing bucket The ahead/astern movement of the boat is controlled with the reversing bucket. The reversing bucket is infinitely variable between three main positions to obtain the speed and control needed for different maneuvers.

1. Full ahead position When driving full ahead the reversing bucket is in its upper position, i.e. completely raised. The jet of water is now unaffected by the reversing bucket and thereby the maximum ahead thrust is obtained.

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2. Zero thrust position At the zero thrust position the reversing bucket deflects the major part of the jet of water in a forward/downward direction, while the remaining part of the jet of water passes unaffected. The forces are equal, and the boat is neither moving ahead nor astern. Zero thrust is obtained when the reversing bucket is lowered about 70%. 3. Full astern position At full astern position the reversing bucket fully deflects the jet of water in a forward/downward direction, i.e. the boat is reversing.

Function of the steering nozzle Sideways movement of the boat is controlled by the steering nozzle. There are three main positions with infinite variables in-between:

1. Full steering lock starboard Full steering lock starboard means that the steering nozzle is turned 30° to starboard side. Due to the deflection of the jet of water a side force is generated which turns the boat to starboard. 2. Steering nozzle straight When the steering nozzle is straight the jet of water is unaffected, which means that the boat will move straight ahead, or astern, depending on the position of the reversing bucket. 3. Full steering lock port Full steering lock to port side means that the jet of water is deflected to port and the generated side force turns the boat to port.

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Advantages General water jet unit advantages to a propeller installation:

•

As a rule of thumb, the water jet unit gives higher overall efficiency, in comparison with a corresponding propeller installation, at speeds exceeding 25 knots.

• •

Superior maneuverability at all speeds.

•

No risk of overloading the engine, low noise and vibration levels. This means longer service life and low maintenance costs.

•

High thrust at low speeds, giving fast acceleration.

No underwater appendages which results in shallow draught and safe operation.

Competitive advantages of the FF-series over other water jet unit manufacture:

•

Lightweight and tough. Fabricated in aluminium and with thorough strength calculations.

•

Easy installation. Delivered painted and complete with a structurally dimensioned inlet duct for easy installation by means of bolting or welding. Direct drive possible.

•

Easy service and maintenance. Wear parts are easy to replace without any special tools. Low risk of damage. No gear shifting.

•

Best corrosion resistance. Fabricated of marine aluminium. Impeller housing is lined with polyurethane to minimize wear and corrosion.

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2.2 The control system General Vector stick is a joystick controlled thrust vectoring system designed specifically for small and medium sized craft. All propulsion devices are integrated into a single joystick such that joystick movements correspond to exact vessel movements. The vector stick system integrates control of water jet steering and reversing functions and engine speed in such a way that translation and rotation commands are as simple as moving the stick in the direction you want the vessel to move and turning the helm in the direction you want the vessel to rotate. The system can be configured for a twin or single water jet installation. The basic system, which includes all necessary functions, can be expanded with a number of standard options in order to fit the actual installation. The control system requires 24V DC for operation.

Basic functions The remote control system is used to control the steering nozzle angle and the reversing bucket position of the Kamewa water jet system, along with RPM of the main engines. The steering nozzle angle determines the port/starboard direction of flow from the water jet, which in turn, induces a turning moment to the vessel in the direction that the nozzle is pointing. The reversing bucket position determines the amount of the total waterjet flow that is deflected ahead, which in turn, induces a proportional reversing force. The engine RPM relates to the power output of the water jet and the thruster RPM relates to the magnitude of transverse thrust applied at the bow. Maneuvering is performed from a control station equipped with the two basic control devices; an electronic helm and a two-axes joystick. If supplied, additional devices such as control levers and steering tiller may also be used to maneuver the vessel.

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System architecture

Figure 2-2. The system architecture of a basic twin jet installation

Each system requires a single control box. The control box is a sealed enclosure that contains the electronics and software required for positioning the steering nozzle and reversing bucket as well as controlling bow thruster and engine RPM. The control box is typically located in the pilothouse or console.

Figure 2-3. The system architecture of a basic single jet installation

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The standard configuration requires a helm and a two-axes joystick. No other controls are necessary, as all three control axes (for-aft, transverse and rotation) are mapped directly to vessel motion. For added versatility, however, separate control levers are offered as an option. Other options such as clutch control and water jet and engine backup systems are discussed in the sections below.

Main components

Figure 2-4. A basic control station

The standard scope of supply for the basic system consists of the following main components:

• • • • •

Control box Two-axes joystick Steering helm Feedback assemblies Cables

NOTE! Refer to the enclosed system diagram for information about the specific configuration of your application.

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Optional equipment In addition to the earlier mentioned basic components necessary for a functional control system, the system can be expanded with a number of additional components/functions.

Additional control station Two-axes joystick with steering wheel provided with cables.

Clutch panel Engage, disengage, and backflush control for each engine, as well as safety interlocks and LED indication of clutch status.

Steering tiller Single axis transverse control lever used for steering control as an alternative to the steering wheel.

Separate control levers Separate control levers incorporate the control of port and stbd reversing buckets into each respective lever while also controlling RPM.

Back-up panel Separate complimentary system providing a simple “non-follow up” (2-axes jog levers directly connected to the hydraulic valves) control if the main remote control is faulty.

Engine back-up panel Separate complimentary system which enables control of the engine RPM by means of a simple knob in the case of an electronically driven engine. The speed signal generated by a rotary knob goes directly to the electronic governor and is isolated from the automatic system by the auto/backup switch.

Indication panel Separate system for indication of the steering nozzle and reversing bucket positions. The positions are shown with analog indicators.

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Operating the boat

3. Operating the boat Operating the boat with water jet units is different from operating a boat with propellers. Read this chapter carefully before casting off on your first trip.

3.1 Maneuvering the vessel The Vector Stick control system has been designed so that all maneuvers, both high speed transiting and docking, can be executed intuitively.

Cruising/Transiting In transit mode, imparting forward and aft thrust to the vessel is accomplished via the control levers, while the vessel’s heading is controlled by turning the helm in the desired direction of rotation. The port control lever controls port reversing bucket and engine RPM, and the stbd lever controls stbd reversing bucket and engine RPM. A programmed relationship between the bucket position and RPM is implemented such that the lever position is proportional to thrust imparted to the vessel. When ordering a thrust magnitude with the levers, the system simultaneously generates a main engine RPM command and a reversing bucket command. When the lever is in its center detent position, the engines are set at idle and reversing buckets are set to a position (neutral bucket) giving equal ahead and astern thrust, resulting in zero thrust. Steering of the craft is accomplished by rotating the steering nozzles from side to side. Steering nozzles and hence the craft heading are controlled by rotating the electronic helm.

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Operating the boat

Transferring to transit mode When transferring from joystick to control lever operation, both the joystick and levers must be placed in their center detent positions. Once this is done, quickly depress the push button located on the control lever panel twice. When the status LED is illuminated steady, the system is in control in transit mode, and the joystick is no longer active.

Maneuvering/docking When maneuvering at slow speeds or docking, the control system should be transferred to the docking mode (see Figure 3-1). In this mode, the joystick is allowed to move freely along the X and Y-axes, and the steering nozzles, reversing buckets and engine RPM are individually controlled such that a net thrust is imposed at the vessel centroid at a magnitude and direction that corresponds to the joystick position. To enter the docking mode, first ensure that the joystick and the control levers are in their respective center detent positions and then quickly depress the push button on the joystick panel twice. (Note: A safety interlock prevents the system from entering docking mode if the joystick is not in the center position). In this mode, vessel translation is controlled by the joystick position along the X and Y-axes, and the turning moment is controlled with the helm, similarly to steering maneuvers in transit mode. If while in docking mode either of the clutches is disengaged, the following takes place: 1. A control system alarm output is generated. 2. The LCD display indicates “Dock mode fault” and that a clutch is disengaged. 3. Sideways vessel translation is inhibited (x-axis movement of the joystick has no effect on thrust imparted to the vessel), while fore/aft movement of the joystick will remain functioning normally (i.e. fore/aft thrust imparted to the vessel is proportional to handle position).

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Operating the boat

Figure 3-1. Docking mode — Thrust ahead

Alongship movements Alongship movements are obtained by moving the joystick lever ahead/astern (direction 0° or 180°). There is a combinator relationship between the reversing buckets and engine RPM. The thrust generated is dependent of the magnitude of the joystick lever movement. For small lever movements the system will work only with position of the reversing buckets, but if more thrust is ordered, the engine speed will be increased as well.

Transverse movement Transverse movement of the vessel is achieved by moving the joystick in the direction of desired thrust. The thrust generated is dependent on the magnitude of the joystick lever movement (direction 90°- thrust to port, see Figure 3-2). In order to develop a pure translational force (no rotation) each water jet is placed in its optimum position (determined during calibration) and operated to achieve the desired transverse motion. Changes in magnitude and direction are controlled by varying the bucket position and engine RPM of each water jet. To compensate for alongship forces/movements imposed by outside forces such as wind and currents, the joystick can be moved slightly in the direction opposite of the disturbance. Accordingly, any unwanted rotational disturbances can be compensated for by rotating the steering wheel.

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Operating the boat

Figure 3-2. Docking mode — Thrust to port

Rotation In all conditions, rotation is controlled through movement of the helm. Whether thrusting ahead, astern or transversely, adding or subtracting small amounts of steering nozzle motion will superimpose a small turning moment. The additional nozzle displacement is increased as the required moment increases. Pure rotation is obtained by maintaining the reversing buckets at the neutral position and turning the nozzles. In both Transit and Docking Modes, this is accomplished by movement of the tiller with the joystick at its neutral thrust position. Small tiller adjustments will translate to small heading changes, and large adjustments will translate to large heading changes.

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Operating the boat

Single water jet

Steering wheel turned to port

Twin water jet

Steering wheel straight

Steering wheel turned to port

Steering wheel straight

Full ahead

Zero thrust

Port thrust

Full astern

Figure 3-3. Single and twin jet maneuvers

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Operating the boat

Braking Braking is very different from braking with a propeller boat. Using the reversing bucket, which can be manoeuvred from full ahead to full astern in 3 seconds, it is possible to apply astern thrust at the beginning of the breaking sequence while the boat still is travelling ahead. This will give a shorter braking distance, but also very high breaking force which has to be considered in order to avoid personal injury and material damage. Emergency braking should therefore only be used when necessary.

Emergency braking 1. Set the lever to full astern. 2. Maintain full astern position until the boat has slowed down (almost stopped). 3. Gradually decrease the thrust, so that zero thrust is ordered when the boat has stopped. While braking, the steering characteristics of the boat is changed and the boat becomes much more sensitive to steering wheel movements. Therefore it is not recommended to steer the boat except for keeping the course.

Warning!

The forces involved in emergency braking can cause personal injury and material damage. When emergency braking is not necessary a regular stopping of the boat should be performed.

Slowing down and stopping 1. Gradually decrease the RPM until the boat has slowed down. 2. When the boat has reached low speed, set the levers in zero thrust position. 3. If necessary, order a little astern thrust until the boat has stopped.

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Operating the boat

Control station transfer Transferring control from one operating station to another is achieved by actuating the indicating push button on the station taking control. As a safety measure, an interlock prevents the system from transferring from one station to another unless both of following conditions are satisfied: 1.) the position of the joystick and/or control levers (depending on the configuration) at each station are matched and, 2) the position of the helms (including the Z-axis of the joystick) are matched. The following procedure must be carried out when transferring the station control: 1. Place both the control levers and joystick in their center detent positions. 2. Quickly press the indicating push button twice at the station taking control. 3. Rotate the steering wheel/Z-axis of the joystick through its range of operation to match the positions of the two stations. 4. Once the steering wheel and Z-axis of the joystick are aligned and within 10% of each other, the transfer takes place immediately, and the LED provides the appropriate status as listed in the table below. Table 3-1. Transfer button LED status

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Transfer button LED status

Indication

Not illuminated

Station not in control

Flashing quickly (0.5 second intervals)

Control transfer pending

Illuminated steady

Station in control

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Operating the boat

Using the control devices Clutch control

Figure 3-4. Clutch panel

The clutch panel handles the ENGAGE, DISENGAGE, and BACKFLUSH (reverse) functions of the clutch. All three states are mutually exclusive and are controlled with two three-position momentary rocker switches per engine. When the ENGAGE button is pressed, it energizes a latching circuit which keeps the clutch engaged until the DISENGAGE button is pressed. The following safety interlocks are integrated into the clutch panel circuit: 1. Neutral start interlock – If the respective gear is engaged, the clutch panel provides an interlock to inhibit the engine from starting. 2. Engine at idle interlock – If provided by the engine manufacturer, an “engine at idle” input is used to inhibit the gear from engaging if the engine is not at idle. The backflush circuit is not provided with latching logic, thus the backflush (reverse) gear remains engaged only while the button remains depressed. The backflush gear is not provided with a neutral thrust permissive, however, it will not engage while the forward gear is engaged for safety reasons. The clutch panel is equipped with an idle knob to control RPM independent of the joystick. Rotation of the idle knob clockwise increases RPM, while rotation counter-clockwise decreases RPM. The RPM range of the idle knob is typically limited to 40% of full RPM, but is adjustable via the control system software during system commissioning. LEDs are provided on the switches to indicate the status of each clutch (see Table 3-2 below). To decrease the brightness of the LEDs, press down the lower portion of the rocker switch labeled DIM. To increase the brightness of the LEDs, press down the lower portion of the rocker switch

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labeled BRIGHT. Press the applicable button repeatedly until desired LED intensity is achieved. This dimming circuit is common for the panel, so increasing or decreasing the LED brightness with these switches affect all four LEDs. Table 3-2. Clutch LED status

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LED Status

Indication

Not illuminated

Clutch not engaged

Illuminated steady

Clutch engaged

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LCD display and alarm panel

Figure 3-5. – LCD display and alarm panel

Panel operation The LCD display serves two primary functions; to display the position of the reversing buckets, steering nozzles, and interceptors/trim tabs as applicable for a given application and also to provide a means for the operator view control system alarms. Additionally, it serves as means to perform the control system calibration functions. To change the screen display at any time, press any one of the first four buttons (beginning on the left) on the display. This action will display the button function menus on the bottom of the LCD display. Once the desired menu button is pressed, the screen will change accordingly. To change the LCD backlight and/or contrast at any time, press the fifth (5th) button (furthest to the right). This will display the function menus for increasing/decreasing the screen contrast and the backlight intensity. Once this submenu open, pressing the buttons under the respective “+/-“ icons will cause the screen display to change accordingly. Steering nozzle, reversing bucket, and interceptor display The LCD display panel continuously indicates the actual position of the steering nozzles, reversing buckets and interceptors (or trim tabs) positions as applicable. The positions are shown via bar graph displays.

•

When the reversing buckets are in the neutral thrust position, only the center bar is darkened on the respective graph. When the reversing buckets are moved in either the up or down direction, the display incrementally darkens additional bars to reflect the actual position of the bucket.

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•

When the steering nozzles are in the center position, only the center bar is darkened on the respective graph. When the steering nozzles are moved in either the port or stbd direction, the display incrementally darkens additional bars to reflect the actual position of the nozzles.

•

When the interceptors are in the fully raised position, only the top bar is darkened on the respective graph. When the interceptors are lowered, the display incrementally darkens additional bars to reflect the actual position of the unit. When the interceptors are fully lowered, the bar graph display is fully darkened.

LCD display data modes The LCD display is capable of receiving data from two separate sources and is capable of displaying the positions of the steering nozzles and reversing buckets from either source for purposes of redundancy. (Note: not applicable for most applications). The two sources of data for the LCD display are:

•

Indication Module (dwg.100506-364) – Provides interface to the reversing bucket steering nozzle, and interceptor potentiometers, converts the analog input signals to digital format and provides a CAN/J1939 data output to the LCD displays.

In the event of a cable failure or an indication module failure, a warning icon displaying !J1939 appears on the LCD display. If the LCD data mode is configured for CAN at the time this fault is generated, change the data mode to 232 until the source of the fault is identified and corrected.

NOTE! For applications that are not supplied with an indication module and dedicated indication circuit, the LCD should not be configured for CAN mode.

•

Control box – Provides an RS232 serial output to the LCD displays containing data for the position of the reversing buckets and steering nozzles as well as any control system faults.

In the event of a cable failure or control box microprocessor failure, a warning icon displaying Serial appears on the LCD display. If the LCD data mode is configured for 232 at the time this fault is generated, change the data mode to CAN until the source of the fault is identified and corrected. While the Serial/RS232 fault exists, communication between the LCD display and the control box ceases, thus the LCD does not display any control system alarms.

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LCD display menu buttons As mentioned above, pressing any one of the first four buttons will display the button function menus on the bottom of the LCD. Once a menu button is pressed, the LCD screen changes accordingly. Pressing the fifth (5th) button displays the function menus for increasing/decreasing the screen contrast and the backlight intensity. Once this submenu opens, pressing the buttons under the respective “+/-“ icons causes the screen display to change accordingly. Screen display

Button

Function

Main screen

1, 2, 3 and 4

Displays the button function menus on the bottom of the LCD.

Main screen

5

Backlight/contrast adjustment - Pressing the buttons under the respective “+/-“ icons causes the screen display to change accordingly.

Main screen

1

Alarm acknowledge: Pressing the button minimizes the size of the “FAULT” icon on the main display screen.

Main screen

2

Fault screen – Display text readout of active control system faults

Main screen

3*

Calib (calibration) screen – Enters the calibration submenu screen.

Main screen

4*†

System screen

Main screen

5

Exit/hide submenu

Fault screen

1

View meters – Returns to the main display screen.

Fault screen

5

Exit/hide submenu.

Main screen → Calib screen

1


2

CAN Calib - Enters the CAN calibration submenu screen. Applicable only for applications that are supplied with an indication module and dedicated indication circuit.


3

Thrust Calib - Enter the thrust calibration submenu screen. Used for setting the neutral thrust position of the reversing buckets (see Control system calibration).


4

INIT CAL - Enters the control box into its automatic calibration mode (see Control system calibration).


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5

Exit/hide submenu

Main screen → Calib screen → CAN calib screen

1



2

System calib – Return to calib screen.


3

Not used.


4

Init Cal – Initializes calibration mode for the LCD display and enters into the corresponding submenu. Applicable only for applications that are supplied with an indication module and dedicated indication circuit


5

Exit/hide submenu

Main screen → Calib screen → CAN calib screen → INIT CAL screen (CAN calib)

1

Finish Cal – Once the calibration procedure has been completed, pressing this button stores the values in a non-volatile memory.


2

Set Z Thr – Records the zero (neutral) thrust position of the reversing buckets to properly scale the display.

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3

Not used.


4

Abort Cal – Exits out of the calibration mode without changing any of the calibrated values.


5

Exit/hide submenu.

Main screen → Calib screen → Thrust calib screen

1



2

System Calib - Return to calib screen


3

INIT ZTHRST - Enter into zero thrust calibration and its corresponding submenu. This operation is also commonly referred to as Set1.

4

INIT TRANSV - Enter into tranverse thrust calibration and the corresponding submenu. This operation is also commonly referred to as Set2.


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5

Exit/hide submenu.

Main screen → Calib screen → Thrust calib screen → INIT ZTHRST screen

1

Set ZTHRST - Saves the new zero (neutral) thrust position of the reversing buckets.


2

Finish CALIB - Deactivate the calibration mode and return to the CALIB screen.


3

Not used.


4

Not used.


5

Exit/hide submenu.

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Main screen → Calib screen → Thrust calib screen → INIT TRANSV screen

1

Set TRANSV - Saves the new nozzle positions in order to achieve transverse motion.


2

Finish CALIB - Deactivate the calibration mode and return to the CALIB screen.


3

Not used.


4

Not used.


5

Exit/hide submenu.

Main screen → Calib screen → Thrust calib screen → INIT CAL screen

1

Finish CALIB - Save new calibration values, deactivate calibration mode, and return to the CALIB screen.

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2

Abort CAL – Exits out of the calibration mode without changing any of the calibrated values. Return to the CALIB screen.


3

Not used.


4

Not used.


5

Exit/hide submenu.

System screen

1


System screen

2

Arrow up - Scroll up through parameters.

System screen

3

Arrow down - Scroll down through parameters.

System screen

4

Toggle - Toggle the current selected parameters values.

System screen

5

Exit/hide submenu.

N/A

Value = ON or OFF. Enables or disables the integrated interceptor steering function of the control system.

N/A

Value = CAN or 232. Changes the data source for displaying the position of the nozzles, buckets and interceptors. Note: CAN is a valid mode only when an indication module is supplied.

System screen → IntSteer System screen → DatMode**

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System screen → 232 Xmit**

N/A

Value = ON or OFF enables or disables the integrated interceptor steering function of the control system.

N/A

Value = NORM or FLIP enables the direction of the nozzle display to be changed to properly correlate to the direction of the steering nozzle movement.

N/A

Value = NORM or FLIP enables the direction of the nozzle display to be changed to properly correlate to the direction of the reversing bucket movement.

System screen → IntMap**

N/A

Value = NORM or FLIP enables the direction of the nozzle display to be changed to properly correlate to the direction of the interceptor movement.

System screen → StaType**

N/A

Value = Main or Wing enables the operating mode of the LCD to be changed between primary (Main) and secondary (Wing).

1 and 2

A. Simultaneously holding down buttons 1 and 2 while the unit is being powered up calls up the loader screen. B. Simultaneously holding down buttons 1 and 2 for approx 2 seconds when the unit is running displays the message “Hold to reboot”. If the buttons remain depressed for an additional 2-3 seconds after this message appears, the loader screen is called up.

System screen → NozMap** System screen → BktMap**

Boot loader – To be accessed by authorized Rolls-Royce personnel only

* When entering the calib screen and the system screen the user is prompted for a password. This password is “1123” and the numbers are clearly marked on the LCD. This is necessary because the functions under these screens should not be touched during normal operation of the craft. It is imperative that these screens are not entered accidentally and altered unknowingly, hence the password. **These values should not be changed once they have been set by an authorized Rolls-Royce service representative. † Under the system screen the DatMode can be toggled between “CAN” and “232”. In “232” mode, the LCD displays the position of the nozzles/buckets/interceptors based on data received from the control box. In “CAN” mode, the LCD displays the position of the nozzles/buckets/interceptors based on data received from separate potentiometers dedicated for the indication circuit (Note: not supplied with most applications).

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LCD fault displays When a control system fault occurs (feedback fault, non follow-up alarm, etc.), a warning icon displaying the word “FAULT” flashes on the main display screen to alert the operator that a fault condition exists. Pressing any one of the first four buttons on the display displays the button function menu on the bottom of the LCD display. The operator may choose one of the following options for alarm handling:

•

Acknowledge (“Ack”) alarm – When this option is selected the fault icon stops flashing, diminishes in size, and remains in the center of the main display sceen.

•

View faults – When this option is selected, the display changes to the “FAULTS” screen. The faults screen provides a real time text display up to 20 active alarms.

NOTE! There is no audible alarm output from this display and alarm panel. If sounding an audible alarm for control system faults is required for the application, it is necessary to interface an external alarm system to the alarm output on the control box (see Installation Manual, Alarm Interface). A complete list of control system alarms is provided in the following table. Note that not all alarms apply to every application; only alarms applicable to the control system configuration are active.

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Alarm

Cause

!FAULT

Common alarm for control system faults; see table below for specific alarms that may appear on the “Fault” screen.

!J1939

Indicates a fault condition with the CAN network or indication module.

!Serial

Indicates that the serial communication link between the LCD display and the control box has failed, possibly the result of a cable failure or control system microprocessor failure.

CAL FAULT

Faulty control system calibration

Roll Cmd Pot

Roll command potentiometer signal failure

Trim Cmd Pot

Trim command potentiometer signal failure

ST1 Joy X

Station #1 Joystick X-axis (port/stb) command potentiometer signal failure

St1 Joy Y

Station #1 Joystick Y-axis (fore/aft) command potentiometer signal failure

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ST1 Port Lever

Station #1 Port control lever command potentiometer signal failure

ST1 Stbd Lever

Station #1 Stbd control lever command potentiometer signal failure

ST1 Helm/Till

Station #1 Helm/tiller command potentiometer signal failure

ST1 Idle Knb

Station #1 Idle knob command potentiometer signal failure

ST2 Joy X

Station #2 Joystick X-axis (port/stbd) command potentiometer signal failure

ST2 Joy Y


ST2 Port Lev


ST2 Stbd Lev


ST2 Helm/Till


ST2 Idle Knb


ST3 Joy X

Station #3 Joystick X-axis (port/stbd) command potentiometer signal failure

ST3 Joy Y


ST3 Port Lev


ST3 Stbd Lev


ST3 Helm/Till


ST3 Idle Knob


Port Bkt Sens.

Port bucket feedback potentiometer signal failure

Stbd Bkt Sens.

Stbd bucket feedback potentiometer signal failure

Port Noz Sens.

Port steering nozzle feedback potentiometer signal failure

Stbd Noz Sens.

Stbd steering nozzle feedback potentiometer signal failure

Port Tab Sens.

Port interceptor/trim tab feedback potentiometer signal failure

Stbd Tab Sens.

Stbd interceptor/trim tab feedback potentiometer signal failure

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Port Bkt NFU

Port bucket non follow-up fault; hydraulic system not responding properly to control system commands

Stbd Bkt NFU

Stbd bucket non follow-up fault; hydraulic system not responding properly to control system commands

Port Noz NFU

Port nozzle non follow-up fault; hydraulic system not responding properly to control system commands

Stbd Noz NFU

Stbd nozzle non follow-up fault; hydraulic system not responding properly to control system commands

Port Tab NFU

Port interceptor/trim tab non follow-up fault; hydraulic system not responding properly to control system commands

Stbd Tab NFU

Stbd interceptor/trim tab non follow-up fault; hydraulic system not responding properly to control system commands

DOCKMODE FAULT – Inbd Cltch Eng.

Dock mode fault; one or both of the inboard clutches are engaged

DOCKMODE FAULT – Otbd Cltch Dis.

Dock mode fault; one or both of the outboard clutches are disengaged

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Waterjet backup system As an optional compliment to the automatic controls, the backup system enables control of the steering nozzles and reversing buckets in the event of a failure in the automatic control system. The backup system is electrically isolated from the main system and is powered from a separate power supply (if available).

Figure 3-6. Backup panel.

The backup system is of “non-follow up” type and controls the reversing buckets and the steering nozzles by direct activation of the hydraulic control valve. To enter the backup mode, actuate the two-position rocker switch to the “backup” position. Once in backup mode, the bucket and nozzle of the given water jet unit is isolated from the automatic system and is no longer influenced by either the joystick/levers or helm/tiller. Each water jet is controlled by a two-axes jog switch. Waterjet backup control Each water jet is controlled by the jog lever as follows:

•

Left/right movements of the switch correspond to port/stbd movement of the steering nozzles.

•

Up/down motion of the switch corresponds to the up/down movement of the reversing buckets.

NOTE! In this mode, the hydraulic control valve will actuate the respective bucket/nozzle cylinders continuously when the jog switch is in the active position. Although not necessary, it is helpful to monitor the display panel while operating the craft in backup control.

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Engine backup system As a compliment to the automatic controls, an engine control backup system enables control of the engines in the event of a failure in the automatic control system. The backup system is electrically isolated from the main system and is powered from a separate power supply.

Figure 3-7. Engine backup panel.

To enter the backup mode, actuate the two-position rocker switch to the “Backup” position. Once in backup mode, the RPM control for the given engine/engines is isolated from the automatic control system and is no longer influenced by either the joystick or control levers. In backup, the engine RPM is modulated by a rotary knob on the panel. Engine RPM is proportional to knob rotation, and the full range of operation can be achieved. In this mode, the engine speed signal goes directly to the engine actuator amplifier.

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Mechanical back-up An additional level of redundancy is inherent in the hydraulic system design. It is possible to move the buckets up or down or the steering nozzles side to side with no electricity. This can be accomplished by pushing the solenoid armature of the proportional valve with a pointy object such as a Phillips head screwdriver.

Figure 3-8. Proportional valve.

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3.2 Operating in shallow water Avoid driving at high engine speed in shallow waters especially when reversing since the jet of water will move up sand etc. from the bottom, therefore sand and stones can be sucked through the water jet unit. This may cause wear to the impeller and guide vane chamber.

Do not accelerate heavily in shallow waters. Stones and sand etc. may be sucked into the water jet unit and cause wear to the impeller and the guide vane chamber.

Drive at idling speed until deeper water is reached. If a foreign object is sucked into the inlet duct temporarily disengage the water jet unit to remove the object.

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Checklist if you run aground

Warning!

Remove the start key and shut off the power using the main switch to make it impossible to start the engine. Checklist:

• •

Check that there are no water leaks. Check if there are any scrap, stones, seaweed etc. in the water jet unit by opening the inspection hatch. If necessary the anode hatch may be opened too.

Warning!

Never open the anode hatch before checking that the water level is lower than the hatch openings. The boat may sink if water can enter the boat through the opening. Never leave an opened hatch unattended.

When starting the engine again:

•

Engage the gear and check that there are no abnormal vibrations in the shaft and hull.

•

Move the steering nozzle from side to side between the limit positions. Check for abnormal noises from the steering gear.

•

Move the reversing bucket up and down. Check for abnormal noises.

Caution!

If there is abnormal vibrations or noises or if the boat has poor performance compared to the performance before the accident, contact a Rolls-Royce workshop. The Rolls-Royce workshop will do an accurate investigation of the inlet duct, shaft system, steering components and reversing components.

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3.3 Operating through flotsam and seaweed Scrap, twigs, seaweed etc. will not usually block or damage the water jet unit. However, avoid operating over such objects because they affect the performance of the water jet unit. It is usually possible to notice when the water jet unit is blocked because:

• • •

engine speed increases, the speed of the boat decreases, abnormal sound and vibrations can be heard from the water jet unit.

Caution!

If fishing nets or lines are sucked into the water jet unit, the water jet unit must be disengaged as quickly as possible to avoid damage to the impeller and impeller housing!

Removing an obstruction of the water jet unit If a blockage of the water jet unit occurs, reduce the engine speed to idling speed or disengage it. The blockage may clear when the boat goes forward and water flows through the water jet unit. If this is not successful: 1. Set the unblocked water jet unit to reverse. The blocked water jet unit, which must be in the ahead position and disengaged, will be flushed by the flow of water through it.

Warning!

Step 2 below is not allowed if the hydraulic pump is mounted on the water jet unit. The hydrulic pump will be damaged if the gear is reversed.

2. If step 1 was not successful, backflush the water jet unit by reversing impeller rotation. Use low engine speed. If step 2 above was not successful, the next step is to open the inspection hatch. Before the inspection hatch is opened: 1. Switch of the engines.

Warning!

Remove the start key and shut off the power using the main switch to make it impossible to start the engine!

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2. Check that the water level is not above the inspection hatch. If the water level is too high, weight can be added to the bow so that the stern rises sufficiently for the inspection hatch to be opened.

Warning!

Never open the anode hatch before checking that the water level is lower than the hatch openings. The boat may sink if water can enter the boat through the opening. Never leave an opened hatch unattended.

3. If the above steps have not removed the blockage, let a diver remove the scrap from the inlet duct or contact a Rolls-Royce workshop.

3.4 Operating in heavy seas When operating in heavy seas note that engine speed may vary as the impeller sucks in air. When the impeller sucks in air, drive and manoeuvring force are reduced. Engine speed should be reduced until engine speed and drive force are stable.

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3.5 Emergency operation

Warning!

Be prepared by familiarising yourself with the emergency procedures. Failure to follow these procedures in emergency situations may result in personal injury and equipment damage.

Operating in the event of electrical failure If an electrical failure in the main control system should occur and cannot be repaired, the boat can be operated by the hydraulic control valves of the hydraulic power pack.

Manual control of the hydraulic control valves If the back-up system is not installed, the hydraulic control valves can be operated manually.

NOTE! Refer to the enclosed “Hydraulic power pack assembly drawing” for more information about the following control valves. To steer the boat: 1. Push the solenoid armature of the steering valve with a pointy object. To slow down or to speed up the boat: 1. Push the solenoid armature of the reversing valve with a pointy object. Note that there are two reversing valves, if activating just one of them the boat will turn.

Warning!

Operating the boat by manually actuating the hydraulic control valves must be limited to emergency operation to the nearest harbour.

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Operating in the event of a hydraulic fault No hydraulic pressure or no hydraulic oil If there is no hydraulic oil available due to leakage or for some other reason, the water jet unit is out of control. Tow the boat to the nearest harbour for service. If the engines are not stopped the hydraulic pumps must be disconnected.

Warning!

If the hydraulic pump is allowed to rotate without being supplied with oil it may run hot and cause a fire in the engine room. 1. Disconnect the hydraulic pump. On installations where the hydraulic pump is located on the engine and is not belt driven, the cover was removed when the hydraulic pump was installed. This cover must be kept on board. The boat operator must know where the cover was taken from and where it is stored.

NOTE! Follow the instructions how to disconnect the hydraulic pump given by the engine manufacturer.

Reversing bucket uncontrollable If the reversing bucket is uncontrollable but the boat is still steerable, you may operate the boat to the nearest harbour with the reversing bucket tied up. How to tie up the reversing bucket: 1. Remove the screws retaining the reversing rods in the reversing bucket. Tie up the reversing bucket. When tied up it should be in ahead position and should not obstruct the jet of water, see Figure 3-9. 2. Operate the boat at reduced speed to the nearest harbour. Use the throttle lever to increase/reduce thrust.

Warning!

The only way to slow down (brake) the boat is to reduce the thrust or to disengage the gear. Therefore is the braking capability poor.

3. Use the reversing bucket in working order (if any) to slow down the boat. Observe that the braking capability is reduced. 4. Let a Rolls-Royce workshop investigate and repair the fault.

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Figure 3-9. The reversing bucket tied up.

Steering control lost Emergency steps: 1. If one of the water jet unit is in working order, disconnect the faulty water jet unit in the control panel (if not already disconnected). Operate the boat with the other water jet unit to the nearest harbour. Let a Rolls-Royce workshop investigate and repair the fault. 2. If both water jet units are out of control, call for help and tow the boat to the nearest harbour. Let a Rolls-Royce workshop investigate and repair the fault.

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3.6 Control system calibration with LCD display Calibration of the control system is necessary only at initial start up and if components in the system are replaced.

Initial calibration NOTE! Prior to performing calibration, ensure that the hydraulic system is running, and that the cylinders are free and clear to move for safety of personnel and equipment.

NOTE! It is necessary to disconnect any cabling between the control box and an interface terminal (PC/handheld unit) before performing the initial calibration. 1. Place the joystick and levers in their center detent positions and lock the joystick in transit mode. 2. Click any one of the first four buttons on the display to call up the function menus on the bottom of the LCD. 3. Select the CALIB SCREEN button to enter the control system calibration submenu. a. Enter password (1–1–2–3) when prompted. 4. Select the INIT CAL button to initialize the calibration. a. The screen displays Autocal status: Active and also: 1. Cylinders moving up/stbd, followed by 2. Cylinder moving down/port 5. When the display shows Autocal Status: Active, Cycle controls, unlock the joystick and move the following station 1 and station 2 components (as applicable) across their respective entire ranges of motion: 1) helm/tiller 2) joystick (full range of both X and Y axes) 3) control levers, 4) trim and roll knobs and 5) idle knob.

NOTE! The sequence of component operation is arbitrary.

NOTE! Do not attempt to transfer station control during the calibration process for station #2. 6. Place the joystick back in their center detent positions.

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7. Once the above procedures have been completed, press the FINISH CALIB button. a. The screen displays Autocal status: Not active. 8. The calibration is complete. Click VIEW METERS to return to the main display screen.

Neutral bucket calibration

Caution!

Prior to performing the following calibration procedure, ensure that the engine clutches are engaged. 1. Click any one of the first four buttons on the display to call up the function menus on the bottom of the LCD. 2. Click the CALIB SCREEN button to enter the control system calibration submenu. a. Enter password (1-1-2-3) when prompted. b. The screen displays Autocal status: Not active. 3. Click the THRUST CALIB button to enter the neutral thrust and side thrust calibration submenu. a. The screen displays Thrust calib status: Not active. 4. Click the INIT Z THRUST button to enter the neutral thrust submenu. 5. Using joystick or levers (as applicable), adjust the bucket position for neutral thrust (no net ahead or astern thrust is being imparted to the vessel). a. The screen displays Thrust Calib Status: Active – Set Neutral Thrust Position. 6. Select the SET Z THRUST to set the neutral thrust position and immediately move the joystick (or levers) back to the center detent position. 7. Repeat steps 5 and 6 if necessary. 8. Click the FINISH CALIB button to exit the neutral thrust submenu.

NOTE! If FINISH CALIB is not shown as an option, click the EXIT button (5th / furthest button to the right), and then press any one of the first four buttons. 9. Click VIEW METERS to return to the main display screen.

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Side thrust calibration NOTE! For best results, perform the following procedure in an area that permits safe maneuvering and where there is minimal wind and current disturbance to the craft. 1. Click any one of the first four buttons on the display to call up the function menus on the bottom of the LCD. 2. Click the CALIB SCREEN button to enter the control system calibration submenu. a. Enter password (1-1-2-3) when prompted. b. The screen displays Autocal status: Not active. 3. Click the THRUST CALIB button to enter the neutral thrust and side thrust calibration submenu. a. The screen displays Autocal status: Not active. 4. Click the INIT TRANSV THRUST button to enter the side thrust submenu. a. The screen displays Thrust Calib Status: Active – Set Transverse Thrust Offset. 5. Slowly move the joystick toward full port. 6. Adjust the helm to eliminate rotational forces. 7. Select the SET TRANSV THRUST to set the TRANSVERSE thrust position. 8. Slowly move the joystick toward full stbd. 9. Adjust the helm to eliminate rotational forces. 10. Select the SET TRANSV THRUST to set the TRANSVERSE thrust position. 11. Click the FINISH CALIB button to exit the transverse thrust submenu. 12. Click VIEW METERS to return to the main display screen.

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Starting and stopping

4. Starting and stopping 4.1 Before starting Water jet unit Check the following before the water jet unit is started: 1. Check that there is no oil or water leakage. 2. Check the oil level in the bearing housing, see page 59 section “Oil level”. 3. Check the oil level in the hydraulic oil tank of the control system.

Caution!

If there is a risk of foreign objects in the inlet duct, remove the objects before starting the engine or engaging the gear. When starting pay special attention to abnormal vibrations. If there is abnormal vibrations, the reason for this must be investigated and remedied else the impeller and impeller housing may be damaged.

4.2 Starting the engine and the water jet unit The start procedure depends on whether the water jet unit is directly engaged to the engine or if it is engaged via a gearbox. Note that it is not possible to move the position of the reversing bucket and the steering nozzle if the engine is not running.

The water jet unit is directly engaged to the engine 1. Check that the engine speed control is in idling position. 2. Be prepared to adjust the reversing bucket to zero thrust position, the steering nozzle in centre position as soon as the engine has started. 3. Start the engine. 4. Set the steering wheel in centre position and the reversing bucket control to zero thrust position.

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The water jet unit is engaged to the engine via a gearbox 1. Check that the engine speed control is in idling position and that the gear is in neutral position. 2. Start the engine. 3. Set the steering wheel in the centre position and the reversing bucket control to zero thrust position. 4. Engage the gear. Only ahead position is used, counter-clockwise rotation viewed from the stern, during normal operation.

4.3 After starting 1. Check that the steering nozzle turns both starboard and port and that the reversing bucket maneuvers correctly.

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4.4 Stopping the engine and water jet unit The water jet unit is directly engaged to the engine 1. Before the engine is stopped, set the reversing bucket in “full ahead” position and turn the steering nozzle so that the piston rod is inside the cylinder as illustrated below.

The piston rods are inside their respective cylinder

Figure 4-1. The water jet unit in correct position.

This must be done so that the piston rods on the reversing cylinder and the steering cylinder are inside their respective cylinders. This protects the piston rods from fouling and corrosion.

Caution!

If the cylinders are above the water line it is recommended that the reversing bucket is kept in reversing position because the anodes provide better anticorrosion protection when the reversing bucket is in the water. 2. Stop the engine.

NOTE! Be aware that the boat will move as soon as the engine RPM is increased the next time the engine is started. This due to the positions of the reversing bucket and steering nozzle. Be prepared to adjust the position of the reversing bucket and steering nozzle as soon as the engine is started again. 3. Check that there is no oil or water leakage.

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The water jet unit is engaged to the engine via a gearbox 1. Set the steering wheel to the centre position and the reversing bucket control to zero thrust position. 2. Disengage the gear. 3. Set the reversing bucket in “full ahead” position and turn the steering nozzle so that the piston rod is inside the cylinder as illustrated in Figure 4-1. This must be done so that the piston rods on the reversing cylinder and the steering cylinder are inside their respective cylinders. This protects the piston rods from fouling and corrosion.

Caution!

If the cylinders are above the water line it is recommended that the reversing bucket is kept in reversing position because the anodes provide better anticorrosion protection when the reversing bucket is in the water. 4. Stop the engine. 5. Check that there is no oil or water leakage.

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Maintenance instructions

5. Maintenance instructions The Kamewa FF-series are constructed for maximum service life and operational safety. Regular maintenance according to the table below maintains these qualities and will avoid unnecessary operational difficulties.

Warning!

Read through the safety instructions before beginning the maintenance work, see page 8 section “Maintenance work”.

Caution!

Never attempt an operation if you are not completely confident of how to do it. Contact Rolls-Royce if necessary.

5.1 Maintenance schedule Maintenance schedule

See

After the first 30 hours

page 58

Daily before the first start-up

page 59

Weekly

page 60

Each month

page 61

After 500 hours of operation

page 62

Yearly service (with the boat docked)

page 63

Painting

page 65

NOTE! The warranty only applies when the instructions in chapter “Maintenance schedule” are followed and documented in a proper way.

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After the first 30 hours Visual checkpoints: 1. Check the bearing housing (1) temperature - after approximately a half hour of operation. Stop the engine and check the temperature of the bearing housing. Normal temperature is approximately 20-40°C higher than the temperature of the water.

Warning!

The engine must be stopped when measuring the temperature. If not, there is a risk of personal injury. Secure a warning sign on the instrument panel “Maintenance work in progress!” to avoid the engine being started. 2. Check that the bearing tensioner nut (2) is tightened. 3. Check that the stud lock nuts (3) are tightened. 4. Check the installation of hydraulic cylinders (4). 5. Check the installation of the reversing bucket (5) and steering nozzle. 6. Check the installation of the steering rod and reversing rod (6). 7. Check the installation of the feedback assemblies installed on the steering and reversing cylinders (7).

6

7

5

1 4

2

3

Figure 5-1. Checkpoints after the first 30 hours of operation.

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Daily before the first start-up Visual check 1. Check the water jet unit visually both inside and outside the boat. Check that there is no oil or water leakage.

Oil level 1. Check the oil level in the bearing housing. The oil level is checked with the dipstick and must be between the max. and min. markings. If a top up is required, oil is filled through the hole where the dipstick is positioned.

Figure 5-2. Checking the oil level.

2. Also check the condition of the oil. The oil must not be mixed with water (greyish) or burned (dark). 3. Check the oil level in the hydraulic oil tank.

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Weekly 1. Check for possible water leak (a few water drops are allowed) or oil leak from the bearing housing inspection hole. If there is water leakage the mechanical sealing in the bearing housing must be replaced. If there is oil leakage the seals in the bearing housing must be replaced. See page 88 for instructions how to replace the seals.

Figure 5-3. The inspection hole of the bearing housing.

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Each month 1. Check the condition of the outer anodes (1). Replace the anodes if more than half has been worn away. 2. Check the anode under the anode hatch (2). Replace if more than half has been worn away. 2

1

1

Figure 5-4. Checkpoints to be inspected monthly.

Warning!

Always check that the water level is lower than the opening for the anode hatch (2). The boat may sink if water can enter the boat through the opening. Never leave the anode hatch open when the boat is in the water. 3. Check if the inspection hole in the bearing housing is open. Clean the inspection hole with a stiff wire if necessary.

NOTE! The consumption of the anodes may vary from case to case. The quality and condition of the water and also incorrect grounding of the boat’s electrical system will affect the system. If the anodes are being used up quickly, the inner anode in the guide vane chamber must also be checked: 1. Dock the boat. 2. Remove the guide vane chamber according to the instructions on page 80 section “Guide vane chamber”. 3. Remove the anode from the guide vane chamber and check the condition. Replace the anode if more than half the anode has been worn away.

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After 500 hours of operation Replace the oil in the bearing housing 1. Remove the plugs (1) and drain the oil into a container. 2. Screw the plugs in to place when all the oil has drained out. 3. Fill the oil through the dipstick (2) hole. 4. Check the oil level with the dipstick (2). The oil level must be between the max. and min. markings on the dipstick.

Figure 5-5. Oil dipstick and plugs of the bearing housing.

NOTE! For the recommended oil grade and the correct volume see page 117 section “Recommended lubricants and sealants”.

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Yearly service (with the boat docked)

Caution!

The water jet unit must not be run dry because the rubber bearing in the guide vane chamber and the mechanical sealing require water lubrication! 1. Check all bearing bushings for wear. Replace the bearing bushings if the play is greater than 1 mm. 2. Check the condition of the piston rods (1) on both the steering and reversing cylinders. Note a thin film of oil on the piston rod is normal. 3. Remove the reversing components, steering components and the guide vane chamber, follow the instructions starting on page 76 section “Reversing rod”. Check the following:

•

Measure the clearance (2) between the impeller and the impeller housing as described on page 107 section “Checking the clearance between the impeller and impeller housing”.

•

Check the condition of the rubber bearing. If the play between the rubber bearing and the shaft sleeve (3) is not between 0.1-1.0 mm the rubber bearing must be replaced.

•

Check the guide vanes in the guide vane chamber. If they are damaged and/or corroded contact Rolls-Royce for further instructions.

4. Check the condition of the inner anodes, in the guide vane chamber and under the anode hatch (4). Replace the anodes if more than half have been worn away or after a maximum of two seasons. 5. Check the o-ring (5) under the inspection hatch. The o-ring must be replaced if it does not provide a perfect seal. 6

5

4

5 1

2

3

Figure 5-6. Checkpoints to be inspected annually.

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6. Remove the impeller and the impeller housing as described on page 82 section “Impeller”, and check the following:

•

Check the impeller. If the tips of the impeller blades are lightly damaged they can be filed off as illustrated below. If the impeller blade is deformed the impeller should be replaced.

Figure 5-7. Cross-section of the impeller blade.

•

Check the impeller housing running surface. Replace the impeller housing if there are 2 mm deep scratches or 10 mm long scratches in the direction of the shaft.

7. Visually check the mounting of all components. Tighten as necessary. 8. Check the condition of the paint on all the water jet unit components. Clean and touch-up the paintwork as necessary.

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Painting Anti-fouling paint The waterjet is not anti-fouling painted at factory expect for the inside of the inlet pipe and the inlet grid. All painted surfaces on the outside of the waterjet must be painted with anti-fouling before the boat is launched. Apply the anti-fouling paint as follows:

•

Clean the surfaces from grease and oil with a suitable washing detergent.

• •

Remove salt and other dirt with high pressured fresh water.

•

Apply the anti-fouling paint within three (3) days after the epoxy tie coating has been applied.

Apply a thin layer off HEMPADUR 45182 or equal epoxy tie coating and let it dry.

The water jet unit can be anti-fouling painted with the same type of antifouling paint as the boat, provided that the paint does not contain copper. If local legalization does not allow the use of anti-fouling paint, contact Rolls-Royce for advice on alternative methods. Drying times according to the paint manufacturer’s instructions.

Touching up paintwork damage Any scratched water jet unit component must be repaired. Observe the following before painting a component:

NOTE! If a corrosive damage to the inlet duct is deeper than 3 mm, contact RollsRoyce. 1. Wash the area to be painted with fresh water.

Caution!

Be careful when using pressure washers. High water pressure can damage components on the water jet unit. 2. Leave the area to dry. 3. Lightly blast the surface and level out any unevenness. 4. Paint the area as described below.

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Painting Spray painting: 1. Spray 3 layers with “Intershield 803”. 2. Spray 1 layer with HEMPADUR 45182 or equal epoxy tie coating. 3. Spray 1 layer with anti-fouling paint. Drying times according to the paint manufacturer’s instructions. Painting with brushes: 1. Apply 5 layers of “Intershield 803”. 2. Apply 1 layer of HEMPADUR 45182 or equal epoxy tie coating. 3. Apply 2 layers of anti-fouling paint. Drying times according to the paint manufacturer’s instructions. Do not apply “anti-fouling paint” on cylinder rods and anodes.

Correction of damages in the painting Should an area or a component of the water jet unit be scratched during installation, the damaged painting must be remedied. Observe the following before painting a component: 1. Blast the area to be painted. 2. Wash the blasted area with fresh water.

Caution!

Be careful when using pressure washers. High water pressure can damage components on the water jet unit. 3. Leave the area to dry for about 12 hours. 4. Lightly blast the surface and level out any unevenness. 5. Paint the area as described earlier.

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5.2 Laying up With the boat in the water If the boat is not going to be in use for a longer period the following actions should be taken to avoid fouling and corrosion:

Once a week Start the engines and take the following actions.

•

Clutch in the water jet and run it for a few minutes to wash out sea growth.

• •

Lower and raise the reversing bucket a few times. Turn the steering wheel to the limit positions a number of times.

Caution!

When the engine is stopped follow the stopping instructions on page 55 to avoid corrosion.

Preventing fouling 1. The water jet unit must be painted with “anti-fouling” paint of prescribed quality. 2. If possible, moor the boat in deep water. 3. Keep the water jet unit out of sunlight as much as possible. A tarpaulin can be used to cover the water jet unit to protect it from sunlight. In shallow waters a similar protection should be placed over the opening for the inlet duct. 4. If there is a risk of frost the engine compartment should be warmed sufficiently to prevent water from freezing in the inlet duct and guide vane chamber. Before starting the water jet unit after a longer period of inactivity, check that no foreign objects are obstructing the moving components or blocking the inlet duct.

Caution!

In regions where it is a risk of frost, the boat should be lifted onto dry land. Seasonal storage of the water jet unit is recommended to avoid that the inlet duct does not crack as a result of freezing.

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Boat docked NOTE! To avoid fouling and corrosion the mechanical seal should be flushed with fresh water every time the boat is docked.

Seasonal storage Carry out the following after the boat has been taken on to dry land: 1. Clean the water jet unit with fresh water.

Caution!

Do not use pressure washers. High water pressure can damage components on the water jet unit. 2. Touch up any damage to the paintwork, as described on page 65 section “Touching up paintwork damage”. 3. Replace the oil in the bearing housing, as described on page 62 section “After 500 hours of operation”. 4. Grease all zinc coated components, for example hydraulic connections, zinc coated screws etc. 5. Wipe up all the water in the guide vane chamber.

Caution!

If the water in the guide vane chamber is not dried off there is a risk of the guide vane chamber cracking due to freezing.

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5.3 Fault-tracing A number of symptoms and possible causes of operational problems are described in the table below. In the event of faults or errors that you cannot remedy yourself you should always contact Rolls-Royce.

Warning!

Read through the safety instructions before beginning the maintenance work, see page 8. Symptom

Possible cause

Steering does not function correctly

1,2,3

The boat does not reverse

1,4,5,6

Poor performance

6,7,8,9,10,11,12,13

Abnormal noise from the impeller housing

9,12,14,15

Abnormal vibrations

9,10,12,16,17

Abnormal noise from the bearing house

11,18,19

Bearing housing leaking oil or water

19,20

The axial bearing is hot

11,18,21

The shaft nut/bearing tensioner nut has loosened

11,16,17,22

1. Hydraulic fault 2. The installation of the steering components 3. The function of the steering wheel 4. Obstruction in the reversing bucket 5. The installation of the reversing bucket components 6. The reversing rod setting 7. Engine fault 8. Control setting 9. Foreign objects in the impeller housing or in the guide vane chamber 10. Foreign objects in the inlet duct 11. Bearing fault

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12. Partially defective impeller 13. The clearance between the impeller and the impeller housing is too great 14. Defective impeller housing 15. Sand in the water jet unit after operating in shallow waters 16. Shaft damaged due to running aground 17. Intermediate shaft not balanced 18. Oil level too low in bearing housing 19. Defective mechanical sealing 20. Defective seals in bearing housing 21. Water in the oil 22. Defective locking washer/locking screws or shaft nut/bearing tensioner nut not sufficiently tightened

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Removing and installing

6. Removing and installing 6.1 General The instruction for removal describe how to correctly remove the water jet unit component by component. Depending on circumstances, several components can be removed from the water jet unit at the same time, as long as the instructions are followed. The water jet unit must be completely out of the water and dry prior to removal. All components should be inspected as they are removed. If any component is worn or damaged a spare part must be ordered. Components can be ordered as described in chapter “Spare Parts” or by contacting Rolls Royce. Installation is carried out in reverse order to removal. Before starting to install, check that all new components are available.

Caution!

Use only components manufactured or approved by Rolls-Royce. Note that components that appear identical to approved components may not fulfil the requirements. Ensure clean conditions and take greate care when installing. There are critical joints which must be tightened using a torque wrench. The tightening torques are listed on page 118 section “Tightening torques”.

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Component

Removal

Installation

Shaft flange

page 74

page 115

Reversing rod

page 76

page 113

Reversing bucket

page 77

page 112

Steering rod

page 78

page 110

Steering nozzle

page 79

page 110

Guide vane chamber

page 80

page 105

Impeller

page 82

page 103

Impeller housing

page 85

page 102

Hydraulic cylinders and through rod arrangement

page 86

page 100

Components of the inlet duct

page 87

page 98

Bearing housing and shaft

page 88

page 91

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6.2 Tools for removal and installation General tools Type

Size

Qty

Box wrench

36 mm

1

Socket wrench

30 mm

1

Socket wrench

24 mm

2

Socket wrench

19 mm

2

Socket wrench

17 mm

2

Socket wrench

13 mm

1

Socket wrench

10 mm

1

Allen key

6 mm

1

Allen key

5 mm

1

Allen key

4 mm

1

Screw driver

1

Adjustable wrench

2

Hammer

1

Plastic mallet

1

Rubber mallet

1

Ø8.5 mm drill & Tap M10

1

Feeler gauge

1

Torque wrench

1

24 mm box wrench for torque wrench

1

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Special tools Pos

Type

Qty

1

Puller for the shaft flange / impeller

1

2

Wrench for the bearing tensioner nut

1

3

Socket for the flange nut

1

4

Wrench for the impeller nut

1

5

Special tool for installing the seals of the bearing housing

1

Figure 6-1. Special tools to be used when removing and installing components.

NOTE! Special tools 1-4 are delivered with the water jet unit.

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6.3 Removal instructions NOTE! If the reason for removal is only to check or remove the impeller, begin by removing the reversing rod as described on page 76.

Shaft flange 1. Disconnect the intermediate shaft by unscrewing the screws retaining the intermediate shaft in the water jet unit flange. 2. Fold back the locking tabs on the locking washer and slacken off the flange nut. 3. Secure the puller in the shaft flange. 4. Tap the puller a couple of times with a hammer. If the shaft flange does not release, tighten the puller further and tap it a few more times.

Tighten the puller

Tap with a hammer so that the shaft flange loosens

Figure 6-2. Removing the shaft flange.

Caution!

Use the flange nut as a stop. This prevents the shaft flange and puller from falling off the shaft when the shaft flange loosens!

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5. When the shaft flange has loosened, unscrew the puller and the flange nut. Pull off the locking washer and the shaft flange.

Figure 6-3. Components to be removed.

Tools:

• • • •

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Socket for flange nut Screw driver Puller Hammer

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Reversing rod 1. Remove the screw retaining the reversing rod in the reversing bucket. If necessary, also remove the reversing rod from the reversing cylinder. 2. Check the bearing bushings. If there is more than 1 mm play, the bearing bushings must be replaced. 3. Check the anode. Replace if less than half the anode remains.

Figure 6-4. Removing the reversing rod.

Tools:

•

2x19 mm socket wrench

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Reversing bucket 1. Fold down the locking tabs. Slacken off the screws securing the reversing bucket in the guide vane chamber. 2. Pull out the distance sleeves.

Caution!

Take care not to damage the bearing bushings or distance sleeves. 3. Check the bearing bushings. If there is more than 1 mm play, the bearing bushings must be replaced. If the bearing bushings are replaced, the bearing seat must be cleaned before installation. 4. Check the anodes on the reversing bucket. Replace if less than half an anode remains.

Figure 6-5. Removing the reversing bucket.

Tools:

• • •

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30 mm socket wrench 17 mm socket wrench Hammer+ screw driver

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Steering rod 1. Remove the screw retaining the steering rod in the steering nozzle. If necessary, also remove the steering rod from the steering cylinder. 2. Check the bearing bushings. If there is more than 1 mm play, the bearing bushings must be replaced.

Figure 6-6. Removing the steering rod.

Tools:

•

2x19 mm socket wrench

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Steering nozzle 1. Disconnect the connecting cable from the upper retaining screw of the steering nozzle. 2. Fold the locking tabs back and slacken off the screws securing the steering nozzle. 3. Pull out the distance sleeves.

Caution!

Take care no to damage the bearing bushings or distance sleeves. 4. Remove the steering nozzle. 5. Check the bearing bushings. If there is more than 1 mm play the bearing bushings must be replaced. If the bearing bushings are replaced, the bearing seat must be cleaned before installation. 6. Check the anode. Replace if less than half the anode remains.

Figure 6-7. Removing the steering nozzle.

Tools:

• • • • •

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30 mm socket wrench 10 mm socket wrench 5 mm Allen key Screw driver Hammer

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Guide vane chamber 1. Remove the screws retaining the anodes in both the guide vane chamber and impeller housing. Remove the anodes. 2. Remove the screws retaining the guide vane chamber. 3. Pull the guide vane chamber from the shaft. The end of the shaft is held in the guide vane chamber with a rubber bearing (a water lubricated slide bearing). 4. Check the condition of the anodes. Replace if less than half an anode remains.

Figure 6-8. Removing the guide vane chamber.

Check the rubber bearing. If the play between the rubber bearing and the shaft sleeve is not between 0.1-1.0 mm the rubber bearing must be replaced. Removing the rubber bearing: 1. Remove the anode. Replace if less than half the anode remains. 2. Remove the locking screws from the rubber bearing. 3. Tap out the end piece from the guide vane chamber. 4. Press out the rubber bearing.

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Figure 6-9. Removing the rubber bearing.

Caution!

When pressing out the rubber bearing, the inner section of the guide vane chamber must be supported. The application force must not be taken up by the outer section of the guide-vane chamber and the guide vanes. Do not damage the mounting surface of the rubber bearing in the guide vane chamber. This may make it difficult to install the new rubber bearing.

Tools:

• • • •

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2x19 mm socket wrench 17 mm socket wrench 5 mm Allen key Hammer

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Impeller Before removing the impeller, the clearance between the impeller and the impeller housing must be measured. Follow the instructions on page 107 and make a note of the clearance. Removing the impeller: 1. Remove the impeller nut locking screws. 2. Unscrew the impeller nut and pull out the shaft sleeve.

Figure 6-10. Removing the shaft sleeve.

3. Secure the puller in the impeller. 4. Tap the puller a couple of times with a hammer. If the impeller does not release, tighten the puller further and tap it a few more times.

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Figure 6-11. Securing the puller.

5. When the impeller has loosened, pull it off the shaft. Slacken off the puller.

Figure 6-12. Pulling out the impeller.

6. Remove the o-ring that is located on the shaft behind the impeller. 7. Check the impeller. If the tips of the impeller blades are lightly damaged they can be filed off as illustrated below. If the impeller blade is deformed the impeller should be replaced.

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Figure 6-13. Cross section of the impeller blade.

Tools:

• • •

4 mm Allen key Special Wrench for impeller nut Puller + Hammer

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Impeller housing 1. Remove the screws retaining the anodes in the impeller housing and inlet duct. Remove the anodes. 2. Check the condition of the anodes. Replace if less than half an anode remains. 3. Remove the screws retaining the impeller housing in the inlet duct. 4. Check the impeller housing surface. If there are 2 mm deep scratches or 10 mm long scratches in the direction of the shaft, the impeller housing must be replaced.

Figure 6-14. Removing the impeller housing.

Tools:

• •

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2x19 mm socket wrench 5 mm Allen key

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Hydraulic cylinders

Caution!

Ensure cleanliness when removing hydraulic components. 1. Remove the hydraulic hoses. Drain the oil into a suitable container.

Warning!

Take great care when removing the hydraulic hoses. The pressure may still be high, the oil may be hot. Carelessness can result in personal injury. 2. Remove the hydraulic cylinders from the water jet unit transom. 3. Check the condition of the hydraulic cylinders. In the event of leakage, scratches on the piston rod or other damage the hydraulic cylinder must be replaced. 4. Check the seals, replace the seal if it is broken.

Figure 6-15. Removing the hydraulic cylinders.

Tools:

• •

19 mm socket wrench Adjustable wrench

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Components of the inlet duct

Figure 6-16. Removing the hatches.

Outer inspection hatch: 1. Unscrew the eye nuts of the inspection hatch. 2. Pull up the inspection hatch with o-ring from the inlet duct. 3. The o-ring must be replaced if it does not provide a perfect seal. If necessary, the wire and inspection hatch can be removed from the inlet duct. Inner inspection hatch: The inner inspection hatch is not installed on this water jet. Anode hatch: 1. Remove the screws retaining the anode hatch. 2. Check the anode. Replace if less than half the anode remains. 3. The o-ring must be replaced if it does not provide a perfect seal.

Tools:

• •

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19 mm socket wrench 13 mm socket wrench

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Bearing housing and shaft General The flange end of the shaft is held in the bearing housing (13) by an oil lubricated axial bearing (7). The bearing housing and bearing housing cover (3) have seals (5, 10) to keep the oil in the bearing housing. A mechanical sealing (19) seals against water. On the underside of the bearing housing there is an inspection hole (11). If any of the seals are leaking, oil or water will come through the hole.

Figure 6-17. Components of the bearing housing.

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Removal 1. Remove the oil drain plugs (12) and drain the oil into a suitable container. 2. Remove the nuts holding the bearing housing (13) in the inlet duct. If there is sufficient space between the water jet unit and the engine, pull the entire shaft assembly into the boat. It can then be taken indoors for further disassembly.

Caution!

Take care not to damage the cone or threads of the shaft. 3. Fold back the locking tabs on the locking washer (2) and remove the bearing tensioner nut (1). 4. Remove the bearing housing cover (3). Check the seal (5). Press out the seal of the bearing housing cover if a new one is required. 5. Pull out the support sleeve (6) from the bearing housing (13). Note that the bearing shell comes with the support sleeve. Slide the bearing housing forwards and backwards so that the o-ring (8) loosens and can be removed. 6. Pull the bearing housing (13) from the shaft. 7. Remove the screws from the mechanical sealing (19) and remove it. Check the sealing surfaces of the mechanical sealing. 8. Lift out the shaft if it has not already been removed. 9. Place the bearing housing (13) indoors. Remove the axial bearing (7) and the support sleeve (9) with bearing shell. The axial bearing must be replaced after 5,000 hours or earlier if abnormal vibrations and noise come from the bearing housing during operation.

NOTE! If the axial bearing (7) does not need to be replaced, the bearing shells must be placed on the same side of the axial bearing as before, but with the axial bearing turned 180°. 10. Pull out the mechanical seal static face. Check the o-ring. 11. The seal (10) can now be checked. Press it out of the bearing housing (13) if a new one is required.

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12. The seal holder (16) does not normally need to be removed. However, if it is necessary remove the screws retaining the seal holder (16) in the bearing housing. 13. The upper cover of the bearing housing can be removed for cleaning purposes. In this case the plugs must also be removed.

Figure 6-18. Removing the seal holder (16) and the upper cover.

Tools:

• • • • • • •

24 mm box wrench 24 mm socket wrench 17 mm socket wrench 6 mm Allen key 4 mm Allen key Hammer Wrench for bearing tensioner nut

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6.4 Installation instructions Bearing housing and shaft NOTE! The position numbers in the text refers to Figure 6-17. 1. Lift the shaft into the water jet unit (from the outside with the shaft flange end foremost) so it is possible to install the mechanical sealing rotary unit. 2. Before installing the mechanical sealing rotary unit, lubricate the shaft surface with oil. Then install the mechanical sealing rotary unit on the shaft until the spring retainer abuts the collar on the shaft. Apply Loctice® 222 on the locking screws; tighten to prescribed tightening torque. When installed, check that the seal is intact and against the collar.

Lubricate the shaft surface with oil Mechanical sealing rotary unit

Figure 6-19. Installing the mechanical sealing rotary unit.

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Installing components in the bearing housing:

NOTE! If there is sufficient room between the engine and the water jet unit, it is easier to carry out steps 3-8 on a bench indoors before installing the entire bearing housing (13) in the boat. 3. Install the seal holder (16):

•

Spread out the gasket adhesive both below and on top of the gasket (15). Tighten the seal holder to prescribed tightening torque. Apply installation paste on the threads.

Figure 6-20. Installing the seal holder (16).

4. Install seal (10):

• •

Lubricate the seal with grease before installing it. Tap the seal into place, spring side towards the bearing, with a rubber mallet and the special tool in the illustration.

Figure 6-21. Installing the seal (10).

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5. Install the o-ring (17). 6. Install the mechanical sealing static face and o-ring:

•

Lubricate the static face o-ring with water resistant grease and install it onto the static face. Position the static face assembly into the seal holder, ensuring the slot within the static face aligns the pin. The static face should be cleaned thoroughly before it is pressed into place by hand.

Lubricate the o-ring with water resistant grease Static face o-ring Mechanical sealing static face

O-ring (17)

Figure 6-22. Installing the o-ring (17) and mechanical sealing static face.

7. Install the support sleeve (9) with bearing shell:

•

Lubricate the support sleeve (9) with oil before installing it.

Figure 6-23. Installing the support sleeve (9).

Caution!

Check that the seal (10) does not deform when the support sleeve (9) is slid into the bearing housing (13).

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8. Install the axial bearing (7):

•

Carefully press the axial bearing into the bearing housing (13) until it comes into contact with the support sleeve (9).

•

Carefully tap the bearing with a plastic mallet to ensure that the bearing is in its correct position.

Figure 6-24. Installing the axial bearing (7).

Caution!

Check that no residue from the mallet is left on the bearing or in the bearing housing! Installing the bearing housing on the shaft: 9. Lubricate the threads on the shaft using installation paste. 10. Before sliding the bearing housing (13) onto the shaft:

• •

Clean the shaft and lubricate it with grease.

•

Check that there are no foreign objects on the shaft by sliding on the support sleeve (6) and then check that it can be slid forwards and backwards.

Clean grease and dirt off the surfaces of the mechanical sealing (19).

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11. Carefully press the bearing housing (13) onto the shaft until the mechanical sealing (19) on the shaft is in contact with the static face inside the bearing housing.

Figure 6-25. Installing the bearing housing on the shaft.

Caution!

The bearing housing (13) must be pressed into place carefully so that the inner seal (10) does not move and bend in the wrong direction. 12. Install the o-ring (8). 13. Install the support sleeve (6) with bearing shell. 14. Install the bearing housing cover (3) and o-ring (4). If necessary, install a new seal (5) with the spring side towards the bearing. Tap in the seal with the special tool. 15. The bearing housing assembly is screwed together with the bearing tensioner nut (1) which is locked with a locking washer (2). Tighten the bearing tensioner nut to prescribed tightening torque. Tighten from different directions.

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Figure 6-26. Installing the remaining components.

Figure 6-27. Tightening the bearing tensioner nut (1).

Caution!

The tightness of the bearing tensioner nut (1) should be checked after approximately 30 hours of operation and re-tightened if necessary.

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16. Install the screws and nuts retaining the bearing housing (13) in the inlet duct. Tighten to prescribed tightening torque.

Figure 6-28. Tightening the entire bearing housing unit.

Caution!

The bearing housing must be filled with oil before the water jet unit is operated. For recommended oil grade and the correct oil volume see page 117 section “Recommended lubricants and sealants”.

Tools:

• • • • • • • • • • •

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24 mm socket wrench 24 mm box wrench 17 mm socket wrench 6 mm Allen key 4 mm Allen key Wrench for bearing tensioner nut 24 mm box wrench for torque wrench Torque wrench Pipe extension, approximately 1 m Screwdriver Plastic mallet

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Components of the inlet duct Outer inspection hatch (1): 1. If the wire is removed, install the wire on the inlet duct. Secure the inspection hatch by attaching it to the wire. 2. Lubricate the o-ring to secure its position. 3. Install the inspection hatch with o-ring. Tighten the eye nuts properly by hand. Inner inspection hatch (2): The inner inspection hatch is not installed on this water jet.

Figure 6-29. Installing the inspection hatches and anode hatch.

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Anode hatch (3): 1. Lubricate the o-ring to secure its position. 2. Screw the anode into place in the anode hatch, tighten to prescribed tightening torque. 3. Screw the anode hatch into place in the inlet duct, tighten to prescribed tightening torque.

Tools:

• • •

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19 mm socket wrench 13 mm socket wrench Torque wrench

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Hydraulic cylinders

Caution!

Ensure cleanliness when installing hydraulic components. 1. Install the seal. 2. Install the hydraulic cylinder on the water jet unit transom. Tighten to prescribed tightening torque. 3. Install the hydraulic hoses.

Figure 6-30. Installing the hydraulic cylinders.

Figure 6-31. Applying sealant.

4. Sealant must be applied on the outside of the transom. 5. Bleed the cylinder.

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Tools:

• • •

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19 mm socket wrench Adjustable wrench Torque wrench

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Impeller housing 1. Install the impeller housing on to the inlet duct. Remember to install the insulation washers both under the bolt and nut. 2. Tighten to prescribed tightening torque.

Figure 6-32. Installing the impeller housing.

3. Install the anodes on the impeller housing/inlet duct. Tighten to prescribed tightening torque.

Tools:

• • •

2x19 mm socket wrench 5 mm Allen key Torque wrench

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Impeller Prior to installing: 1. Clean the shaft. 2. Check the key and the key-way in the shaft and in the impeller. 3. Install the o-ring. 4. Before the impeller nut and shaft sleeve are installed, lubricated them with installation paste so they can be removed again as required.

Figure 6-33. Installing the o-ring, impeller, shaft sleeve and impeller nut.

Caution!

The impeller cone must not be lubricated! 5. Insert the impeller on the shaft in the impeller housing until correct contact between the impeller and shaft surface has been obtained. Check that the key is correctly installed. 6. Use a plastic mallet to tap the impeller further along the shaft. 7. Install the shaft sleeve and the impeller nut. 8. Tighten the impeller nut to prescribed tightening torque. Counterhold the flange end of the shaft to enable tightening. 9. Screw the locking screws into place on the impeller nut. Apply thread sealant.

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Tools:

• • • •

4 mm Allen key Wrench for impeller nut Torque wrench Plastic mallet

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Guide vane chamber Installing the new rubber bearing 1. Press in the new rubber bearing in the guide vane chamber. Apply soap as a lubricant.

Caution!

When pressing in the rubber bearing, the inner section of the guide vane chamber must be supported. The application force must not be taken up by the outer section of the guide vane chamber and the guide vanes. 2. Drill Ø8.5 mm diameter holes in the rubber bearing for the locking screws. Do not drill all the way through. Drill only in the bakelite layer. 3. Thread the holes with M10. 4. Screw the locking screws into place. Apply thread sealant.

Caution!

The locking screws must not press against the rubber bearing. 5. Install the anode, tighten to prescribed tightening torque. 6. Install the end piece. Use a rubber mallet to tap the end piece into the guide vane chamber. Seal between the rubber bearing and the guide vane chamber with sealant.

Figure 6-34. Installing the rubber bearing, anode and end piece.

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Caution!

The hole in the end piece must always be open so that the rubber bearing can be lubricated by the water flowing through it.

Installing the guide vane chamber 1. Install the anodes, tighten to prescribed tightening torque. 2. Check that the contact surface between the guide vane chamber and the impeller housing is clean. 3. Before installing the guide vane chamber, lubricate the contact surface with grease. 4. Install the guide vane chamber with 4 screws. Remember to install the insulation washers. 5. Check that the impeller rotates freely in the impeller housing. 6. Screw in the remaining screws and tighten the guide vane chamber, tighten to prescribed tightening torque. 7. Install the anodes on the guide vane chamber/impeller housing, tighten to prescribed tightening torque.

Figure 6-35. Installing the guide vane chamber.

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Checking the clearance between the impeller and the impeller housing 1. Check the clearance between the impeller blade and the impeller housing running surface. The minimum distance is 0.3 mm. If the impeller is hanging and touches the bottom of the impeller housing, then the maximum clearance on the opposite side must not exceed 2.0 mm.

Figure 6-36. Measuring the clearance.

Tools:

• • • • • • • • •

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2x19 mm socket wrench 17 mm socket wrench 5 mm Allen key Screw driver Ø8,5 mm drill Tap M10 Rubber mallet Feeler gauge Torque wrench

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Steering nozzle 1. Install the anode on the steering nozzle, tighten to prescribed tightening torque. 2. Install the bearing bushings. Seal between the bearing bushing and the steering nozzle with sealant. 3. Position the steering nozzle. 4. Press in the distance sleeves. Check the locking of the distance sleeves. 5. Install the steering nozzle on the guide vane chamber. Tighten to prescribed tightening torque. 6. Fold up the locking tabs on the locking washer towards the screw head. 7. Install the connecting cable to the upper retaining screw of the steering nozzle.

Figure 6-37. Installing the steering nozzle.

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Tools:

• • • • • •

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30 mm socket wrench 10 mm socket wrench Hammer Screwdriver 5 mm Allen key Torque wrench

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Steering rod Installing: 1. Install new bearing bushings if necessary. The bearing bushings must rotate in the rod connections and must not be locked. 2. Install the steering rod in the steering nozzle. Remember to install the insulation washers. 3. Set the steering cylinder in central position and check that the steering nozzle is straight.

Figure 6-38. Installing the steering rod.

4. Install the steering rod on to the steering cylinder. Checking the installation: 1. Check that the steering nozzle can be turned slightly more when the steering cylinder piston rod is in its outer limit position. This must also be checked when the piston rod is at its inner limit position.

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2. Check that the steering nozzle does not touch the guide vane chamber.

Figure 6-39. Checking the steering rod installation.

3. If the criteria in the steps above are not fulfilled the length of the steering rod must be adjusted as follows:

•

Fold up the locking washer and unscrew the nut on the rod connection.

•

Adjust the length of the steering rod by screwing the steering rod in and out as necessary.

•

When the steering rod is adjusted, tighten the nut on the rod connection to prescribed tightening torque. Fold down the locking washer.

4. Tighten the steering rod to prescribed tightening torque. Apply thread sealant.

Tools:

• • • •

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36 mm box wrench 2x19 mm socket wrench Hammer + screwdriver Torque wrench

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Reversing bucket 1. Install the anodes on the reversing bucket. Tighten to prescribed tightening torque. 2. Install the bearing bushings. Apply sealant between the reversing bucket and bearing bushing. 3. Install the reversing bucket on the guide vane chamber. 4. Press in the distance sleeves. Check the locking of the distance sleeves. 5. Tighten the reversing bucket to prescribed tightening torque 6. Fold up the locking tabs towards the screw head.

Figure 6-40. Installing the reversing bucket.

Tools:

• • • •

30 mm socket wrench 17 mm socket wrench Screwdriver Torque wrench

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Reversing rod Installing: 1. Install the anode on the reversing rod. 2. Install the bearing bushings. The bearing bushings must rotate in the rod connections and must not be locked. 3. Install the reversing rod on the reversing bucket. Remember to install the insulation washers. Checking the installation: 1. Check that the reversing bucket does not knock against the steering nozzle when it is raised and lowered. At the same time check also that the reversing bucket does not knock against the steering nozzle when turning the steering nozzle from side to side. 2. Check that the reversing bucket raises sufficiently so that it does not obstruct the jet of water when driving ahead. 3. Check that the reversing bucket lowers sufficiently to allow reversing.

Figure 6-41. Checking the reversing rod installation.

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4. If the criteria in steps above are not fulfilled the length of the reversing rod must be adjusted as follows:

•

Fold up the locking washer and unscrew the nut on the rod connection.

•

Adjust the length of the reversing rod by screwing the reversing rod in and out as necessary.

•

When the reversing rod is adjusted, tighten the nut on the rod connection to prescribed tightening torque. Fold down the locking washer.

5. Tighten the reversing rod to prescribed tightening torque.

Tools:

• • • • •

30 mm box wrench 2x19 mm socket wrench Hammer Screwdriver Torque wrench

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Shaft flange Prior to installation: 1. Check the key and the key-way in the shaft flange and shaft. 2. Warm up the shaft flange so that it is 15-20°C warmer than its surroundings. Installation: 1. Install the shaft flange. 2. Install the flange nut and locking washer. 3. Tighten the flange nut to prescribed tightening torque. 4. Allow the shaft flange to cool down and then check the tightening torque. 5. Fold down the locking tabs on the locking washer.

Figure 6-42. Installing the shaft flange.

Tools:

• • •

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Socket for flange nut Screw driver Torque wrench

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Technical information

7. Technical information 7.1 Technical data Type designation

FF410

Weight (water jet only)

420 kg

Water volume in inlet duct

160 l

Power range

100–600 kW

Oil quantity in bearing housing

1.8 l approx. 90 bar

Hydraulic pressure of the control system

7.2 Recommended lubricants and sealants

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Type

Rolls-Royce recommend

Oil in bearing housing

Same as in the engine

Hydraulic oil for the control system

Standard mineral oil ISO VG46

Sealant when installing

Sikaflex® 252 Bostik® 2639 3M® 5200

Gasket adhesive

Loctite® 5203

Water resistance grease

SKF LGWA 2/0.4

Installation paste

CRC® aluminium paste

Thread sealant, securing Thread sealant, securing Thread sealant, locking

Loctite® 243 Loctite® 222 Loctite® 270

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7.3 Tightening torques Component

FF410

Mechanical sealing, locking screws

8 Nm

Seal holder

30 Nm

Bearing tensioner nut

350 Nm

Bearing housing assembly

120 Nm

Bearing housing assembly lock nut

160 Nm

Anodes on the inlet duct

20 Nm

Anode below the anode hatch

30 Nm

Anode hatch

25 Nm

Reversing cylinder

80 Nm

Steering cylinder

80 Nm

Impeller housing

70 Nm

Anodes on the impeller housing / inlet duct

10 Nm

Impeller nut

550 Nm

Anode in the guide vane chamber

20 Nm

Anodes on the guide vane chamber

20 Nm

Guide vane chamber

70 Nm

Anodes on the guide vane chamber / impeller housing

10 Nm

Anode on the steering nozzle

8 Nm

Steering nozzle

180 Nm

Steering rod

10–15 Nm

Lock nut for steering rod coupling

250 Nm

Anodes on the reversing bucket

30 Nm

Reversing bucket

180 Nm

Reversing rod

10–15 Nm

Lock nut for reversing rod

180 Nm

Shaft flange

410 Nm

Anode below the inspection hatch

40 Nm

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7.4 Conversion factors Metric to U.S. factors

Multiply by

mm to inches

0.03937

kg to lb

2.205

N to lbf

0.2248

Nm to lbf ft

0.738

l to U.S. gallon

0.2642

m3 to cu ft

35.315

m/s to ft/min

196.85

°C to °F:

U.S. to metric factors

Multiply by

inches to mm

25.40

lb to kg

0.454

lbf to N

4.448

lbf ft to Nm

1.356

U.S. gallon to l

3.785

cu ft to

m3

0.0283 0.00508

ft/min to m/s

°F to °C:

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Spare parts

8. Spare parts 8.1 Ordering spare parts In this chapter and from the enclosed “assembly drawing” you will find the information you need to order spare parts. Complete the spare parts form with the information needed, you will find a copy of the form in section “DRAWINGS”.

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Spare parts

3

2

8

2

3

1

2

7

4

6

3

1

10

12

9

4

11

5

1

8.2 Spare part series 1, 1–2 seasons or a maximum of 1500 hours of operation

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Pos

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Spare parts

Qty

Spare part

Part number

1

8

Bearing bushing

101 084 12

2

4

Bearing bushing

101 051 42

3

4

Anode

101 077 01

4

2

Anode

101 082 30

5

1

Anode

101 082 10

6

1

Anode

375 174 11

7

1

Anode

102 082 20

8

1

Anode

872175

9

4

Anode

101 082 20

10

1

O-ring

102 026 29

11

1

O-ring

102 026 39

12

1

Anode

101 082 28

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Spare parts

8.3 Other spare parts

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Pos

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Spare parts

Qty

Spare part

Part number

13

1

Rubber bearing

376 014 72

14

1

Shaft sleeve

410 013 01

15

1

Impeller nut

450 016 11

16

1

Mechanical sealing

17

1

O-ring

102 026 31

18

2

O-ring

102 026 25

19

2

Seal

102 025 90

20

1

Axial bearing

21

1

Bearing tensioner nut

102 029 12

22

1

Locking washer

102 030 12

23

1

O-ring

102 026 03

24

2

Support sleeve

450 021 13

25

1

Flange nut

102 029 08

26

1

Locking washer

102 030 08

27

1

Impeller housing

410 003 01

28

1

Guide vane chamber

410 186__

29

1

Impeller

410 007 __

30

1

O-ring

102 026 07

31

2

Distance sleeve

101 052 42

32

2

Distance sleeve

410 052 03

33

2

Seal

101 189 03

34

1

Reversing cylinder

101 210 36

35

1

Steering cylinder

101 210 35

2411845

102 034 80 A

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Spare parts

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Glossary

Glossary Anode

A metal that protects the water jet unit from corrosion by sacrificing itself.

Anti-fouling paint

Paint that prevents fouling.

Booster

Water jet unit without steering and reversing bucket. Often used as the centre water jet unit on boats with three water jet units.

Cavitation

Cavitation is a phenomenon that may occur in any fluid subjected to velocity increase or a body moving rapidly through the fluid. According to Bernoulli’s equation an increase in velocity causes a drop in static pressure. If the pressure drops to the vapour pressure of the fluid, pockets of vapour will be formed. The vapour pressure varies with the temperature of the fluid. These pockets may suddenly collapse, either because they are carried along by the liquid until they arrive at a point of higher pressure, or because the pressure increases again at the point in question. The forces then exerted by the liquid rushing into the cavities may cause very high local pressures which can lead to serious erosion of boundary surfaces. In extreme cases light may be emitted when the cavity collapses.

Displacement boat

Type of boat on which the hull never planes on the water but ploughs through the water. In contrast a planing craft functions as a displacement craft up to a certain speed when the hull rises out of the water and reaches planing position.

Docked

Dock, equipment (fixed or floating) which allows the boat to stand dry on the bottom when the water has been pumped out of the dock. Docks are usually used for larger craft. Smaller craft are usually lifted onto land.

Laid up water jet unit

Boat docked.

Marine gear

Transmission for boats, also designated reverse gear. Usually has only two gear positions, forward and reverse, plus neutral po-

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Glossary

sition. Generally produces a reduction in engine speed (RPM). Single installation

Boat with one water jet unit installed.

Thrust

The pressure force generated by the jet of water that forces the boat forward.

Twin installation

Boat with two water jet units installed.

Zero thrust position

All ahead and astern thrusts are equal. See “Function of the reversing bucket chapter“ and section “Zero thrust position”.

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ROLLS-ROYCE Oy Ab P.O. Box 579 FIN-67701 Kokkola FINLAND Telephone: +358 6 832 4500 Telefax: +358 6 832 4512 E-mail: [email protected]

MANUAL FOR WATERJET FF410

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