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Kamewa FF410
FF410
Instruction manual
Kamewa water jets
Table of Contents
Preface
....................................................
...............................
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Driving the boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
8
1. Safety instructions
19
43
45
46
47
50
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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FF410
Instruction manual
Kamewa water jets
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, 12 seasons or a maximum of 1500 hours of
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.3 Other spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Glossary
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Instruction manual
Kamewa water jets
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.
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2000-09-19
Rolls-Royce Oy Ab
FF410
Instruction manual
Kamewa water jets
Preface
Rolls-Royce Oy Ab
182001
2000-09-19
FF410
Instruction manual
Kamewa water jets
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.
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 mates course. We recommend that you contact a regional boating or marine safety organisation for information about
suitable courses.
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Safety instructions
Caution!
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!
Caution!
Caution!
Caution!
Check that there are no foreign objects in the inlet duct or impeller housing.
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Instruction manual
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Safety instructions
Maneuvering
Warning!
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
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 users 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 users responsibility to make all relevant hazard identifications and
risk assessments of all the activities associated with the use of this document.
It is the users 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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Instruction manual
Kamewa water jets
Safety instructions
Warning!
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!
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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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
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)
water density (kg/m3)
Q volumetric flow (m3/s)
Vout average speed out (m/s)
Vin average speed in (m/s)
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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.
No risk of overloading the engine, low noise and vibration levels. This
means longer service life and low maintenance costs.
Competitive advantages of the FF-series over other water jet unit manufacture:
Easy service and maintenance. Wear parts are easy to replace without any special tools. Low risk of damage. No gear shifting.
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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
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.
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Main components
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.
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.
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.
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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Cruising/Transiting
In transit mode, imparting forward and aft thrust to the vessel is accomplished via the control levers, while the vessels 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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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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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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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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Steering wheel
turned to port
Steering wheel
straight
Steering wheel
turned to port
Steering wheel
straight
Full ahead
Zero thrust
Port thrust
Full astern
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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.
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Indication
Not illuminated
Illuminated steady
Station in control
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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
Illuminated steady
Clutch engaged
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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.
NOTE!
For applications that are not supplied with an indication module and dedicated indication circuit, the LCD should not be configured for CAN mode.
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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Button
Function
Main screen
1, 2, 3
and 4
Main screen
Main screen
Main screen
Main screen
3*
Main screen
4*
System screen
Main screen
Exit/hide submenu
Fault screen
Fault screen
Exit/hide submenu.
Main screen
Calib
screen
Main screen
Calib
screen
Main screen
Calib
screen
Main screen
Calib
screen
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Main screen
Calib
screen
Exit/hide submenu
Main screen
Calib
screen
CAN calib
screen
Main screen
Calib
screen
CAN calib
screen
Main screen
Calib
screen
CAN calib
screen
Not used.
Main screen
Calib
screen
CAN calib
screen
Main screen
Calib
screen
CAN calib
screen
Exit/hide submenu
Main screen
Calib
screen
CAN calib
screen
INIT CAL
screen (CAN
calib)
Main screen
Calib
screen
CAN calib
screen
INIT CAL
screen (CAN
calib)
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Main screen
Calib
screen
CAN calib
screen
INIT CAL
screen (CAN
calib)
Not used.
Main screen
Calib
screen
CAN calib
screen
INIT CAL
screen (CAN
calib)
Main screen
Calib
screen
CAN calib
screen
INIT CAL
screen (CAN
calib)
Exit/hide submenu.
Main screen
Calib
screen
Thrust calib
screen
Main screen
Calib
screen
Thrust calib
screen
Main screen
Calib
screen
Thrust calib
screen
Main screen
Calib
screen
Thrust calib
screen
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Main screen
Calib
screen
Thrust calib
screen
Exit/hide submenu.
Main screen
Calib
screen
Thrust calib
screen
INIT
ZTHRST
screen
Main screen
Calib
screen
Thrust calib
screen
INIT
ZTHRST
screen
Main screen
Calib
screen
Thrust calib
screen
INIT
ZTHRST
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT
ZTHRST
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT
ZTHRST
screen
Exit/hide submenu.
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Main screen
Calib
screen
Thrust calib
screen
INIT
TRANSV
screen
Main screen
Calib
screen
Thrust calib
screen
INIT
TRANSV
screen
Main screen
Calib
screen
Thrust calib
screen
INIT
TRANSV
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT
TRANSV
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT
TRANSV
screen
Exit/hide submenu.
Main screen
Calib
screen
Thrust calib
screen
INIT CAL
screen
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Main screen
Calib
screen
Thrust calib
screen
INIT CAL
screen
Main screen
Calib
screen
Thrust calib
screen
INIT CAL
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT CAL
screen
Not used.
Main screen
Calib
screen
Thrust calib
screen
INIT CAL
screen
Exit/hide submenu.
System
screen
System
screen
System
screen
System
screen
System
screen
Exit/hide submenu.
N/A
N/A
System
screen
IntSteer
System
screen
DatMode**
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System
screen 232
Xmit**
N/A
N/A
N/A
System
screen
IntMap**
N/A
System
screen
StaType**
N/A
1 and
2
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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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
!J1939
!Serial
CAL FAULT
ST1 Joy X
St1 Joy Y
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ST1 Helm/Till
ST2 Joy X
ST2 Joy Y
ST2 Helm/Till
ST3 Joy X
ST3 Joy Y
ST3 Helm/Till
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DOCKMODE
FAULT Inbd
Cltch Eng.
DOCKMODE
FAULT Otbd
Cltch Dis.
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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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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.
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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.
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Warning!
Remove the start key and shut off the power using the main switch to make
it impossible to start the engine.
Checklist:
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.
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!
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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!
Warning!
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.
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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.
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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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.
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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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 (1123) 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.
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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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.
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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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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!
Caution!
See
page 58
page 59
Weekly
page 60
Each month
page 61
page 62
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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Maintenance instructions
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).
1
4
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Maintenance instructions
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.
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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Maintenance instructions
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.
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Maintenance instructions
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
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 boats
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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Maintenance instructions
NOTE!
For the recommended oil grade and the correct volume see page 117
section Recommended lubricants and sealants.
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Maintenance instructions
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.
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
1
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Maintenance instructions
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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Maintenance instructions
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 manufacturers instructions.
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!
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Maintenance instructions
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 manufacturers 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 manufacturers instructions.
Do not apply anti-fouling paint on cylinder rods and anodes.
Caution!
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Maintenance instructions
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.
Caution!
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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Maintenance instructions
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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Maintenance instructions
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!
Possible cause
1,2,3
1,4,5,6
Poor performance
6,7,8,9,10,11,12,13
9,12,14,15
Abnormal vibrations
9,10,12,16,17
11,18,19
19,20
11,18,21
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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Caution!
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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
page 80
page 105
Impeller
page 82
page 103
Impeller housing
page 85
page 102
page 86
page 100
page 87
page 98
page 88
page 91
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Size
Qty
Box wrench
36 mm
Socket wrench
30 mm
Socket wrench
24 mm
Socket wrench
19 mm
Socket wrench
17 mm
Socket wrench
13 mm
Socket wrench
10 mm
Allen key
6 mm
Allen key
5 mm
Allen key
4 mm
Screw driver
Adjustable wrench
Hammer
Plastic mallet
Rubber mallet
Feeler gauge
Torque wrench
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Special tools
Pos
Type
Qty
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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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.
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.
Tools:
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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.
Tools:
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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!
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.
Tools:
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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!
Tools:
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30 mm socket wrench
10 mm socket wrench
5 mm Allen key
Screw driver
Hammer
79
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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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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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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.
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5. When the impeller has loosened, pull it off the shaft. Slacken off the
puller.
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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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.
Tools:
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85
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Hydraulic cylinders
Caution!
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.
Tools:
19 mm socket wrench
Adjustable wrench
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Tools:
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19 mm socket wrench
13 mm socket wrench
87
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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!
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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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.
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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.
O-ring (17)
Figure 6-22. Installing the o-ring (17) and mechanical sealing static face.
Lubricate the support sleeve (9) with oil before installing it.
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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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.
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 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.
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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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.
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
97
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Tools:
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19 mm socket wrench
13 mm socket wrench
Torque wrench
99
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Hydraulic cylinders
Caution!
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Tools:
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19 mm socket wrench
Adjustable wrench
Torque wrench
101
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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.
3. Install the anodes on the impeller housing/inlet duct. Tighten to prescribed tightening torque.
Tools:
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102
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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!
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Tools:
4 mm Allen key
Wrench for impeller nut
Torque wrench
Plastic mallet
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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 8.5 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.
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Tools:
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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.
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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
109
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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.
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2. Check that the steering nozzle does not touch the guide vane chamber.
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.
Tools:
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36 mm box wrench
2x19 mm socket wrench
Hammer + screwdriver
Torque wrench
111
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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.
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.
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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.
When the reversing rod is adjusted, tighten the nut on the rod
connection to prescribed tightening torque. Fold down the locking washer.
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 15-20C 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.
Tools:
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Technical information
7. Technical information
7.1 Technical data
Type designation
FF410
420 kg
160 l
Power range
100600 kW
1.8 l
approx. 90 bar
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Type
Rolls-Royce recommend
Sikaflex 252
Bostik 2639
3M 5200
Gasket adhesive
Loctite 5203
Installation paste
Loctite 243
Loctite 222
Loctite 270
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Technical information
FF410
8 Nm
Seal holder
30 Nm
350 Nm
120 Nm
160 Nm
20 Nm
30 Nm
Anode hatch
25 Nm
Reversing cylinder
80 Nm
Steering cylinder
80 Nm
Impeller housing
70 Nm
10 Nm
Impeller nut
550 Nm
20 Nm
20 Nm
70 Nm
10 Nm
8 Nm
Steering nozzle
180 Nm
Steering rod
1015 Nm
250 Nm
30 Nm
Reversing bucket
180 Nm
Reversing rod
1015 Nm
180 Nm
Shaft flange
410 Nm
40 Nm
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Technical information
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:
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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Technical information
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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
10
12
11
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Pos
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Spare parts
Qty
Spare part
Part number
Bearing bushing
101 084 12
Bearing bushing
101 051 42
Anode
101 077 01
Anode
101 082 30
Anode
101 082 10
Anode
375 174 11
Anode
102 082 20
Anode
872175
Anode
101 082 20
10
O-ring
102 026 29
11
O-ring
102 026 39
12
Anode
101 082 28
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Pos
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Spare parts
Qty
Spare part
Part number
13
Rubber bearing
376 014 72
14
Shaft sleeve
410 013 01
15
Impeller nut
450 016 11
16
Mechanical sealing
17
O-ring
102 026 31
18
O-ring
102 026 25
19
Seal
102 025 90
20
Axial bearing
21
102 029 12
22
Locking washer
102 030 12
23
O-ring
102 026 03
24
Support sleeve
450 021 13
25
Flange nut
102 029 08
26
Locking washer
102 030 08
27
Impeller housing
410 003 01
28
410 186__
29
Impeller
410 007 __
30
O-ring
102 026 07
31
Distance sleeve
101 052 42
32
Distance sleeve
410 052 03
33
Seal
101 189 03
34
Reversing cylinder
101 210 36
35
Steering cylinder
101 210 35
2411845
102 034 80 A
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Glossary
Glossary
Anode
Anti-fouling paint
Booster
Cavitation
Displacement boat
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.
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
Thrust
Twin installation
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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: info.kokkola@rolls-royce.com