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UJ 305 – Installation and maintenance manual

1. 8966 815 000 HYDRAULIC PUMP KIT 8985 816 00B RESERVOIR ASSEMBLY 9616 10A 38R HOSE 9610 628 00W HOSE CLIP 9610 629 00T HOSE CLIP 9162 940 005 909 STANDPIPE 9616 43M 53A HOSE 9616 635 79 HOSE 8 WHEN USED WITH A HYDRO MECHANICAL UNIT THE FOLLOWING HOSES ARE REQUIRED P TO PUMP OUTLET S T TO INTEGRAL COOLER 1 2 3 4 5 INCHES ANGE PROECTON 9 61 20 40 60 80 100 120 UNLESS OTHERWISE STATED ULTRA DYNAMICS TITLE ALL DIMENSIONS IN MILLIMETRES LIMTED 2003 GENERAL MANUFACTURING STANDARDS THIS DRAWING IS THE PROPERTY OF ULTRA HYDRAULIC PUMP SYSTEM 1 2 3 TO HDS 200 DYNAMICS LIMTED IS CONFIDENTIAL IT IS ISSUED SUBJECT TO THE CONDITIONS THAT GEOMETRIC TOLERANCES AND SYMBOLS 1 THE INFORMATION OR ANY PART THEREOF TO BS 308 CONTAINED IT SHALL BE DISCLOSED DRAWING No ISSUE_No 3 4 MATERIAL IN ANY FORM TO A THIRD PARTY AND 2 0 0 5 0 0 5 0 01 1 2155 0 ON 3867 7872 5579 5605 2 IT OR ANY PART OF IT SHALL NOT BE Strawn kts kra pce pce REPRODUCED N ANY For 2 70 0 0 5 O A M gt 19 02 03 30 11 11 12 1 12 TREATMENT SCALE SIZE 2 CHECKED ramaza pter rta _ 227 ULTRA ULTRA DYNAMICS LTD lt APPROVED atanezsza atanera natare CHELTENHAM GLOS ENGLAND 1 2 3 4 5 6 66 001 0 8966 000 0 9
2. j COMPRISING eorom D lt L T COMPRISING 1 00 P lt I T COMPRISING oeoo 1 1 P lt l _ COMPRISING Sep Fr pee omen SEE CUSTOMER ORDERING FOR PART NUMBER eee mur SEE CUSTOMER ORDERING FOR PART NUMBER G eeeee woer SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8966 906 OOK _ cover 3 o 1 MAKE FROM CASTING 8966 907 OOF 5 a7as 075 00K tever I 1 1 Fe 1 012 wear sieeve ws 3 T3 3 1 T ee ee 5 wee i o o o F gt SCHEDULE No APPROVED SHEET 20 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNIT No 8966 000 OGY OHX 0J3 P M sE amp meTN PER UT aaoo sewe eron Li T T T T T r SS ve apcs o71 0on exorare case TT TT FROM CASTING 8981 921 00 sero nome SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8700 922 00H Es eeroncc T i T T SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8700 922 00H ero i L SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8700 922 00H
3. Please note the final sheet is the Modifications sheet ISSUE No DO NOT C ULTRA DYNAMICS LIMITED 2011 KINGSDITCH TRADING EST SCALE 4 D CHELTENHAM GLOS DRAWING UNLESS OTHERWISE SPECIFIED THIS DRAWING IS THE PROPERTY OF YNAMICS ULTRA DYNAMICS LIMITED AND IS ISSUED ON DIMENSIONS ARE IN MILLIMETERS CONFIDENTIAL IT IS ISSUED SUBJECT TITLE TO THE FOLLOWING CONDITIONS GENERAL MANUFACTURING m ENG TANDARDS TO HDS200 1 THE INFORMATION OR ANY PART DRAWN BY MT re Um THEREOF CONTAINED IN IT SHALL INTAKE BLOC K Watts EOMETRIC TOLERANCES AND NOT BE DISCLOSEDIN ANY FORM SYMBOLS TO BS308 TO A THIRD PARTY AND ALUMINIUM HULL 2 IT OR ANY PART OF IT SHALL NOT P Berry BE REPRODUCED IN ANY FORM 28 02 2011 MATERIAL Make from 8966 980 003 Aluminium Alloy LM M DWG NO APPROVED BY e Raine a 8966 080 000 THIRD ANGLE PROJECTION 02 03 2011 DEBUR AND 03 BREAKSHARP SHEET 1 OF2 SCALE 1 2 WEIGHT 23 58 Kg 2 3 13 14 15 16 17 18 600 REF 2 12 SECTION _ 12 MIN WALL THICKNESS Minimum Mechanical Properties Tensile strength 160 N m
4. NOTE REMOVE GASKET FIT amp SEAL WITH MARINE SECTION A A GRADE SILICONE SEALANT DO NOT AFFIX THIS LABEL WHEN CUSTOMER SPECIFIES NON STANDARD OIL SEE CUSTOMER ORDER X CODE CREATE A LABEL TO COVER OIL SPECIFIED BY CUSTOMER 4315 LON 00 NOTE THIS IS REDUCED DRAWING PLEASE DO SCALE ULTRA DYNAMICS LIMITED 2001 THS ORAWNG IS THE PROPERTY OF ULTRA RESERVOIR ASSEMBLY CONFIDENTIAL SHEET 1 of 1 214757 AUTT68S 47706 aun 14779 60 ses _ ewm PBery KBrodey KBrodey KBrodey KBradey PLB ere sto 02708704 2706705 26 09 05 12 10 05 2 1 os 28 09 06 z __ severe mar men rrr mmn _ ULTRA DYNAMCS LTO now mm cow amen e nen en CHELTENHAM ENGLAND z 3 T 5 z I 5 17 T E I 17 pARTNUMBER DESCRIPTION QY NO 1 8922 030 005 MAIN FRAME I REVERSE ND ERTRAV 9611 040 000 COMBINED CHECK KICK DOWN VALVE 1 HYDRO MECHANICAL SYSTEM 8728 014 00R CONTROLVALVE 1 8922 031 00 MAIN LINK 1 8922 032 00 CONTROLLUNK 1 8922 038 00P MAIN PIVOT 1 8922 037 00T SCREW ADJ USTER 2 8728 041 00N CLEVIS 1 8728 026 00C THICK WASHER 2 PORTP 870 049 004 WASHER 1 Connect to Pump 8976 032 00Z NAME PLATE 1 9521 452 00 PLAIN BEARING BU
5. 11 4 1 The following Service Kits are available 8978 804 00B Input Bearing amp Seal Kit Front 8978 805 570 Anode Kit Zinc Salt Water 8978 805 FMY Anode Kit Magnesium Fresh Water 8978 809 00L Input Bearing Seal Kit Front 9611 210 00T Reverse Hydraulic Cylinder Seal Kit Kobelt Bronze Cylinder 9611 212 00K Reverse Hydraulic Cylinder Seal Kit Hypro Stainless Steel Cylinder 9611 232 009 Steering Hydralic Cylinder Seal Kit Hypro Steering Cylinder Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 12 SCHEDULE OF PARTS Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 ULTRA DYNAMICS LTD CHEL TENHAM GLOS ENGLAND DESCRIPTION Ere sm LESS IMPELLER amp DRIVE FLANGE BALANCED STEERING REVERSE DEFLECTOR UNBALANCED STEERING REVERSE DEFLECTOR NBALANCED STEERING FOR POWER TEERING REVERSE DEFLECTOR NO STEERING NO REVERSE DEFLECTOR DaN 5966 000 DATE REASON FOR ISSUE ISSUE No OF UNIT 30 5 06 PRODUCTION RELEASE 5 12 11 5581 STEERING SEAL UPDATE DRAWN BAW ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNT No 7 596 000 OGYJOHX OJ3 PJM PARTNe DESCRIPTION _ QUANTITY PER UNIT 8966 001 063 ULTRAKT sosht assy DK
6. 23 25 Ibf ft The double link should be connected to the index rod of the cylinder using the M8 bolt 23 cup washer 28 ball joint spacer 15 nut 31 and washer 26 Apply Loctite 243 to the threads and tighten to 17 19 Nm 12 5 14 Ibf ft Flexible hose connections between the directional control valve and the reverse oylinder are 7 16 JIC fittings suitable for working at a pressure of 100 bar Port A1 on the directional control valve manifold is connected to the cylinder rod end of the cylinder and Port B1 to the cylinder blind end The pressure in Port P on the directional control valve manifold has 7 16 JIC fittings and the return Port T with 9 16 JIC fittings Connect the push pull cable to the push pull control unit in accordance with the manufacturer s instructions Ensure that a full 3 of the cable travel is achieved when the head is moved from full ahead to full astern Use or disclosure of data contained herein is subject to the restriction on the title page of this document 00446 Iss 1 DTP 3 2011 6 4 6 4 1 6 4 2 6 4 3 6 4 4 Attach the control cable outer sleeve to the cable mounting plate on the top of the hydro mechanical reverse control unit using the clamps supplied with the cable and attach the inner cable to the control link 5 Hydro mechanical Reverse System Commissioning The UltraJet reverse deflector should be fully down in the astern position if it is n
7. 5 All threaded holes not in use to be protected 6 Dimension must be achieved to ensure 3mm min gap between bushes REF 119 To Iololil lol u CHELTENHAM GLOS LJ n 2 6 7 m ase i D 1 2 3 4 5 6 SEE 15684 FOR LOCTITE EQUIVALENTS M50 CHE Grae M10 M12 M100 APPLY LOCTITE BEND TAB LIGHTLY TIGHTEN LOCTITE 243 Blue LAM SEN HYDRAULIC FITTINGS LOCKING FLUID E HYDRAULIC FITTINGS LOCKING FLUID APPLY LOCTITE AND EVENLY NE c ES LUBRICATION a d ON ASSEMBLY SOCKET HEAD CAP SCREW TORQUES NUT TORQUES for REVERSE CYLINDER APPLY LOCTITE 638 Green ATTACH LABEL SIZE SIZE FOR SHIPPING TORQUE AND M 3r 3 23 s ASSEMBLE ed REQUIR BRONZE PINS ORY BL 31 34 23 25 SMEAR STEEL PINS WITH COATING M Ll R LOC TTE ANTI SEE 8023 COAT BRONZE PINS WITH LOCTITE 243 Blue COAT STEEL PINS WITH LOCTITE ANTI SIEZE 8023 TORQUE AS SPECIFIED A P 4104 Aut7942 Au18074 5207A 5330 5 DRAWING IS THE PROPERTY OF ULTRA DYNAMICS LIMITED AND GENERAL ASSEMBLY IS CONFIDENTIAL IS ISSUED SUBJECT TO THE CONDITIONS THAT UNLESS OTHERWISE STATED INSTRUCTIONS PSR pce pce ALL DIMENSIONS IN MM Rood Tener Se 21 3 07 30 11 07 17 9 08 8 1 10 3 8 10 t THE INFORMATION OR ANY PART THEREOF CONTAINED IN IT GENER
8. 7 2 1 Small currents generated by the crafts electrical systems can often cause considerable corrosion to metal parts over a period of time Itis for this reason that the following general points should be addressed 7 2 2 A bonding strip of a reasonable cross section area to keep the resistance as low as pos sible should be connected to all the major metal parts and electrical equipment casings 7 2 3 These maior items should include the engine block negative earth system waterjet cas ing electrical equipment casings and all anodes attached to the hull The bonding strip should also be connected to the negative terminal of the battery 7 2 4 Elements of the electrical system should use both a positive and negative wire Major electrical components should incorporate a separate cable returning directly to the nega tive terminal of the battery and not connected through the earth bonding system via the engine or other casings 7 2 5 Electrical auxiliaries such as radios or transceivers should not be earthed to the UltraJet unit casings These systems should be either completely insulated using a separate insulated alternator dedicated battery etc or linked to the earth bonding strip If they are linked to the earth bonding strip then they should connect to a separate earth plate that is as far from the earth bonding strip and UltraJet as possible The metal used for the earth plate must be compatible with the earth bonding strip and hull ma
9. The mixing ratio for PRC Desoto Titanine Epoxide Finish EC75 is Finish EC75 1 part by volume Activator 65 1 part by volume Thinners T17 should not be required for brush painting 305 SECTION 11 OVERHAUL Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 11 11 0 11 1 1 11 1 2 11 1 3 11 1 4 11 1 5 11 1 6 11 1 7 11 1 8 11 1 9 ULTRAJET 305HT DISASSEMBLY Refer to the back of this Section for a list of Service kits available Refer to Section 12 for Parts List and Ultrajet drawings STEERING ASSEMBLY Before undertaking the strip procedure put the reverse deflector in the ahead position up and the steering straight ahead Disconnect the reverse control system from the reverse cylinder index rod Remove the cylinder pivot bolt washers and nut 69 93 amp 85 attaching the reverse cylinder 37 to the reverse deflector 17 Undo the pivot pins 19 and remove reverse deflector 17 Remove the steering lever outboard 25 by undoing and removing the clamp bolt nuts and washers 67 82 amp 89 and pushing the steering shaft 30 through the lever Remove the earthing strip 40 from between the nozzle 15 and reaction tailpipe case 14 Undo the 4 off M16 nuts and washers 85 93 amp 103 and remove the nozzle 15 complete with the steering deflector Remove the end cone 18 by first
10. Weekly Monthly Annual Minutes Jet Intake Free of Debris o x Hydraulic Fluid Level for Controis x T 5 Condition Of Hydraulic Fluid x 5 Hydraulic Fluid Leaks or Oilin Bige x T 5 Bearing Housing Drain Hole Clear o o x T 10 Inspect For Damage to Intake Gril x 15 X Inspect For Damage to Reverse Deflector x 15 DriveshaftsRotateFrely x o x x T 10 Condition of Cardan or CV Joints x O x 15 Condition oflmpeller x 415 Impeller Free of Debris x x 415 Tension of Hydraulic Pump DriveBeltsi x T 10 Security of Hydraulic Hoses Fittings 2 x x 15 Hydraulic Hose Condition o o o O x 15 Anode Condition J x 415 Electrical Bonding Between JetandHull x x 15 Security of Steering Links amp Tiebbar o Z O o x x 2 Security of Wiring Harness amp Connectors x J x 2 Electrical Connectors Dry And Secure 2 x 5 Reverse Deflector s Fuly Up3 x l I 1 Routine Annual Service Performed by Boat Owner O Estimated Time Actions f Monthy Annual Minutes Jet Grease Thrust Bearing T X x 30 Replace Hydraulic Fluid Filter T T J x X 30 Check Condition of Hydra
11. s oco ou DATE 30 5 6 4 2 1 CHECKED APPROVED MaeZ w 2 SHEET 7 0F 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT ANT No 8966 000 ocv omxors ePm rw pse OUANTTYPERUNT 145 18 007 ser Loena norme sIsIsI NOZZLE 4 amp REVERSE DEFLECTOR CYLINDER 1 Fe suscwso suriwmewrmo z z z DRIVE SHAFT Ew szxsewo wee 22 22 2202 C eeoa 2 2 2 REVERSE DEFLECTOR PIVOT PIN 2 Je Jele l T END CONE 4 SUPPORT BRACKET 2 LEVER 2 ANODES 5 ozaro een wo ue s TRANSOM 13 REAC CASE 10 ANODES 2 LEVER 1 INSPEC HATCH EARTH BONDING 5 COVER 4 HEAT EX 8 Em woos s Jejeje STEERING PIVOT 2 5223 282 002 wee Js s s T ANODE 1 BEARING CAP 4 m sm ceewo ewe j NOZZLE 4 REVERSE DEFLECTOR CYLINDER 2 se 75s0 056 o0u swerwee wo 2 2 z 2 DRIVE SHAFT i I j nS ee EMEE 57 703 05s 00P __wswarne waver 2 2 2 1 REVERSE DEFLECTOR PIVOT Ge zomos we wee 2 2 T STEERING PIVOT gt _ _ Ee Foo s273 210 00c suma waver ve 717 7 1 SUPPORT BRACKET SUPPORT BRACKET 2 ANODES 5 ISSUE No 1 2 3 SCHEDULE ISSUED ON 4057 2 54 11 8966 DR
12. 010 1 02 15557 _ PCD FIXING POINT FOR EARTH BONDING TO HULL ANODE WATER TAKE OFF VIEW OF SAE 1600 DRIVE FLANGE 1 115 NPTF OPTIONAL FLANGES AVAILABLE ON REQUEST STEERING LEVER MOVEMENT STEERING LEVER T INSPECTION COVER CYLINDER MOVEMENT OUTBOARD VIEW OF ULTRAJET UNIT INBOARD VIEW OF ULTRAJET UNIT NOTE THIS IS A REDUCED DRAWING PLEASE DO NOT SCALE 2 Somes mz Exe avos ULTRAJET UNT pce pce NOTE bar 31 5 06 20 6081 All threads ISO metric unless otherwise stated BED 7 CO UNT No THIS DRAWING 55 8966 001 0 x DETAIL E Transom Intake Block INSTALLATION NOTES INSTALLATION OF THE INTAKE BLOCK TO INTERFACE WITH AN ULTRAJET 305 1 Cut hole for Intake Block in hull VIEW ON ARROW A a For twin jet mounting in flat of hull any camber in hull 1140 should blend smoothly to Intake Block NOTE b For single jet mounting in vee of hull blend hull from SEE DETAIL E Rear of Intake vee bottom to Intake Block This should be a sloping Block flush with surface of 59 maximum from the edge of the Intake Block outside edge of 447 REF transom Position Intake Block into hull and check alignment Weld Intake Block into hull The intake block when fitted becomes part of the hull structure As such it is the responibility of the boat designer to be satisfi
13. 3 2011 FILLING THE STEERING SYSTEM Filling a Single Station System 11 12 13 The pump s should be set to maximum volume prior to filling and bleeding the system Fill the pump with oil using a funnel or filling tube If a header tank is installed fill the header tank Turn the wheel slowly in one direction until the pump starts to operate at which point the level in the helm pump will go down Check the oil level frequently and top up if required Continue to turn the wheel in the same direction until some resistance is felt At this point the cylinder may be observed to move Loosen the fitting on the cylinder on the side into which the oil is passing Continue to turn the wheel once again ensuring a good head of oil on the pump until clear oil emerges from the loosened fitting on the cylinder Tighten the fitting Provided that the head has been maintained and the wheel has been turned slowly this side of the system should now be reasonably free of air Continue to turn the wheel until the cylinder moves to the hardover position There should at this point be a significant resistance to further turning Now turn the wheel in the opposite direction There may be at this point a blow back of air up the pipes into the pump which can expel oil with some force from the funnel or filling tube A rag held over the top will prevent the oil from splashing over on to the surrounding area Use or disclosure of d
14. 9612 215 000 BALLJ OINTM8 LH 42 9612 216 00R OINTM8 43 9145 129 00 M8 THIN NUT 44 9145 315 00 M8 THIN NUTLH 45 8984 010 0D6 TIE BAR TURNBUC KLE FEEDBACK 1 1 1 1 1 1 ITEMS TO BE BAGGED IF SUPPLIED SEPERATELY TO ULTRAJ ETUNIT BENNEN CENTRES AD USTIF REQUIRED 18MSCAP j l GVERIGINTWHEN SETWITH HEAT SHRINK SCREW TO i i REPLACECAP EDEN hate ETE i SCREWS SUPPLIED WHHTEM 1 Care to be taken not to get any loctite on bea ing 30 2 For general assembly instructions see TD621331 000 429 Please note the final sheet is the Modifications sheet rm Pa umapnuoncsueo zo ae DRAWING 2 umoran Dynamics re comnts oran par HYDRO MECHANICAL i 288 mL e a aa ASSEMBLY T 2 ITOR ANY PARTOF ITSHALL NOT d uen ON ULTRAJ ET305HD Mataral not F ea ITEMS TO BE BAGGED IF SUPPLIED 2002 207 0 SEPERATELY i 08 09 2010 SHEET1OF2 SCALE 1 1 0 WEGHT4 21 Kg EDGES ud 7 T z 3 T I 5 7 5 5 10 En I ry 15 15 17 15 For general locking adhesives grease and torque settings see TD621331 000 Studs are fitted into I
15. Berzo _ 1 I 1 SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8700 922 00H seme senec SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8700 923 000 Fis oeruecror 1 1 SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8978 933 OOP 981 323 000 oeer 31 1 1 SEE CUSTOMER ORDERING FOR PART NUMBER MAKE FROM CASTING 8978 923 000 v 978 024 001 reverse orero 313 1 MAKE FROM CASTING 8978 924 000 w moc a _ MAKE FROM CASTING 8700 925 00 s esos morem 2 2 1 REVERSE DEFLECTOR 25 2 005 31413141 T MAKE FROM CASTING 8978 928 00Z Un sseron oc Transon senno ens a T MAKE FROM CASTING 8978 929 004 gt ISSUE No 1 SCHEDULE NS SUED AON ORAN 10 gp S o ist s _ DATE 395 5 64 APPROVED L L SHET 3 0F 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNIT No 8966 000 OGY OHX 0J3 P M PER UT m smeese sc eee IIIS 1 TRANSOM FLANGE ee 7 2 00 eracker L T L T MAKE FROM CASTING 8700 932 00 as seems even
16. MANUFACTURING STANDARDS 8966 000 00A 966 001 006 ULTRAJET 305HT pe TRANSOM ULTRA DYNAMICS LIMTED 2001 THIS ORAWING IS THE PROPERTY OF ULTRA DYNAMCS LIMITED AND 15 CONFIDENTIAL JET MOUNTING FACE TRANSOM CUTOUT DETAIL IS ISSUED SUB ECT TO THE CoNDTONS THAT ULTRAJET 305 ALUMINIUM HULL 13 DETAIL B TRANSOM PLAIN GASKET WASHER 12 TRANSOM STUD 12 FLANGE NOTE ENSURE STUD IS FITTED THE CORRECT WAY WITH TURNED DIA AT TOP DOO s 10 INSULATING WASHER 12 DETAIL Transom For Hull cutout details and d 9 i fitting of intake block see 7 dr g 8966 300 00M 10 STUD 22 00G CAPSCREW 2 NOTE ENSURE STUD IS FITTED THE CORRECT WAY M10 SPRING WITH TURNED DIA AT TOP WASHER 2 TUI s 9149N M10 SELF DETAIL 180 LOCKING NUT 22 M10 PLAIN WASHER 22 FILL WITH R T V SILICONE SEALANT For Transom cutout details IT ZF see dr g 8966 301 00H R T V SILICONE NIN SEALANT D OF JET UNT Rear face of Transom KK must be flat and free of n obstructions within area of Transom Flange Flat Bottom Hull Flat Bottom Hull Vee Bottom Hull Flat Bottom Hull NOTE 1 Studs bolts nuts and washers to be 316 Stainless Steel ULTRA DYNAMICS 2 Use Loctite grade 270 when fitting studs into Intake Block N MLLMETRES LIMITED 2001 UNIT INSTALLATION 3 Use Loctite grade 243 on all remaining f
17. SHEET 60 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT EE B966 000 pev omousem T rw mau pe sursscow armero ii T REVERSE DEFLECTOR CYLINDER Uep eseoeswm swm I I l I I HEAT EXCHANGER Um emewesw ww END CONE 4 amp REACTION CASE 2 Uz wsewswss soem s sIsI I ANODES sis swo ANODE amp EARTH BONDING m esceeso sww hje INTAKE CASE Es sseorss smo 5 5 5 5 ANODE 1 COVER 4 Uep esewsss swwo Is 9 9 9 TRANSOM FLANGE 12 INSPECTION HATCH 3 GRILL 4 m ssewssse sew ese IEEE a GN NN MN CENE Ums exerss sowa ls s sIs 1 ANODE 1 BEARING CAP 4 Ge emrewess sowo 4 amp 1 REACTION TAILPIPE CASE 931 49 09 wre tread mserr z z z 2 10MC15S PRE ASSEMBLED ON INTAKE CASE Fm suswsw v vIz END 4 SUPPORT 2 LEVER 1 amp AN0DES 5 945 100 001 sarium e a TRANSOM 12 CASE 10 AN0DES 2 1 INSPEC HATCH 3 EARTH BONDING 2 CYL 2 COVER 4 HEAT EX 8 GRILL 4 fox 915 101 008 serie wre 7 7 7 s BEARING CAP 0 STEERNG PMOT D amp ANODE BEARING CAP 4 STEERING PIVOT 2 amp ANODE 1 ISSUE No 1 2 SCHEDULE No ISSUED ON 4057 AUT8T2 DRAWN PLE
18. ULTRAJET 305HT USED ON UNIT No NOTE FOR GENERAL TORQUE SETTINGS AND LOCKING ADHESIVE SEE TD621331 000 8 x 25 19 BOLT 1 8 x 80 Ig BOLT 2 M8 NUT 2 M10 WASHER 2 SPRING WASHER 3 M10 SELF LOCKING NUT 2 WASHER 2 10 STUD 2 BELT 2 PULLY PUMP M6 CAP SCREW 3 M6 SPRING WASHER 3 UNLESS OTHERWISE STATED ULTRA DYNAMICS TITLE ALL DIMENSIONS IN MILLIMETRES LIMITED 2007 GENERAL MANUFACTURING STANDARDS TO HDS 200 THS ORAWNG IS THE PROPERTY OF ULTRA HYDRAULIC PUMP KIT ASS Y GEOMETRIC TOLERANCES AND SYMBOLS TO she CONUTONS THAT TO BS 308 0 THE INFORMATION OR ANY PART THEREOF DRAWING No MATERIAL CONTAINED IN IT SHALL NOT DISCLOSED IN ANY FORM TO A THIRD PARTY AND 2 IT OR ANY PART OF IT SHALL NOT BE REPRODUCED IN ANY FORM pss vue ee 2 PLT RA 2 he J ai g CHELTENHAM GL0S ENGLAND 5 6 7 8 USED oN ULTRAJET CONTROLS LID RETAINING SCREW AND WASHER SUPPLIED WITH RESERVOIR WHEN ORDERED AS SPARE USE PART No s SCREW 9143 230 000 SEAL TO RESERVOIR LID WITH WASHER 9221 278 00N MARINE GRADE SILICONE SEALANT Al Ev All SUPPLIED WITH RESERVOIR Li cl j FIX RESERVOIR BASE WITH MARINE GRADE SILICONE SEALANT WHEN ORDERED AS A SPARE USE PART No 8978 132 00H 8 WASHER 2 CX E M8 SELF LOCKING NUT 2 M8 STUD 2 FIT STUD USING LOCTITE 270
19. been removed from the reaction tailpipe case 14 then a new one should be pressed into place 11 3 8 Lightly grease the gasket 32 and fit into place on the intake case 7 followed by the reaction tailpipe case 14 secured with 8 off M10 self locking nuts 83 and washers 90 amp 101 Apply Loctite 243 to the threads and torque tighten the nuts to 31 34 Nm 23 25 b ft NOTE The earthing strap fits between one of these fasteners and the anode boss 11 3 9 Fit the external snap ring 47 and seal plate 12 to the drive shaft 27 followed by the mechanical seal 45 When fitting the mechanical seal lightly grease the driveshaft 27 and slide the seal into place taking care not to get grease on the sealing face Remove excess grease from the shaft 11 3 10 Fit the shaft seal 64 into the seal housing 6 and pack the seal cavity with recom mended grease See Section 10 Lightly grease the ring 61 and fit it into place on the seal housing 6 11 3 11 Push the static ring of the mechanical seal 45 into the seal housing 6 Do not get grease on the sealing faces of the mechanical seal 11 3 12 The mechanical seal should be handled with care Oil and grease on the sealing faces will cause a failure so after assembly wipe the sealing faces with a clean dry lint free cloth 11 3 13 Slide the seal housing 6 onto the drive shaft 27 taking care not to damage or taminate the sealing faces of the mechanical
20. data contained herein is subject to the restriction the title page of this document UD248 19 DTP 3 12 CORROSION PROTECTION The Ultrajet 305HT unit has been manufactured from materials that are resistant to salt water corrosion and have also been finished using high build 2 pack epoxy paint systems Despite these precautions the Ultrajet 305HT unit can still be affected by stray currents as a result of poorly installed electrical systems and it is therefore a condition of warranty that craft fitted with Ultrajet propulsion systems have a negative earth bonding system fitted Major parts of the UltraJet 305HT have been electrically connected to an earthing stud on the intake case This stud should be used to connect the UltraJet to the earth bonding strip running along the hull ENSURE THAT ALL EARTH BONDING STRAPS ARE REFITTED CORRECTLY AFTER ROUTINE MAINTENANCE Anodes have been incorporated to provide additional sacrificial protection to salt or fresh water corrosion When the anodes are showing signs of being eaten away they are providing protection If the anodes have been eaten away to 50 or less of their original volume then they should be replaced with new anodes The anodes fitted to the Ultrajet are solely for the protection of the waterjet additional anodes should be fitted to the hull where appropriate for protection of the metal hull On no account should these anodes be painted 305 7 2 ELECTRICAL SYSTEMS
21. of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 6 3 6 3 1 6 3 2 HYDRO MECHANICAL REVERSE CONTROL SYSTEM hydro mechanical reverse control system comes fully assembled and tested as an integral part of the UltraJet unit This section is for information and future maintenance only Reverse Cylinder See Section 12 for Drawing 8966 001 0XX Sheet 2 The reverse cylinder is fitted through the intake case from the inside of the boat using a backing plate 31 securing the cylinder bearing 44 in place The studs 74 are fitted with self locking nuts 83 Ensure that the O rings 58 amp 59 are lightly greased and fitted correctly Finally torque tighten these nuts to 31 34 Nm 23 25 Ibf ft apply Loctite 243 or similar low strength locking product to the threads of the stud prior to fitting the self locking nut Hydromechanical Reverse Control See Drawings at the end of this section The hydro mechanical reverse control system is fitted to the M10 studs on the side of the intake case Use or disclosure of data contained herein is subject to the restriction on the title page of this document 00446 Iss 1 DTP 3 2011 6 3 3 hydro mechanical reverse control assembly should be fitted first followed by the washers 27 and self locking nuts 35 Loctite 243 should be applied to the nuts and then torque tightened to 31 34 Nm
22. ooo 1 MAKE FROM CASTING 8700 933 00Z Es woron wo 2 2 2 FOR IMPELLER AND DRIVE FLANGE mre x I FOR IMPELLER Esse Raw Iz z z 1 REVERSE DEFLECTOR Ge emwos wv sees iL T ANODE Em sevzmww we T 5604000 a rss Re ISSUE No 1 2 SCHEDULE ISSUED ON 4057 54 TT DRAWN C PCB if 10 222 j DATE 130 506 8 M 1 CHECKED 0 JAPPROVED Mesos _ 2 SHEET 4 0F 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNIT No 8966 000 OGY OHX 0J3 PJM PER UMT Em sus us caste 3ls s s _ E o oron FOR USE ON STANDARD ULTRAJET 2 waer eens T FOR USE DRY RUNNING ULTRAJET OPTION CODE W 525 _ 2 2 FOR REACTION TAILPIPE CASE ve z z z 21 WARNING we T FOR USE ON STANDARD ULTRAJET seoor T FOR USE DRY RUNNING ULTRAJET OPTION CODE W suem f o 1 E ee WARNING ISSUE No 1 2 SCHEDULE ISSUED ON 4057 AUT8T2 DRAWN A PER M PLE 02 10222 j DATE 1 30 5 6 4 2 CHECKED AP
23. seal 45 When fitting the seal housing 6 the drain hole should point down Check that the drive shaft 27 has been pushed far enough into the unit to stop the spring on the mechanical seal being over compressed 11 3 14 Lightly grease and fit O ring 62 into place Slide one seal sleeve 4 onto the shaft and fill the cavity in the seal housing 6 with the recommended grease See Section 10 11 3 15 If the bearing 46 is being replaced or has been removed from the bearing sleeve 13 it should be regreased and the bearing sleeve 13 pressed back into place Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 11 3 16 Lightly grease O ring 60 and fit into place the shaft 27 followed by the bearing sleeve 13 bearing 46 second lightly greased O ring 60 and seal sleeve 4 11 3 17 Fit shaft seal 64 into bearing cap 5 11 3 18 Pack the bearing cap 5 cavity with the recommended grease See Section 10 and fit into place using 4 off M12 self locking nuts 84 and washers 92 Use Loctite 243 on the threads and torque tighten the nuts to 60 65 Nm 44 48 Ib ft 11 3 19 Fit the M6 set screw 120 in the side of the intake case and tighten until firm contact is made with the seal housing 6 Apply Loctite 542 thread sealant to the exposed threads then fit and tighten the M6 nut 121 Ensure that the set screw 120 is in
24. signalled by the control link that is connected by cable to the push pull control unit supplies oil to either side of the reverse cylinder via pilot operated check valves As the cylinder moves the reverse deflector the feedback index rod which is connected to the main link restores the spool of the directional control valve to the centre position With the valve in this position the pilot operated check valves close hydraulically locking the reverse cylinder in the selected position Return line oil flows through a cooler before being filtered back into the oil reservoir Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 6 2 6 2 1 6 2 2 6 2 3 steering is standard manual hydraulic system comprising of a helm pump connected to an UltraJet mounted balanced steering cylinder via copper tubing If a second UltraJet is fitted a tie bar linked to the steering on the first unit can operate its steering DESCRIPTION OF REVERSE CONTROL SYSTEM COMPONENTS See drawings at the end of this section Hydraulic Pump The pump supplied with this system has internally controlled output flow to ensure a constant reverse operating speed is maintained regardless of the engine rpm The pump also includes a pressure relief valve Oil Reservoir Oil is supplied to the pump from an oil reservoir with a return flow filter fluid leve
25. undoing the M12 nut and washer 84 amp 92 and removing the anode Then undo the 4 off M8 nuts and washers 82 amp 89 Slacken but do not remove the M20 impeller nut 86 Note the drive flange will have to be locked to stop it rotating while the impeller nut is undone Remove the 8 off M10 self locking nuts and washers 83 90 amp 101 then slide the reaction tailpipe case 14 off the shaft Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 11 1 10 Remove the M20 impeller nut 86 then slide the drive shaft sleeve 28 from the shaft Remove the retaining pin 41 11 1 11 The impeller must be withdrawn from the shaft with a direct lateral movement using the extraction tool TD120891 if necessary Any twisting motion of the impeller could result in scoring of both the impeller and shaft In extreme cases seizure could result 11 1 12 WARNING the drive shaft should be supported through the inspec tion cover 8 opening prior to removing the impeller to avoid undue loads on the front bearing seals and shaft 11 1 13 If the rear water lubricated bearing 48 is worn it should be pressed out of the reaction tailpipe case 14 11 1 14 Undo the M12 self locking nut 84 and slide the cap screw 66 and steering pivot 26 from the steering deflector 16 11 1 15 Check all steering bushes 56 amp 57 and reverse bushes 42 for wear replace
26. 248 19 DTP 3 12 305HT SECTION 3 SCOPE OF APPLICATION Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 3 3 0 SCOPE APPLICATION 3 1 TYPE OF VESSEL Designed for applications where high thrust without cavitation is required at low boat speed such as Bridge erection Boats Landing Craft towing and salvage workboats 3 2 Planing Craft Maximum input power 298 kW 400 bhp Single jet up to 9 tonnes 19 836 Ib Twin jets up to 20 tonnes 44 080 Ib Triple jets up to 32 tonnes 70 528 Ib Displacement Craft Maximum input power 261 kW 350 bhp Single jet up to 15 tonnes 33 060 Ib Twin jets up to 33 tonnes 72 732 Ib Triple jets up to 55 tonnes 121 220 Ib Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 4 PERFORMANCE AND POWER ABSORPTION CHARACTERISTICS 305 SECTION 4 4 0 4 1 4 1 2 4 1 3 4 2 4 2 1 4 2 2 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 PERFORMANCE THRUST The UltraJet thrust performance graphs that follow can be compared with the resistance curves of the
27. 27 and mechanical seal 45 can now be removed through the front of the jet All items should be cleaned and visually examined for wear or damage Areas where paint has chipped off should be lightly sanded and repainted See Section 10 for repairing damaged paint ASSEMBLY OF AN ULTRAJET 305HT Clean all components and if necessary discard all seals gaskets and O rings If the impeller wear sleeve 11 was removed from the intake case 7 then a new wear sleeve 11 and wear sleeve insulation 10 should be fitted Fit the wear sleeve insulation 10 into place in the intake case 7 with its joint line along the bottom of the intake The impeller wear sleeve 11 should be fitted with its joint line at the top of the intake case When fitted into the intake case there should be a 0 8mm 1 32 gap between the edge of the wear sleeve and the intake case Fit the cone 33 key 34 impeller 2 retaining pin 41 drive shaft sleeve 28 washer 94 and M20 self locking nut 86 to the drive shaft 27 The M20 nut 86 should be tightened after the reaction tailpipe case 14 and front bearing assembly has been fitted NOTE The cone 33 should be pushed along the driveshaft 27 until it is hard against the shoulder before fitting the impeller 305HT 11 3 6 Slide the drive shaft 27 into the intake case 7 and support the shaft through the inspec tion cover 8 opening 11 3 7 If the water lubricated bearing 48 has
28. 48 19 DTP 3 12 305HT OPTIONAL EQUIPMENT Steering wheel Pulleys hoses and driveline for the engine driven pump system Steering cylinder and helm pump Driveshafts and flexible couplings Overflow preventer Intake block for aluminium or GRP hulls Certification Lloyds NKK Norske Veritas or other Reverse Control Options Jet mounted hydraulic pump complete with flow and pressure controls Electro hydraulic reverse control system Combined reverse and steer by joystick control SEPU Stored Energy Power unit powered by a 12 or 24V DC electric motor Reverse controller Wiring harness Jet driven hydro mechanical reverse system Electro hydraulic jog control Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 Moment of Inertia Data for Vibrational Analysis DRIVE ANGULAR SHAFT SHAFT CONTACT BEARING BEARING LLL UltraJet Dimension Dimension Dimension Dimension Model A B D UJ305HT ida 4 Blade Impeller 0 146 kg m 3 465 Ib ft 15 07 kgs 33 2 Ib Shaft 0 002 kg m 0 047 lb ft 11 8 kgs 26 0 Ib UJ305HT DIN 150 Drive Flange 0 091 kg m 2 16 Ib ft 4 21 kgs 9 3 Ib SAE 1600 Drive Flange 0 014 kg m 0 342 Ib ft 5 0 kgs 11 0 Ib Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD
29. 75mm not less JOYSTICK if fitted Over heating of Pump remaining on Hydraulic loading hydraulic fluid load valve faulty replace Reverse Deflector Faulty solenoid Replace or Steering will Directional valve operate in one direction only Reverse Deflector Faulty solelnoid Replace or Steering will not Loading valve operate in either direction Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT SECTION 10 SERVICING Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 10 10 0 10 1 10 2 10 2 1 10 2 2 10 2 3 10 3 10 3 1 10 3 2 Use or disclosure of data contained herein is subject to the restriction the title page of this document UD248 19 DTP 3 12 SERVICING The Ultrajet 305HT is designed as a low maintenance unit requiring only minor checks between services The impeller bearing is a water lubricated type and does not require regular attention Reverse scoop and steering deflector bushes are also water lubricated requiring only the occasional cleaning of the area directly surrounding the bushes INITIAL OPERATION During the first few hours of operation check the oil level in the reverse system reservoir topping up as necessary If the oil level does not stabalise then check the reverse system for si
30. A and check belt tension as per drawing If belts are the correct tension torque nuts A and B to 31 34 Nm 23 25 Ibf ft Check the earth bonding system for loose or corroded connections The electrical resistance between UltraJet components and the ves sel s earth bonding strip should be very low Six monthly examine the sacrificial anodes and replace if necessary 305HT The anode should be replaced when it has been reduced to 50 of its original volume It is important that the new anode is left unpainted 10 3 8 If the Ultrajet has not been operated for a long period engage the drive to the Ultrajet and rotate the input shaft slowly for a short period to lubricate bearings 10 3 9 Periodic service instructions are summarised on the following chart 10 4 SERVICE INSTRUCTIONS Operating Hours 50 Hours or Weekly Check that the intake case drain hole is not blocked Check reverse control hydraulic reservoir oil level Grease bearing cap and reverse cylinder rod end Monthly Inspect unit for damage and repair Remove foreign objects from UltraJet Check and adjust V belts if fitted Check earth bonding system 6 Monthly Check condition of anodes Rotate drive shaft if UltraJet has not been used Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 10 5 FLUIDS AND LUBRICANTS TO BE USED BEARING HOUSING LUBRICANT GREASE TYPE EXA
31. AL MANUFACTURING Kingsditch Trading Estate Pawan nar teaser paeem rerom SHALL BE DISCLOSED IN ANY FORM A THIRD PARTY AND STANDARDS TO HDS 200 Cheltenham Glos GL51 9NY EI NRW 6 GEOMETRIC TOLERANCES Telephone 44 041242 707900 21 3 07 PReine30 1 07 PRoi 5 PRanes 8 0 02 IT OR ANY PART OF IT SHALL BE REPRODUCED ANY FORM SYMBOLS TO BS 308 Facsimile 44 0242 707901 2
32. AWN PCB PCB j DATE 30 5 06 4 2 08 84 11 CHECKED Moneto 5 8 OF 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNT No 8966 000 werpoous pe esens OUANTTY PER UNT fai 5223 211 002 mswano waster mo a 2 z 2 J e e NOZZLE o o jj j j E a ARM C wo j e e 9162 952 000 EE E ee ee E ISSUE No 1 2 3 SCHEDULE ISSUED ON 4057 8 2 54 11 8966 DRAWN PCB PCB DATE 30 5 06 4 2 08 84 17 Manes 1 1 SHEET 9 0F t ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNT No 8966 000 werpoous e T O Pan senon OUANTTY PER MT pL 11 E E 5222222 i iL iL L T STEERING SHAFT Eas vex ser serscrew cone rom 1 4T T Rg ONG CREE NC Pm suscowo wewwrm Li L TT T parece ee E s _ fal 203 060 006 II 1 1 ee UY 99 T T DRAIN PLUG 1 fas escono uw 1 1 To fas 0978 0722003 sEmesweraw 1 1 I 1 T fas 9141 350 00K vex eno s
33. Goods replaced under this warranty shall be deemed to be rewarranted in the terms of this warranty for the unexpired period of the warranty under paragraph 2 above 6 This warranty excludes normal wear and tear goods which have been subject to any alteration not authorised by UDL goods which have not been serviced or maintained strictly in accordance with UDL instructions and goods on or from which the trademark or serial number has been altered removed or obliterated 7 goods supplied are supplied only upon the terms that save as provided above all conditions and warranties in respect thereof whether express or implied and whether statutory or otherwise are hereby excluded and extinguished and neither UDL nor its servants or agents shall be under any liability whatever for any personal injury or for any loss or damage of whatever kind howsoever such personal injury loss or damage be caused arising directly or indirectly out of or in connection with the design manufacture supply installation of such goods or the unsuitability or defectiveness thereof or any advice or services rendered in connection therewith the intent of this Clause being to exclude save as provided otherwise in this Clause any liability for acts omissions or matters which are or but for this Clause would be breaches of contract whether of a fundamental term or nature or not or torts The Buyer shall on demand indemnify UDL and its servants and agents against any clai
34. INSTALLATION amp MAINTENANCE MANUAL for ULTRA JET 305HT This document is the property of Ultra Dynamics Limited and the information contained herein is confidential Its contents may not be disclosed copied or used for any purpose other than that for which it is supplied without the written authority of Ultra Dynamics Limited Ultra Dynamics Limited Head Office Upperfield Road Kingsditch Trading Estate Cheltenham Glos GL51 9NY England Tel 44 1242 707900 Fax 44 1242 707901 Email sales ultrajet co uk USA Sales amp Service 1110A Claycraft Road Columbus Ohio 43230 USA Tel 614 759 9000 Fax 614 759 9046 Email sales ultradynamics com www ultradynamics com Ultra Dynamics Limited 2005 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 INSTALLATION amp MAINTENANCE MANUAL CONTENTS WARRANTY FORM SECTION 1 GENERAL DESCRIPTION SECTION 2 SPECIFICATION SECTION 3 SCOPE OF APPLICATION SECTION 4 PERFORMANCE SECTION 5 INSTALLATION DETAILS SECTION 6 CONTROL SYSTEM SECTION 7 CORROSION PROTECTION SECTION 8 OPERATION SECTION 9 FAULT FINDING CHART SECTION 10 SERVICING SECTION 11 OVERHAUL SECTION 12 SCHEDULE OF PARTS Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 WARRANTY AND LIABILITY 1 Ultra Dynamics Limited hereinafter ref
35. MPLE JET DRIVEN HYDRAULIC PUMP SYSTEM FLUID TYPE UJ305HT TOTAL OIL CAPACITY EXAMPLE PREMIUM ALL PURPOSE GREASE SHELL ALVANIA RL2 OR EQUIVALENT HIGH PERFORMANCE HYDRAULIC OIL OF VISCOSITY 1 5 0 GRADE 32 DO NOT USE BRAKE FLUID OR HEAVIER VISCOSITY FLUIDS 4 litres RECOMMENDED FLUIDS BP ENERGOL HLP HM32 TOTAL AZOLLA VG32 CHEVRON AW MACHINE 32 ESSO NUTO H32 MOBIL DTE 24 or DTE 13 GULF HARMONY AW32 SHELL TELLUS 32 TEXACO RANDO HD32 PETROFINA HYDRAN 32 CASTROL AWS 32 OR EQUIVALENT FLUIDS If using a different oil it is advisable to completely drain and refill the system Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT KOBELT MANUAL STEERING HELM PUMP SYSTEM FLUID TYPE EXAMPLE HIGH PERFORMANCE HYDRAULIC OIL OF VISCOSITY 1 5 0 GRADE 32 DO NOT USE BRAKE FLUID OR HEAVIER VISCOSITY FLUIDS BP ENERGOL HLP HM32 OR EQUIVALENT If using a different oil it is advisable to completely drain and refill the system A lower viscosity fluid can be used in colder climates i e 1 5 0 Grade 22 or 10 ELECTRIC HYDRAULIC POWER UNIT S E P U or O D P U if fitted FLUID TYPE EXAMPLE SEALS AND GENERAL LUBRICATION GREASE TYPE EXAMPLE Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 HIGH PERFORMANCE HYD
36. PROVED Mmee SHEET 5 0F 10 ULTRA DYNAMICS LTD DESCRIPTION CHELTENHAM GLOS ENGLAND ULTRAJET 305HT UNIT No 8966 000 OGY OHX 0J3 P M PER UT 5 97 2 02 7 wane ure 1 2 5 _ ___ 20 2 1 06 assy a 1 T ee SM MEE Es sseseow GLACIER BEARING 3020 EP FOR STEERING SHAFT 2 2 STEERING PIVOT Tiri T T LEVER OUTBOARD STEERING DEFECTOR sew _ ems o a T CYLINDER BEARING ovens CYLINDER BEARING TO TRANSOM FLANGE oromon omne Jeje ee T BEARING SLEEVE roo oee 1 SEAL HOUSING aroso ome 1 BEARING CAP e sen w ome I 13I3I 1 1 INSPECTION HATCH a panao erse 80 100 10 merse I7 I 30 42 8 Fe susm wn cwesmwwremu 2 z 2 L STEERING PIVOT a gt u advo xo T OUTBOARD STEERING LEVER fea 902 357 002 eor woro 3 1 CNOA STEERING LEVER INBOARD STEERING LEVER ISSUE No 1 2 3 4 f SCHEDULE No ISSUED ON 4057 AU17916 872 2 5580 8966 JORAWN MH PCB BAW j DATE 30 5 06 5 9 07 4 12 08 5 2 711 CHECKED 64 2 9 07 0 0 Penry SE JAPPROVED Ate 8 9 07 PRaietz 12 08 FE
37. RAULIC OIL OF VISCOSITY 1 5 0 GRADE 32 DO NOT USE BRAKE FLUID OR HEAVIER VISCOSITY FLUIDS BP ENERGOL HLP HM32 OR EQUIVALENT If using a different oil it is advisable to completely drain and refill the system PREMIUM ALL PURPOSE GREASE SHELL ALVANIA RL2 OR EQUIVALENT 305 10 6 10 6 1 10 6 2 10 6 3 10 6 4 10 6 5 10 6 6 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 REPAIRING DAMAGED PAINT Where the paint has been damaged it should be repaired using paint of the same construction as the original paint system For paint mixing details see Section 10 6 6 If the damage is down to bare metal but the surface anodizing is still intact the area should be cleaned of contamination and painted as detailed in 10 6 4 If the anodizing has been damaged then the area should be cleaned and abraded then an even coat of PR30B etch primer applied and allowed to dry for 1 hour before continuing with the paint system Apply 1 coat of primer PR143 and allow a minimum of 4 hours maximum of 48 hours before applying the finish coat Apply 1 coat of EC75 and allow 16 hours for the paint to harden before using the UltraJet Paint Mixing Ratios The mixing ratio for PRC Desoto Titanine Epoxide Primer PR143 is Primer PR143 2 parts by volume Activator 143 1 part by volume Thinners T17 should not be required for brush painting
38. SH 9612 204 009 1 4 BALL OINT 8922 036 13N BALLJ OINTSPACER 9162 600 006 3 8 BSP x 7 16 IC ADAPTOR 9162 601 00W 3 8 BSP x 9 16 IC ADAPTOR 9341 023 00R 3 8 BSP BONDED SEAL 9146 211 009 5 x 25 HEX SOCKET CAP SCREW 9146 259 00F M6 x 20 HEX SOCKET CAP SC REW 4 ASSEMBLE TURNBUC KLE 1 3 1 4 4 2 9142 251 00 M6 x 25 HEX HEAD BOLT 1 1 X 1 4 5 2 3 1 2 TO APPROX 112 mm BETWEEN BALL JOINT CENTRES THEN ATTACH TO HOLE D ON MAIN LINK PORTB Connectto Blind end of cylinder Flex hose 9616 34 370 Cylinder port fitting 9162 921 003 J IC 9142 254 00X M6 x 30 HEX HEAD BOLT 9142 302 003 8 x 35 HEX HEAD BOLT 9142 305 00L 8 x 50 HEX HEAD BOLT 9223 403 00N M5 SPRING WASHER 9223 259 00 M6 PLAIN WASHER form 9223 260 00G M8 PLAIN WASHER form A 9223 261 00C M10 PLAIN WASHER form A 8984 012 000 CUP WASHER 29 9145 409 006 M8 PLAIN NUT 31 9145 179 00 M8 SELF LOCKING NUT 4 32 1 9145 181 00G M12 SELF LOCKING NUT PORTT Connect to Rod end of cylinder Connectto Integral cooler Flex hose 9616 33A 33Z Cylinder port fitting 9162 921 003 J IC 33 9145 226 00L 1 4 UNF LOCKING NUT 1 34 8731 053 55 M10 STUD 17 21 3 35 9145 180 001 M10 SELF LOCKING NUT 3 2 36 9162 921 003 1 4 NPTx 7 16 JIC UNION 37 9616 34 370 HYDRAULIC HOSE 1 39 9603 254 00 7 16 PROTEC TION 3 40 9603 258 007 9 16 PROTEC TION 41
39. TY OF ULTRA DYN CONFIDENTIAL IT IS ISSUED SUBJECT TO THE FOLLOWING CONDITIONS AMICS LIMITED AND IS 1 THE INFORMATION OR ANY PART THEREOF CONTAINED IN IT SHALL NOT BE DISCLOSEDIN ANY FORM TO A THIRD PARTY AND 2 IT OR ANY PART OF IT SHALL NOT BE REPRODUCED IN ANY FORM ULTRA Dynamics UPPERFIELD ROAD KINGSDITCH TRADING EST CHELTENHAM GLOS ENGLAND TITLE INTAKE BLOCK CASTING FINISH DWG NO 8966 980 003 THIRD ANGLE PROJECTION DEBUR AND WEIGHT 24 69 Kg BREAK SHARP EDGES SHEET 1 OF 2 SCALE 1 2 17 18 SECTION 6 CONTROL SYSTEM Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 6 ULTRAJET 305 6 0 6 1 CONTROL SYSTEM GENERAL DESCRIPTION See Drawings at end of Section The hydro mechanical reversing system is supplied fitted to the UltraJet unit as standard the control system has been adjusted and tested requiring only the addition of a standard Series 3 or 4 push pull cable and a push pull control unit in order to complete the reverse control installation The controlled flow hydraulic pump which is belt driven from the UltraJet input flange supplies oil to a manifold mounted directional control valve This directional control valve when
40. across a wide range of boat speeds and incorporates an intake grill both items are manufactured from a marine grade aluminium alloy which has been finished with a two pack marine epoxy paint system The impeller is manufactured from Stainless Steel or Aluminium Bronze to ensure maximum durability even in arduous contaminated water conditions The impeller for the UltraJet 305HT will be matched to the power curve of the selected engine gearbox The impeller is a four bladed option to suit the specified power and craft duty The intake and impeller casing are combined into one casting manufactured from marine grade aluminium alloy and incorporates a stainless steel liner to provide maximum durability and to allow for replacement at service intervals if required The reaction casing nozzle steering and reverse deflectors are also manufactured from marine grade aluminium alloy which has been finished with an epoxy based marine paint The standard steering deflector is a balanced design which can be operated by the normal helm pump hydraulic steering system or an electro hydraulic steering control system The reverse deflector is of the twin duct type which in conjunction with the steering deflector gives excellent low speed manoeuvrability The reverse deflector is operated by the Ultra hydro mechanical or electro hydraulic reversing system which gives precise control of the reverse deflector with minimal effort at the helm See Figure 1 fo
41. asteners THES ORAWNG IS THE PROPERTY OF ULTRA ULTRAJET 305HT ALUMINIUM HULL ISSUED SUBAT TO THE COMMONS THAT With Ultra supplied Intake Block welded into Hull 8966 000 ww 8966 001 JULTRAJET 305HT HT 885 C Yo Yo Yo Yo Yo Yo LO N N N N N N N N OX OX OX OX OX OX OX OX CN eo E Yo N M B A B B B B i KO non UJ A 22 HOLES DRILL TAPPING x 25 DEEP 10 1 5 H x 20 MIN FULL TH D TREE C BORE 10 x 3 DEEP CHAM FIRST TH D AT 115 125 INCL TO DEPTH OF TH D o 0 5 115 REF 6 219 195 FN w BS EL 1 E 2 C 3 Ay LO 3 LL LLI x _ 2 HOLES DRILL 12 THRO C BORE AS PER SECTION 9 05 E SECTION B B 147 5 839 157 5 EN S u 836 REF 1565 REF E 4053 1 6 V Ke X LC LO 9454 0 504 2 89 di 1 Components should be examined for any burrs sharo edges SECTION A A casting imperfections which may require attention 19 020
42. ata contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 If the oil level in the funnel has dropped refill to ensure that the head of oil is maintained 14 Loosen the fitting on the pressure side of the cylinder and continue to pump until clear oil is issuing from the loosened fitting 15 Tighten the fitting The system should now be reasonably free of air and the cylinder should operate in both directions when the wheel is turned either to starboard or to port Residual air may be removed from the system as follows Put the wheel hardover in one direction and apply pressure to the wheel On breaking the lock and turning in the opposite direction air may be observed coming up the funnel or filling tube Repeat this procedure in both directions several times Allow a period of several hours for any air bubbles in the system to group together and then repeat the hardover to hardover procedure While there is still air in the system the pump may be quite stiff to turn and on reversing the wheel there is quite a distinct noise as the lock valve moves across Once air is out of the system the pump should turn smoothly and the lock valve will move quietly from one side to the other on reversing the rotation of the wheel Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 4 00
43. boat hull to obtain an estimate of the achievable speed The thrust shown is for a single jet installation on twin or triple jet installations the thrust will be two or three times the illustrated thrust The available reverse thrust will depend on the installation but thrust figures up to 50 percent of forward thrust can be achieved Power Absorption The following curves show typical power absorption characteristics for the UltraJet 305HT Should power absorption characteristics be required outside of those shown on the graphs included then please consult Ultra Dynamics Ltd for evaluation 305HT THRUST PERFORMANCE CURVES 305HT Performance knots kN 16 The 305HT performance graphs can be 15 iD dee ale compared with the resistance curves of the 14 808 18 boat hull to obtain an estimate of the achiev able speed 12 11 Thrust shown is for a single jet installation ig 5 On twin or triple jet installation the thrust will gt be two or three times the illustrated thrust X lt 4 m i lt The available reverse thrust will depend on m o4 55 DM the installation but thrust figures up to 50 6 lt p
44. cking nut 85 See Detail F Apply Loctite 243 to the threads and torque tighten to 31 34 Nm 23 25 lb ft Ensure Locking Washer 54 is assembled as shown on drawing The drive flange can now be connected to the engine NOTE The reverse deflector pins are not fully tightened if unit is fitted without removing reverse deflector ensure pins are tightened as per 5 1 11 305 5 2 5 3 FOR INSTALLATION G R P HULLS Details for mounting the intake block into the hull and the transom cut out dimensions are shown on Drawing No s 8966 303 009 8966 304 00X and 8966 305 00V The procedure for installing the UltraJet 305HT unit onto the intake block are identical to those used for the aluminium hull covered in 5 1 of this section Drawings of the Intake Blocks are also included as part of this section to assist the boat builder if he prefers to construct a intake frame within the hull as opposed to using one supplied by Ultra Dynamics Limited Intake Block Casting Alum and G R P hulls 8966 980 003 Intake Block Machining Alum hulls 8966 080 00U Intake Block Machining G R P hulls 8996 081 00Q Remove the UltraJet 305HT unit from its packing NOTE Do not lift the unit by the steering shaft or by the input drive flange FOR INSTALLATION IN STEEL HULLS For steel hulls the UltraJet is normally mounted directly onto a mounting frame constructed as part of hull by boat builder All aluminium components and fixi
45. contact with the seal housing 6 when locking 11 3 20 Fit the key 29 and drive flange 1 Ensure that the seal sleeves 4 bearing sleeve 13 and drive flange are pressed tightly up against the shoulder on the drive shaft 27 before the cone 33 washer 94 and self locking nut 86 are fitted Apply Loctite 243 to the threads and torque tighten the nut to 234 260 Nm 172 192 Ib ft 11 3 21 The M20 Impeller Nut 86 can now be tightened Apply Loctite 243 to the threads and torque tighten the nut to 234 260 Nm 172 192 Ib ft 11 3 22 Fit the end cone 18 to the reaction tailpipe case 14 with 4 off M8 self locking nuts 82 and washers 89 Apply Loctite 243 to the threads and torque tighten to 17 19 Nm 12 5 14 Ib ft 11 3 23 The anode is fitted to the M12 stud using a self locking nut 84 and washer 92 apply Loctite 243 to the thread and torque tighten to 60 65 Nm 44 48 Ib ft 11 3 24 Fit the nozzle 15 and retain with insulating washers 103 washers 93 and M16 self locking nuts 85 Apply Loctite 243 to threads and torque tighten to 60 65 Nm 44 48 Ib ft 11 3 25 Install the steering deflector 16 using steering pivots 26 Ensure that the two washers 98 and washer 91 are correctly fitted prior to tightening the cap screw 66 and self locking nut 84 Apply Loctite 243 to threads and torque tighten to 60 65 Nm 44 48 Ib ft Use or disclosure of data contained herein is subject t
46. d as the best method for clearing debris from the waterjet intake grill Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 5 INSTALLATION DETAILS Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 5 5 0 5 1 5 1 2 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 INSTALLATION DETAILS FOR INSTALLATION IN ALUMINIUM HULLS Refer to Section 12 for parts list and UltraJet Drawing Details for mounting the intake block into the boat hull and the transom cut out dimensions are shown on Drawing No s 8966 300 00M 8966 301 00H and 8966 302 00D at the back of Section 5 Remove the UltraJet 305HT unit from its packing Note Do not lift the unit by the steering shaft or by the input drive flange To remove the reverse deflector 17 first remove the cylinder pivot bolt washers and nut 69 93 amp 85 attaching the reverse cylinder 37 to the reverse deflector 17 Undo the pivot pins 19 and remove the reverse deflector 17 Coat the intake block and the underside of the intake flange with a thin layer approx 1mm thick of RTV sealant Mount the Ultrajet as shown on installation Drawing No 8966 302 00D Fit the insulating washers and nuts and tighten the
47. drive failure Debris restricting deflector movement Re fill with suitable fluid see Section 10 5 and bleed any air from the system Re adjust belts or replace if worn Remove debris and recheck 6 5 2 Deflector will not move full travel Debris restricting deflector movement Cable adjustment incorrect Hydraulic cylinder movement restricted inboard Remove debris and recheck Re adjust cable or push pull control unit stops Remove restriction 6 5 3 At end of deflector travel hydraulic pump stays on Debris restricting deflector movement Remove debris and recheck load Cable adjustment incorrect Re adjust cable or push pull Control unit stops Hydro mechanical Replace damaged parts mechanism damaged or and or re adjust mechanism incorrect adjustment Hydraulic cylinder movement Remove restriction restricted inboard 6 6 DESCRIPTION OF STEERING SYSTEM COMPONENTS See Drawings at the end of this section 6 6 1 Steering Helm Pump The steering helm pump is a proprietary item and should be fitted in line with the manufacturer s instructions Suitable oil types are listed in Section 10 6 6 2 UltraJet Mounted Steering Cylinder The Steering cylinder is mounted off of a bracket that is attached to the UltraJet for details see drawing at end of section Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP
48. e wo xa 1 wis kar k t kusipa ISSUE No 2 1 L ISSUED ON 4057 _ Au18035 Aute067 5580 8966 DRAWN PB PCB BAW _ 000 DATE 30 5 06 79 6 08 1 9 08 5 2 1 CHECKED 0 60 5 0 2 0 8 OGY 0J3 APPROVED ae 824 PRane 08 e SHEET 10 OF 10 n DETAIL D 2 PLACES SCALE 1 S ST VY TV 7777 lt lt 4 Z GZ SCALE 2 1 16730 040 STUD 4 55 Ca W DDDB E see EFS D CE DETAL 24 4 n ells QE SCALE 4 9 zm HS jie 2 ERAIN LLN th c www www NN M lt lt lt j Vln XZ Z lt 9 7 7Z Sf AEN SSS WA ONIN IE ASh T 2 1 qc 3 0 m lt Li A Li 7 SS SSS SSS et WY N lt lt OY B Z d 3 rhe N I 2 f Coat TN f 87 lt pau A BED 6 7 sena N 9 de VENT HOLE AT 1 For general assembly instructions ie Thread locking Torques see 70621331 000 me ULTRAJET 305HT 2 Pack with Shell Alvania Grease RL2 or equivalent where specified og eet ay 3 Use marine grade Silicone Sealant where specified ASSEMBLY 4 Quality acceptance test to IS 674
49. ed that the strength attachements and integrity of this area and its surroundings is in accordance with the hull design criteria and any applicable classification society or other marine authority requirements Prepare minimum flat transom area to keel line as shown For transom cutout details see dr g 8966 301 00H Transom Intake Block NOTE For jet units in a vee bottom hull this area to blend from intake block to keel line at 5 maximum to improve water Intake Block flow into intake Length of NOTE Rear face of transom blend depends on deadrise must be flat and free of obstructions within this area For unit installation details see dr g 8966 302 00D DETAIL D Vee Bottom Hull B B Flat Bottom Hull I I SEE DETAIL D 90 30 OF JET UNIT SEE DETAIL Flat Bottom Hull Flat Bottom Hull Vee Bottom MT nd Vee Bottom Hull NOTE 5 maximum SEE DETAIL See note above DETAIL Intake Block UNLESS OTHERWISE STATED TLE ALL OMENSIONS N MLUMETRES HULL DETAIL CT STANDARDS ne wm ULTRAJET 305HT ALUMINIUM HULL ULTRAJET 305HT 8966 000 00A 4 PROFILE OF TRANSOM FLANGE 12 HOLES 011 THRO or 12 HOLES EQUISPACED ON 572 P CD 011 THRO FOR M10 STUDS 0 25 DETAILS OF TRANSOM HOLES VIEWED ON ARROW A UNLESS OTHERWISE STATED ALL IN MLLIMETRES GENERAL
50. ercent of forward thrust can be achieved b 90 3 a hb 1 0 10 20 30 40 CRAFT SPEED KNOTS Performance knots Ibs MINIMUM SPEED LINE Thrust predictions assume 3000 Correct installation of jet 2500 gt Suitable hull shape and trim S e Ahull wake factor of 0 05 Wo L 5 2000 a i Rae Minor thrust variations _ 1500 Wo 2 Occur with impeller and 4000 nozzle changes 500 4 C 10 20 3 40 CRAFT SPEED KNOTS Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT POWER ABSORPTION CHARACTERISTICS 350 ER kW R hp NPUT POWE OWE INPUT POWE 200 m Power Absorption Curves The above curves show the power absorption characteristics for a range of impellers available for direct coupling to the engine fly wheel It is recommended that an impeller be used which restricts the engine speed to slightly below its operating maximum speed to ensure that its maximum available power is effectively absorbed Impellers are available to match engines outside of those shown above please consult Ultra Dynamics for evaluation A gearbox can also be used to obtain the required power rpm characteristic but will result in extra cost weight and efficiency losses This could be incorporated with a reverse gearbox facility which is recommende
51. erred to as UDL warrants that subject to all terms of this warranty UltraJet goods will be free from defects due to faulty material or faulty workmanship UDL s obligations under this Warranty being limited to make good at its factory or at the factory of any subsidiary or branch of UDL the product or any part or parts thereof which shall be returned to it 2 This warranty shall remain in force for 15 calendar months from date of despatch from UDL and relates to all such defects discovered within such period and notified in writing to UDL within forty five days of discovery subject to the provisions herein 3 Any goods alleged to be defective and under warranty should initially be reported to UDL in writing with adequate details of the failure periods of service and full identification to UDL Under no circumstances should units be returned without first gaining prior consent from UDL in writing 4 When UDL consent in writing the Buyer must return the alleged defective unit to UDL as failed identified properly packed and full carriage paid UDL will not accept any units where the full carriage has not been paid UDL will not accept any charges associated with removal of goods from an installation nor the refitment of goods into the installation In matters of warranty UDL shall decide if goods are defective and under warranty and whether to replace or give credit for goods and credit for reasonable carriage costs on accepted claims 5
52. erse deflector control lever If a joystick type controller is utilised then these manoeuvres can be carried out with one hand 8 8 In strong wind or tide conditions the engine rpm can be raised to increase the response as necessary Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT 8 9 8 10 8 11 8 12 8 13 8 14 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 Blocked Intake Grill A blocked intake grill can be cleared by either Selecting reverse on the engine gearbox selector if fitted and giving a 2 3 second burst of power This will blow obstructions away from the grill Removing the inspection cover in the intake casing gives access to the grill If an over flow protector is not fitted ensure that the inspection cover is above the waterline before removing CAUTIONARY NOTES With a light boat moving at speed under full power selecting full astern at the control head will cause the boat to decelerate very rapidly This procedure should only be used in an emergency If the boat is in very shallow water avoid using high rpm when manoeuvring to prevent stones being drawn through the intake grill and causing damage to the impeller It is recommended that the reverse deflector is left in the fully up position to prevent marine growth forming on the c
53. ghtened as per 5 3 11 Transom Ring bonding Occasional damage to the transom flange or transom sealing ring can lead to corrosion developing The earthing cable supplied with flange and ring is to be fitted when the unit is fitted into the boat With the UltraJet unit and transom flange fitted fit the transom O ring and transom sealing ring NOTE The transom sealing ring is supplied with the paint removed from around one hole this hole is to be used at location 3 under the cable see Fig 1 Remove the nut and steel washer from the stud projecting through the reaction case clamping earthing cable to anode Fit a steel washer to the stud 3 which clamps the transom sealing ring to the transom plate Fit earthing cable 8729 086 12S supplied Fit steel washers and nuts to studs tighten to 31 34 Nm 23 25 Ibs ft using Loctite 243 Fit insulating washers steel washers and nuts to all other studs tighten to 31 34 Nm 23 25 Ibs ft using Loctite 243 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 3 0 5 HT Reaction Case Anode Reaction Transom Flange Transom Sealing Ring FIGURE 1 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 785 REVERSE 690 FORWARD DIRECTION STEERING LEVER MOVEMENT ROTATION 916 THRO 8 HOLES
54. gns of leakage Check around the UltraJet for signs of water leakage SERVICE INTERVALS Weekly or every 50 hours of operation check the oil level in the reverse system hydraulic reservoir Check that the drain hole in the intake case is not blocked Add the recommended grease to the bearing cap 5 until a slight witness of it appears around the front seal Grease the reverse cylinder rod end where it attaches to the reverse SCOOP 305 10 3 3 10 3 4 10 3 5 10 3 6 10 3 7 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 Monthly inspect the unit for damage especially the grill 38 steering deflector 16 and reverse scoop 17 Repair as required Any damage to the protective epoxy paint coat internally or externally should be repaired as soon as possible using the approved method outlined at the end of this section If an antifouling paint has been used it should be repaired using a com patible type suitable for use on aluminium components Examine the inside of the Ultrajet unit as far as possible and remove any foreign matter such as rope which may have become entangled around the impeller hub If fitted check the hydraulic pump V belts for wear and correct tension and adjust or replace as necessary See Fig A Belt Tensioning Procedure Ensure nuts A and B are loose Pull pump to tension belts Lightly tighten nut
55. if neces sary 11 1 16 If the impeller case wear sleeve 11 shows signs of excessive wear i e more than a 1mm step when compared with an unworn section then the wear sleeve should be removed from the intake case 11 2 FRONT BEARING ASSEMBLY 11 2 1 Lock the drive flange then remove the M20 self locking nut 86 and cone 33 11 2 2 Remove the drive flange and key 29 11 2 3 Undo the 4 off M12 self locking nuts 84 and remove the bearing cap 5 WARNING On no account should the bearing cap be removed if the boat is still in the water 11 2 4 Slide the seal sleeve 4 the bearing 46 off the shaft 27 11 2 5 Remove the bearing sleeve 13 O Rings 60 and seal sleeve 4 from the shaft 27 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT 11 2 6 11 2 7 11 2 8 11 3 11 3 1 11 3 2 11 3 3 11 3 4 11 3 5 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 Undo the M6 nut 121 and set screw 120 from the side of the intake case 7 before removing the seal housing 6 Remove the seal housing 6 from the intake case 7 Two M5 tappings are provided to aid removal WARNING The seal housing should be removed without banging the static element of the mechanical seal against the shaft as chip ping of the seal face could result The shaft
56. l site glass and a filler strainer Reverse Cylinder This is a fully marinised hydraulic cylinder mounted through the transom flange of the UltraJet using self lubricating spherical bearing arrangement It is fitted with an index rod for connection to the hydro mechanical reverse control system Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 6 2 4 6 2 5 6 2 6 Oil Cooler To avoid excessive heating of the oil the UltraJet unit is fitted with an integral oil cooler which requires no cooling water connections Push Pull Cables Optional supply by Ultra Dynamics The hydro mechanical reverse control system is designed to accept any Series 3 or 4 push pull cables with the appropriate mounting hardware giving a stroke of 76mm 3 Push Pull Control Unit Optional supply by Ultra Dynamics Most types of push pull cable push pull control units can be used with this hydro mechanical reverse control Mounting details and features vary dependent on the manufacture and type The push pull control unit should be capable of a cable travel of 76mm 3 The push pull control unit should be mounted on a flat surface and the cable connected accordance with the manufacturer s instructions Cable runs should be kept as straight as possible with any bends being smooth and as large a radius as practicable Use or disclosure
57. le page of this document UD248 19 DTP 3 12 305 SECTION 8 OPERATION Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 8 8 0 OPERATION 8 1 Itis recommended that prior to starting the engine the Ultrajet reverse scoop control lever is put in the neutral position This is particularly important if there is not a gearbox fitted between the engine and the Ultrajet unit 8 2 The steering of an Ultrajet is done by deflecting the water jet so if the engine is stopped or its gearbox is in neutral there will be no water jet and no steering 8 3 Remember NO POWER TO THE ULTRAJET NO CONTROL 8 4 The bow of the boat always turns in the direction that the steering wheel turns If the steering wheel is turned to port the bow will turn to port whether the Ultrajet reverse scoop control lever is ahead astern or neutral 8 5 Steering effect is proportional to engine rpm The wider the throttle opening the faster the turn 8 6 For slow speed manoeuvrability the engine should be set to around 1000 rpm which will give a sufficiently high jet thrust to ensure good responsive steering Boat speed is con trolled with the Ultrajet reverse scoop control lever moving it forward to increase speed or backward to decrease speed 8 7 For most slow speed and docking manoeuvres the operator will have one hand on the steer ing wheel and one hand on the rev
58. m in even increments to bed the intake down Torque the intake nuts to 31 34 Nm 23 25 Ibf ft 305HT 5 17 5 1 8 5 1 9 5 1 10 5 1 11 5 1 12 5 1 13 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 Clean excess RTV sealant from inside and outside the unit If the transom is not pre drilled use the transom flange 20 as a drilling guide by centralising it over the intake case 7 by fitting transom O Ring 22 and sealing ring 21 and marking or spot drilling the hole positions Drill the mounting holes in the transom out to 011mm If the transom has been pre drilled for the transom flange 20 thinly coat the transom face with RTV sealant and mount it on the boat using M10 bolts and self locking nuts The bolts should be tightened in even increments until a torque of 31 34 Nm 23 25 Ibf ft is reached Remove excess sealant Fit the transom O ring 22 and transom sealing ring 21 tighten the 12 off M10 self locking nuts to 31 34 Nm 23 25 Ibf ft Mount the reverse deflector 17 using the 2 off pivot pins 19 with washers 88 and insulating washers 97 Apply Loctite Anti Seize or equivalent to the pivot pin threads prior to assembly and torque tighten to 320 360 Nm 236 266 Ib ft Fit the cylinder rose joint to the reverse deflector using the M16 bolt 69 washers 93 and self lo
59. m sq Elongation 5 5 1140 REF T B F 53 R20 x 2 LO LO lt lox Pp x x 3 2 2 8 22 R10 R10 x BOAT ARROW AND CENTRE LINE x CAST RAISED 1mm HIGH 50 x E ce EA x R10 R10 O LO ni s SECTION B B 147 5 839 1575 146 5 __ 836 __ 156 5 _ Si 80 192 4250 CASTING NOTES 12 159 2 Casting tolerance size 0 75 material unless otherwise stated R20 A A 2 a nm T a o Casting to be free from porosity blow holes finning and flash 5 220 5 Casting tolerances are not accumulative REE II e RT Q R200 MATERIAL Sand casting in Aluminium Alloy LM6M with grain refinement by modification using Sodium Strontium or similar approved equivalent Please note the final sheet is the Modifications sheet Where required draft angle 1 maximum additional material to dimension specified No repairs of flaws in casting is acceptable without prior permission from Ultra Dynamics ISSUE No DO NOT SCALE 4 DRAWING ISSUED ON 07 02 2011 DRAWN BY B Watts CHECKED BY P Berry 28 02 2011 APPROVED BY P Raine 02 03 2011 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS GENERAL MANUFACTURING STANDARDS TO HDS200 GEOMETRIC TOLERANCES AND SYMBOLS TO BS308 MATERIAL Aluminium Alloy LM6M C ULTRA DYNAMICS LIMITED 2011 THIS DRAWING IS THE PROPER
60. moving approximately 6mm 1 4 before the ends of stroke It is important to check that the cylinder has stopped moving before it reaches the end of its travel out stops and the control valve has centred It is advisable to cycle the reverse control from full ahead to full astern several times before checking the status of the system Checking if the cylinder has not reached the end of its travel can be done by pushing or pulling the directional control valve spool see directions of movement sheet If the full ahead movement is being checked the clevis attached to the directional control valve can be pushed this should cause a small movement of the cylinder On the inside of the craft this will be visible as a small downward movement of the index rod attached to the rear of the cylinder If movement does not take place the cylinder has reached the end of its travel out stopped before the directional valve has centred The full astern movement should also be checked the same way If both ends of travel can not be set in this way check the travel of the control cable and adjust the control head stops to suit Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 6 5 SYMPTOMS POSSIBLE CAUSES FAULT FINDING CHART Hydro mechanical Unit SOLUTION 6 5 1 Deflector will not move No hydraulic fluid in reservoir Hydraulic pump belt
61. ms in respect of any such personal injury loss or damage For the purpose of this Clause UDL contracts on its own behalf and as agents and trustees for its employees servants and agents 8 Inno circumstances shall UDL incur any higher liability to the Buyer hereunder than the total of the sums paid by the Buyers to UDL for the contract goods in respect of which the liability arises 9 Any obligation on the part of UDL under this Warranty does not apply to any UDL product which may have been re paired or altered in any way other than by UDL or to damages caused in the opinion of UDL by overloading misuse mis application improper storage abnormal wear and tear due to exposure to the elements negligence accident or whilst being operated in any other way other than in accordance with the operating and maintenance instructions of the company nor does it apply to repairs made necessary by the use of parts or accessories not recommended by UDL Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT 10 There is no liability on the part of UDL with respect to any items incorporated any UDL product when such items have been manufactured by others and are warranted by their respective manufacturers in favour of the purchaser or when they are supplied by UDL on special order UDL shall not be liable for any consequential loss or damage resulting directly or indirectly fr
62. n 11 Evidence of water Faulty mechanical Strip and replace faulty mixing with grease in seal or damaged components the bearing housing seal faces See Section 11 Blocked drain hole Clear drain hole Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 ULTRAJET FAULT FINDING CHART SYMPTOMS POSSIBLE CAUSES SOLUTION Excessive vibration Faulty or worn Strip and replace faulty bearings components See Section 11 Damaged impeller Strip and replace i e sections missing damaged components from impeller blades See Section 11 Worn driveshaft Strip or repair universal joints driveshaft universal joints Excessive operating Check steering Remove debris and loads for steering deflector for signs of recheck debris obstructing the operation Operating linkage not Clean and recheck moving freely operation Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 ULTRAJET FAULT FINDING CHART HYDRO MECHANICAL if fitted SYMPTOMS POSSIBLE CAUSES SOLUTION Over heating of Pump remaining on Re adjust hydraulic fluid load Hydro mechanical hydro mechanical adjustment incorrect settings as Hydraulic cylinder 6 4 6 reaching end of stroke before the hydraulic valve has reset Reverse Deflector Cable travel short Check cable travel travel Insufficient is 3
63. n oil and not subject to surface contaminants such as barnacles 4 If hydraulic fluid is degraded due to overheating contamination etc drain fluid flush system amp replace fluid Estimated time to perform the check or service item on each jet Frequency based on commercial operation of 8 hours per day seven days per week Refer to UltraJet manual supplied with the jets for details of these checks and operations 2012 Ultra Dynamics Page 1 of 1 Printed 1 12 12 SECTION 9 FAULT FINDING CHART Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 9 9 0 ULTRAJET FAULT FINDING CHART SYMPTOMS POSSIBLE CAUSES SOLUTION Noisy waterjet with Intake grill blocked Clear debris from aerated water at exit with debris or weeds intake nozzle Loss of thrust from Blocked intake grill Clear intake grill waterjet Damaged impeller Remove intake grill blades or reaction and examine as far tailpipe case blades as possible condition of impeller and reaction tailpipe case of blades Decreased engine Check engine output power power Excessive engine Blocked intake grill Clear intake grill speed Increased impeller Check condition of tip clearances or impeller and tip damaged impeller clearances for excess blades wear Noisy waterjet with Faulty or worn Strip and replace faulty no loss of power or bearings components speed See Sectio
64. ngs to be insulated from steel hull Details of mounting frame constructed into hull transom cutout and unit installation are shown on drawings 8966 309 00E 8966 310 00G and 8966 311 00C atthe back of Section 5 To remove the reverse deflector 17 first remove the cylinder pivot bolt washers and nut 69 93 amp 85 attaching the reverse cylinder 37 to the reverse deflector 17 Undo the pivot pins 19 and remove the reverse deflector 17 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT 5 3 4 5 3 5 5 3 6 5 3 7 5 3 8 5 3 9 5 3 10 5 3 11 5 3 12 Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 Coat the mounting frame with a thin layer approx 0 5mm thick of RTV sealant position gasket onto mounting frame Coat the underside of intake flange with a thin layer approx 0 5mm thick of RTV sealant Mount the UltraJet as shown on installation Drawing No 8966 311 00 Fit the insulated bolts insulating washers and washers Tighten them in even increments to bed the intake down Torque the intake bolts to 31 34 Nm 23 25 Ibf ft Clean excess RTV sealant from inside and outside the unit If the transom is not pre drilled use the transom flange 20 as a drilling guide achieve this centralise it over the intake case 7 by fitting Tra
65. nsom O ring 22 and sealing ring 21 and marking or spot drilling the hole positions Drill the mounting holes in the transom out to 12mm If the transom has been pre drilled for the transom flange 20 thinly coat transom flange 20 and transom with RTV sealant Position gasket 23 over transom flange studs Fit transom flange with gasket onto transom using insulating washer washer and nuts The nuts should be tightened in even increments until a torque of 31 34 Nm 23 25 Ibf ft is reached Remove excess sealant Fit the transom O ring 22 and transom sealing ring 21 and earthing strip NOTE See Section 5 4 for transom ring bonding Mount the reverse deflector 17 using the 2 off pivot pins 19 with washers 88 and insulating washers 97 Apply Loctite Anti Seize or equivalent to the pivot pin threads prior to assembly and torque tighten to 320 360 Nm 236 266 Ib ft Reconnect the reverse cylinder 37 to the reverse deflector using the M16 pivot bolt 69 and M16 self locking nut 85 making sure to correctly position the M16 plain washers 93 and torque tighten to 31 34 Nm 23 25 Ibf ft 305 5 3 13 5 4 5 4 1 5 4 2 5 4 3 5 4 4 5 4 5 5 4 6 The drive flange can now be connected to the engine taking care to use an insulated drive shaft system NOTE The reverse scoop pins are not fully tightened if unit is fitted without removing reverse scoop ensure pins are ti
66. ntake Case PART NUMBER DESCRIPTION 1 8984 002 000 HYDRAULIC STEERING MOUNTING FRAME 1 2 2006 018 01F STOP PLATE 3 2006 026 01J CYLINDER BLOCK l 4 9611 225 00W STEERING CYLINDER 5 8984 004 00M BOLT l 6 8731 040 SSQ M10 STUD 12 20 4 7 9146 261 00D M x 25 HEX SOCKET CAP SCREW 2 Please note the final sheet is the Modifications sheet 8 9146 312 000 M8 x 30 HEX SOCKET CAP SCREW 4 so nor BUEN wraomAncsumeo 20n 9 9223 405 00 8 SPRING WASHER 4 pour ULTRA Dynamics 10 9223 261 00C 10 PLAIN WASHER form A 4 up Pe ONSET O 11 9223 264 000 M16 PLAIN WASHER form A 3 um S 12 9145 180 00L M10 SELF LOCKING NUT 4 Loo 2006 022 00Y 13 9145 183 007 M16 SELF LOCKING NUT I 16 09 2011 4 50Kg BREAK SHARP SHEET 1 OF 2 SCALE 1 2 A3 1 2 4 5 6 DIRECTIONS OF MOVEMENT TO GO 70 GU AHEAD ASTERN REVERSE DEFLECTOR MOVES CYLINDER PISTON ROD MOVES CYLINDER INDEX RUD END MOVES DIRECTIONAL CONTROL VALVE SPOOL MOVES CONTROL CABLE MOVES CONTROL HEAD MOVES SECTION 7 CORROSION PROTECTION Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 7 7 1 Use or disclosure of
67. o the restriction on the title page of this document UD248 19 DTP 3 12 305HT 11 3 26 Fit seal 119 and press the shaft seal 65 into the intake case 7 and pack the seal cavity with the recommended grease See Section 10 11 3 27 Slide the steering shaft 30 into place and fit the steering lever outboard 25 apply Loctite 243 to the threads of the M8 bolt 67 and fit the washer 89 and self locking nut 82 tightened to 17 19 Nm 12 5 14 Ib ft 11 3 28 Fit the inboard lever 9 and secure using M10 bolt 68 washer 90 and self locking nut 83 apply Loctite 243 to the threads and torque tighten to 31 34 Nm 23 25 Ib ft 11 3 29 If the Ultrajet 305HT has been removed from the boat it should be refitted at this stage refer to Section 5 for relevant details 11 3 30 Mount the reverse deflector 17 using the pivot pins 19 with washers 88 and insulat ing washers 97 Tighten the pivot pin 19 to 320 360 Nm 236 266 Ib ft 11 3 31 Fit the cylinder rose joint to the reverse deflector using the M16 bolt 69 washers 93 and self locking nut 85 See Detail F Apply Loctite 243 to the threads and torque tighten to 31 34 Nm 23 25 Ib ft NOTE position of locking washer assembly 54 11 3 32 Ensure that all anodes and earth bonding straps are refitted Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 11 4 SERVICE KITS
68. om any defect in the product the subject of this agreement 11 No liability on the part of UDL with respect to this Warranty shall extend to second hand and reconditioned goods and the Warranty does not cover the cost of labour involved in the replacement of defective parts 12 No liability on the part of UDL with respect to this Warranty shall exist if the UDL product is not in the opinion of UDL installed as per the Installation and Maintenance Manual or Designer s Manual 13 Warranty will not apply unless a negative earth bonding system has been installed in the vessel ULTRA DYNAMICS LIMITED NOTE This Section must be completed fully and sent by return to Ultra Dynamics Limited Upperfield Road Kingsditch Trading Estate Cheltenham Glos GL51 9NY United Kingdom 5 l un Use or disclosure of data contained herein is subject to the restriction the title page of this document UD248 19 DTP 3 12 305 SECTION 1 GENERAL DESCRIPTION Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 1 GENERAL DESCRIPTION The UltraJet 305HT comprises of a single stage axial flow pump incorporating the latest computer generated impeller technology The intake section has been designed to ensure optimum efficiency
69. ot then loosening the pipe connections to the cylinder will allow the deflector to drop With the push pull control unit in the full astern position connect the push pull cable to the hydro mechanical reverse control Fill the oil reservoir with suitable hydraulic oil and ensure that the reservoir is full at all times Suitable oil types are listed in section 10 Turn the engine over a few times on the starter to ensure that the hydraulic system is primed and to check for any leaks With the engine running operate the push pull control unit until the reverse deflector is moving smoothly The system will normally self bleed however should there be any problem bleed the system by loosening the hose connection to the relevant end of the reverse cylinder Because the push pull control unit is connected to the reverse deflector via the hydro mechanical reverse control it will mimic the actions of that deflector A light forward pressure on the helm control lever will make the reverse deflector rise allowing the helm lever to move forward If the light forward pressure is stopped the deflector will stop moving and the position of the helm lever will give an indication of the position of the deflector Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD446 Iss 1 DTP 3 2011 6 4 5 6 4 6 Set the travel stops on the push pull control unit so that the reverse cylinder stops
70. r general construction Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 IHO 9 b3uJ pnis 3 4I0 18S93 19 00 10 4 aug s Je jeduu exoju wr so uojoH uonoedsu JepuiK 9SJ9 9M JepuiKo Buueejs Jana buueejs JO UO D907 2 9 ZZON JOjoe jeg 305HT Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 SECTION 2 SPECIFICATION Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 SECTION 2 ULTRAJET 305HT SPECIFICATION Pump Type Single Stage Axial Flow Rotation Clockwise viewed on input drive flange Impeller Option 4 bladed Nozzle Type 184 7 25 dia standard other options available Reverse System Hydraulically controlled twin duct deflector system Unit Weight Dry Unit Weight 205 kgs 452 lbs Entrained water 38 kgs 82 lbs STANDARD EQUIPMENT Intake including inspection hatch Intake grill Single stage axial flow pump with 4 bladed impeller Balanced steering deflector with inboard operating lever Twin duct reverse deflector Auxiliary water take off Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD2
71. terial stainless steel is probably the best option Consult your electrical technician for specific recommendations for your application 7 3 STEEL HULLS 7 3 1 On steel hulls the waterjet unit must be electrically insulated from the hull and engine The driveshaft should also be insulated from the waterjet by means of a flexible rubber coupling or an insulating spacer at the flywheel Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305HT 7 4 Do not use copper or graphite based anti seize compounds when assembling the UltraJet as this could cause corrosion 7 5 ANTI FOULING When the UltraJet is to be operated in areas prone to high levels of marine growth an anti fouling paint should be applied The anti fouling paint that is used must be suitable for use on aluminium components and compatible with the epoxy paint finish of the UltraJet ENSURE THAT THE ANODES ARE LEFT UNPAINTED Use or disclosure of data contained herein is subject to the restriction on the title page of this document UD248 19 DTP 3 12 305 METAL ITEMS FUEL TANKS ELECTRICAL ACCESSORIES ETC EARTH BONDING TWO WIRE SUPPLY STRIP TO BOAT ELECTRICAL SYSTEMS _ BATTERY ve Ve HEAVY DUTY CABLES TO STARTER ULTRAJET ANODES TYPICAL EARTH BONDING LAYOUT FOR AND ALUMINIUM HULLS Use or disclosure of data contained herein is subject to the restriction on the tit
72. ulic Fluid4 f oOo o J x 15 Check amp Record Hydraulic Pressures f 30 Verify Reversing amp Steering Cycle Times 12 x 15 Verify Operation Of Control System x x 30 Suggested Annual Service By Owner or Boatyard During Annual Haulout Estimated Time Actions U U Annual Minutes Jet Check Torque of Reversing Pivot Pins T T J x 20 Check Torque of Steering Pivot Bolts f fd x 10 Check Condition of Impeller J o CTC J x 20 J Check amp Record Impeller Tip Clearance x 20 Check Condition of Cutlass Bearing O T 2 Remove Intake Grill 1 _ x 3 Check Condition Intake Grill amp Fasteners x 15 Antifoul Paint Inside Intake Housing C T f x o Reinstall Intake ST x X20 Replace Anodes x 45 All of the above items can be performed by owner s crew or by competent boatyard personnel at the local labor rate and using parts when required from provisioned inventory 1 If installed Not applicable for systems with transmission driven hydraulic pumps 2 If electrohydraulic control system is installed Not applicable for HM control 3 Park the reversing deflectors in full up forward position at end of trip to reduce damage to cylinder rods and rod seals When fully up the cylinder rod is i
73. ylinder rod which may when operated damage the hydraulic cylinder seals It is also recommended that when the jet has not been operated for an extended period that the reverse cylinder rod and steering shaft outboard is cleaned of any marine growth to prevent damage to the seals that these control rods pass through Reverse at full throttle can cause the jet to cavitate and damage the jet While in reverse the engine rpm should be adjusted to avoid cavitation 305 8 15 8 16 8 17 Use or disclosure of data contained herein is subject to the restriction the title page of this document UD248 19 DTP 3 12 If an electronic steering and or reverse system is used to control the UltraJet s please note The position of the deflector s will not change unless the jet mounted hydraulic pump is rotating If the deflectors are left in one position and the jet stopped moving the electronic controls sub sequently will not move the deflectors to a new position This can cause unexpected movement when the jet is next started NOTE SPECIFIC ONLY TO JETS FITTED WITH SOLAS WATER BEARING AND SEAL Damage will occur to water bearing and seal if dry running of the jet at engine idle exceeds 5 minutes REMEMBER NO POWER TO THE ULTRAJET NO CONTROL 305 Twin UltraJet 305HT Check List Service Summary Commercial Operation Routine Checks Performed By Boat Owner Operator Check List Daily

UJ 305 – Installation and maintenance manual

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UJ 305 &ndash; Installation and maintenance manual

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UJ 305 – Installation and maintenance manual