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1. Go with ha How alamarin Jet Tg OPERATION AND MAINTENANCE MANUAL Entin 2006 aa J amar 7 nj et Operation and Maintenance Manu alamarinjet We congratulate You on purchasing a new aMmarin Jet water jet propulsion unit and hope that you can enjoy it Alamarin Jet Oy has developed and manufactured water jet propulsion units since 1976 The propulsion units are used e g in pleasure and work boats as well as m fast rescue boats with a number of different engines Thousands of users around the world rely on the a amarin Jet water jet propulsion unit The aim of this instruction is to give important information on the operation use and maintenance of the unit We recommend reading this manual carefully before the implementation of the unit and before You set out to test Your new jet boat for the first time This is how You get the most pleasure and benefit out of it With best regards alamarinzyet Alamarin Jet Oy Tuomisentie 16 62300 Harma Finland tel 358 10 7745 260 fax 358 10 7745 269 www alamarinjet com Version 1 4 eration and Maintenance Manual al ci ma ar f n bj et alamarin jet water jet propulsion unit OPERATION AND MAINTENANCE MANUAL Alamarin Jet Oy has published this manual in order to guide the owners and users of boats equipped with a amarin Jet water jet propulsion unit Alamarin Jet Oy has published other manuals separately for technical designers mechanics a
2. 3 ah Operation and a f ama ri n jet Appendix 5 EXPLODED VIEWS When delivering this manual in paper form the manufacturer has added to the following pages the exploded views of the propulsion unit model with which the manual is delivered In the electronic version the exploded views as a separate file Version 1 4
3. Controlling Driving direction 1s controlled with the reversing deflector The reversing deflector is moved with the lever which is usually next to the throttle lever With this lever it is possible to control the hydraulic system mechanically or the mechanical system electrically In models Jet 160 and Jet 180 185 a fully mechanical system can be used as long as it is sturdy enough The reversing deflector can be lowered in front of the jet flow changing its direction forward and down There are two different types of deflectors Figure 2 2 2 1 Version 1 4 13 Version 1 4 eration and Maintenance Manual alamar in bj etf The round type reversing deflector figure 2 2 2 1 fits in assemblies in which width is critical By using the tube type reversing deflector figure 2 2 2 2 a higher reversing power is attained but the deflector 15 wider The second tube type reversing deflector model figure 2 2 2 3 is primarily designed for double installations but it can also be used for single installations Figure 2 2 1 2 Figures 2 2 2 2 and 2 2 2 3 illustrate the hydraulic control system used in Jet 230 For models Jet 160 and Jet 180 185 only the round type reversing deflector is available Figure 2 2 2 3 When the reversing deflector control lever is in forward position the deflector is not blocking the jet flow and the boat moves forward figure 2 2 2 4 When the lever is in t
4. Remove the joint between the reversing deflector and the hydraulic cylinder by opening the bolt marked by the arrow A Jet 230 In models that do not have a hydraulic reversing deflector control the loop joint B which connects the reversing deflector and the steering shaft is removed Figure 4 3 1 1 2 Remove the joint between the steering nozzle and the steering shaft figure 4 3 1 2 Figure 4 3 1 2 A f ci mea ri n bj et Operation and Maintenance Manu 3 Open the fastening bolts 4 pcs of the stator After this the stator the deflector and the nozzle come off as a whole In figure 4 3 1 3 the reversing deflector has been removed for clarity Figure 4 3 1 3 shy The fitting of the stator and the hull of the propulsion unit with E each other is tight You can help the detachment by cranking with a 7 7 IN screwdriver 4 Loosen the impeller s fastening bolts figure 4 3 1 4 and completely remove one of them Screw it in the adjacent threaded hole in line with the wedge groove and tighten carefully The plastic fastening cone is released and the impeller can be pulled off the shaft If the fitting 1s very tight multiple bolts are used as help Figure 4 3 1 4 Version 1 4 ration and Maintenance Manual 4 3 2 Fitting the Impeller 1 Screw the adjuster sleeve A and the possible additional ring on the shaft The sleeve has a left handed threading Set the wedge B in the
5. 2 4 1 on the axle has a left handed threading If the engine is run at too high revolutions on reverse gear the sleeve may loosen and the impeller may get stuck against the duct walls Figure 2 4 1 If clogging occurs on a boat that does not have a gear box the following procedures are recommended 1 Stop the engine This causes the extraneous objects in the grass rake simply to drop off 2 Let the engine run on high revolutions for a few times This often sucks the extraneous objects through the jet and cleans it 3 Ifthe boat is moving forward raise the boat speed as much as possible and then shut down the engine The speed of the boat often sweeps the grass rake clean 4 Drive the boat on reverse as fast as possible As the boat moves astern shut down the engine and move the deflector control lever to forward position This causes water to flow backwards through the jet and usually opens any blockage whatsoever alamarinjet operation and maintenance Mania With these simple instructions it is possible practically without exception to clean the jet even after the boat has stopped completely in reedy water Unlike with other propulsions in boats equipped with the jet the engine stops very rarely as a result of a reed blockage If the measures mentioned above are not of help the propulsion is equipped with an inspection hatch figure 2 4 2 through which the blockage can be seen Figure 2 4 2 and removed
6. Directive 2006 42 EC and the validating national regulations In addition the company guarantees that the specific technical documents related to the partially completed machinery have been created according to section B of Annex VII in the Machinery Directive 2006 42 EC and the following harmonised standards are applied SFS EN ISO 12100 1 and SFS EN ISO 14121 1 Alamarin Jet Oy also undertakes to deliver the documents related to the partially completed machinery to the relevant national authority in electronic format if so reguested The partially completed machinery must not be introduced to use before the final eguipment to which it is intended to be attached has been declared to conform to the reguirements of this Directive Place Kauhava Finland Date and Signature Version 1 4 eration and Maintenance Manual al a ma ri m bj et 1 The Jet Propulsion Unit Alamarin jet water jet propulsion unit is a single stage axial flow pump which produces a high volume flow rate and thrust with high efficiency The operation of the unit is based on increasing the water flow rate in the nozzle The change in the flow rate creates a reacting force in the direction of the flow which thrusts the boat forward By changing the direction of the jet it is possible to steer the boat in the desired direction Main Parts figure 1 1 The intake duct A whose function is to lead the water from outside the boat to the inta
7. SHAFT START TO ROTATE AT THIS STAGE IT IS NOT ALLOWED TO GO NEAR THE ROTATING PARTS THE INSPECTION HATCH MUST BE KEPT CLOSED WHILE THE ENGINE IS RUNNING 2 2 Steering and Controlling Version 1 4 IN THIS SECTION CONTROLLING THE jet boat IS DESCRIBED IN A WAY THAT IT IS DONE THROUGH A SYSTEM THAT HAS BEEN INSTALLED AS INTENTED BY THE MANUFACTURER WARRANTY Alamarin Jet Oy IS NOT LIABLE FOR DAMAGES WHICH DERIVE FROM INCORRECT INSTALLATION OF THE SYSTEM Steering denotes exclusively moving the steering nozzle Steering means changing the boat s bow angle Controlling denotes exclusively moving the reversing deflector Controlling means changing the boat s driving direction forward astern al arm ar 7 nj et Operation and Maintenance Manua 2 2 1 Steering The boat is steered by turning the steering wheel The connection from the wheel to the steering lever can be either mechanical or hydraulic figure 2 2 1 1 The lever moves the nozzle through the shaft and the joint Figure 2 2 1 1 Steering is possible when the power of the jet flow is sufficient This is why the engine must run on sufficiently high revs when steering 1200 1800 rpm is a suitable number of revolutions depending on the engine In sharp curves turning the nozzle causes the boat to slow down This is normal and increases safety The turning of the nozzle from one extreme position to the other takes 2 turns of the wheel 2 2 2
8. experiences of retailer s manufacturer s services Spare parts services Other comments Version 1 4 MT arrer SALES QUESTIONNAIRE alamarin bj et Return address ALAMARIN JET OY Tuomisentie 16 FI 62300 HARMA FINLAND EUROPE Fax 00 358 10 7745 269 E mail sales alamarinjet com TEST REPORT Date Test weight of boat Number of persons Wind speed m s Water temperature Jet serial number Engine and gear GPS clock Engine speed Speed in direction 1 Speed in direction 2 Average speed Notes If possible include pictures in your feedback Version 1 4 alamarinjet Operation and Maintenance Manual MAN DECLARATION OF INCORPORATION FOR PARTIALLY COMPLETED MACHINERY Machinery Directive 2006 42 EC Annex II 1 B Manufacturer Alamarin Jet Oy Tuomisentie 16 F1 62300 Harma Finland Compiler of the technical file Hannu Rantala Technical Manager Alamarin Jet Oy Tuomisentie 16 F1 62300 Harma Finland Description of the partially completed machinery Water jet propulsion device Operation of the partially completed machinery The device is intended to be used as the propulsion device of a motor boat A propulsion device transforms the torgue of the motor into propulsive force Model and type of the partially completed machinery Serial number of the partially completed machinery Alamarin Jet Oy guarantees that the abovementioned partially completed machinery meets the reguirements of the Machinery
9. groove reserved for it 2 The place of the fastening cone wedge groove is marked on the impeller with a line Set the cone so that the wedge groove is aligned with the line as in figure 4 3 2 2 Version 1 4 alamarinzjet Figure 4 3 2 2 aa J aa ma aa r 7 nj et Operation and Maintenance Manu 3 Place the impeller on the shaft along with the cone Tighten the screws finger tight 4 Push the impeller as far in the intake duct as it goes B BE CAREFUL NOT TO LEAVE YOUR FINGERS BETWEEN THE IMPELLER AND THE CONE Use the working position A shown in figure 4 3 2 1 Tighten the screws to a torque of 20 Nm Screw the adjuster sleeve through the inspection hatch so that it sits tightly against the impeller s plastic cone If the adjusting sleeve is left loose B the impeller gets stuck in the duct cone Reference C shows a correctly tightened sleeve Figure 4 3 2 1 There can be a gap of 0 2 mm between the impeller blade and the cone D During installation the lower edge lies on the cone and there can be a slightly bigger gap at the upper part of the impeller due to the weight of the impeller and the axle This gap disappears when the stator finally centers the shaft Too wide a gap between the cone and the impeller blade leads to loss of power If the impeller does not rotate properly after the installation open the impeller screws pull it slightly outwards and tighten the screws 5 Close the inspecti
10. impeller In this case the impeller wears also and its efficiency is reduced A worn bearing should be replaced with a new one when the aforementioned symptoms appear alamarinjet cperation and maintenance Mani Technical specifications for the lubricant greases Example greases Wurth Multi Purpose Grease lithium soap and a thickener with EP III additives FAG Multi2 mineral oil as a base oil FAG Load 220 NLGI class 2 Mobil XHP 222 operating temperature range 25 130 C Neste Allrex EP2 continuous operating temp min 75 C Sheli RetinaxGrease EP 4 2 3 Lubricating the Control System The joints and shaft bushings that belong to the control systems are essentially maintenance free but lubrication prolongs their operating life Below figure 4 2 3 1 15 a list of objects in which water proof vaseline is added in connection with maintenance When the plastic bearings of the joints wear and gaps are created they must be replaced 1 Shaft bushing in the stern 3 Pivoting of the reversing deflector on both sides of the stator 2 Shaft bushings in the rear flange 4 Pivoting of the nozzle on both sides of the stator Figure 4 2 3 1 If the boat has two propulsion units the propulsion unit 1s equipped with a different kind of reversing deflector Figure 4 2 3 2 shows the joints of this kind of deflector The lower joint is located underneath a zinc anode Figure 4 2 3 2 Version 1 4
11. lubricating the bearings of the propulsion unit must meet the requirements below lithium soap and a thickener with EP additives mineral oil as a base oil NLGI class 2 operating temperature range 25 130 C continuous operating temperature min 75 C The following grease brands are recommended as an example Wurth Multi Purpose Grease III FAG Multi2 FAG Load 220 Mobil XHP 222 Neste Allrex EP2 Shell Retinax Grease EP2 A grease that has equivalent properties to those mentioned above can also be used for lubricating 2 The operating hydraulic system of the reversing deflector has been designed operate with automatic transmission oil Kinematic viscosity 40 C 33 36 mm2 s Kinematic viscosity 100 C 7 1 7 7 mm2 s Viscosity index min 170 Density 15 C 0 835 0 890 g cm3 Pour point max 42 C Flashpoint min 180 C The following oil brands are recommended as an example Mobil ATF 320 FormulaShell ATF DEXRON III Neste ATF X BP Autran DX III 3 The tightening torques in the table below must be used when tightening the screws on the propulsion unit The values 8 8 10 9 and 12 9 signify the strength classes of the screws The strength class of the A4 80 acid proof screw corresponds to a 8 8 class screw Tightening torques of the Screws Tightening torque Nm A suitable thread locking compound for all purposes is one of medium strength for example Loctite 242 or similar Version 1 4 Maintenance Manual
12. to be used has been described in appendix 4 c Max level sp Min level ij A Cooler B Filter C Oil reservoir Figure 3 3 2 2 Version 1 4 a J aa Im aa ri 7 n bj et Operation and Maintenance Manua 3 4 Raw Water Cooling The jet comes complete with the possibility to connect the engine cooling water cf Figure 3 4 1 The engine does not need a separate water pump However if the cooling water is taken with a separate pump the jet s raw water line is stoppered At the beginning of the line there must be a tap with which the line can be shut temporarily for example during cleaning of the filter or other maintenance Figure 3 4 1 1 Raw water connector G 3 4 2 Tap 3 Filter 4 Raw water intake 3 5 Corrosion Protection 3 5 1 Cathodic Protection The raw materials used for manufacturing the jet parts are mainly aluminum acid proof steel and plastic Materials that have different electrochemical properties can form a so called galvanic couple while they are in electrolytic fluid salt water A galvanic couple forms an electric circuit because the materials have different inherent voltages This in turn leads to electron movement and corrosion of the weaker material Cathodic protection is used to try and prevent the propagation of galvanic corrosion Cathodic protection means introducing into the same circuit a third material the electrochemical properties of which are weake
13. to the reduction of corrosive effect due to conditions 4 2 2 Lubricating the Bearings 4 2 2 1 Lubricating the Front Bearing The lubrication of the front bearing is carried out from the engine compartment side To facilitate greasing there 1s a hose with a grease nipple at one end connected to the bearing housing The end of the hose can be attached in the loose space so that using the grease gun 15 easy Excess grease exits the bearing housing automatically When lubricating only add 4 5 injections of grease with the grease gun The lubrication interval for the bearing is 50 hours or twice a year at minimum 4 2 2 2 Lubricating the Rear Bearing It 1s easiest to carry out the lubrication of the rear bearing when the boat is out of the water but it can also be done while the boat is in the water The lubrication 1s carried out through the steering nozzle from the nipple in the middle of the stator figure 4 2 2 2 1 Excess grease exits the bearing housing automatically When lubricating only add 2 3 injections of grease with the grease gun The lubrication interval for the bearing is 50 hours or twice a year at minimum The rear end bearing supports the shaft and centers it in respect of the duct This is why excessive wearing Figure 4 2 2 2 1 of the bearing affects the behaviour of the impeller a When the bearing has been worn enough excess vibration builds up in the unit and clinking can be heard from the
14. 2 3 9 GOTOSION PIOIEGUODIK sarsana anaa EEN ER EES EE EERE EE NAGA EA GA Aa 22 sa D We GANOIC PTOLECUOM sasa paga adie aa aaa aa a aa ga aga aa ee a ra aa aaa aa aaa 22 a DA GANG NGG aana a aaa aa Gen aa a ER SA aa KG E ag A KE aa a aa RE E Aa Ba Bag 23 4 MG SNG Gina ae aga aeree ajara DADAN aaa ak a ag a sate aneng aa ga AR I Ben NNS 24 MN oo Ag Na KRENA AN AN RE E EE NA Kg ME 24 4 2 Periodical Maintenance aaa agama aana kanaka ANG ak sija aan aa aa a veces aaa EN a DEN 24 sdh 21 WASHING ME JOT aaa aaa ai aaa aaa aaa Na kaga E E aa elan a a aa a ag den da aka 25 4 2 2 Lubricating the Bearings saanane aee naa e eaaa ee ee a ee anana aee e eee 25 4 2 3 Lubricating the Control System sanusa anaa eaaa anana nenen een 26 4 2 4 Changing the Zinc ANOdes saaa tse cece emesis 271 4 2 0 Adjusting the Impeller anana aananana nenen ae oka oka ee naen kao ee eee eaaa nee 21 4 2 6 Checking the Seals ene eee ee nee ee ee 2 4 2 7 Maintenance of the Hydraulic System cccccceeccseeeceeeseeeseeeeees 21 do TING PEET a sa aaa nnn ee a aaa aa aaa ee eee 29 4 3 1 Removing the Impeller aaa catenin aane nana aane anae naen aane nana 31 eh Za FUNG NS NDENG pse ag aaa sekte EE EE ore A a KAE NA aa DA 33 Version 1 4 garon and Maintenance Manual a la mar f n jet APPENDIXES Appendix 1 Maintenance Manual c ccccecceccseceeeceeeeecesecee
15. 27 Version 1 4 4 2 4 Changing the Zinc Anodes The jet is protected with passive cathodic protection The functioning of the zinc anodes is crucial from the point of view of corrosion The zinc anodes must be changed when they have worn down to half of their original size Every aluminum component has been protected separately with a zinc anode The places of the anodes are described in chapter 331 4 2 5 Adjusting the Impeller Depending on driving conditions the impeller wears and a gap develops between the duct wall and the tip of the blade When it expands enough the jet s performance decreases By adjusting the impeller the operating life can be prolonged considerably The adjustment of the impeller should be done whenever it is necessary but checking must be done at least once a year Adjusting the impeller is done by removing the impeller and reinstalling it See next chapter 4 2 6 Checking the Seals The seals to be checked are e g the O ring seal of the inspection hatch A and the sealings of the steering shaft bushings B figures on the side When the inspection hatch seal leaks 1t causes ventilation and the sealings of the steering shaft bushings cause water to leak in the bilge If water gathers in the bilge the cause for this must be determined immediately and the possible leak must be IYAN repaired Water can damage e g the starter motor 4 2 7 Maintenance of the Hydraulic System Th
16. KANAN 9 J ODS Fat OW aja aia aga aaa anaa a BAS NINA aa I E E E E TEGESE AT a E SOL 10 2 1 Using for the First TIME ss sas aaa aa NGAEN EA AE a TAKEN NANA WE naroda ta Peta se 10 yaar PENO and LONTONG saa aaa eee Renee ne aa Na aa ga aa aaa a aa ene E a aan 11 ee kaa 21 gt 0 Se he aan Aa eh en a a AE KA EEE Ba a ee 12 sve Bd KONON ee ere EENE a Bg a an eee aa 12 2 3 Operating in Shallow Water aee e enere Rok aee eaaa nenen n anana eee e eee e ene 14 2 4 Operating in Reedy Water aaa eaaa a koke ee ee ee e ee nana aaa eaaa eee nace 15 2 5 Cavitation and Ventilation sasae ee eee eee eee e Reka nana a eee e enere nee 16 wee ba KANAN AOI saa gaen a a a Aga E AE a E EEN ag O a BG AE Ga aa Ka 16 ngg es VONIA ON sanesa pa ina Kan anaa ae pa Ba aa k TASEK a EEE Aa a BR aa a DENENG A EBEN 17 a KANG NOK aaa ana a aa asa cee anaa ens ee ere NG TEK aaa a ag te IG ga aaa A A a aa ig a a AURE 18 Oe Wg LAKI SIENI SOI aan sa a aaa scree taeda aa Ta DEE GT NEG EE a PO a ga Pt aaa aaa 18 DL MO AN AG aab a bena aa E NG donated De aa a a aka ted Ne aba aan aa kai papaka aaa aaa eka 19 San ije b SLOMI ANAN AN MENGEH ENE NENG NANA NR EN KEN G PA 19 3 3 1 Electronic Reversing Deflector Control System aaa eaaran 19 3 3 2 Hydraulic Reversing Deflector Control SysteM cccceeeeeeeee es 20 34 Raw Water OO ING asa kaag aaa aga a BN ag a Ka a KE GAR a NE aa KA NE DA aaa a a aaa 2
17. OULING PAINT IS USED FOR PAINTING THE PROPULSION UNIT THE RESULT WILL BE HEAVY CORRO SION AND DESTRUCTION OF THE PROPULSION UNIT DO NOT USE ANY OTHER ANTIFOULING PAINTS FOR PAINTING THE PROPULSI ON UNIT EXCEPT THOSE INTENDED FOR ALUMINIUM SURFACES Version 1 4 aa J a m ci ri 7 mn bj et Operation and Maintenance Manual MH Instead a boat bottom made of reinforced plastic can be painted using copper bearing antifouling paint In this case leave a 50mm unpainted area around the propulsion unit in the stern and on the bottom of the boat See picture 2 3 1 Mounting wi template Mounting template E Figure 3 5 3 1 4 Maintenance 4 1 Tools The following items are included in the tool kit delivered with the propulsion unit if or dered separately Wrench 10 mm Allen wrench 6mm Wrench 13 mm Allen wrench 8 mm Wrench 17 mm Knife Allen wrench 5 mm Universal pliers Most of the maintenance and repair procedures can be carried out with these tools 4 2 Periodical Maintenance The jet is designed and manufactured to be as simple as possible This is why the need for maintenance is low and maintenance can be carried out on shore Version 1 4 Version 1 4 eration and Maintenance Manual al a ma ri m bj et 4 2 1 Washing the Jet Every time the boat is lifted out of the water it is advisable to wash it with fresh water This clears possible salt accruals and impurities which leads
18. Remember to close the hatch The wing screw is tightened by hand 2 5 Cavitation and Ventilation 2 9 1 Cavitation The most common malfunction in water jet propulsion units manifests as cavitation Engine overdrive and stopping of thrust are signs of this Cavitation is a phenomenon in which the water pressure decreases locally in such an extent that water vaporizes on the surface of the impeller blade creating steam bubbles The bubbles move on the surface of the blade and when they reach a higher pressure area they collapse Cavitation incurs considerable reduction in capacity and damages the impeller Usually the cause is the reduction of pressure in the whole intake duct which is induced by a blockage Cavitation can often be heard as a rumbling sound Any factor that hinders the flow of water in the jet increases the chance of cavitation Version 1 4 Version 1 4 ration and Maintenance Manual A f ci mar f nn bj et If cavitation 1s apparent the following things should be checked Check through the inspection hatch that 1 The grass rake figure 2 5 1 1 is not clogged by grass reed plastic stones etc 2 There are no extraneous objects in the stator or nozzle unit or the impeller figure 2 5 1 2 rope reed entagled in the drive shaft stones in the outlet port Figure 2 5 1 2 3 The impeller figure 2 5 1 3 is not damaged It should be smooth and it should not have any sharp cuts If the
19. The pitch and the length and number of blades naturally also affect the power demand Version 1 4 alamarinj et Operation and Maintenance Manu The size marking of the impeller can be found both at the front and rear end figure 4 3 1 It can be seen through the inspection hatch and by removing the stator Marking showing the size of the impeller Figure 4 3 1 The condition of the front edge of the impeller blades is important A damaged front edge causes cavitation The front edge can be repaired by carefully hammering the marks caused by bigger stones and grinding them smooth The front edge must not be sharpened it must be left about 2mm thick and rounded r 2 mm Figure 4 3 2 You can also return the impeller to the factory for checking and repairing If you suspect that there is a malfunction in the impeller do as follows 1 Shut down the engine and open the inspection hatch 2 Check that nothing is blocking the intake duct 3 Check the impeller visually Notice especially the gap between the outer edge of the blade and the duct wall Version 1 4 Version 1 4 tion and Maintenance Manual 4 If there is no apparent fault the boat must be lifted out of the water for closer inspection 5 Remove the impeller See section Removing the Impeller below 6 Check the impeller more closely You can always ask the importer or manufacturer for instructions 4 3 1 Removing the Impeller 1
20. boat runs slowly even though the engine runs on high revolutions find out the cause Figure 2 5 1 3 2 5 2 Ventilation Ventilation produces similar symptoms as cavitation but is caused by different reasons Ventilation is created when air gets to drift into the intake duct The air causes the impeller to lose grip and the thrust weakens Ventilation can be heard as a similar sound as cavitation Ventilation can be caused e g by the following things The inspection hatch cover is open or a seal is damaged The installation height of the jet is wrong air is allowed to pass along the surface of the cavitation plate into the intake duct During installation places accordant with the instructions have not been sealed alamarinjet Operation and Maintenance manual MAH 3 Functions 3 1 Transmission The jet takes its propulsion power from a petrol or a diesel engine The most common way to transmit the power is through a 1 1 gear box but direct drive is also possible and functional The greatest benefits of a gear box are a real neutral gear and an intake duct backflush In the direct drive or so called bobtail installation it is commendable to use a flywheel adapter provided by the engine manufacturer It protects the flywheel from mechanical damages and e g corrosion The auxiliary shaft which is connected between the jet and the engine usually depends on the boat manufacturer If necessary the jet manufacturer suppl
21. ceseeeeeseeseeeeeenaes 35 POS A ESU eE a EN EN AH KARENA E NR E KEN RN 36 APPENA S DESO 2 se pe aaa er ag E ga ag Na aa NG E aa aa a Aga a A ene a a aa a aaa 37 Appendix 4 Recommended Greases and Oils and Tightening Torques S EEEE lt i ee ec E E ee T 38 Appendix 5 EXplod d VIEW Lara an pa apaa aaa DAAR Ba P A KAIN AGE a EA IEA A Ned aaa kaa ak 39 Version 1 4 alamarinjet AFTER SALES QUESTIONNAIRE 6 cr AFTER SALES QUESTIONNAIRE In order to improve our products and operations we at Alamarin Jet Oy are collecting feedback from the end users of water jet propulsion units This form is intended to make it as simple as possible for you to give us that feedback You can fill out the form in the User s Manual and send it to us via mail fax or e mail if you are using the electronic form on the CD Only answer questions to which you know the answer Customer s end user s contact information Boat owner Contact information of person answering the questionnaire Delivery information of project device For instance the serial number of the propulsion unit or other relevant document Test information for ALAMARIN JET Use table on the next page Customer service received from retailer importer manufacturer prior to delivery Quotation technical guidance documentation etc Delivery of propulsion unit Timeliness of delivery contents of delivery packaging documentation After sales services Include prior
22. e reversing deflector hydraulic control system requires maintenance as follows checking the oil level checking the condition of the V belt and replacing it if necessary checking the condition of the hoses and replacing them if necessary oO and Maintenance Manual a lamar f nn bj et a J AM aa r 7 mn bj et Operation and Maintenance Manual The Maintenance and Repair Table gives detailed instructions for checking different targets Service and Maintenance Chart Jai Jory monty every 6 montis yeariy Hvara reverse buckot operating system are taman Ti TO possible aks roses couning t x ffi TT amsema Ooo a xs ee test run and accuracy of reverse bucket K movement Kg AA DANA NAN NATA NAN DANA ES goneral technical ona STi id Kd TIT TD engine raw water cooling system f Sid Preooingwaterrom t i A A A Prose eats roses counings Sid S Cid unotonorvave mone PTT KT possble boeksin sistem SPO dT i Coo E S T NAN DANA C a TIT DANA acme S KT mess SSS i o S S wmo S S T T o o ee SEO CoS E S S T o Fame OOOO S S S o o m O S S o T e o C a E aaron passee oonan OOOO o NT TD Se TU NANA NAN DANA wsm DANG NANG NANG NANA DANA wess O S KK wwa O S S S NK C S ES T ee E NK Coo T S T T NAN Steoring nozzlo and steoring st S Cid S msme OOOO DANG NANG NAN NANA NAN uncon osteningroaaioandateemnganiem Ki mesos PO Od teohrical conditon of control sta OOO O t S
23. h combined motion of the nozzle and the deflector If you have never driven a jet boat before familiarize yourself with the separate guide Steering and controlling jet boats You can find the guide on the CD attached to the back cover of the paper version of the Operation and maintenance manual for example 2 3 Operating in Shallow Water The jet boat can be used in very shallow water but it must be taken into account that especially on high revolutions the suction power of the intake is high cf figure 2 3 1 Loose objects may get sucked into the intake screen and small objects wash through the jet Stones may cause damage In sandy conditions wearing inevitably takes place The maintenance procedures required by a worn impeller are described in the maintenance section of this manual See Adjusting and Fitting the Impeller page 24 Figure 2 3 1 eration and Maintenance Manual al afi A r 7 n jet 2 4 Operating in Reedy Water Version 1 4 At planing speeds a jet boat usually crosses reed fields without difficulty In difficult conditions however clogging may be possible In boats equipped with a gear box cleaning the intake duct is easy because at reverse gear a back flow is created in the duct THE JET HAS BEEN DESIGNED TO RUN ON REVERSE GEAR ONLY MOMENTARILY AND ON LOW REVOLUTIONS A TOO HEAVY LOAD ON REVERSE GEAR CAN LEAD TO JAMMING OF THE IMPELLER OR BREAKING DOWN OF HYDRAULICS The sleeve shown in figure
24. he rear position figure 2 2 2 5 the deflector is in front of the jet flow and the boat moves astern Figure 2 2 2 5 alamarin bi et Operation and Maintenance Manu The centre position of the reversing deflector corresponds to gear s idle position even though the drive is on the boat stays still The centre position is not absolute it depends on the power of the jet flow Finding the centre position is done by testing during the first driving hours When moving at low speeds the reversing deflector is used to control the boat s speed Because the engine is being run at 1200 1800 rpm to enhance steering the boat may travel faster than desired In this case the deflector is lowered in front of the jet flow to reduce the thrust directed towards the driving direction Steerability remains good however At high speeds the deflector is not used to reduce speed Instead speed is controlled with engine revolution It 1s possible to turn the boat in place when the deflector is in centre position When the nozzle is turned to the desired direction the boat rotates about its central axis When reversing steering is inversed in comparison to driving forward If you want to turn the boat to the left the wheel must be turned to the right A good mnemonic is that the boat s bow always turns in the same direction as the wheel When fast turns are needed the engine revolutions are not reduced but instead the turn is done throug
25. id steta roze MU NEK Cee KK Version 1 4 gaton and Maintenance Manual a la mar f n jet Jetinlet KR cleaness of inlet surfaces TET no marine growth etc KU Nn nn nn I o Front bearing tubrication o o o gnnessofbots EE general technical condition of bearing End bearing iubicaton Cd general technical condition of bearing MA TE meet DT NAN alovance otimpolr UT _ ece conaton otimpoler ades OOOO lgm of adjustor te O Tignes otb Si technical condton of mpsler moving ene f technical ondtonofimpeterrousing KIK IT general technical conan SiC concn or sat sleeve war no 28029 ff technical conaton ofjettange sf TO Tignes of termediate shat fastening bots ooo a a a All maintenance that has been done to the propulsion unit can be entered in the Maintenance Manual The Maintenance Manual is Appendix 1 4 3 The Impeller The impeller usually wears on the outer edge of the blades It operates in a cone shaped space and its position can be adjusted in the direction of the shaft in accordance with the blade wear The gap between the outer edge of the blades and the cone should be as small as possible to achieve best efficiency Factory installation gap 0 2 mm The longitudinal position of the impeller in the duct reveals its power demand The deeper the impeller sits the less power it takes from the engine because the diameter of the impeller is smaller
26. ies the auxiliary shaft with the propulsion unit It is also possible to get instructions and recommendations from the manufacturer on which auxiliary shaft to use In the end the shaft manufacturer gives instructions on the installation and maintenance of the shaft Below is a list of example shafts which have been used with the jet 1 Constant speed shaft Joint structure based on balls rolling on a spherical surface 2 Cardan shaft Joint structure based on pivoted grids 3 Silent block shaft Joint structure based on an elastic rubber element THE AUXILIARY SHAFT MUST ABSOLUTELY BE OF HIGH ENOUGH QUALITY AND PROPERLY BALANCED A POOR SHAFT CAN CAUSE EXCESSIVE DAMAGE TO THE PROPULSION UNIT THE ALIGNMENT OF THE AUXILIARY SHAFT MUST BE KEPT ACCURATE IT MUST BE CHECKED AT LEAST ONCE EVERY DRIVING SEASON YEAR Version 1 4 eration and Maintenance Manual alamar in bj et 3 2 Bearing The jet s bearing is very simple figure 3 2 1 There are bearings at both ends of the direct shaft The structure of the front bearing A is receptive to axial pressure In addition at the front end there is the supporting bearing B of the coupling flange and the auxiliary shaft Rolling type bearing is used at the front end and slide bearings are used at the rear C Both bearings are stock grease lubricated It is possible to install a water lubricated bearing at the rear end Figure 3 2 1 Lubricate front bearings eve
27. ke side of the impeller with as little loss as possible and an even distribution of velocity The impeller B which is rotated by the driving motor through direct drive increases the water s flow rate The nozzle converts the pressure energy produced by the impeller to motion energy The steering device C is used to change the direction of the jet flow coming out of the nozzle which creates the force needed for turning The controlling device D Lowering the reversing deflector causes the boat to reverse The direction of the jet flow changes obliquely forward under the boat which is when the thrust is directed forward and down The reversing deflector is also Figure 1 1 used for stopping the boat See section Steering and Controlling page 10 Version 1 4 Fz f ci Im aa T n bj et Operation and Maintenance Manu 2 Every propulsion unit has its own serial number The serial number has been marked on the type label and in addition it has been stamped both on the frame of the propulsion unit and on the inspection hatch cover The places in which the serial number can be found have been designated in figures 1 2 and 1 3 The serial number has also been recorded on page 6 of the Instructions for Use and Maintenance Figure 1 3 Operation 2 1 Using for the First Time Before you set the boat afloat for the first time make sure that the jet has been installed according to the Installa
28. nd repair men From here on in this manual the a amarin jet water jet propulsion unit will be referred to as jet This term refers exlusively to a propulsion unit manufactured by Alamarin Jet Oy The instruction covers the following jet propulsion models Jet 160 Jet 180 Jet 185 Jet 230 If the given information is type specific this will be expressed in the text In this manual clarifying figures will be used The symbols used in the manual ARROW DESCRIBING MOTION INDICATOR ARROW PART MARKING SIMA a N TJN HINT the text includes useful additional information or a hint which facilitates the work performance or procedure N TAN NOTE the text includes a warning of a slight danger or a possibility of minor damage to equipment GUARANTEE MATTER the text includes a guarantee clause WARRANTY WARNING the text includes a warning of a danger that can lead to personal injury breaking down of equipment or serious malfunction of equipment gt gt gt gt SERIOUS DANGER the text includes a warning of danger to life Q O U Version 1 4 A J a mi aa ri 7 mn bj et Operation and Maintenance Manual MAH After Sales GOuestionnalire sesa eaaa aaa e rekao ee ee cantacaonsaduceseessseanesecdanacces 6 Declaration of Incorporation for Partially Completed Machinery 8 Le Ne JOE PROD UISION ONI saraje Sa KANAAN SINGANGSANA GAN ER ej a poh KANAAN BAE GE IA
29. on hatch 6 Install the reversing deflector the steering nozzle and the stator in place as a whole in a reverse order than when removing The tightening torque for M10 bolts is 50Nm and 80Nm for M12 bolts Version 1 4 an Operation and Maintenance Manual Appendix 1 MAINTENANCE MANUAL MAINTENANCE LOG Made by Date Made by Date Made by Date Made by Date Made by Date Version 1 4 Commissioning Commissioning Commissioning Commissioning Commissioning Commissioning alamarinzjet Service Service Service Service Service Service de G SEE lt O s ss sg os 4 x Q rT ah Q x rinjet Appendix 2 SE 01 alama kl T I n 1 UOGISJIP Gurup z Jana ri TEH BANA Woy esr Version 1 4 rinjet alama Maintenance Manual PPENDIXES Operation and Appendix 3 SE 02 9 ft tf fT E fof ft ft ft 2LlL W4 MIS UMOJG Deo jUBUNSNIPO jo julod s ppiw aspei9u ASDINDOD 9 e SD849Uu Ju puana O aspei9u 4 pseds Djs Oo paio juswujsnipo _e SasDaJjepD Delo e JOJASIPU pu puasana WOSL A DOE VI AVN Ar l Jejewonuerod UM Jojotu a jpujds Li Version 1 4 Maintenance Manual a f ama ri n Je APPENDIXES Operation and Appendix 4 RECOMMENDED GREASES AND OILS AND TIGHTENING TORQUES OF THE SCREWS 1 The grease used for
30. r The jet is protected from galvanic corrosion with passive cathodic protection Every critical aluminum casting has its own zinc anode In figure 3 5 1 are shown the places of the anodes Version 1 4 23 aration and Maintenance Manual alama r in jet 1 Inspection hatch cover 2 Reversing deflector 3 Steering nozzle 4 Stator 5 Frame 2 pcs Figure 3 5 1 3 5 2 Painting The aluminum castings have also been protected by painting Painting efficiently prevents the propagation of various forms of corrosion e g pit corrosion Bare aluminum is liable to corrosion in difficult conditions This 1s why it is important to carry out touch up painting if paint comes loose and aluminum is exposed Touch up painting can be done in various ways What is important is that the paints used are suitable for aluminum and that the paint manufacturer s instructions are followed during painting If the boat 1s going to be used in waterways where the growth and sticking of organisms around the boat s bottom and the propulsion unit is heavy the propulsion unit can be painted with antifouling paint after installation Generally speaking antifouling paints are based on various soluble substances for example copper Because the propulsion unit is made mainly of aluminium copper forms a highly unfavourable galvanic couple with the propulsion unit The aluminium starts to corrode because it functions as an anode IF COPPER BEARING ANTIF
31. ry 50 hours or twice a year at minimum The bearings are lubricated through the hose in the engine room The boat should be lifted out of water when lubricating the rear bearings It 1s advisable to add grease to the rear bearings whenever the boat is lifted out of water At minimum however this should be done every 100 hours or twice a year 3 3 Control System Version 1 4 3 3 1 Electronic Reversing Deflector Control System The system is available for models Jet 160 Jet 180 and Jet 185 The main components that the system consists of are 1 a control lever potentiometer 3 an electronics unit and 4 a spindle motor See figure SE 01 in Appendixes The electronics unit changes the position of the lever into a signal to to the spindle motor The repair and adjustment instructions for the system can be found in Repair Manual 1 aa J aa ma aa ri 7 mn Je fF Operation and Maintenance Manual E d 3 3 2 Hydraulic Reversing Deflector Control System The system is available for Jet 230 It includes a rotary valve which simplifies the system considerably The reversing deflector is controlled cf figure 3 3 2 1 mechanically with a cable A which operates the valve regulator B Figure 3 3 2 1 The cylinder gets its power from the oil pump which has been integrated in the propulsion unit In a stock delivery the system does not include a control lever or a cable so their type varies depending on the boat manufac
32. tion Instruction This prevents the emergence of unexpected fault situations which can lead to damages Starting In starting an engine equipped with the jet the following things should be observed The reversing deflector control lever must be in centre position The possible gear must be in neutral position In a system without a gear the accelerator must be in idle position See the effect of the position of the reversing deflector control lever on the position of the reversing deflector on page 11 Version 1 4 eration and Maintenance Manual al ci ma ar f n bj etf When you start the engine for the first time It may be possible that clinking is heard from the jet during the first minutes This should usually disappear however when the impeller gap becomes fit The reversing deflector s hydraulic control system needs more oil because the hoses and cooler are empty The oil pump noise may be loud at first but as the system fills up with oil the noise disappears Observe the oil level in the beginning because leakages cause environmental pollution Checking the oil level has been described in section 3 3 2 The oil type has been given in appendix 4 Ensure the functioning of the system carefully at low speeds Observe the engine manufacturer s instructions on running in The jet does not require special running in WHEN THE ENGINE IS STARTED UP THE INTERMEDIATE SHAFT AND THE MAIN
33. turer However the different types of systems have the following things in common The operation of the deflector must be separate from the throttle and the gear The stroke length of the cylinder is always the same The incoming direction of the cable can be chosen freely The oil circulating in the system must be cooled in order to prevent excessive heating This is done with a separate heat exchanger or a possible cooler in the engine Version 1 4 aration and Maintenance Manual al ci Imi ar f n bj et IF THE OIL IN THE SYSTEM IS NOT COOLED THE MANUFACTURER IS NOT RESPONSIBLE FOR POSSIBLE DAMAGES WHICH DERIVE DIRECTLY OR INDIRECTLY FROM THE OIL OVERHEATING An extra cooler must be installed in the following cases 1 If there is no cooler in the engine 2 If the cooler in the engine is reserved e g for cooling the transmission oil In the figure below 3 3 2 2 is a system in which the cooling water comes from the jet see next chapter The system can consist of different looking components depending on the boat manufacturer What is essential is the correct order of the components Notice especially the cooler s place after the filter A system equipped with a separate raw water intake pump has the same main components If it is necessary to add oil to the system add it in the oil reservoir There is a dipstick on the reservoir cap with markings for maximum and minimum level See picture 3 3 2 2 The type of oil

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