Operation and maintenance manual
Contents
1. Tuomisentie 16 FI 62300 Harma Finland Telephone 358 10 7745 260 Fax 358 10 7745 269 Internet www alamarinjet com All rights reserved The information in this manual may not be copied published or reproduced in any way whatsoever or exploited for commercial purposes without explicit written permission from Alamarin Jet Oy The information in this manual is subject to change without notice Alamarin Jet Oy reserves the right to modify the contents without notice 1 1 Safety precautions Read this instruction carefully before you operate the boat equipped with the jet the engine or carry out any maintenance procedures Also read the boat s manual Always follow the instructions and the safety precautions below e Only a person with with adequate training is allowed to carry out the demanding maintenance procedures described in this manual The person carrying out the procedures must always be wearing appropriate protective equipment e The work premises must be sufficiently large safe and well lit The tools used must be clean and appropriate for the purpose 1 2 Symbols Please refer to table 1 for a description of the symbols used in this manual Table 1 The symbols used in the manual Icon Description DANGER A Negligence in the performance of a procedure can cause a threat to your life KHO 288 EN 1 3 0 1 7 F Introduction alamarinjet Operation and maintenance manual I2. alamarinzet In the first few drives the reversing deflector s hydraulic control system needs more oil than usually because the hoses and the cooler are empty Check the oil level and add more if necessary Follow in the instruction from section 4 3 1 Lubricating the front bearing page 15 l NOTE e An oil leak may pollute the environment Observe the oil level and make sure that oil does not leak out 3 2 Steering WARRANTY A 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 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 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 4 The lever moves the nozzle through the shaft and the joint Figure 4 Steering lever Steering is possible only when the power of the jet flow is sufficient This is why the engine must run on sufficiently high revs when steering A suitable number of revolutions depends on the engine Usually it is between 1 000 and 1 500 rpm 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
3. Di dadozestavseasebiwasneeezes 11 A 2 COTTOSION PLOCECTION cecceccsccsscceecneceeceeeeeceeeceeeeneeeeeeeeseeeeeeeeeeeeenes 11 4 2 1 Changing the anodes 0 0 cecccccccsecccescceeceaeeeeeeseeeeeeeseneeeaes 11 4 2 2 Touch up painting and antifouling cece cecceseseeeeeeeees 13 43 gt BEATING aeisisnas EET EE EEI EA EATA 15 4 3 1 Lubricating the front bearing ssessessssssessrssssssrserssrssersers 15 4 3 2 Lubrication of the rear end bearing sssessessessssserserssesses 16 4 4 Control system searre oriire inna a doses devs sedesetauscessiesvacsccasdonvsnaserderte 18 4D Seals anene ye noae EEEE E E E E e Ra a r eo sne 19 4 6 Hydraulic reversing deflector control system ssesssessessessersersse 19 4 7 Raw water COOLING mone errient i E EEEE a E E 22 ABs IMpelEr occ sesccd ses cececes iite cous cas votes sank ME eS Ea ASA o ESSR E EEEa 23 4 8 1 Checking the impeller sssessesssssersessssssessessesserserssessersesssess 24 4 8 2 Removing the impeller oss ssessssssessessessersessssssessessessersersse 24 4 8 3 Installing the impeller s ssssssessessssssessrssesserserssessessrssssseesee 26 4 9 Intermediate shaft 0 0 ceecccsccccescccssecenseeecnsecccneeceeneeeeseesensuseenea 28 5s Problemi Situations vesscctessccise cateedsvetenndgseeinebeseyseteaehen spade REE cons EER e 31 Del Cavitation seor deact acd a aE a E E EAEE EAEE shad eaten tescbendsbedesventds 31 5 2 Ve
4. 20 Steering nozzle rear Figure 21 Reversing deflector end joints 18 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual 4 5 Seals f The seals to check are the O ring seal of the the inspection hatch Figure 22 point A and the sealings of the steering shaft bushings Figure 22 point B Figure 22 Seals If the inspection hatch seal leaks it causes ventilation see chapter 5 2 Ventilation page 33 Leaking 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 Any possible leaks must be repaired immediately Water can damage e g the starter motor 4 6 Hydraulic reversing deflector control system For controlling the reversing deflector the jet has a hydraulic cylinder which is operated mechanically with a cable The cable Figure 23 point C operates the valve regulator point A The cylinder gets its power from the pump which has been integrated in the propulsion unit KHO 288 EN 1 3 0 19 Maintenance alamarinzjet Operation and maintenance manual Figure 23 Hydraulic cylinder In a stock delivery the system does not include a control lever or a cable so their type varies depending on the boat manufacturer However the different types of systems have the following things in common The operation of the deflector is always separate from the thr
5. 8 EN 1 3 0 25 alamarinzjet Maintenance Operation and maintenance manual Figure 29 Removing the stator and the steering nozzle 4 Loosen the impeller fastening screws Figure 30 point A Figure 30 Impeller fastening screws 5 Remove one screw completely and screw it into the threaded hole in the plastic mounting cone Figure 30 point B When you tighten the screw in the threaded hole the fastening cone is released and the impeller can be pulled off the shaft If the adapter is very tight use multiple screws to release it 4 8 3 Installing the impeller f New and repaired impellers are fitted in the same way Installing the impeller 1 Attach the plastic fastening cone to the impeller hub and tighten the screws so that they are fingertight 26 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual Note that the place of the wedge groove is marked on the impeller hub Figure 31 Figure 31 Position of the wedge groove The thrust caused by the impeller is transmitted through the adjuster sleeve to the shaft Figure 32 The sleeve consists of rings of different thickness The length of the sleeve can be adjusted in 0 5 mm approx 0 02 increments by changing the number of the rings This way the impeller gap on the outer race Figure 30 point C becomes fit Figure 32 Adjuster sleeve 2 Find the right adjuster sleeve length by testing el Place the impeller
6. Operation and maintenance manual Go w ith the flow alamarin Jet 5 EG a i 2 n A h j a es m 7 Table of contents alamarinzjet Operation and maintenance manual Table of contents 1 Introd ti M cccesscasscabeneehiciedsnedadcuedued duecodesadanbialdadevetiuedcedsates a n iin 1 Tl Safety precautions eener in E E aeae e Sra S EEN eT eaS 1 V2 sSYMDOIS csssassceasve sveecSecas ier eriein EEE EIEEE TESE EAEEREN EET SaS a biat 1 2 THE jet propulsi n Unit wies cc vsescsssees sesdecksarwowcseeehes Er O E EE ot 3 Dod StrUCT TE oirir eine eE A E EEEE IOE EE E E a E e 3 2 2 Se al NUMDET rnor ese e EE E Le ee E debe T eb 4 3 Operation seiss sierras ressis EA a EEEE A EEEE ALASE EAA AELE TALEE AEEA EERE EE 5 Sel Sarn eritreo e Nea SLANE E PE ERE ETENA ES EOE EANAN ROEA 5 3A Steering oleraea usi riene seas an r RE E RE EAS aana ASES EEE 6 33s COMELOMING oee ie o o cod TEE EN TA E EET E E EO ase 7 3 3 1 The positions of the reversing deflector control lever 7 3 3 2 Using the reversing deflector s essessessoeserssessessesssesersersses 8 3 4 Driving under difficult conditions 20 0 0 ccc cee cc eeceeeeceeeeeeeeneeeees 9 3 0 Dry TUNING snare eieh see ies cece bs hadnes event eS ah ae ae aS ete 9 A Maintenance vais sean ch cden ei e dnansduchestieat toa teek ih wactedss dadagn edowss ie aatseasanattsendeavasteces 11 1 Washing teier eisses to rE EEE E E Secneateoeeedae
7. con Description WARNING Negligence in the performance of the procedures can lead to personal injury breakdown of equipment or serious malfunction of the equipment CAUTION The procedure involves minor danger or a possibility of minor damage to equipment WARRANTY The warranty is voided if the procedure is carried out incorrectly DD NOTE Important notice or fact il N L S Tip TIP Additional information that facilitates the performance of work or a procedure MAINTENANCE ON LAND The boat must be lifted out of the water for maintenance MAINTENANCE IN WATER The maintenance procedure can be carried out in water CARRIED OUT BY ONE PERSON One person can carry out the procedure CARRIED OUT BY TWO PERSONS Two persons must carry out the procedure 2 0 INDICATOR ARROW ARROW DESCRIBING MOTION Please note that this instruction uses the terms jet and jet propulsion unit They mainly refer to the same thing KHO 288 EN 1 3 0 The jet propulsion unit Operation and maintenance manual alamarinjet 2 The jet propulsion unit The Alamarin Jet water jet propulsion unit jet 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 reactive force in the direction of the flow w
8. d for the motor sea water cycle to cool the engine KHO 288 EN 1 3 0 9 gt Operation alamarinjet Operation and maintenance manual 10 KHO 288 EN 1 3 0 Maintenance Operation and maintenance manual alamarinjet 4 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 However maintenance must be performed regularly and whenever the need arises Alamarin Jet can provide you with a toolkit available through separate order for maintenance purposes The toolkit includes the tools needed to perform most maintenance and repair procedures on the jet The tools included in the toolkit are specified in Table 3 Table 3 Toolkit Tool Pcs Size Wrench 4 10 0 4 13 0 5 17 0 7 and 19 0 7 mm Allen wrench 3 5 0 19 6 0 24 and 8 0 3 mm Knife 1 Universal pliers 1 4 1 Washing f Washing the jet regularly removes possible salt accruals and impurities thus reducing the risk of corrosion Every time you lift the jet out of the water it is a good idea to rinse it with fresh water 4 2 Corrosion protection The jet has been protected against corrosion in the manufacturing and installation phases However the protection requires regular maintenance 4 2 1 Changing the anodes f The main raw materials used for manufacturing the jet parts are a
9. d stop Lowering the D 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 2 2 Serial number Every jet has a unique serial number The serial number has been marked on the type label which is on the side of the bearing oil reservoir Figure 2 The serial number is also stamped on the body of the jet above the bearing housing Figure 3 alamarinzyet ALAMARIN JET OY ALAHARMA FINLAND TYPE JET 288 SERIAL NO XXXXX MADE IN FINLAND WWW ALAMARIN JET COM Figure 2 Serial number on the oil reservoir Figure 3 Serial number on the body KHO 288 EN 1 3 0 Operation Operation and maintenance manual alamarinjet 3 Operation If you have never driven a jet boat before familiarize yourself with the separate guide Steering and controlling jet boats before driving the boat for the first time You can find the guide on the CD attached to the back cover of the paper version of the Operation and maintenance manual 3 1 Starting Before you start the engine equipped with the jet make sure that e the reversing deflector control lever is in centre position e the gear is disengaged If the engine has no gearbox it must be in idle position before you start it The positions of the reversing deflector control lever are described in section 3 3 Controlling page 7 Op
10. e Replacing the anodes Most of the anodes are attached with simple screws Below you will find instructions for changing the anodes that are attached differently A End of the steering shaft Figure 10 End of the steering shaft The end of the steering shaft has a threaded stud to which the anode Figure 10 point A is attached with a nut Figure 10 point B Rotating the anode also rotates and tightens the nut 12 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual F Frame Figure 11 Frame anodes The sides of the intake duct house holes for attaching anodes with the help of a mounting plate To remove the anodes first open the mounting plate screws Figure 11 point A after which you can remove the mounting plate along with the anode After this open the screw in the centre of the mounting plate Figure 11 point B Now you can attach a new anode to the mounting plate The mounting plate should be fastened to the frame using a sealing compound such as Sikaflex 221 G Inside of the stator Figure 12 Stator anodes The inside of the stator is protected by anodes housed under plastic plugs located on both sides of the stator To remove the anode first open the arrester screw Figure 12 point A and unscrew the plug Now you can replace the anode located inside the plug Leave the screw that holds the anode in place Figure 12 point B loose and fasten the plug into plac
11. e using a sealing compound such as Sikaflex 221 Only then attach the other end of the arrester to the stator After this tighten the screw that holds the anode in place 4 2 2 Touch up painting and antifouling f KHO 288 EN 1 3 0 13 alamarinzet Maintenance Operation and maintenance manual The aluminium castings have been protected with paint Painting efficiently prevents the propagation of various forms of corrosion e g pit corrosion Bare aluminium on the other hand is liable to corrosion in difficult conditions This is why it is important to carry out touch up painting if paint comes loose and aluminium is exposed Touch up painting can be done in various ways What is important is that the paints used are suitable for aluminium and that the paint manufacturer s instructions are followed during painting If the boat is 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 such as copper Because the propulsion unit is made mainly of aluminium copper forms a highly unfavourable galvanic couple with the propulsion unit In other words the aluminium starts to corrode because it functions as an anode Painting the propulsion unit with antifouling paint that contains copper will resu
12. eed in Average speed direction 2 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 Maximum rpm Observations 40 KHO 288 EN 1 3 0 Grease recommendations Operation and maintenance manual alamarinjet Appendix 3 Grease recommendations The grease used for lubricating the propulsion unit bearing must meet the following requirements e lithium soap and a thickener with EP additives e mineral oil as a base oil e NLGI class 2 e operating temperature range 25 to 130 C 13 266 F e continuous operating temperature min 75 C 167 F Recommended grease brands e Wurth Multi Purpose Grease III e FAG Multi2 e FAG Load 220 e Mobil XHP 222 e Neste Allrex EP2 Shell Retinax Grease EP2 A grease that has equivalent properties to those mentioned above can also be used for lubrication KHO 288 EN 1 3 0 4l alamarinzet Oil recommendations Operation and maintenance manual Appendix 4 Oil recommendations The operating hydraulic system of the reversing deflector is designed to use oil that is specifically intended for automatic transmission systems The oil must meet the following requirements Kinematic viscosity 40 C 104 F 33 36 mm s 0 05 0 06 sq in s Kinematic viscosity 100 C 212 F 7 1 7 7 mm s 0 01 0 01 sq in s Viscosity inde
13. eration 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 installation instructions If you have not personally installed the jet check with the boat s retailer that the jet has been installed correctly Correct installation helps to prevent the emergence of unexpected fault situations which can lead to damages The jet does not require separate running in However follow the engine manufacturer s instructions about running in during the first few drives Ensure the functioning of the jet carefully at low speeds DANGER The jet can be dangerous when running Do not go near the rotating parts Do not open the jet s inspection hatch when the engine is running When running the jet propulsion unit sprays water backwards at a great pressure Make sure that there is no one in the water behind the boat The intake in the bottom of the boat causes suction power at the back of the boat when the jet propulsion unit is running Make sure that there is no one in the water affected by the intake When you start the engine for the first time you may hear a jingling sound for a few minutes This is normal and the sound will end when the impeller gap sets in place The noise from the oil pump may be loud at first but is disappears as the system fills up with oil KHO 288 EN 1 3 0 5 Operation Operation and maintenance manual
14. extreme position to the other takes approximately 2 turns of the wheel 6 KHO 288 EN 1 3 0 Operation alamarinjet Operation and maintenance manual 3 3 Controlling Controlling denotes exclusively moving the reversing deflector Controlling means changing the boat s driving direction forward astern The reversing deflector is moved with the lever which is usually next to the throttle lever The lever controls the hydraulic system mechanically the cable operates the cylinder valve The reversing deflector can be lowered in front of the jet flow using hydraulics causing the boat to reverse Figure 5 Figure 5 Lowering the reversing deflector 3 3 1 The positions of the reversing deflector control lever The reversing deflector control lever can be in one of three positions forward rear or centre Forward position When the reversing deflector control lever is in forward position the deflector is not blocking the jet flow and the boat moves forward Figure 6 W A Figure 6 Ahead A Throttle lever B Control lever Rear position When the reversing deflector control lever is in rear position the deflector is blocking the jet flow and the boat moves astern Figure 7 KHO 288 EN 1 3 0 7 alamarinjet Operation Operation and maintenance manual Figure 7 Astern A Throttle lever B Control lever Centre position The centre position of the control lever corresponds to the idle posi
15. hich thrusts the boat forward By changing the direction of the jet flow the boat can be steered in the desired direction The jet gets its propulsion power from a petrol or diesel engine The most common way to transmit the power is through a gearbox but a direct drive installation is also possible and functional The greatest benefits of a gearbox are a real neutral gear and an intake duct backflush In bobtail installation it is commendable to use a flywheel adapter provided by the engine manufacturer This will protect the engine from mechanical damage and corrosion for example 2 1 Structure The jet consists of four main parts Figure 1 These are specified in the table 2 Figure 1 Main parts of the jet Table 2 Purpose of the main parts of the jet Part Purpose Intake duct A Leads the water from outside the boat to the intake side of the impeller Keeps the loss of power as small as possible and distributes velocity evenly Impeller B Increases the water s flow rate The impeller is rotated by the driving motor The nozzle converts the pressure energy produced by the impeller into motion energy Steering device Changes the direction of the jet flow coming out of the C nozzle which creates the force needed for turning KHO 288 EN 1 3 0 3 alamarinzyet The jet propulsion unit Operation and maintenance manual Part Purpose Controlling device Causes the boat to reverse an
16. ing the reversing deflector When the reversing deflector is lowered quickly the boat stops at a very short distance The emergency stop is to be used in emergencies only Alert the passengers and tell them to hold on to something if you are planning an emergency stop Without preparation a passenger may be thrown overboard 8 KHO 288 EN 1 3 0 Operation alamarinjet Operation and maintenance manual 3 4 Driving under difficult conditions Shallow water The jet boat can be used in very shallow water However note that especially on high revolutions the suction power of the intake is high Figure 8 Figure 8 Suction power of the intake Loose objects may get sucked into the intake screen and small objects wash through the jet Stones may cause damage to the jet and its parts In sandy conditions the impeller inevitably wears A worn impeller requires maintenance section 4 8 Impeller page 23 Reed fields At planing speeds a jet boat usually crosses reed fields without difficulty In difficult conditions however clogging may be possible A clogged jet must be cleaned immediately section 5 3 Clogged jet page 33 3 5 Dry running The jet may be run by the engine even out of the water because the bearings are greased an oiled This is a significant benefit in comparison to water lubricated bearings that do not sustain dry running well During dry runs a temporary water inlet must be arrange
17. into the duct At this point the screws of the plastic mounting cone must be fingertight 22 Measure the gap on the impeller outer race An ideal gap is between 0 4 and 0 6 mm approx 0 016 and 0 024 When you measure the gap note that the shaft is not centered when the stator is removed but the shaft s rear end hangs low and the whole gap is visible in the upper part of the duct KHO 288 EN 1 3 0 27 Maintenance alamarinzjet Operation and maintenance manual If the gap is too big it will cause loss of power and reduce performance 3 When you find the right adjuster sleeve length place the wedge in the shaft s groove Figure 33 and push the impeller on the shaft against the adjuster sleeve Figure 33 Wedge groove 4 Tighten the impeller fastening screws evenly in a crosswise sequence The tightening torque is 20 Nm approx 15 lb ft While tightening the impeller moves back a bit and a small gap develops on the front The gap will disappear when the impeller is being loaded 5 Install the stator and the steering nozzle in place in reverse order to that when removing Section 4 8 2 Removing the impeller page 24 The torque to be used is the tightening torque for M10 bolts 4 9 Intermediate shaft f The intermediate shaft which is connected between the jet and the engine usually depends on the boat manufacturer Contact the shaft s manufacturer for information on the maintenance of
18. ion f Ventilation produces similar symptoms and sounds as cavitation section 5 1 Cavitation page 31 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 caused by e g the following The inspection hatch cover is open or the seal is damaged Close the inspection hatch if it is open Change the seal if it is damaged section 4 5 Seals page 19 The installation height of the jet is wrong and air is allowed to pass along the surface of the cavitation plate into the intake duct In this case the jest must be reinstalled Consult the boat s retailer During installation places accordant with the instructions have not been sealed In this case the sealing must be done again Consult the boat s retailer 5 3 Clogged jet Driving among water plants or in ice sludge can clog the jet If this happens the blockage can stop the boat from moving With these simple instructions it is possible practically without exception to clean very difficult blockages from the jet Unlike with other propulsion units KHO 288 EN 1 3 0 33 alamarinzet Problem situations Operation and maintenance manual in boats equipped with a jet the engine stops very rarely as a result of a water plant blockage However ice sludge can clog the jet so badly that it cannot be removed without lifting the boat out
19. lt in heavy corrosion and destruction of the propulsion unit Do not use any other antifouling paints for painting the propulsion unit except those intended for aluminium surfaces A boat bottom made of reinforced plastic can be painted using antifouling paint that contains copper In this case leave a 50 mm 2 unpainted area around the propulsion unit in the stern and on the bottom of the boat Figure 13 SB Figure 13 Antifouling A Unpainted area B Painted area Zinc anodes and their fastening screws must not be painted 14 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual 4 3 Bearing The jet s bearing is very simple There are bearings at both ends of the direct shaft The structure of the front bearing Figure 14 point A is receptive to axial pressure It also carries the radial loads caused by the weight of the shaft and the parts attached to it At the rear end a grease lubricated needle bearing supports the shaft Figure 14 point B A water lubricated bushing can also be used Figure 14 Bearing 4 3 1 Lubricating the front bearing f The front bearing is oil lubricated and the housing is secured with a mechanical sealing When the shaft rotates the oil circulates through the reservoir and impurities gather to the bottom of the reservoir on the drain plug magnet Figure 15 point A e B Figure 15 Drain plug magnet and oil retur
20. luminium acid proof steel and plastic Materials that have different electrochemical properties can form a galvanic couple when they are submerged in electrolytic fluid salt water A galvanic couple forms an electrical 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 prevent the propagation of galvanic corrosion Cathodic protection means introducing a third material with weaker electrochemical properties into the same circuit The jet is protected from galvanic corrosion with passive cathodic protection i e with anodes Every critical aluminium casting has its own anode Some acid resistant parts are also equipped with anodes The anodes can be either aluminium or zinc The locations of the anodes are shown in the Figure 9 KHO 288 EN 1 3 0 11 alamarinzjet Maintenance Operation and maintenance manual Figure 9 Anodes End of the steering shaft Stator 2 pcs above and below Reversing deflector 2 pcs right and left Reversing deflector joint 2 pcs right and left Body 2 pcs right and left Frame 4 pcs two inside and two outside Inside of the stator 2 pcs right and left Body 2 pcs right and left Hydraulic cylinder r 0mm gt The functioning of the anodes is absolutely crucial to prevent corrosion The anodes must be replaced when they have worn down to half their original siz
21. n hose A Drain plug magnet B Oil reservoir return hose connection KHO 288 EN 1 3 0 15 alamarinzet Maintenance Operation and maintenance manual Oil change Use protective gloves while handling oil The front bearing oil must be changed after the first 20 hours of driving and then after every 500 hours or once every driving season Before you start changing the oil make sure you have a container for draining the used oil Changing the oil 1 Open the reservoir cap and stir the oil inside Impurities are easier to remove from the reservoir when they are mixed in with the oil 2 Open the drain plug Figure 15 point A and drain the oil into the container 3 Clean the plug magnet close the drain plug and fill the reservoir with new oil Oil recommendations can be found in the appendix 4 Oil recommendations page 42 This prevents air from drifting into the system and ensures that lubrication functions well from the start 4 Remove the reservoir return hose Figure 15 point B and keep it below the reservoir This way the oil drains out from the bearing housing and the hoses and the system fills up with new oil The time it takes to drain the oil depends on how far the reservoir is from the bearing housing The colour of the oil indicates whether all the old oil has drained out 5 Attach the oil return hose to the reservoir once the system is filled with new oil 6 Check the oil level f
22. n the unit is 0 3 1 18 cu in With these settings the reservoir will empty in 300 hours If you notice that the reservoir empties slower or faster than this adjust the pressure to the desired direction KHO 288 EN 1 3 0 17 alamarinzjet Maintenance Operation and maintenance manual You can fill the reservoir by pushing grease into it with a grease gun through the nipple Figure 16 point D This will cause the piston to protrude out of the reservoir The properties of the grease to use are described in Appendix 3 Grease recommendations page 41 NOTE e Any excess grease exits the bearing housing into the water Only use environmentally friendly grease for lubricating the bearing If there is no automatic lubrication unit installed into the system there is a nipple at the end of the lubrication hose through which grease can be pumped to the rear bearing 0 5 dl 6 cu in of grease should be added every 50 hrs 4 4 Control system f The joints and shaft bushings that belong to the control systems are essentially maintenance free but lubrication prolongs their operating life Locations where waterproof petroleum jelly should be added during maintenance are marked in Figures 18 21 When the plastic bearings of the joints wear and gaps are created they must be replaced Figure 18 Steering shaft bushing Figure 19 Steering nozzle joints nipple greasing or automatic lubrication Figure
23. ncy Factory installation gap is 0 2 mm approx 0 008 When the gap expands too much the jet s performance decreases The impeller usually wears on the outer edge of the blades The impeller 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 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 The pitch and the length and number of blades naturally also affect the power demand By adjusting the impeller its operating life can be prolonged considerably The adjustment of the impeller should be done whenever it is necessary but checks must be carried out at least once a year The impeller is adjusted by removing the impeller and then reinstalling it KHO 288 EN 1 3 0 23 alamarinzet Maintenance Operation and maintenance manual 4 8 1 Checking the impeller The condition of the front edge of the impeller blades is important A damaged front edge causes cavitation The impeller blade edges can be sharp and cut your hands Protect your hands with protective gloves before you remove the impeller The front edge can be repaired by carefully hammering the marks caused by bigger stones and grinding them smooth Sharpen the front edge to a thickness of approximately 1 mm approx 0 04 and rou
24. nd it off so that is not sharp enough to cut 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 there is no blockage in the intake duct 3 Check the impeller visually Notice especially the gap between the outer edge of the blade and the duct wall If there is no apparent fault do as follows 1 Lift the boat out of the water 2 Remove the impeller Chapter 4 8 2 Removing the impeller page 24 3 Check the impeller more closely Contact the importer or the manufacturer if necessary and ask for additional instructions 4 8 2 Removing the impeller f Before the impeller can be removed the reversing deflector the steering nozzle and the stator must be removed Removing the impeller 1 Open the screws indicated by arrows in Figure 27 Make sure that the reversing deflector is not accidentally lowered This may result in serious injury Support the reversing deflector in the upper position 24 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual Figure 27 Reversing deflector screws 2 Open the six fastening screws of the stator Figure 28 There are six screws Figure 28 Stator fastening screws 3 Remove the stator and the steering nozzle as a complete unit Figure 29 KHO 28
25. nd type of the partially Jet 288 completed machinery Serial number of the partially completed machinery Alamarin Jet Oy guarantees that the abovementioned partially completed machinery meets the requirements of the Machinery Directive 2006 42 EC and the validating national regulations In addition the company guarantees that e 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 e 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 requested The partially completed machinery must not be introduced to use before the final equipment to which it is intended to be attached has been declared to conform to the requirements of this Directive Place Kauhava Finland Date and Signature KHO 288 EN 1 3 0 37 alamarinzet After sales questionnaire Operation and maintenance manual Appendix 2 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 to give us that feedback You either fill out the printed form or the electronic f
26. ntlati n iarere ino as E vets E Ea E E E E T KET Ra EE a Ea 33 59s Clogged Jet ves cecscessecsicsawesaecee iris siewi aens VEEE EAA sven saveaueien ae vet sed EEE 33 Appendix 1 Declaration of incorporation for partially completed machinery esidecvecessde she Sede dessa esd edews sive cd band vad EE cee geden deel Suan eed a E t 37 Appendix 2 After sales questionnaire ssessssserserssesserserssesseseessesserserese 38 Appendix 3 Grease recommendations cccccecccseccesceesecscceeceueceeesceaeeeaees 41 Appendix 4 Oil recommendations s ssseseessesssesersssssersessesseeseresessersersseseese 42 Appendix 5 Tightening torques s ssessessssssrssessssssrserssrssrrsrssesserserssessersess 43 KHO 288 EN 1 3 0 ili Introduction alamarinzjet Operation and maintenance manual 1 Introduction Congratulations on puchasing a new Alamarin Jet Jet 288 water jet propulsion unit This manual contains important information on the operation use and maintenance of the unit Read these instructions carefully before implementing the unit This way the unit is safe to operate Keep this manual throughout the product s life cycle If you lose the instructions contact your nearest distributor for a new one If you sell the unit make sure to deliver this manual to the new owner Contact your nearest distributor if you have any queries regarding the operation or maintenance of the unit Alamarin Jet Oy
27. of the water Boats equipped with a gearbox In boats equipped with a gearbox cleaning the jet is easy because in reverse gear a back flow is created in the intake duct Cleaning the jet 1 Put the gear in reverse 2 Use some acceleration to detach the blockage The jet is designed to run in reverse only for one minute at a time and at under 2 000 rpm This is usually enough to clear the blockage Too heavy a load in reverse gear can lead to jamming of the impeller or breaking down of hydraulics Boats without gearbox st If the boat has no gearbox cleaning the jet may require several phases Cleaning the jet 1 Stop the engine This usually helps drop any extraneous objects from the grass rake 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 ahead raise the speed of the boat as high 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 all kinds of blockages 34 KHO 288 EN 1 3 0 Problem situations Operation and maintenance manual alamarinzjet Difficult blockages f If the aforementioned measures do not
28. orm on the CD Only answer questions to which you know the answer If possible include pictures in your feedback Return addresses Returning the printed version By mail Alamarin Jet Oy Tuomisentie 16 FI 62300 Harma FINLAND Europe By fax 358 10 7745 269 Returning the electronic version By e mail to the address sales alamarinjet com 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 38 KHO 288 EN 1 3 0 After sales questionnaire alamarinjet Operation and maintenance manual 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 experiences of retailer s manufacturer s services Spare parts services Other comments KHO 288 EN 1 3 0 39 alamarinzet After sales questionnaire Operation and maintenance manual Test information for Alamarin Jet Oy Date of testing Table 4 Testing report direction 1 Test weight of Number of Wind speed m s Water boat persons temperature Jet serial number Engine and GPS clock Signature gearbox Engine speed Speed in Sp
29. ottle and the gearbox The stroke length of the cylinder is always the same e The incoming direction of the cable can be chosen freely The oil circulating in the system must be cooled down in order to prevent excessive heating This is done with a separate heat exchanger or a cooler in the engine WARRANTY 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 If the valve regulator is removed the cylinder must be readjusted The adjustment instructions can be found in the Repair manual Figure 24 shows a system in which the cooling water comes from the jet Chapter 4 7 Raw water cooling page 22 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 20 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual Figure 24 Cooling system Cylinder Oil pump Oil reservoir Raw water filter Cooler Line to the engine cooler TmHoeaw py The system must have the right amount of oil If you need to add oil to the system add it in the oil reservoir through the cap Figure 25 point C There is a dipstick on the reservoir cap with markings fo
30. r maximum and minimum oil levels Figure 25 KHO 288 EN 1 3 0 21 Maintenance alamarinjet Operation and maintenance manual C o Figure 25 Checking the oil level A Maximum level B Minimum level C Cap Note that you must change the oil once every driving season section 4 3 1 Lubricating the front bearing page 15 The type of oil used is described in appendix 4 Oil recommendations page 42 You can also change the filter through the oil reservoir cap You must change the filter every 500 hours 4 7 Raw water cooling The jet comes complete with the possibility to connect the engine cooling water Figure 26 The engine does not need a separate water pump In case 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 such as during cleaning of the filter or other maintenance The raw water line requires no other separate maintenance procedures 22 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual ny i Figure 26 Raw water cooling A Raw water connector B Tap C Filter D Input for the engine 4 8 Impeller Depending on driving conditions the impeller will wear down causing a gap to develop between the duct wall and the tip of the impeller blade The gap should be as small as possible to achieve maximum efficie
31. remove the blockage you can locate the blockage through the jet s inspection hatch and remove it manually Removing the blockage through the inspection hatch 1 Open the inspection hatch Figure 38 Figure 38 Inspection hatch 2 Locate the blockage and remove it manually 3 Close the inspection hatch 4 Tighten the inspection hatch screw by hand A Do not open the inspection hatch when the motor is running There is a rotating shaft behind the hatch Tg TIP Bw Keep a long tube in the boat for removing stones or other objects wedged between the grass rake KHO 288 EN 1 3 0 35 gt Problem situations alamarinjet Operation and maintenance manual 36 KHO 288 EN 1 3 0 Declaration of incorporation for partially completed machinery alamarinjet Operation and maintenance manual Appendix 1 Declaration of incorporation for partially completed machinery Machinery Directive 2006 42 EC Annex II 1 B Manufacturer Alamarin Jet Oy Tuomisentie 16 FI 62300 Harma Finland Compiler of the technical file Hannu Rantala Technical Manager Alamarin Jet Oy Tuomisentie 16 FI 62300 Harma Finland Description of the partially completed Water jet propulsion device machinery Operation of the partially completed The device is intended to be used as machinery the propulsion device of a motor boat A propulsion device transforms the torque of the motor into propulsive force Model a
32. rom the dipstick on the reservoir cap Figure 25 point B When the shaft starts to rotate the system generates pressure into the return line causing oil to start circulating in the system 4 3 2 Lubrication of the rear end bearing f The rear end bearing is lubricated from the engine room with petroleum jelly The lubrication channel runs from the engine room to the rear end bearing housing An automatic lubrication unit is delivered with the propulsion unit to make sure the rear end bearing is lubricated regularly It also prevents water from leaking into the bearing housing 16 KHO 288 EN 1 3 0 Maintenance alamarinzjet Operation and maintenance manual Figure 16 Automatic lubrication unit A Oil pressure hose from the D Grease nipple for refill hydraulic cylinder B Adjusting the feed volume E Grease hose to the lubrication channel C Scale F Piston Feeding You can adjust the feed as follows If the automatic lubrication unit is feeding too much grease the reservoir gets empty too soon decrease the pressure by loosening the adjusting screw Figure 17 point C e If the automatic lubrication unit is not feeding grease to the rear bearing cold conditions thick grease type increase the pressure by tightening the adjusting screw Figure 17 point C Figure 17 Lubricating the Rear Bearing The amount of grease fed to the rear bearing must be 0 1 1 100 h 6 cu in 100 h The grease volume i
33. t hinders the flow of water in the jet increases the chance of cavitation Usually the cause is the reduction of pressure in the whole intake duct caused by a blockage If cavitation is apparent or the boat runs slowly even though the engine runs on high revolutions find out the cause Checking the causes for cavitation 1 Open the inspection hatch Figure 34 Figure 34 Opened inspection hatch 2 Check the grass rake Figure 35 Make sure that grass reed plastic stone or other extraneous object is not clogging the grass rake Remove possible blockages KHO 288 EN 1 3 0 31 alamarinzjet Problem situations Operation and maintenance manual Figure 35 Checking the grass rake for blockages 3 Check the stator or nozzle unit Figure 36 Make sure there are no extraneous objects such as rope reed entagled in the drive shaft stones in the outlet port Remove possible blockages Figure 36 Checking the stator for blockages 4 Check the impeller Figure 37 Make sure there are no extraneous objects and that it is not damaged The impeller should be smooth with no sharp cuts Remove possible extraneous objects and fix the impeller if it is damaged section 4 8 Impeller page 23 32 KHO 288 EN 1 3 0 Problem situations Operation and maintenance manual alamarinjet Figure 37 Smooth impeller 5 Close the inspection hatch 6 Tighten the inspection hatch wing screw by hand 5 2 Ventilat
34. the intermediate shaft Regardless of the manufacturer the alignment of the intermediate shaft must be kept accurate The alignment must be checked at least once every driving season year 28 KHO 288 EN 1 3 0 Maintenance Operation and maintenance manual alamarinzjet The intermediate shaft must absolutely be of high enough quality and properly balanced An intermediate shaft that has been installed or balanced incorrectly can cause excessive damage to the propulsion unit WARRANTY J If an intermediate shaft that has been installed or balanced incorrectly causes damage this will not be covered by the warranty KHO 288 EN 1 3 0 29 Maintenance alamarinjet Operation and maintenance manual 30 KHO 288 EN 1 3 0 Problem situations alamarinzjet Operation and maintenance manual 5 Problem situations 5 1 Cavitation f The most common malfunction in water jet propulsion units manifests as cavitation 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 Signs of cavitation are engine overdrive and stopping of thrust and it can often be heard as a thundering sound Cavitation incurs considerable reduction in capacity and damages the impeller Any factor tha
35. tion of the gearbox even though the drive is on the boat does not move The centre position is not absolute it depends on the power of the jet flow You can find the centre position by testing during the first driving hours 3 3 2 Using the reversing deflector When moving at low speeds the reversing deflector is used to control the boat s speed Because the engine is being run at 1 000 1 500 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 This does not affect the steerability which remains good At high speeds the deflector is not used to reduce speed Instead speed is controlled with engine revolutions It is 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 reverse the boat to the left you must turn the wheel to the right A good rule to remember is that the boat s bow always turns in the same direction as the wheel when reversing When fast turns are needed the engine revolutions are not reduced but instead the turn is done through combined motion of the nozzle and the deflector Emergency stop When the boat is run forwards at great speed it is possible to stop the boat by only us
36. x min 170 Density 15 C 59 F 0 835 0 890 g cm 0 030 0 032 lb sq in Pour point max 42 C 43 6 F Flashpoint min 180 C 356 F Recommended oil brands e Mobil ATF 320 e FormulaShell ATF DEXRON III e Neste ATF X e BP Autran DX III 42 KHO 288 EN 1 3 0 Tightening torques Operation and maintenance manual alamarinzjet Appendix 5 Tightening torques Use the tightening torques from the table 5 when tightening the propulsion unit screws The strength grade of an acid proof A4 80 screw is equivalent to a class 8 8 screw Table 5 Tightening torques of the screws Strength grade 8 8 10 9 12 9 Thread Tightening torque Nm M5 5 5 4 8 1 6 9 5 7 M6 9 6 7 14 10 16 12 M8 23 17 34 25 40 30 M10 46 34 67 49 79 58 M12 79 58 115 85 135 100 M16 145 107 215 159 250 184 The tightening torque in pound feet approximate value is marked in the table in parentheses after the corresponding value in Nm A suitable thread locking compound that is good for all purposes is one of medium strength for example Loctite 242 or similar KHO 288 EN 1 3 0 43 gt gt Tightening torques alamarinjet Operation and maintenance manual 44 KHO 288 EN 1 3 0
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