Alamarin Jet AJ 340 Operation And Maintenance Manual Download

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Introduction

Operation and maintenance manual

KHO/340/EN/1.0.0.

1. Introduction

Congratulations on purchasing your new Alamarin-Jet AJ 340 water jet

propulsion unit!
This manual contains important information on the operation, use and

maintenance of the unit. Please read these instructions carefully before using

the unit. This way the unit will be safe to operate.
Please retain this manual throughout the product's life cycle. If you lose the

manual, contact your nearest distributor for a new one. If you sell the unit,

make sure to hand over this manual to the new owner.
Please contact your nearest distributor if you have any queries regarding the

operation or maintenance of the unit.
© Alamarin-Jet Oy
Tuomisentie 16

FI-62300 Härmä, 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 these instructions carefully before you operate a boat equipped with the

water jet propulsion unit or carry out any maintenance procedures. Please also

read the boat's manual.
Always follow the instructions and the safety precautions below.
• Only a person with adequate training is permitted to carry out the

demanding maintenance procedures described in this manual.

• The person carrying out the procedures must always wear the appropriate

protective equipment.

• The work premises must be sufficiently large, safe and well-lit.
• The tools that are to be used must be clean and appropriate for the intended

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

Negligence in the performance of a procedure can cause a threat

to your life.

Summary of Contents for AJ 340

Page 1: ...Operation and maintenance manual ...

Page 2: ......

Page 3: ... Changing the anodes 15 4 2 2 Touch up painting and antifouling 17 4 3 Bearing 18 4 3 1 Lubricating the front bearing 19 4 3 2 Lubrication of the rear end bearing 20 4 4 Control system 21 4 5 Seals 22 4 6 Hydraulic reversing deflector control system 23 4 7 Raw water cooling 26 4 8 Impeller 26 4 8 1 Checking the impeller 26 4 8 2 Removing the impeller 27 4 8 3 Installing the impeller 30 4 9 Interme...

Page 4: ......

Page 5: ...y 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 these instructions carefully before you operate a boat equipped with the water jet propulsion unit or carry out any maint...

Page 6: ...arried out incorrectly NOTE Important notice or fact 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 car...

Page 7: ...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 th...

Page 8: ...tion 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 next to the shaft housing figure 3 Figure 2 Serial number on ...

Page 9: ...The jet propulsion unit Operation and maintenance manual KHO 340 EN 1 0 0 5 Figure 3 Serial number on the body ...

Page 10: ...The jet propulsion unit Operation and maintenance manual 6 KHO 340 EN 1 0 0 ...

Page 11: ...ed 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 ...

Page 12: ...e front bearing page 19 NOTE An oil leak may pollute the environment Monitor the oil level and make sure that oil does not leak out 3 2 Steering WARRANTY In this section controlling the jet boat is described in a way that it is performed using a system that has been installed as intended by the manufacturer Alamarin Jet Oy is not liable for damages which derive from incorrect installation of the s...

Page 13: ...fety Turning the nozzle from one extreme position to the other takes between 1 and 3 revolutions of the steering wheel depending on the capacity of the steering pump used 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 th...

Page 14: ...The movement of the deflector between these three positions is stepless Forward position When the reversing deflector control lever is in the forward position the deflector is not blocking the jet flow and the boat moves forward figure 6 Figure 6 Ahead A Throttle lever B Control lever Rear position When the reversing deflector control lever is in the rear position the deflector is blocking the jet...

Page 15: ...pright position by tying it from the lifting loop to the stern of the boat 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 500 1 000 rpm to enhance steering the boat may travel faster than desired If this is the case the deflector can be lowered in front of the jet flow to reduce the thrust...

Page 16: ...out being prepared a passenger may be thrown overboard 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 grass rake and small objects may wash through the jet Stones may cause d...

Page 17: ...iled This is a significant benefit in comparison to water lubricated bearings which do not sustain dry running well The water lubricated model should not be run dry as this may permanently damage the propulsion unit s bearings During dry runs a temporary water inlet must be arranged for the motor sea water cycle to cool the engine ...

Page 18: ...Operation Operation and maintenance manual 14 KHO 340 EN 1 0 0 ...

Page 19: ...uals 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 The raw materials used for manufacturing the jet parts are ...

Page 20: ...eversing deflector 2 pcs C Stator outside 1 pc D Stator inside 1 pc E Frame inside 2 pcs 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 size Replacing the anodes Most of the anodes are attached with simple screws Below you will find instructions for changing the anodes that are attached differentl...

Page 21: ...1 point B Place the new anode so that the screw attached to the frame goes through the hole in the centre of the anode Lock the anode in place by tightening the nut over the centre screw During installation make sure that the curved surface of the anode is placed against the dome located on the frame and that the screw stays in place 4 2 2 Touch up painting and antifouling The aluminium castings h...

Page 22: ...n 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 12 ...

Page 23: ...ubricating the front bearing 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 14 point A Figure 14 Drain plug magnet and oil return hose A Drain plug magnet B Oil reservoir return hose connection Oil change ...

Page 24: ...mpurities in the oil such as metal particles the entire system must be drained and cleaned first In this case the bearings must also be replaced Only then should the new oil be poured into the system 4 Remove the reservoir return hose figure 14 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...

Page 25: ... is lubricated with petroleum jelly through a grease nipple The lubrication channel runs from the grease nipple to the rear bearing housing The properties of the grease to use are described in appendix 2 Grease recommendations page 42 4 4 Control system The joints and shaft bushings that belong to the control systems are essentially maintenance free but lubrication prolongs their operating life Lo...

Page 26: ...eds to be checked is the inspection hatch seal figure 17 Figure 17 Inspection hatch seal A leaking inspection hatch seal causes ventilation or water leakage see section 5 2 Ventilation page 37 The inspection hatch must be equipped with an elevation collar if the surface of the hatch is below the waterline See the Installation Manual ...

Page 27: ...mp which has been integrated in the propulsion unit Figure 18 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 throttle and the gearbox The stroke length of the cyli...

Page 28: ...If you need to add oil to the system add it in the oil reservoir through the cap Figure 20 point C There is a dipstick on the reservoir cap with markings for maximum and minimum oil levels figure 20 points A and B The cooling system is located inside the engine room Figure 20 Checking the oil level A Maximum level B Minimum level C Cap ...

Page 29: ...r every 500 operating hours 1 Open the six cover screws figure 21 Figure 21 Oil reservoir cover screws The filter is located under the cover and has a spring on top of it that keeps the filter in place figure 22 Figure 22 Oil filter spring 2 Remove and replace the spring and the filter It is not necessary to replace the spring unless it is damaged 3 Put the cover back into place Make sure that the...

Page 30: ...d space and its position can be adjusted in the direction of the shaft in accordance with the blade wear 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 4 8 1 Checking the imp...

Page 31: ...8 2 Removing the impeller page 27 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 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 24 WARNING Make sure that the reve...

Page 32: ...25 Stator fastening screws The stator is attached to the frame with 12 screws all located on the same ring The figure only shows the screws located on the port side of the frame On the starboard side the screws are in reverse order 3 Remove the stator reversing deflector and steering nozzle as a complete unit figure 26 ...

Page 33: ...ure 26 Removing the stator reversing deflector and steering nozzle 4 Unscrew the screw located at the end of the shaft figure 27 point A and pull out the spacer figure 27 point B and the shaft sleeve figure 27 point C Figure 27 Removing the shaft sleeve A Screw B Spacer ...

Page 34: ...A Extraction tool B Screw 4 Once the impeller starts moving it can be pulled out the rest of the way by hand 4 8 3 Installing the impeller New and repaired impellers are fitted in the same way The thrust caused by the impeller is transmitted to the shaft through a spacer Before installing the impeller make sure that the spacer plate figure 29 point B and the spacers figure 29 point A are in place ...

Page 35: ...ers B Spacer plate Installing the impeller 1 Place the wedge figure 30 point A in the wedge groove on the shaft figure 30 point B and push the impeller figure 30 point C on to the shaft When installing the impeller make sure that the position of the impeller s wedge groove corresponds with the position of the shaft wedge ...

Page 36: ...he oil pump belt If the gap between the impeller and the upper wall is too small add more spacers on to the shaft until the correct gap 0 8 1 4 mm is reached Correspondingly if the gap is too wide reduce it by removing spacers CAUTION If the gap is too big it will cause loss of power and reduce performance 3 Install the shaft sleeve the spacer and the screw in place in reverse to that when removin...

Page 37: ...nufacturer the alignment of the intermediate shaft must be kept accurate The alignment must be checked at least once every driving season year WARNING 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 If an intermediate shaft that has...

Page 38: ...Maintenance Operation and maintenance manual 34 KHO 340 EN 1 0 0 ...

Page 39: ... stopping of thrust and it can often be heard as a thundering sound Cavitation reduces performance considerably and damages the impeller Any factor that 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 h...

Page 40: ...in the drive shaft stones in the outlet port Remove any possible blockages Figure 33 Checking the stator for blockages 4 Check the impeller 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 26 5 Close the inspection hatch 6 Tighten t...

Page 41: ...ult 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 ver...

Page 42: ...w times This often sucks the extraneous objects through the jet and cleans it 3 If the 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 in reverse as fast as possible As the boat moves astern shut down the engine and move the deflector control lever to the forward position Thi...

Page 43: ...e and remove it manually 3 Close the inspection hatch 4 Tighten the inspection hatch nuts 4 pcs using a wrench WARNING Do not open the inspection hatch when the engine is running There is a rotating shaft behind the hatch TIP Keep a long tube in the boat for removing stones or other objects wedged between the grass rake ...

Page 44: ...Problem situations Operation and maintenance manual 40 KHO 340 EN 1 0 0 ...

Page 45: ...eted 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 the specific technical documents related to the partially completed machinery have been created according to section B of Ann...

Page 46: ...ium soap and a thickener with EP additives mineral oil as a base oil NLGI class 2 operating temperature range 25 to 130 C 13 266 F continuous operating temperature min 75 C 167 F Recommended grease brands Würth 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 fo...

Page 47: ...ing are designed to use oil that is specifically intended for automatic transmission systems The oil must meet the following requirements Kinematic viscosity 40 33 36 mm 2 s Kinematic viscosity 100 C 7 1 7 7 mm 2 s Viscosity index min 170 Density 15 C 0 835 0 890 g cm 3 Pour point max 42 Flashpoint min 180 Recommended oil brands Mobil ATF 320 FormulaShell ATF DEXRON III Neste ATF X BP Autran DX II...

Page 48: ...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 g...

Page 49: ...endix 5 Test report It is recommended that a speed test report is filled out when the boat is commissioned The performance of the boat can later be compared to this report for the purpose of finding potential faults The report template can be found on the following page ...

Page 50: ... Jet type Number of units Impeller type Nozzle size Engine type Rated power kW crankshaft rpm Transmission type Reduction ratio Load condition total weight including all Test 1 kg LCG m Test 2 kg LCG m Test 1 RPM Speed 1 Speed 2 Average 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 Test 2 RPM Speed 1 Speed 2 Average 1000 1200 1400 1600 1800 2000 220...

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