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Alamarin Jet AJ 285 Installation Manual

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Summary of Contents for Alamarin Jet AJ 285

  • Page 1 Installation Manual...

  • Page 3: Table Of Contents

    Appendix 2. Oil recommendations ..............52 Appendix 3. Tightening torques ..............53 Appendix 4. Control system hydraulic line ............ 54 Appendix 5. Movement range of the hydraulic cylinder control lever ... 57 Appendix 6. Fastening screws AJ 285 ............58 AM/285/EN/1.0.0...

  • Page 5: Introduction

    Introduction Installation Manual 1. Introduction This is the installation manual for Alamarin-Jet's AJ 285 water jet propulsion unit. This manual is intended for mechanics who install the Alamarin-Jet water jet propulsion unit to a suitable boat. © Alamarin-Jet Oy Tuomisentie 16 FI-62300 Härmä, Finland...
  • Page 6 Introduction Installation Manual Icon Description WARRANTY The warranty is voided if the procedure is carried out incorrectly. NOTE Important notice or fact. Additional information that facilitates the performance of work or a procedure. CARRIED OUT BY ONE PERSON One person can carry out the procedure. CARRIED OUT BY TWO PERSONS Two persons must carry out the procedure.

  • Page 7: General Description Of Installation

    General description of installation Installation Manual 2. General description of installation Alamarin-Jet water jet propulsion units can be installed on a reinforced plastic, aluminium, steel, polyethylene, or wooden boat. Perform the installation in the following order: 1. Attach the mounting template to the boat's hull (section 3. Installation , page 5).
  • Page 8 General description of installation Installation Manual AM/285/EN/1.0.0...

  • Page 9: Installation Methods

    Installation Methods Installation Manual 3. Installation Methods The Alamarin-Jet water jet propulsion unit is installed on the boat using a mounting template. Several mounting templates are available, depending on the installation methods and materials used. For combi-frames, there are two primary installation methods available: a) ”short tail”, which minimises the installation length outside the stern b) ”long tail”, which minimises the installation length inside the stern Both methods have their advantages, and it is up to the boat designer to...
  • Page 10 Installation Methods Installation Manual Figure 2. Long tail installation The mounting template can be installed into a hole at the bottom and the stern of the boat, or the shape of the mounting template can be added to the boat's template (GRP boats). The correct positioning of the mounting template is crucial since it determines the position of the jet.

  • Page 11: Repowering Installation

    Installation Methods Installation Manual Figure 4. Aluminium mounting templates 3.1. Repowering installation The repowering installation method is used in the propulsion system's modification installation. In addition, it is an appropriate installation method for prototype or one-off boats. In aluminium boats, the propulsion unit is always installed using the repowering principle.
  • Page 12 Installation Methods Installation Manual Hull and stern laminate must be dry and clean before work can be commenced. Cutting and attaching the mounting template: 1. Make a hole at the bottom and the stern of the boat for the mounting template.
  • Page 13 Installation Methods Installation Manual V-bottom adaptor plate Figure 8. V-bottom adaptor plate 3. Chamfer the edges of the hole on the bottom and stern of the boat. The chamfered part must be 150 mm wide and the hole edge thickness must be 3 mm. If the boat's hull is made of sandwich laminate, first remove 100 mm of core material round the hole and then chamfer the core material as well as about 100 mm of the exterior surface.
  • Page 14 Installation Methods Installation Manual Figure 9. Cross-section of the mounting template Figure 10. Mounting template alignment A  The edge of the mounting template parallel to the keel 5. Close the seam with tape from the outside. 6. Run gelcoat paint onto the seam from above until it is filled. 7.
  • Page 15 Installation Methods Installation Manual Figure 11. Laminating A  Boat hull laminate B  Attachment laminate C  Mounting template laminate D  Seam E  Original gelcoat F  Seam-filling gelcoat 9. Fit engine supports and possible bracings. 10. Cut off the excess collar on the mounting template outside the stern (figure 12).

  • Page 16: Aluminium Mounting Template

    Installation Methods Installation Manual 11. Smooth the seams and paint the visible reinforced plastic surfaces with topcoat paint. This is important because an uncovered laminate absorbs water. 3.1.2. Aluminium mounting template 1. Cut a hole of appropriate size in the bottom and the stern of the boat. In a long tail installation, the collar of the mounting template covers the inner surface of the stern and the excess material must be cut after installation (figure 13).

  • Page 17: Removable Mounting Template Mould

    Installation Methods Installation Manual If you want to produce one type of boat with several varying propulsion unit options, it is possible to make a mould of the mounting template and fit it to the standard hull mould (figure 14). This speeds up installation of the propulsion unit without adding to mould expenses.

  • Page 18: Fixed Mounting Template

    Installation Methods Installation Manual Figure 15. Cutting the collar (twin installation) The edges of the mounting template must be smoothed so that the end product shows no big notches. Reinforce the mounting template negative with a wooden frame, plywood plate or, for example, urethane foam. This way the collar will not bend inwards during laminating.
  • Page 19 Installation Methods Installation Manual Twin installation 1. Make two negatives of the mounting template. 2. Fit and install the mounting templates on the boat's mould (section 3.2.1. , page 13). Removable mounting template mould 3. Laminate the rear end of the boat in the mould and remove it. 4.
  • Page 20 Installation Methods Installation Manual AM/285/EN/1.0.0...

  • Page 21: Attaching The Propulsion Unit

    Attaching the propulsion unit Installation Manual 4. Attaching the propulsion unit The propulsion unit is attached to the boat one part at a time. Attachment is carried out in the following order: 1. Propulsion unit body 2. Lubrication system for the bearings 3.

  • Page 22: Attaching The Body

    Attaching the propulsion unit Installation Manual Figure 16. Drilling template Before installation, make sure that 1. The installation surface is straight and clean. 2. The holes are drilled/sawn correctly. 3. Stern laminate does not get in the way of the propulsion unit and its auxiliaries, which means that the laminate is not too thick.
  • Page 23 The fastening screws specific to each installation and their placement are detailed in appendix 6. , page 58. Fastening screws AJ 285 Please note that the threads of the mounting holes on the body of the jet are only meant to make installation easier and that the screws must always be secured from the other side using a nut, as shown in figure 18.
  • Page 24 Attaching the propulsion unit Installation Manual Figure 18. Fastening screw Mounting template Jet body Fastening screw Some of the screws are already attached during jet manufacture. Ask your assistant in the boat to fasten the nuts. 4. Tighten the nuts evenly on opposite sides and make sure that sealing compound squeezes out slightly on every side.
  • Page 25 Attaching the propulsion unit Installation Manual Figure 19. Sealing the bottom plate WARNING! If the seam between the bottom plate and the mounting template is not appropriately sealed, ventilation may occur. This will have an adverse effect on the performance of the propulsion unit. 7.

  • Page 26: Installing The Lubrication System For The Bearing

    Attaching the propulsion unit Installation Manual 4.3. Installing the lubrication system for the bearing 4.3.1. Front bearing The front bearing carries the axial and radial loads. The bearing is oil- lubricated and the housing is secured with 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 21, point D).

  • Page 27: Rear Bearing

    Attaching the propulsion unit Installation Manual 2. Remove the plug from the bearing housing IN connector, push the hose coming from the reservoir into place, and tighten the joint using pipe straps. 3. Pour oil into the reservoir and let the hose fill up for approx. 5 minutes. The type of oil to use is described in appendix 2.
  • Page 28 Attaching the propulsion unit Installation Manual it also prevents water from leaking into the bearing housing. The amount of grease is adjusted with a screw in the hydraulic cylinder, which tightens the spring (figure 24). When you loosen the screw, the amount of grease decreases.
  • Page 29 Attaching the propulsion unit Installation Manual Note the lengths of the oil pressure hose and the grease hose. The oil pressure hose (figure 25, point B) must not be tight. Also make sure that the piston (figure 25, point A) can move freely, as it protrudes the length of the scale when the reservoir fills up.
  • Page 30 Attaching the propulsion unit Installation Manual 5. Screw the oil pressure hose into place (figure 27). Please note that the cylinder must be rotated slightly before the pressure hose can be attached. However, if you want to retain the position of the cable clamp, rotate the plate in accordance with the instructions in section 5.1.

  • Page 31: Attaching The Hydraulic Cylinders

    Installation Manual 4.4. Attaching the hydraulic cylinders The AJ 285 has two hydraulic cylinders, one for the reversing deflector and one for the steering nozzle. Both cylinders are installed the same way. 1. Make sure that the cylinders are attached without the sealing compound.
  • Page 32 Attaching the propulsion unit Installation Manual Figure 29. Dimensions of the hydraulic cylinders 6. Check that the reversing deflector and the steering nozzle move correctly. The steering nozzle should move the same distance in both ways. For the reversing deflector, the determining limit is the deflector's bottom position.

  • Page 33: Filling The Hydraulic Cylinder Installation Holes With Grease

    Attaching the propulsion unit Installation Manual 4.4.1. Filling the hydraulic cylinder installation holes with grease Before the propulsion unit is put into use, the hydraulic cylinder installation holes of the assembled unit should be filled with grease. This procedure prevents corrosion if the rear seal leaks and is not replaced. Remove the plugs located on the side of the propulsion unit's body (2 pcs) and screw a grease nipple into the hole closer to the bow (figure 31, point A).

  • Page 34: Attaching The Hydraulic Pump

    Attaching the propulsion unit Installation Manual 4.5. Attaching the hydraulic pump Attaching the hydraulic pump: 1. Install the pump rack and the pump with screws to the front surface of the bearing housing. Leave the screws slightly loose. There are a total of four screws, two on both sides (figure 33, points A and Figure 33. Attaching the hydraulic pump Hydraulic pump rack fastening screw, lower (2 pcs) Hydraulic pump rack fastening screw, upper (2 pcs)
  • Page 35 Attaching the propulsion unit Installation Manual 7. Install the oil reservoir and its rack to a suitable place above the pump. Figure 34. Oil reservoir and rack In figure 34, the 16 mm (5/8'') connector (A) is intended for the hose that goes to the pump and the 12 mm (1/2'') connector (B) for the return hose.

  • Page 36: Oil Cooling

    Attaching the propulsion unit Installation Manual Maximum level Minimum level Amount of oil in the hydraulic system and the front bearing Hydraulics: 1.3–1.7 L Front bearing: 0.9–1.2 L 4.6. Oil cooling The oil circulating in the system must be cooled down in order to prevent excessive heating.

  • Page 37: Attaching The Grass Rake

    Attaching the propulsion unit Installation Manual 4.7. Attaching the grass rake The grass rake (figure 37) is attached in front of the intake opening with four screws. Figure 37. Grass rake Attaching the grass rake: 1. Seal the fixing area in the same manner as when installing the propulsion unit body.
  • Page 38 Attaching the propulsion unit Installation Manual Figure 38. Raw water intake The intake has a G3/4" external thread (3/4" BSP). The line to the engine can be constructed using normal pipe parts or can be plugged into the engine using the plugs delivered with the propulsion unit. The raw water intake can also be used for other purposes that require pressure water.

  • Page 39: Installing The Inspection Hatch Elevation Collar

    Attaching the propulsion unit Installation Manual Figure 39. Raw water cooling Raw water connector Filter Input for the engine Note the following when installing the raw water cooling line: • There must be a shut-off valve at the beginning of the line so that the line can be cut off when the boat is in water.
  • Page 40 Attaching the propulsion unit Installation Manual Figure 40. Inspection hatch elevation collar The elevation collar is an accessory that is available to order when required. The collar is installed using four M6 screws (figure 41), and the coupling is sealed using a sealing compound. Figure 41. Installing the elevation collar.

  • Page 41: Installing The Control System

    Installing the control system Installation Manual 5. Installing the control system The propulsion unit's control system must be installed correctly. Incorrect installation of the system will reduce performance. Because the propulsion unit can be used with or without gears, there are various methods of installation.
  • Page 42 Installing the control system Installation Manual Figure 42. Hydraulic cylinder Changing the position of the cable support: 1. If the control cable is attached, detach the end of the cable (figure 42, point C) from the cylinder's operating lever and detach the cable fastener from the support plate (figure 42, point D).
  • Page 43 Installing the control system Installation Manual Figure 44. Support plate fastening screws 4. Turn the support plate into the desired position and attach it with screws to the valve housing (tightening torque: 10 Nm (7 lb ft)). Check that the support plate or control cable do not interfere with the rotating intermediate shaft, for example.

  • Page 44: Connecting The Control Cables

    Installing the control system Installation Manual 5. Place the lever (figure 46, point A) on the operating shaft so that it lies between the limiters on the support plate (figure 46, point B). The tightening torque of the lever screw is a non-standard 10 Nm (7 lb ft). Figure 46. Attaching the operating lever Lever Limiters...
  • Page 45 Installing the control system Installation Manual Figure 47. Idle running Accelerator Reversing deflector Steering cylinder's operating lever   Full astern The control lever is down, the cylinder operating lever on the left (figure 48) Figure 48. Full astern Full ahead The control lever is up, the cylinder operating lever on the right (figure 49) Figure 49. Full ahead AM/285/EN/1.0.0...

  • Page 46: Cylinder Adjustment

    Installing the control system Installation Manual 5.1.2. Cylinder adjustment When you start the engine for the first time, make sure that you have oil available to add to the reversing deflector control hydraulic system. Fill the reservoir with oil before you start the engine. After you start the engine and put it into forward gear, the oil is transferred from the reservoir into the system and the pump automatically removes air from the system.
  • Page 47 Installing the control system Installation Manual Figure 51. Operating shaft and limiter 4. Turn on the engine and put it into gear. 5. Using a wrench, turn the operating shaft (figure 51, point B) 13 mm (0.4") clockwise so that the reversing deflector is down, blocking the jet flow. If you turn the shaft too much, it will no longer move smoothly, indicating that the cylinder has reached the end of its movement range.

  • Page 48: Connecting The Steering Nozzle To The Control System

    Installing the control system Installation Manual Figure 52. Deflector in the up position Figure 53. Deflector in the down position 5.2. Connecting the steering nozzle to the control system The jet features a compact integrated hydraulic cylinder for steering. The cylinder is easy to use and enables comfortable steering. The cylinder is compatible with most steering pumps available on the market.
  • Page 49 Installing the control system Installation Manual Figure 54. Steering nozzle hydraulic cylinder Figure 55. Hydraulic cylinder parts Bleeding connections Connector for an emergency steering system Installation: 1. Make sure that the cylinder is installed in accordance with instructions (4.4. , page 27) and that the steering nozzle Attaching the hydraulic cylinders moves the same distance in both directions.
  • Page 50 Installing the control system Installation Manual AM/285/EN/1.0.0...

  • Page 51: Engine Installation

    Otherwise, engine installation must always be carried out in accordance with the engine manufacturer's instructions. The AJ 285 propulsion unit can be used with various engines, either with gears or with a direct connection to the flywheel adapter. The gear is selected in accordance with the engine power and speed.
  • Page 52 Engine installation Installation Manual Figure 57. Cardan shaft Intermediate shaft with rubber stop Shafts with rubber stops effectively prevent vibrations that travel along the shaft to the hull of the boat. This is why they are particularly popular in boats with a metal structure. Figure 58 , there is a rubber joint at one end and a constant speed joint at the other.

  • Page 53: Antifouling

    Antifouling Installation Manual 7. Antifouling 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.
  • Page 54 Antifouling Installation Manual WARNING! Anodes and their fastening screws must not be painted with antifouling paint. AM/285/EN/1.0.0...

  • Page 55: Appendix 1. Grease Recommendations

    Grease recommendations Installation Manual Appendix 1. Grease recommendations The grease used for lubricating the propulsion unit bearing must meet the following requirements: • lithium soap and a thickener with EP additives • mineral oil as a base oil • NLGI class 2 •...

  • Page 56: Appendix 2. Oil Recommendations

    Oil recommendations Installation Manual Appendix 2. Oil recommendations The operating hydraulic system of the reversing deflector and the lubrication of the front bearing are designed to use oil that is specifically intended for automatic transmission systems. The oil must meet the following requirements: Kinematic viscosity 40℃...

  • Page 57: Appendix 3. Tightening Torques

    Tightening torques Installation Manual Appendix 3. Tightening torques Use the tightening torques from the table 2 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 2. Tightening torques of the screws  ...

  • Page 58: Appendix 4. Control System Hydraulic Line

    Control system hydraulic line Installation Manual Appendix 4. Control system hydraulic line Single installation with an automatic lubrication unit Green Low-pressure hose High-pressure hose Blue Grease hose Oil pump Reversing deflector cylinder Oil reservoir Automatic lubrication unit Bearing housing Bearing housing oil reservoir Single installation without an automatic lubrication unit Green Low-pressure hose...
  • Page 59 Control system hydraulic line Installation Manual Oil pump Reversing deflector cylinder Oil reservoir Bearing housing Bearing housing oil reservoir Twin installation with automatic lubrication units In a twin installation that includes automatic lubrication units, the hydraulic connections of both jets are made in the same way as in a single installation that includes an automatic lubrication unit.
  • Page 60 Control system hydraulic line Installation Manual Yellow Hose to the steering pump Steering cylinder Available steering nozzle control accessories are listed below Code Applicability H2-018B and H2-018C Steering kit, single installation H2-018E Steering kit, twin installation H2-018F Synchronisation valve H2-041 Steering kit with power steering, single installation H2-041C Steering kit with power steering, twin installation...

  • Page 61: Appendix 5. Movement Range Of The Hydraulic Cylinder Control Lever

    Movement range of the hydraulic cylinder control lever Installation Manual Appendix 5. Movement range of the hydraulic cylinder control lever The length of a full stroke at point A is approx. 64 mm (2.5"). The length of a full stroke at point B is approx. 46 mm (1.8"). AM/285/EN/1.0.0...

  • Page 62: Appendix 6. Fastening Screws Aj 285

    Fastening screws AJ 285 Installation Manual Appendix 6. Fastening screws AJ 285 Table 3. Fastening screws, aluminium, short tail Aluminium Short tail R9909 Component Quantity Position M8x20 screw A, B M8x35 screw C, D M8 body spacer A, B, C, D M8 locking nut...
  • Page 63 Fastening screws AJ 285 Installation Manual M8 body spacer B, C, E M8 locking nut M8 spacer Plastic screw A, D M8 grease nipple Table 5. Fastening screws, GRP, short tail R9911 Short tail Component Quantity Position M8x30 screw A, B...
  • Page 64 Fastening screws AJ 285 Installation Manual AM/285/EN/1.0.0...

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