Alamarin Jet Jet-160 Repair Manual
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Alamarin Jet Jet-160 Repair Manual

Water jet propulsion unit
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Summary of Contents for Alamarin Jet Jet-160

  • Page 2 ”jet”. This term refers exclusively to a propulsion unit manufactured by Ala- marin-Jet Oy. The instruction covers the following jet propulsion models: Jet-160 Jet-180 Jet-185 If the given information is type specific, this will be expressed in the text. Clarifying figures will be used in this manual.
  • Page 3 1.4. Coupling Flanges ..................7 2. Bearing and Main Shaft ................... 8 2.1. Front Bearing ................... 8 ... 2.1.1. Disassembly ..................8 2.1.1.1. Jet-160 ..................8 2.1.1.2. Jet-180/185 ................11 ... 2.1.2. Assembly and Installation ............... 13 2.1.2.1. Jet-160 ..................13 2.1.2.2.
  • Page 4 Repair Manual 1 6.2. Repair ......................27 6.3. Installation ....................27 7. Electronic Reversing Deflector Control.............. 27 7.1. Installation Instructions ................28 7.2. Adjustment Instructions ................29 APPENDIXES Appendix 1. Recommended Greases and Tightening Torgues ......30 Appendix 2. Impeller Dimensions ................31 Appendix 3.
  • Page 5 Repair Manual 1 Drive Shafts and Coupling Flanges Between the jet and the engine there is always an intermediate shaft which transmits the power from the engine to the jet propulsion unit’s main shaft. There are various types of shafts. Normally, the shaft has been chosen and installed by the boat’s manufacturer. 1.1.

  • Page 6: Cardan Shaft

    Repair Manual 1 1.1.2. Rubber Joint The rubber joint is an elastic rubber element on the intermediate shaft between the en- gine and the jet. The rubber element dampens the vibrations and sudden torsional loads that are transmitted from the engine to the boat’s hull, and allows some angle deviation. An intermediate shaft equipped with rubber joints is installed similarly to a constant velocity shaft.
  • Page 7 Repair Manual 1 IF AN INTERMEDIATE SHAFT THAT HAS BEEN INSTALLED OR BALANCED INCORRECTLY CAUSES DAMAGE, THE GUA- RANTEE IS NOT VALID! WARRANTY 1.4. Coupling Flanges Different kind of coupling flanges are installed to the jet’s main shaft depending on the type of the intermediate shaft and engine power.

  • Page 8: Front Bearing

    Bearing and Main Shaft 2.1. Front Bearing 2.1.1. Disassembly 2.1.1.1 Jet-160 The bearing housing is fixed in the casting. Only the support bearing housing is remova- ble. Before the shaft can be disassembled, the reversing deflector, the steering nozzle, the stator (see sections 4-6), and the impeller (see section 3) must be removed from the rear of the jet.
  • Page 9 Repair Manual 1 The shaft protrudes into the en- gine room with the bearings. The fit may be tight, but when pushed from the outside, enough force is produced to remove the shaft (figu- re 2.1.1.1-3). There are still two shaft seals in the bearing housing.
  • Page 10 Repair Manual 1 To remove the bearings, first remove the safety ring (A) and then push the bearings off the shaft (B) (figure 2.1.1.1-5). Figure 2.1.1.1-5 There is a needle bearing in the support bearing housing, which carries radial forces. There is a shaft seal behind the bearing, and a safety ring in front of it, which stops the bearing from...
  • Page 11 Repair Manual 1 2.1.1.1 Jet-180/185 In removing the shaft, the Jet-180/185 requires the same procedures as the Jet-160. Open the fastening screws of the support bearing housing (4 pcs) and remove the sup- port bearing housing (figures 2.1.1.2-1 and 2.1.1.2-2).
  • Page 12 Repair Manual 1 One four-point bearing is fitted to the shaft, which receives the thrust and carries some radial loads. The safety ring (A) stops the bearing from sliding off the shaft. The actual forces are received with the shoulder in the support bearing housing, which presses on the outer race of the bearing.

  • Page 13: Assembly And Installation

    See figure 2.1.1.2-7. Figure 2.1.1.2-7 2.1.2. Assembly and Installation 2.1.2.1 Jet-160 Make sure that the bearing housing and the support bearing housing are absolu- tely clean. Push the thrust bearing on the shaft.
  • Page 14 Repair Manual 1 Place the shaft seals in the bearing housing. Pay attention to the direction of the lips! As the seal is being pushed into place, the lips must point away from the installer. WARNING! If the shaft seal is installed backwards, water gets into the bearing housing! Also, make sure that the ring that supports the lip is made of rubber.
  • Page 15 Repair Manual 1 2.2. Rear End Bearing Disassembly and Assembly The rear end bearing is similar in Jet-160 and Jet180/185 models. Most commonly the rear bearing is grease lubricated. The alternative is a water lubricated bearing. Remo- ving and installing is done the same way in both cases.
  • Page 16 Repair Manual 1 When installing a new housing or water lubricated bearing, clean the old adhesive resi- dues off the stator. After removing the adhesive residues, spread adhesive on the outer surface of the bearing housing (figure 2.2-3) and push the bearing housing in place.
  • Page 17 Repair Manual 1 Impeller 3.1. Detachment The boat must be lifted out of the water to remove the impeller. Before you can get to the impeller, the reversing deflector, the steering nozzle and the stator must be removed. See sections 4-6. Before the rear end bearing can be disassembled, the reversing deflec- tor, the steering nozzle and the stator (see sections 4-6) must be remo- ved from the rear end of the jet.

  • Page 18: Installation

    Repair Manual 1 Welding can create heat stress, which may cause the impeller to bre- ak when used. This is why the manufacturer is not responsible for the breaking down of a repaired impeller. Impeller material: GTp10 Filler metal: EL-CuSn7 (ESAB OK 94.24). If the impeller has been repaired with filler metal, it is to be machined if necessary and it is imperative that it be balanced! 3.3.
  • Page 19 Repair Manual 1 Push the impeller with the cone on the shaft (figure 3.3-3). Tighten the screws fingertight and push the impeller as far in the intake duct as it goes. Figure 3.3-3 When installing the impeller, be careful not to leave your fingers bet- ween the impeller blade and the cone wall! Use the working position shown in figure 3.3-3! Tighten the screws to a torque...
  • Page 20 Repair Manual 1 If the impeller does not rotate properly after installation, open the impeller screws, pull it out a little and tighten the screws again. Close the inspection hatch. Install the reversing deflector, the steering nozzle and the stator in place as one whole. (Section 6.1.3.) Attach the loop joint on the reversing deflector to the lever at the end of the control shaft.
  • Page 21 Repair Manual 1 If there are no markings or they are worn, it is easiest to check the impeller type as fol- lows: 1. Push the impeller in the cone as deep as it goes. 2. Place a straight ruler against the rear edge of the cone as in- dicated in figure 3.4-3 and me- asure the distance from the rear...
  • Page 22 Repair Manual 1 Reversing Deflector and Control Shafts 4.1. Reversing deflector 4.1.1. Detachment The three fastenings indicated in figure 4.1.1-1 must be removed to take off the rever- sing deflector. Figure 4.1.1-1 The control shaft of the reversing deflector is attached to the reversing deflector with loop joints (A).
  • Page 23 Repair Manual 1 4.1.2. Repair The wearing parts of the reversing deflector are plastic bearings, hard plastic spacer pla- tes, joint loops and zinc anode. The parts must be replaced if they have cracks or they are highly worn. The joint is maintenance-free so it does not require lubricating. The plastic bearings are removed by using a suitable sleeve and new ones are installed using sealing compound.
  • Page 24 Repair Manual 1 Steering Nozzle and Shafts 5.1. Steering nozzle 5.1.1. Detachment To remove the steering nozzle, the reversing deflector must be taken off first (section 4.1.1). The steering nozzle is pivoted to the stator with acid-proof sleeves and two hex screws (A).
  • Page 25 Repair Manual 1 Small cracks on the steering nozzle can be repaired by welding filler metal into the not- ches. If the steering nozzle’s fastening screw brackets or operating lever have broken, they must not be welded, but instead the nozzle must be replaced. After welding, the repaired sections must be abraded and bare aluminium must be painted with appropriate paint.
  • Page 26 Repair Manual 1 6.1.1. Detachment One Part at a Time First remove the reversing deflector and the steering nozzle (sections 6.1 and 5.1). Open the stator’s four fastening screws as indicated in figure 6.1.1-1. Carefully crank the stator loose using a screwdriver (figure 6.1.1-2). Figure 6.1.1-1 Figure 6.1.1-2 6.1.2.
  • Page 27 Repair Manual 1 6.2. Repair The wearing parts of the stator are the plastic bearings of the steering nozzle (see secti- on 5.1.2), the rear bearing (see section 2.2), and the zinc anode. Small cracks on the stator can be repaired by welding filler metal into the notches. Ho- wever, at the ends of the blades this is practically impossible, and there are no guaran- tees of a durable result.

  • Page 28: Installation Instructions

    Repair Manual 1 Stages of system check: 1. Check that there is no short circuit anywhere, and that the fuses are intact. Also check that voltage is present in the system. 2. Check the conductivity of all connections by measuring. 3.

  • Page 29: Adjustment Instructions

    Repair Manual 1 7.2. Adjustment Instructions PREPARATION - Set the STICK to middle position. - Adjust the AREA trim completely counterclockwise 25 cycles or until the trim starts to “snap”, after which adjust about 4 cycles back. - Adjust the ZERO trim completely counterclockwise 25 cycles or until the trim starts to “snap”, after which adjust about 8 cycles back.
  • Page 30 APPENDIXES - Repair Manual 1 Appendix 1: RECOMMENDED GREASES AND TIGHTENING TORQUES Specification of the properties of the greases used for lubricating the bea- alamarin-jet rings in water jet propulsion units Alamarin-Jet recommends that the greases that are used have the following properties: - lithium soap and a thickener with EP additives - mineral oil as a base oil...
  • Page 31 APPENDIXES - Repair Manual 1 Appendix 2: IMPELLER DIMENSIONS Version 1.00...
  • Page 32 APPENDIXES - Repair Manual 1 Appendix 3: ORDERING AN IMPELLER SPARE PART IMPELLER INFORMATION If there are no type markings on the impeller, the following information is required for manufacturing a spare part impeller. 1. Engine information Type: _______________________________________________________________ Propulsion (petrol/diesel): _______________________________________________ Power kW/hv: ________________________________________________________ Number of cylinders:___________________________________________________ Capacity in litres: _____________________________________________________...
  • Page 33 APPENDIXES - Repair Manual 1 Appendix 4: SE-01 Version 1.00...
  • Page 34 APPENDIXES - Repair Manual 1 Appendix 5: SE-02 Version 1.00 Version 1.00...

  • Page 35: Appendix 6: Exploded Views

    APPENDIXES - Repair Manual 1 Appendix 6: 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 delive- red. In the electronic version the exploded views are as a separate file. Version 1.00...

This manual is also suitable for:

Jet-180Jet-185

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