Alamarin Jet COMBI-FRAME AJ 285 Repair Manual
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Alamarin Jet COMBI-FRAME AJ 285 Repair Manual

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  • Page 1 Repair manual...

  • Page 3: Table Of Contents

    Table of contents Repair manual Table of contents 1. Introduction ....................1 1.1. Safety precautions ................1 1.2. Symbols ..................... 1 2. Main shaft and bearing ................3 2.1. Front bearing ..................4 2.1.1. Front bearing disassembly ............4 2.1.2. Repairing the front bearing ..........10 2.1.3.
  • Page 4 WARRANTY TERMS Warranty for the Alamarin-Jet products is 12 months from the first sea trial. However no longer than 18 months from the date of delivery from our factory. Alamarin-Jet Warranty covers defects in Alamarin-Jet workmanship and materials for the Warranty period. Alamarin-Jet warranty terms will not cover normal part wear nor following cases with external source of issue: incorrect installation, damage caused by outside affect, vessel overloading, misuse, abnormal wear and tear, accident, improper application, improper transportation or storage, natural calamity, unsuitable...

  • Page 5: Introduction

    Introduction Repair manual 1. Introduction This is the repair manual for Alamarin-Jet's AJ 285 water jet propulsion unit. This manual is intended for the owners, users, and repair persons of boats that are equipped with the Alamarin-Jet water jet propulsion unit. With the help of this manual, they can carry out the most common repair procedures for AJ 285 water jet propulsion units.
  • Page 6 Introduction Repair manual Icon Description 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. NOTE Important notice or fact. Additional information that facilitates the performance of work or a procedure.

  • Page 7: Main Shaft And Bearing

    Main shaft and bearing Repair manual 2. Main shaft and bearing The power from the engine that runs the jet is transmitted to the main shaft using an intermediate shaft. The intermediate shaft is attached to the drive flange in one end, and either the gear box or the engine flywheel adapter in the other end.

  • Page 8: Front Bearing

    Main shaft and bearing Repair manual 2.1. Front bearing 2.1.1. Front bearing disassembly Before the bearing can be disassembled, remove • the stator (section 6.1. , page 65) Removing the stator • the impeller (section 3.2. , page 29). Removing the Impeller Then, remove •...
  • Page 9 Main shaft and bearing Repair manual Figure 3. Drive flange fastening nut 3. Unscrew the nut (figure 3, point A) and use pliers to remove the spacer under the nut. Pull the drive flange out of the cone with a sturdy extraction tool.
  • Page 10 Main shaft and bearing Repair manual Figure 4. Removing the bearing housing 5. Open the bearing housing screws (6 pcs, figure 4, point B). 6. Pull the shaft off the frame. Use the two M6 holes, from which the screws must first be removed (figure 4, point C).
  • Page 11 Main shaft and bearing Repair manual 9. Open the shaft nut screws (6 pcs, figure 6, point A) and turn the tooth of the lock washer (figure 6, point C) up from the shaft nut groove (figure 6, point B). Figure 6. Shaft nut 10.
  • Page 12 Main shaft and bearing Repair manual Figure 8. Removing the bearings from the bearing housing Mechanical seal The mechanical seal consists of several parts (figure 9). Figure 9. Cross-section of the mechanical seal Static slip-ring seal Static slip-ring Rotating slip-ring Spring for pressing the sealing faces against each other Rubber bellows Sealing support ring The slip surfaces are of silicon carbide, which is an extremely durable...
  • Page 13 Main shaft and bearing Repair manual Support ring F (figure 9) is attached to the shaft with a crimped joint. It can be removed by heating, for example. Parts A and B (figure 9) are removed by pushing them from the bearing side. O-ring An o-ring is used as sealing between the bearing housing and the jet's frame (figure 10).

  • Page 14: Repairing The Front Bearing

    Main shaft and bearing Repair manual Figure 11. Shaft seal of the bearing housing A shaft seal is also attached to the drive flange to keep oil off of the cone joint surface. It can be removed with a screwdriver, for example (figure 12). As this seal does not move against the shaft, it will not wear like the others.

  • Page 15: Assembly Of The Front Bearing

    Main shaft and bearing Repair manual When replacing the bearings, check the following issues: • straightness of the shaft • location of the mechanical seal on the shaft (the surface must be free of scratches) • external condition of the bearing housings •...
  • Page 16 Main shaft and bearing Repair manual Be careful not to damage the slip-ring (figure 14, point B) during installation. If the seal is pressed into its place in a slanted position, and the slip-ring can scratch the surface of the shaft, the slip-ring may be damaged.
  • Page 17 Main shaft and bearing Repair manual Figure 15. Static ring 3. Place the bearings into the bearing housing and press them on to the shaft together (figure 16). Please note that the bearings must be installed in the correct way. See figure 17. 4.
  • Page 18 Main shaft and bearing Repair manual Figure 17. Bearings (cross-section) 5. Lubricate the inner rim of the bearing housing cover and press the shaft seal (figure 18, point B) into the bearing housing cover, making sure that it is correctly oriented. Make sure that the shaft seal is installed in the correct way (figure 19). 6.
  • Page 19 Main shaft and bearing Repair manual Figure 19. Assembled bearing housing cover (cross-section) 7. Press the bearing housing cover on to the bearings, making sure that the lubricating oil connectors are facing the same way. This ensures that the screw holes are aligned (figure 20, point B). 8.
  • Page 20 Main shaft and bearing Repair manual Figure 21. Installing the drive flange seal in the correct way 10. Place the bearing housing fastening screws (6 pcs, figure 22, point B) in the holes and install the drive flange. 10.1. Place the key (figure22, point C) in the keyway (figure 22, point D). 10.2.

  • Page 21: Installing The Front Bearing

    Main shaft and bearing Repair manual Figure 23. Bearing housing connectors Figure 24. Lubricating the bearing housing (cross-section) Lubricating oil is indicated in red. 2.1.4. Installing the front bearing Assemble the front bearing before installing (section 2.1.3. Assembly of the front , page 11). bearing Front bearing installation: 1.
  • Page 22 Main shaft and bearing Repair manual 2. Make sure the seal is tight by spreading sealing compound (such as Sikaflex 291i) on the shoulder (figure 25) at the o-ring. Figure 25. Shoulder 3. Push the shaft bearing into place through the hole in the jet's frame (figure 26, point A) and tighten the bearing housing fastening screws (6 pcs, figure 26, point B) through the holes in the drive flange using a long Allen wrench (figure 26, point C).

  • Page 23: Rear-End Bearing

    Main shaft and bearing Repair manual 5. Install the stator (section 6.3. , page 69), the steering Installing the stator nozzle (section 5.1.3. , page 61) and the Installing the steering nozzle reversing deflector (section 4.1.3. , page Installing the reversing deflector 6.

  • Page 24: Repairing The Rear-End Bearings

    Main shaft and bearing Repair manual Figure 28. Detaching the rear bearing housing from the stator 4. Tighten the screws carefully until the bearing housing comes loose. 5. Pull the bearing housing off the stator. 2.2.2. Repairing the rear-end bearings Repair operations on the rear bearings are limited to replacing worn parts. The wearing parts include the bearing, seals, and shaft sleeves, which are replaced as necessary.
  • Page 25 Main shaft and bearing Repair manual Replacing the seals: 1. Remove the seals with a screwdriver, for example (figure 29). Figure 29. Removing the rear bearing seals The second seal is attached to the plastic cover. 2. Replace the old seals with new ones. Bearing Replacing the bearing: 1.

  • Page 26: Assembling The Rear-End Bearing

    Main shaft and bearing Repair manual Figure 31. Shaft sleeve Removing the shaft sleeve: Open the screw at the end of the shaft and pull the sleeve off the shaft. 2.2.3. Assembling the rear-end bearing Assembly of the rear bearing: 1. Push the bearing into the bearing housing from the back (figure 32). Use a bearing retaining compound to ensure that the bearing stays in place (such as Loctite 648 or similar).

  • Page 27: Installing The Rear End Bearing

    Main shaft and bearing Repair manual Figure 32. Assembly of the rear bearing 2. Push the seal into place from the front of the bearing housing. The second seal is attached to the plastic cover. Ensure that the seals are inserted in the correct way (figure 33). Figure 33. Installation direction of the seals 2.2.4. Installing the rear end bearing Before installation, ensure that the bearing housing hole in the stator is clean...
  • Page 28 Main shaft and bearing Repair manual Installing the rear-end bearing: 1. Spread adhesive sealing compound around the bearing housing on the area indicated in figure 34 . Figure 34. Spreading area of the adhesive compound 2. Clean the rear end bearing lubrication channel located on the stator (figure 35, point E) of old grease.

  • Page 29: Intermediate Shaft

    Main shaft and bearing Repair manual 5. Remove excess adhesive compound from the hole (figure 35, point D). 6. Install the sleeve at the end of the shaft on to the shaft along with the o- ring. The correct installation sequence is illustrated in figure 36. Use thread locking compound (such as Loctite 243) on the fastening screw in order to prevent any unintentional loosening of the screw.
  • Page 30 Main shaft and bearing Repair manual KM/285/EN/1.1.0...

  • Page 31: Impeller

    Impeller Repair manual 3. Impeller The impeller (figure 37, point A) is attached to the jet's main shaft. As the impeller rotates, it generates pressure that is then transformed into the flow rate. Figure 37. Impeller The impeller is attached to the shaft with a mounting flange (figure 37, point B), which is attached to the impeller with bolts (6 pcs, figure 37, point C).

  • Page 32: Impeller Type

    Impeller Repair manual Figure 38. Impeller rings 3.1. Impeller type The type of the impeller is defined according to the number, pitch, and surface area of the blades. The number and total pitch of the blades are unambiguous, but the surface area may vary according to the diameter and length of the blades.

  • Page 33: Removing The Impeller

    Impeller Repair manual 3.2. Removing the Impeller Before removing the impeller, remove the stator (section 6.1. Removing the , page 65). stator Removing the impeller: 1. Open the screw keeping the sleeve (figure 37, point D) at the rear end of the shaft in place and pull the sleeve off the shaft.

  • Page 34: Installing The Impeller

    Impeller Repair manual Figure 40. Front edge Repairing bent blades Bends in the blades can be carefully tapped back into their original shape with a hammer. 3.4. Installing the impeller New and repaired impellers are fitted in the same way. Installing the impeller: 1.
  • Page 35 Impeller Repair manual Figure 41. Position of the keyway The thrust caused by the impeller is transmitted through the adjuster sleeve to the shaft (figure 42, point A). The sleeve consists of rings of different thickness. The length of the sleeve can be adjusted in 0.5 mm (approx.
  • Page 36 Impeller Repair manual Figure 42. Adjuster sleeve Find the right sleeve thickness by testing as follows: 3. Lubricate the shaft and the inner surface of the impeller mounting flange with waterproof petroleum jelly (such as Shell Gadus S2 V220AC or similar). 4. Place the impeller into the duct and push it against the shim rings. 5.
  • Page 37 Impeller Repair manual Figure 43. Keyway If you adjusted the impeller during periodical maintenance and had to remove shim rings due to the impeller having worn down, do not throw away the shim rings. They are placed between the impeller and the shaft sleeve (figure 44).

  • Page 38: Impeller Tunnel

    Impeller Repair manual 8. Place the o-ring on to the shaft against the shoulder (figure 46, point A) and the shim rings against the rear surface of the impeller. 9. Push the sleeve on to the shaft. Checking the position of the sleeve: You can check whether there is an adequate number of shim rings behind the impeller by measuring distance d from the end of the shaft to the rear end of the sleeve (figure 46).
  • Page 39 Impeller Repair manual Figure 47. Impeller tunnel Removing the impeller tunnel Before removing the impeller tunnel, detach the stator (section 6.1. Removing , page 65) and the the impeller (section 3.2. the stator Removing the , page 29). Impeller 1. Open the connection to the raw water line at the pipe end on the engine room side (figure 48, point A).
  • Page 40 Impeller Repair manual Figure 48. Raw water line 3. Open the tunnel locking nuts (8 pcs, figure 47, point C). 4. Pull the tunnel off the frame. You can assist the detachment by inserting a blunt wedge in the holes included for this purpose (figure 49). Figure 49. Removing the impeller tunnel from the frame Installing the impeller tunnel 1.
  • Page 41 Impeller Repair manual 3. Ensure that the dowel pins of the impeller tunnel are in place (figure 50, point C). 4. Press the impeller tunnel into place. 5. Tighten the nuts and the washers (8 pcs) into place to a torque of 46 Nm. Figure 50. Installing the impeller tunnel KM/285/EN/1.1.0...
  • Page 42 Impeller Repair manual KM/285/EN/1.1.0...

  • Page 43: Reversing Deflector And Operating Hydraulics

    Reversing deflector and operating hydraulics Repair manual 4. Reversing deflector and operating hydraulics The purpose of the reversing deflector is to create sufficient reverse thrust for reversing the boat. When the deflector (figure 51, point A) is lowered in front of the jet flow, it will turn the jet flow entirely or partially towards the bow, creating thrust.
  • Page 44 Reversing deflector and operating hydraulics Repair manual Figure 52. Removing the reversing deflector 2. Open the joint pin screws (2 pcs, figure 53). WARNING! Be careful not to drop the deflector. The deflector weighs approximately 16 kg. Figure 53. Joint pin screws 3. If you need to replace the plastic bearings on the joint pins, they can be removed with a suitable mandrel.

  • Page 45: Repairing The Reversing Deflector

    Reversing deflector and operating hydraulics Repair manual Figure 54. Removing the plastic bearings 4.1.2. Repairing the reversing deflector The wearing parts of the reversing deflector are the plastic bearings and anodes. When the gap in the plastic bearings of the joint pins expands too much, the bearings must be replaced.

  • Page 46: Operating Hydraulics

    Reversing deflector and operating hydraulics Repair manual Figure 55. Direction of the plastic bearing flange 2. Lift the reversing deflector in place and push the joint pins in the holes. 3. Tighten the fastening screws (2 on each side) (figure 56). Figure 56. Attaching the joint pins 4.
  • Page 47 Reversing deflector and operating hydraulics Repair manual Before you remove the cylinder, make sure you have a container for draining the oil from the hoses. Please note that it may not be necessary to completely drain the system: you can also put plugs at the ends of the hoses. Removing the cylinder: 1.
  • Page 48 Reversing deflector and operating hydraulics Repair manual Figure 58. Removing the hoses 3. Open the joint screw of the intermediate bar between the hydraulic cylinder and the reversing deflector (figure 59, point A). Figure 59. Removing the cylinder 4. Open the fastening nut of the hydraulic cylinder (figure 59, point B). If you cannot open the nut with conventional tools, you can use special tool 10718.

  • Page 49: Repairing The Cylinder

    Reversing deflector and operating hydraulics Repair manual Figure 60. Pushing the cylinder 4.2.2. Repairing the cylinder Worn or damaged parts of the cylinder can be replaced. The product code for the sealing kit is P9904. NOTE! Only a person with appropriate training is allowed to open the cylinder or carry out the maintenance and repair operations of the cylinder.

  • Page 50: Installing The Cylinder

    Reversing deflector and operating hydraulics Repair manual Figure 61. Cylinder rear end seal 2. Unscrew the seal sleeve using the holes in the sleeve. 3. Install the new sleeve, making sure to apply some sealing compound (such as Sikaflex 291i) to the thread. 4.
  • Page 51 Reversing deflector and operating hydraulics Repair manual Figure 62. Installing the cylinder KM/285/EN/1.1.0...
  • Page 52 Reversing deflector and operating hydraulics Repair manual Figure 63. Cylinder dimensions 4. When the correct measurement X ~31 mm is met (figure 63), apply some sealing compound (such as Sikaflex 291i) to the thread, and tighten the nut. You can turn the cylinder slightly if you want the cable clamp to point directly in the cable’s direction of entry (figure 64).
  • Page 53 Reversing deflector and operating hydraulics Repair manual Figure 64. Adjusting the cylinder's position If the nut cannot be tightened with a normal wrench, special tool 10718 is available. 5. Install the intermediate bar between the cylinder and the deflector. Check the correct alignment of the bar (figure 65). Figure 65. Installing the cylinder's intermediate bar KM/285/EN/1.1.0...

  • Page 54: Cylinder Adjustment

    Reversing deflector and operating hydraulics Repair manual 4.2.4. 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 55 Reversing deflector and operating hydraulics Repair manual Figure 67. Operating lever Adjusting the cylinder: 1. Detach the control cable from the end of the cylinder operating lever (figure 68, point A). Figure 68. Removing the control cable 2. Loosen the operating lever screw (figure 68, point B) but do not pull the lever off the shaft yet.
  • Page 56 Reversing deflector and operating hydraulics Repair manual Figure 69. Operating lever and limiter 4. Turn on the engine and put it into gear. 5. Using a wrench, turn the operating shaft (figure 69, 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 57: Hydraulic Pump

    Reversing deflector and operating hydraulics Repair manual Figure 71. Deflector in the down position 4.3. Hydraulic pump 4.3.1. Removing the hydraulic pump Before you remove the hydraulic pump, ensure that you have a container for draining the oil from the hoses. Please note that it may not be necessary to completely drain the system: you can also put plugs at the ends of the hoses.

  • Page 58: Repairing The Hydraulic Pump

    Reversing deflector and operating hydraulics Repair manual Figure 73. Hydraulic pump bracket fastening screws 3. Remove the hydraulic pump from the bracket by opening its fastening screws (3 pcs, figure 74). Figure 74. Hydraulic pump fastening screws 4.3.2. Repairing the hydraulic pump A worn belt pulley in the hydraulic pump can be replaced. It can also be replaced with the pump attached to the bracket.
  • Page 59 Reversing deflector and operating hydraulics Repair manual Replacing the belt pulley: 1. Loosen the fastening screws of the hydraulic pump rack (figure 73). 2. Open the three screws that attach the belt pulley to the rack (3 pcs, figure 75). Figure 75. Belt pulley fastening screws 3.

  • Page 60: Installing The Hydraulic Pump

    Reversing deflector and operating hydraulics Repair manual Figure 76. Hydraulic pump pressure relief valve 3. Lift out the pressure relief valve (figure 77) and clean it of any debris and impurities. Figure 77. The hydraulic pump and the pressure relief valve 4. Set the cleaned pressure relief valve back in the pump. 5.

  • Page 61: Replacing The Oil Filter

    Reversing deflector and operating hydraulics Repair manual Use thread locking compound. 3. Set the belt in its place and lift the bracket until the belt tightens. 4. Tighten the bracket fastening screws at the same time. The tightening torque is 46 Nm. 5.
  • Page 62 Reversing deflector and operating hydraulics Repair manual Figure 79. 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 cover seal is correctly positioned in the groove (figure 80, point A).

  • Page 63: Steering Nozzle And Actuating Cylinder

    Steering nozzle and actuating cylinder Repair manual 5. Steering nozzle and actuating cylinder The steering nozzle (figure 81, point A) is used to turn the direction of the water from the jet, causing the boat to turn. The steering nozzle is turned with a hydraulic cylinder (figure 81, point B).
  • Page 64 Steering nozzle and actuating cylinder Repair manual Figure 82. Reversing deflector intermediate bar connection 2. Detach the steering cylinder connection from the steering nozzle (figure 83, point A). 3. Open the steering nozzle joint screws (figure 83, point B). Figure 83. Removing the steering nozzle KM/285/EN/1.1.0...

  • Page 65: Repairing The Steering Nozzle

    Steering nozzle and actuating cylinder Repair manual 5.1.2. Repairing the steering nozzle A worn or damaged intermediate bar 11134, joint pivot 11137, joint pivots 11331 (2 pcs), lock washer 11332 and anode can be replaced from the steering nozzle. The steering nozzle is cast aluminium (AlSi7Mg), and minor breakages can be repaired by welding.

  • Page 66: Steering Cylinder

    Steering nozzle and actuating cylinder Repair manual 5. Tighten the screws to a torque of 65 Nm. 6. Attach the cylinder intermediate bar with the steering nozzle's joint pivot and screw. Use a thread locking compound (such as Loctite 242) and tighten the screw to a torque of 65 Nm.

  • Page 67: Repairing The Control Cylinder

    Steering nozzle and actuating cylinder Repair manual Figure 86. Connection between the steering cylinder intermediate bar and piston rod 3. Open the fastening nut of the cylinder (figure 85, point B). If the opening is not possible with normal tools, you can use special tool 10718.

  • Page 68: Installing The Control Cylinder

    Steering nozzle and actuating cylinder Repair manual Replacement is described in section 4.2.2. , page 45. Repairing the cylinder 5.2.3. Installing the control cylinder The control cylinder is installed in the same way as the reversing deflector cylinder. This is described in section 4.2.3. , page 46.

  • Page 69: Stator

    Stator Repair manual 6. Stator 6.1. Removing the stator The stator can be removed as a complete unit with the reversing deflector and steering nozzle or one part at a time. Be sure to always first disconnect the lubrication hose from the stator angle fitting (figure 87). Figure 87. Disconnecting the lubrication hose Detachment one part at a time: 1.
  • Page 70 Stator Repair manual Figure 88. Stator fastening screws 3. Pull the stator off. If the stator cannot be detached easily, you can use a screwdriver by inserting it between the stator and impeller tunnel (figure 89). There is a groove in the seal between the parts for inserting the screwdriver. Figure 89. Removing the stator Removing the stator as a complete unit: 1.

  • Page 71: Repairing The Stator

    Stator Repair manual 3. Remove the stator carefully using a screwdriver (figure 89). 4. Pull the stator, the steering nozzle and the reversing deflector out as a single assembly (figure 90). Figure 90. Removing the stator as a complete unit 6.2. Repairing the stator Replaceable parts in the stator include: •...
  • Page 72 Stator Repair manual Figure 91. Stator's replaceable parts The stator is cast aluminium (AlSi7Mg), and minor breakages can be repaired by welding. The filler metal for the welding is AlMg5. Typically the tips of the blades suffer most damages in the stator (figure 92). These kinds of damage can be prevented by repair painting any minor damage.

  • Page 73: Installing The Stator

    Stator Repair manual NOTE! Bare aluminium areas must be painted when welding the stator. Use paints suitable for aluminium. Check the correct paint type from the paint supplier. Seals Leaking seals must be replaced. Changing the choker seal: 1. Remove the choker (figure 91, point C) fastening screws (6 pcs). 2.
  • Page 74 Stator Repair manual Figure 94. Installing the stator 2. Clean the end of the impeller shaft and push the stator into place so that the shaft end enters the rear bearing housing and the dowel pins enter the holes that are intended for them. 3.

  • Page 75: Appendix 1. Grease Recommendations

    Grease recommendations Repair 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 76: Appendix 2. Oil Recommendations

    Oil recommendations Repair 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 77: Appendix 3. Tightening Torques

    Tightening torques Repair 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 78 Tightening torques Repair manual KM/285/EN/1.1.0...

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