Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Alamarin Jet AJ 160
Summary of Contents for Alamarin Jet AJ 160
-
Page 2: Installation Manual
Alamarin-Jet Oy. The instruction covers the following jet propulsion models: AJ 160 AJ 180 AJ 185 AJ 230 If the given information is type specific, this will be expressed in the text. In this manual, clarifying figures will be used. -
Page 3: Table Of Contents
Installation Manual 1. Attaching a Mounting Template Part to the Hull of the Boat ......5 1.1. Mounting Template ................... 5 1.2. Installation Methods ................. 6 ... 1.2.1. ”Repowering” ..................6 1.2.1.1. Reinforced Plastic ..............6 1.2.1.2. Aluminium ................11 ... - Page 4 Appendix 6. Control Lever Movement - AJ 230 ..........41 Appendix 7. Control Lever Movement - AJ 180 and 185 ........42 Appendix 8. Control Lever Movement - AJ 160 ..........43 Appendix 9. SE-01..................... 44 Appendix 10. SE-02................... 45 Appendix 11.
-
Page 5: Attaching A Mounting Template Part To The Hull Of The Boat
Installation Manual Attaching a Mounting Template to the Shell of the Boat Installation of the Alamarin-Jet water jet propulsion unit to the boat is done with a mounting template. Fitting the mounting template to the boat can be done in various ways. -
Page 6: Installation Methods
Installation Manual 1.2. Installation Methods 1.2.1. ”Repowering” In accordance with its name, the ”repowering” installation method is used in a modification installation of the propulsion system. In addition, it is an appropriate installation method for prototype or ”one-off” boats. In aluminium boats, the jet propulsion unit is always installed using the ”repowering”... - Page 7 Installation Manual Attaching the Mounting Template in Phases 1. Prepare the mounting template by cutting it to the right size at the front. The v-angle of the mounting template is alterable, and the mounting template is cut to suit the v-angle of the boat Level bottom or twin installation...
- Page 8 Installation Manual 2. Cut a hole of appropriate size for the mounting template in the stern and the bottom of the boat. The hole should be cut so that the mounting template is as far back as possible. Figure 1.2.1.1-4 The mounting template must be on the same level with the bottom of the boat.
- Page 9 Installation Manual 3. Chamfer the edges of the hole all around. The chamfered part must be 100 mm and the hole edge thickness 3 mm. Chamfer the edges of the mounting template as well, however the chamfered part does not have to be as long as on the shell. If the boat’s shell is made of sandwich laminate, first remove 100 mm of core material around the hole and then chamfer the core material and the exterior surface about 100 mm.
- Page 10 Installation Manual 6. Spill gelcoat paint on the seam from above so that it becomes filled. 7. Laminate 100 mm wide carpet strips on the seam. 8. Continue laminating over the whole mounting template and the chamfers until the final thickness, 12-14 mm, is reached. Attachment laminate Mounting template laminate...
-
Page 11: Aluminium
Installation Manual 10. Cut off the excess collar on the mounting template outside the stern. Figure 1.2.1.1-8 11. Smooth the seams and paint visible reinforced plastic surfaces with topcoat paint. Uncovered laminate absorbs water. 1.2.1.2. Aluminium Installation of an aluminium mounting template does not differ from installation of a reinforced plastic mounting template, except for the free shell surface and the chamfering. -
Page 12: Mounting Template Directly Out Of The Mould
Installation Manual 5. Fit the mounting template in place. Read section 4 in the instructions for the installation of a reinforced plastic mounting template. 6. Weld the mounting template in place both on the inside and the outside and make the seam watertight. - Page 13 Installation Manual I The following things are to be taken into account in moulding the negative: 1. For twin installation, excess fibreglass must be cut off the mould of the mounting template. See cutting instructions in appendix 1. Figure 1.2.2.1-2 2.
- Page 14 Installation Manual 3. Sharpen the front edge and the sides of the intake duct negative, so that no thick edge is left between the boat mould and the negative. See figure 1.2.2.1-4. (If this is not done, the thick edge is copied to the final boat and the boat’s performance may suffer.) Figure 1.2.2.1-4 4.
- Page 15 Installation Manual Fit the mounting template negative in the mould. The following instructions apply both to single and twin installations: 1. Set the mounting template negative in the boat mould so that the intake duct is parallel with the keel. 2.
-
Page 16: Fixed Mounting Templates
Installation Manual 3. Fix the mounting template negative on the boat’s mould with tape or other temporary method. Make sure that there are no big notches in the seams of the negative and the boat’s mould. A notch caused by tape is not detrimental. For the part of the jet’s mounting template, the boat’s mould is now ready for laminating. -
Page 17: Attaching The Jet Propulsion Unit To The Shell
Installation Manual Attaching the Jet Propulsion Unit to the Shell 2.1. Preparations Holes must be made on the installation surface of the mounting template for attaching the jet propulsion unit and for the required bushings. An aluminium mounting template is already equipped with the holes. Sawing/drilling the holes is carried out with the drilling templates that come with the delivery. -
Page 18: Attaching The Jet Propulsion Unit In Phases
Installation Manual The following parts are removed from the jet propulsion unit before installation: AJ 230 AJ 185/180/160 - hydraulic cylinder - steering shaft - raw water intake tube - control shaft of the reversing deflector - steering shaft - raw water connector - cavitation plate - cavitation plate - lubrication hose... -
Page 19: Cavitation Plate
Installation Manual 2.2.1. Cavitation Plate 1. Fit the cavitation plate in place and mark with marker pen the part that is to be cut off, as indicated in figure 2.2.1-1. Cut the blades to the right shape so that they fit in the stern. -
Page 20: Grass Rake
Installation Manual 2.2.2. Grass Rake 1. The grass rake is attached in front of the intake opening with two or four screws. The fixing area must be sealed the same way as when installing the jet propulsion unit body. 2. Fit the grass rake in place in the intake duct and tighten the screws in place. - Page 21 Installation Manual 2. Spread sealing compound (e.g. Sikaflex 221) on the collar of the hydraulic cylinder and fit the wedge (figure 2.2.3.3-2) in place. Push the cylinder from inside the boat into the appropriate hole. Spread sealing compound also on the outside, on the threading (figure 2.2.3.3-3, A).
-
Page 22: Oil Pump (Aj 230)
Installation Manual 2.2.3.4. Oil Pump (AJ 230) The cylinder that moves the reversing deflector requires a hydraulic pump which is installed on the bearing housing as standard. 1. The bearing housing has four screws. Set the pump with the rack on the bearing housing as indicated in figure 2.2.3.4-1 and screw the screws fingertight. - Page 23 Installation Manual 6. The oil return hose must be taken to the reservoir through a cooler. A normal heat exchanger intended for oil cooling can be used as a cooler. The exchanger is installed to the engine cooling water line after the filter. The hydraulic return hose is only included in deliveries that include a heat exchanger.
-
Page 24: Raw Water Cooling
Installation Manual 2.2.3.5. Raw Water Cooling Cooling water for the engine can be taken from the pressure face of the jet propulsion unit. The jet propulsion unit has raw water intake as standard for this purpose. Taking cooling water from the jet propulsion unit enables dry running of the system (NB. Observe the manufacturer’s instructions on dry running). -
Page 25: Antifouling
Installation Manual 2.3. 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, for example copper. -
Page 26: Control System
Installation Manual Control System This section describes the installation of control systems for the jet propulsion units. Using the correct method when installing the systems is important, because a wrong method may cause the jet propulsion unit to be used wrong and lead to poor performance. -
Page 27: Turning The Cable Support
Installation Manual 3.2.1. Turning the Cable Support In a standard installation, the support plate of the hydraulic cylinder’s operating cable points to the starboard side. If necessary, you can turn the plate to a more suitable direction depending on the incoming direction of the cable. 1. -
Page 28: Connecting The Control Cables
Installation Manual 5. Place the lever (figure 3.2.1- 5, A) on the operating shaft so that it lies between the limiters on the support plate (figure 3.2.1-5, B). The tigh- tening torque of the lever screw is an unusual 10 Nm. Attach the control cable with a fastener (figure 3.2.1-5, C) to the support plate and with... -
Page 29: Adjusting The Cylinder
Installation Manual Full ahead: Reversing deflector up, cylinder operating lever on the right. Figure 3.2.2-3 3.2.3. Adjusting the Cylinder 1. Detach the control cable from the end of the cylinder operating lever (figure 3.2.3-1, A). 2. Loosen the operating lever screw (figure 3.2.3-1, B) but do not pull the lever off the shaft. - Page 30 Installation Manual Tube-type reversing deflector The down position is correct when the entire jet flow enters the deflector (figure 3.2.3-4, A). When viewed from the outside, the steering nozzle and the reversing deflector must be level (figure 3.2.3-2, B). Figure 3.2.3-3 Figure 3.2.3-4 Round-type reversing deflector The top of the deflector must be almost on the same level as the steering nozzle (figure...
-
Page 31: Connecting The Steering Nozzle To The Control System
2. End plate 3. Hex screw 4. Joint Figure 3.3-1 3.4. Installing an Electronic Reversing Deflector Control System An electronic reversing deflector control system is available for smaller models (AJ 160 and AJ 180/185). The system consists of the following main components: #1 control lever (potentiometer) #3 electronic unit #4 spindle motor. -
Page 32: Installation Instructions
Installation Manual 3.4.1. Installation Instructions The control system has been preadjusted as in drawing SE-01 (appendix 8). When the water jet unit has been installed on the boat, the installation of the re- versing deflector control system can begin. 2.1. Set the reversing deflector in centre position so that lever 5 (figure SE-01) points up perpendicularly. -
Page 33: Engine Installation
Installation Manual Area too wide: - STICK in middle position, - adjust the AREA trim slightly clockwise (for example 1 cycle), - adjust the spindle motor back to centre position with the ZERO trim. - Test the suitability of the area again with the STICK. If the area is still too wide, repeat the procedure above. -
Page 34: Intermediate Shafts
Installation Manual 4.2.1. Intermediate Shafts THE NEXT SECTION DEMONSTRATES PRINCIPLES OF COMMONLY USED SHAFTS. ALWAYS ASK THE MANUFACTURER OF THE INTERMEDIATE SHAFT FOR INSTALLATION AND OPERATION INSTRUCTIONS! 4.2.1.1. Constant Velocity Shaft At the both ends of the constant velocity shaft there is a joint based on balls rolling on a spherical surface. -
Page 35: Intermediate Shaft With Rubber Stop
Installation Manual 4.2.1.3. Intermediate Shaft with Rubber Stop Shafts with rubber stops effectively prevent vibrations that travel along the shaft to the shell of the boat. This is why they are popular especially in boats with a metal structure. In the example shaft in figure 4.2.1.3-1 there is a rubber joint at the other end and a constant speed joint at the other. -
Page 36: Appendix 1. Mounting Template
APPENDIXES - Installation Manual Appendix 1: MOUNTING TEMPLATE Version 1.4 Version 1.4... -
Page 37: Appendix 2. Control System 1
APPENDIXES - Installation Manual Appendix 2: CONTROL SYSTEM 1 Version 1.4... -
Page 38: Appendix 3. Control System 2
APPENDIXES - Installation Manual Appendix 3: CONTROL SYSTEM 2 Version 1.4... -
Page 39: Appendix 4. Control System - Twin 1
APPENDIXES - Installation Manual Appendix 4: CONTROL SYSTEM-TWIN 1 Version 1.4... -
Page 40: Appendix 5. Control System - Twin 2
APPENDIXES - Installation Manual Appendix 5: CONTROL SYSTEM-TWIN 2 Version 1.4... -
Page 41: Appendix 6: Control Lever Movement-Aj 230
APPENDIXES - Installation Manual Appendix 6: CONTROL LEVER MOVEMENT-AJ 230 Version 1.4... -
Page 42: Appendix 7: Control Lever Movement-Aj 180 And 185
APPENDIXES - Installation Manual Appendix 7: CONTROL LEVER MOVEMENT-AJ 180 and 185 Version 1.4... -
Page 43: Appendix 8: Control Lever Movement-Aj 160
APPENDIXES - Installation Manual Appendix 8: CONTROL LEVER MOVEMENT-AJ 160 Version 1.4... -
Page 44: Appendix 9. Se-01
APPENDIXES - Installation Manual Appendix 9: SE-01 Version 1.4... -
Page 45: Appendix 10. Se-02
APPENDIXES - Installation Manual Appendix 10: SE-02 Version 1.4... -
Page 46: Appendix 11. Recommended Greases And Oils And Tightening Torgues Of
APPENDIXES - Installation Manual Appendix 11: RECOMMENDED GREASES AND OILS AND TIGHTEN- ING TORQUES OF THE SCREWS 1. The grease used for lubricating the bearings of the propulsion unit must meet the requirements below. - lithium soap and a thickener with EP additives - mineral oil as a base oil - NLGI class 2 - operating temperature range –25…130˚C... -
Page 47: Appendix 12. Exploded Views
APPENDIXES - Installation Manual Appendix 12: 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 1.4...
Need help?
Do you have a question about the AJ 160 and is the answer not in the manual?
Questions and answers