• SECTION 1: Foreword

• SECTION 2: Technical characteristics

• SECTION 3: Performance

• SECTION 4: Installation

• SECTION 5: Start-up

• SECTION 6: Operation

• SECTION 7: Corrosion protection

• SECTION 8: Trouble shooting

• SECTION 9: Service instructions

• SECTION 10: Warranty

• SECTION 11: Drawings

• SECTION 12: Schedule of parts

SECTION 1: Foreword    table of contents

The basic principle of a hydrojet is to propel a boat by means of the thrust produced with the violent ejection of water.

In fact, water is draw through a dynamic water intake, accelerated by the impeller, and expelled at high speed through the nozzle at the boat’s stern.

Hence, this is actually a jet propulsion system. In view of its characteristics, the 356 Alpha Power Jet propulsor can be coupled to any type of engine, with power ratings from 200 to 600 HP, in accordance with boat’s potential speed and its displacement.

SECTION 2: Technical characteristics    table of contents

• All stainless steel, elliptically shaped water intake flange, with inboard inspection cover;

• Stainless steel protected shaft;

• Splined stainless steel impeller with built-in impeller puller system;

• Stainless steel Balanced steering nozzle with stainless steel self-aligning bearing;

• Stainless steel reverse deflector with stainless steel self-aligning bearing;

• Stainless steel thrust nozzles;

• Stainless steel pump housing;

• Oil lubricated factory pre-set thrust bearing;

• Oil lubricated tail bearing;

• Precision mechanical face-seal;

• 1610 type input flange.

• 5 vaned intake grill;

• Balanced steering cylinder with chromed stainless steel pushrods and attachments;

• Balanced reverse deflector cylinder with chromed stainless steel pushrod and    attachments;

• Gear driven hydraulic piston pump system including :

• Pump and manifold

• Manual relief valve

• Pressure gauge

• Energy accumulator

• Oil tank and strainer

• Filter, hose and brackets;

• 33C style hydro-mechanical follower control system for reversing deflector with hoses;

• Full hydraulic follower control system including hoses for reversing deflector;

• Electronic proportional control system with hoses and levels for the deflector;

• Power steering helm pump;

• Automatic transfer valve for power steering helm pump;

• Steering tie-bar.

SECTION 3: Performance    table of contents

Water jets can have a propulsive efficiency equivalent to other propulsion drive at speeds over 18 knots.

At lower speeds water jets have the advantage of shallow draught, excellent manoeuvrability and the ability to deliver more thrust than a fast propeller driven boat at low speed without overloading the motor.

This performance is achieved through the use of a special impeller profile developed by Alpha Power Jet, which is more resistant to low-speed cavitation than other impeller designs. It allows the Alpha Power Jet to produce higher thrust at lower speeds, as compared to conventional water jets. This high-thrust jet is a direct drive design, saving weight, initial cost and maintenance expenses. With 10 to 15 percent higher operating speed under load, the benefits are obvious.

This new jet offers several exclusive benefits; in particular, a unique system of adjusting the impeller blade pitch and the jet nozzle vortex to achieve the best performance, whether operating under light or full loads. As a result, an optimum performance curve is achievable for various hull configurations and engine power outputs.

Other benefits of this hydro-jet included:

• All stainless steel construction;

• Fully hydraulic controls;

• Permanently lubricated bearings throughout;

• Faster, less expensive installation time ("Plug and Play" design);

• Adaptable to very flat bottomed hulls as typically used in Maine’s lobster fishing boats.

SECTION 4: Installation    table of contents

4.1 Water jet installation

1. Cut the hull and transom according to the "installation drawings" in section 11;

2. Use the water jet as a drilling guide to fit the opening;

3. Install 1/16² shim stock between the hull and the water jet. Drill 5/16² holes for the attachment bolts.

4. Remove the water jet and 1/16² shim;

5. Resize all 5/16² hole in the hull with a 11/32² drill;

6. Clean the hull and water jet with acetone;

7. Apply 1/4² of polyurethane scellant around the water jet flange;

8. In a metal hull plastic insulation should be put in each hole;

9. Install the water jet with 5/16² stainless steel bolts and nuts;

10. Torque the 5/16² bolts and nuts to 11-13 Nm (8-10 ft.lbs.);

11. Clean excess polyurethane scellant from the jet flange inside and outside;

12. Check the tightness on all hoses and fittings;

13. Install the control cable or the hose or the harness according to the appropriate option drawings;

14. Fill the gear box with "Petro-Canada Ultima AP68" gear oil or equivalent;

15. Fill the hydraulic tank (option) with "Petro-Canada Harmony AW32" hydraulic oil or equivalent;

16. Run the hydraulic steering hose to the steering cylinder and connect.

4.2 Twin installation

1. Measure and cut the transfer tie-rod tube and weld the supplied 5/8 UNF nut;

2. Attach transfer tie-rod and steering levers on port and starboard water jet with supplied 5/8 UNC bolt and nylon jamb nut;

3. Torque 5/8 bolt and nut to 100 - 110 Nm (70 - 75 ft.lbs.);

4. Run the 2 supplied 1/2² hose from the transom and connect to the port and starboard reverse control valve (see option drawings).
   
   Note: For measuring the tie-rod tube, put steering nozzles at the dead center position.

4.3 Extracting the impeller

1. Remove all screws #40 fig. 12.1.2;

2. Remove the rear section of the jet screw #38 at the bolts fig. 12.1.2;

3. Extract the whole removable rear section of the jet drive;

4. Loosen the impeller retainer screw #32 fig. 12.1.3 using the opposite spanner #24 and remove the impeller.

5. If the edge of the impeller blades should become damaged, round it off with a file.

To assemble:

1. Clean the spline on the shaft and impeller carefully, put anti-seize on spline;

2. Engage the impeller on spline, screw and tighten (25 - 30 ft.lbs.);

3. Reassemble the rear section of the jet (make sure there is no contact between impeller and any part of the jet casing, i.e. pump #2 fig. 12.1.2 or nozzle #3 fig. 12.1.2);

4. If necessary use a file to correct imperfections, but never on the impeller blade;

5. Make sure the impeller and the controls are running freely.

6. One method is to turn the shaft manually and check that there is no contact anywhere.

SECTION 5: Start-up    table of contents

The Alpha Power Jet can run dry for up to fifteen minutes. We suggest for the initial start-up, to run the engine and jet briefly to check over all functions.

Before start-up:

1. Check all oil levels;

2. Check impeller, reversing deflector and steering nozzle rediness and clear all debris;

3. Start the engine and run it at low speed;

4. Correct hydraulic oil levels if they have changed;

5. Check for any oil leakage;

6. Check hydraulic oil pressure (1900 to 2000 psi);

7. Move the lever to all positions and make sure forward position (deflector up) and reverse position (deflector down) correspond with the lever control;

8. Move the steering wheel to all positions and make sure steering deflector corresponds with steering wheel;

9. Check and correct hydraulic oil levels again.

SECTION 6: Operation    table of contents

6.1 Notes

• The reverse deflector is powered by a hydraulic system;

• The hydraulic system consist of a gear pump system and a hydraulic accumulator;

• The hydraulic accumulator produces an up or down movement of the reverse deflector, through the reverse deflector lever;

• After long periods of rest; it is possible that pressure in hydraulic accumulator is insufficient to move the reverse deflector until the pressure builds up again.

6.2 Start-up of a single installation

• We recommended before starting the engine to:

• Put the steering at the center position;

• Put the reverse deflector control lever in neutral position;

• Start engine.
  
  Note: If it is impossible to move the reverse deflector lever because the hydraulic pressure is low, move it at the same time as you start.

6.3 Start-up of a twin installation

1. Start the port side engine using the same procedure used in section 6.2

2. With the port side engine running, move the starboard deflector control lever to the neutral position;

3. Start the starboard engine.

6.4 Operation and docking

1. The bow of the vessel always turns in the same direction of the wheel position in (forward, neutral, reverse).

2. The steering effect is proportional to the engine RPM.

3. For slow speed manoeuvrability the engine should be set to around 1000 RPM which will give a sufficiently jet reaction to ensure good thrust and responsive steering. Boat speed is controlled with the reverse deflector control lever. Moving it forward increases speed or backward decreases speed.

4. For most slow speed and docking manoeuvres, the operator will have one hand on the steering wheel and one hand on the reverse deflector control lever.

5. In a strong wind or tidal condition the engine speed can be raise to increase the reaction as requested.

• Removing the inspection cover on the intake casing which provides access to the intake grill. Ensure that the cover is above the waterline before removing it.

• Select the reverse position on the engine marine gear selector (if fitted) and giving a 2-3 seconds burst power. This will blow obstructions away from the grill.

6.6 Caution notes

• With a light boat moving at speed under power, selecting reverse on the control head will cause the boat to decelerate very rapidly. This procedure should be use only in an emergency.

• If the boat is in shallow water avoid using high RPM when manoeuvring, to prevent stones from being draw through the intake grill and causing damage to the impeller.

6.7 Remember

If there is no power to the Alpha Power Jet, there is no steering effect.

SECTION 7: Corrosion protection    table of contents

7.1 Corrosion protection

• The Alpha Power Jet has been manufactured of 316L in stainless steel plate and provides an excellent resistance to corrosion;

• Anodes have been incorporated to provide additional sacrificial protection to galvanic corrosion. When the anodes are showing signs of deterioration they are providing protection;

• If the anodes have been eaten away to 50% or more of their original volume, they should be replaced with new ones;

• The anodes fitted to the Alpha Power Jet are only for the protection of the jet unit. Additional anodes should be fitted to the hull for protection of the vessel itself;

• Do not paint anodes.

7.2 Electrical system

• Stray currents generated by the boat electrical systems can often cause considerable corrosion to metal parts over a period of time;

• A bonding strip with a reasonable cross section area (to keep the resistance as low as possible) should be connected to all major metal components and hull anodes.

Major items should include:

• Main engine;

• Water jet casing;

• Ship service engine;

• AC generator (frame only);

• Etc.

Note: The water jet should not be used to ground any electrical equipment. The bonding system must be independent of the electrical grounding system.

SECTION 8: Trouble shooting    table of contents

9.1 10 hours (or daily) inspection

Check level and colour of the gear oil:

• If level is low, add oil;

• If colour is changed, change gear oil with "Petro-Canada Ultima EP 68" gear oil;

Check level and colour of the hydraulic oil:

• If level is low, add oil;

• If colour is changed, change filter and hydraulic oil with "Petro-Canada Harmony AW32" hydraulic oil;

Clean all debris in deflectors and grill.

9.2 250 hours (or monthly) inspection

Check anodes and replace if necessary.

• Check anodes and replace if necessary;

• Replace hydraulic oil filter;

• Replace hydraulic oil with "Petro-Canada Harmony AW32" oil;

• Replace gear oil with "Petro-Canada Ultima EP68" oil;

• Clean hydraulic oil strainer;

• Clean gear oil magnetic plug;

• Inspect unit for damage;

• Inspect all control, bearings and linkage.

SECTION 10: Warranty    table of contents

10.1 Certificate of warranty

The shipyard, retailer or importer should fill out the certificate of Warranty in the Buyer’s presence, and return it to Alpha Power Jet within 10 days of the date of delivery of the unit to of the customer.

The return of this certificate is compulsory to assure the validity of the Warranty.

Alpha Power Jet guarantees their products for a period of 12 months from the date of delivery to the Titular; however, the warranty ceases to be applicable 18 months after the date of shipment from Alpha Power Jet.

The warranty is limited to the first Owner/User, and commits Alpha Power Jet to replace or repair such parts as should be acknowledged unfit because of defective material or manufacturing.

Terms

The guarantee includes the free supply of replacements for the parts under warranty, and for labour for their substitution as per labour schedule issued by Alpha Power Jet.

Any expenses that should possibly derive for the removal and re-installation of the boat’s engine, with regard both to labour and to the use of cranes or other equipment, are at customer’s expense.

Travel and living expenses for personnel, as well as the necessary commonly used materials (lubrication oil, filter cartridges, belts, impellers, etc.) are not covered by this warranty.

The acknowledgement of warranty is to be determined solely by Alpha Power Jet, after examination of the parts that have been replaced by their engineers.

Warranty work must be conducted only by an authorized workshop, in accordance with the dealership agreement.

The guarantee is understood to be invalidated by, or not applicable in the following cases:

• Failure to carry out within the scheduled times the operations listed in the control coupon, if any;

• Damages incurred during transportation;

• Incorrect installations or repairs;

• Incorrect use (insufficient lubrication, use of spare parts other than original ones);

• The use of the jet in competitive events or for rental purposes;

• Normal wear;

• Failure to follow the instructions listed in the operation and maintenance manual;

• Modifications that, in the Manufacturer’s judgement, may alter the original characteristics of the product; or

• Change of settings, or removal of seals and components.

Furthermore, the guarantee does not cover commonly used materials such as lubricants, filters, belts, injectors, impellers for water pump, impellers for the jet.

Concerning components and accessories supplied as original equipment, such as accumulator, hydraulic pump, instrumentation etc., the guarantee clauses of their respective Manufacturers will apply.

The warranty issued by Alpha Power Jet is the only one valid and applicable to the products of their own manufacture.

Alpha Power Jet does not take any responsibility for potential damage that could be caused directly or indirectly by defects in the product, nor do they authorize any third party to take responsibilities in their name.

Alpha Power Jet is neither directly nor indirectly responsible for losses, damages or injuries caused by defective construction, material, or installation of the product.

SECTION 11: Drawings    table of contents

SECTION 12: Schedule of parts    table of contents

12.1.1 Schedule of basic unit parts

12.2 Hydraulic arrangement

12.2.1. Schedule of the “A” arrangement parts

12.3 Hydraulic piston and pump arrangement

12.3.1 Schedule of Hydraulic pump parts