American Turbine SD-312 - User Manual

THE POWER IS IN THE PUMP!
OWNERS MANUAL
MODELS: 12-S & 12-TD
MODELS: AT-309 TJ-309 SD-309 SD-312
MODEL: J120-AT

Summary

Before Operating Your Jet Boat

Boat Horsepower Capacity

Discusses the importance of matching engine power to boat capacity to prevent accidents and damage.

Boaters Responsibilities

Outlines the operator's duty for safe operation and passenger instruction before the trip.

Pre-Operation Inspection Checklist

Thrust Bearing Lubrication

Details the procedure and frequency for lubricating the thrust bearing before operation.

Hand Hole Cover Check

Instructions to check if the hand hole cover is tightly fastened for safety.

Steering System Check

Guide to check steering operation by verifying nozzle movement with the engine off.

Reverse Shift Control Operation

How to check the reverse bucket's position in full reverse, forward, and neutral.

Throttle Operation Check

Verifies the smooth and proper operation of the throttle control lever.

Transom Seal Integrity

Checks for leaks at the housing seal to the boat or the housing seal to the bowl.

Additional Pre-Operation Checks

Packing Gland Inspection & Adjustment

Instructions for inspecting and adjusting packing gland nuts for proper seal compression.

Weep Hole Seal Inspection

How to check the weep hole for mechanical seal condition and potential obstructions.

Engine Cooling Connections

Verifies that all engine cooling hose connections are secure and leak-free.

Operational Procedures and Break-In

Trailer Launching and Starting

Guidance on safely launching the boat from a trailer and starting the engine properly.

Break-In Period Significance

Explains the necessity of a break-in period for component longevity and optimal performance.

Initial Gland and Seal Checks

Reiterates inspection of packing glands and weep holes during the initial break-in period.

General Maintenance and Lubrication

Lubrication Intervals and Types

Details lubrication intervals and recommended grease for thrust and bowl bearings.

Shaft Packing Adjustment

How to adjust shaft packing for proper compression to prevent leaks and heat damage.

Reverse Components Inspection

Inspection of reverse bucket function, cable security, and potential adjustments.

Maintenance Checks and Troubleshooting

Steering Cable Connection Checks

Checks steering cable connections on each trip for overall safety and proper function.

Hand Hole Cover Tightness

Advises periodic checks of the hand hole cover tightness while the boat is on land.

Lack of Performance Troubleshooting

Troubleshooting pump over-revving due to impeller obstructions like leaves or debris.

Impeller Information and Selection

Critical Safety Guidelines

Retrieving Skiers Safely

Recommends shutting off the engine when retrieving downed skiers to prevent accidents.

Ski Rope Hazards

Advises avoiding ski ropes near the pump to prevent entanglement and injury.

Shallow Water Operation Risks

Warns about potential damage to internal parts from rocks in shallow water.

Braking At Speed Caution

Advises conservative use of braking action due to its effectiveness being similar to emergency stops.

Engine Cooling Without Water

Prohibits operating the engine out of water to prevent severe damage to the engine and jet drive.

Limited Warranty Terms

Warranty Coverage Details

Details the duration and scope of the warranty for new jet drive units against defects.

Warranty Claim Process

Explains how to make a warranty claim by returning defective parts freight prepaid.

Liability and Design Rights

States liability limits and reserves the right to change product designs.

Warranty Exclusions and Limitations

Non-Covered Items

Lists items not covered by the warranty, such as normal wear, misuse, or non-manufacturer parts.

Damage and State Variations

Discusses limitations on consequential damages and acknowledges state-specific variations.

Optional Steering Assemblies

Understanding Your Boat Performance

Tachometer as Performance Indicator

Emphasizes the tachometer as a key instrument for monitoring engine RPM and diagnosing performance issues.

Performance Troubleshooting: Hull and Jet Unit

Hull Related Issues (Normal RPM)

Addresses performance problems when maximum RPM is normal, pointing to hull issues like overload or drag.

Jet Unit Issues (High RPM)

Identifies causes for high RPM with low thrust, such as blockages, impeller wear, or stator vane damage.

Performance Troubleshooting: Engine and Noise

Engine Related Issues (Low RPM)

Explains that low RPM typically indicates an engine problem related to fuel, air, or ignition.

Excessive Noise Causes

Details common causes of excessive noise like cavitation, bearing issues, or exhaust back pressure.

Troubleshooting Excessive Noise

Cavitation and Moan;Whine Identification

Describes cavitation sounds and the causes of bearing-related moans or whines in the jet unit.

Warranty Registration Form

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

This document is an owner's manual for American Turbine jet drives, including models AT-309, TJ-309, SD-309, SD-312, Dominator 12-S & 12-TD, and Legend J120-AT. It provides essential information for the safe operation, maintenance, and understanding of these jet propulsion systems.

Function Description

The American Turbine jet drives are propulsion systems for boats that use a pump to expel a high-velocity jet of water, generating thrust. Unlike propeller-driven boats, jet boats do not have external propellers, making them suitable for shallow water operation and reducing the risk of injury from rotating blades. The system includes an intake adaptor, suction piece, impeller (not explicitly labeled but implied by "pump"), bowl, nozzle housing, nozzle, reverse bucket, and tiller arm for steering.

Important Technical Specifications

The manual includes impeller selection charts for different models, indicating horsepower (H.P.) and corresponding RPM values for various impeller sizes.

For Models 12-S, 12-TD, AT-309, TJ-309, SD-309, & J120-AT (Aluminum Impeller):

• Maximum Rating: 400 BHP and 5000 RPM for aluminum impellers.
• Impeller Sizes: 9.5, 9.25, AA, A, B, C (9.5" being the largest, C being the smallest).
• Horsepower Range: 150 H.P. to 550 H.P.
• RPM Range (approximate, varies by H.P. and impeller size):
  • 150 H.P.: 2900 RPM (9.5) to 4050 RPM (C)
  • 550 H.P.: 4800 RPM (9.5) to 5850 RPM (B) (C is N/A)
• Note: Horsepower requirements are at the pump shaft. RPM values may vary depending on how the boat loads the pump.

For Model SD-312 Gen 1 Aluminum & Stainless:

• Impeller Sizes: 8.1S, 8.1A, 5.7S, 5.7A, 4.3S, 4.3A.
• Horsepower Range: 150 H.P. to 550 H.P.
• RPM Range (approximate, varies by H.P. and impeller size):
  • 150 H.P.: 3075 RPM (8.1S) to 3800 RPM (4.3A)
  • 550 H.P.: 4725 RPM (8.1S) to 5900 RPM (4.3A)
• Note: Horsepower requirements are at the pump shaft. RPM values may vary depending on how the boat loads the pump.

For Model SD-312 Gen 2 Stainless:

• Impeller Sizes (in KW): 2.4 KW, 2.6 KW, 2.9 KW, 3.3 KW, 4.0 KW, 5.0 KW.
• Horsepower Range: 150 H.P. to 550 H.P.
• RPM Range (approximate, varies by H.P. and impeller size):
  • 150 H.P.: 3600 RPM (2.4 KW) to 2825 RPM (5.0 KW)
  • 550 H.P.: 5550 RPM (2.4 KW) to 4350 RPM (5.0 KW)
• Note: Horsepower requirements are at the pump shaft. RPM values may vary depending on how the boat loads the pump.

The manual emphasizes that a larger impeller is generally more efficient, requiring less RPM for a given boat speed, leading to better fuel economy, less engine noise, and longer engine life, potentially at the expense of a slight loss in top-end speed (1-2 mph). The jet drive demands a constant load against the engine, preventing lugging as in an overloaded propeller-driven craft.

Usage Features

• Steering: Jet boats are highly responsive to steering due to the absence of torque. Tighter turns can be made, but practice at lower speeds is recommended.
• No Steering Without Power: A critical safety feature is that jet boats will not steer without power to the jet.
• Braking: Jet drives allow for quick braking by pulling the control into reverse. However, shifting into reverse at planing or high speed can result in serious injury, death, or boat damage. Conservative use of braking action is advised.
• Reverse Shift Control: The reverse bucket covers the nozzle's discharge opening in full reverse, clears it in full forward, and covers about 3/4 of the opening in neutral. It should have a provision to lock in the forward position.
• Shallow Water Operation: Jet drives are suitable for shallow water, but operating in rocky areas can lead to ingestion of small rocks and debris, causing damage to internal parts. Caution is advised in rocky water.
• Engine Cooling: The jet drive provides engine cooling. Operating the engine out of water can cause severe damage to both the engine and the jet drive.
• Hand Hole Cover: This cover provides access for inspection and maintenance. It should be tightly fastened and generally not removed in the water unless clearly above the waterline (for AT-309, 12-S, & J120-AT models).
• Boater's Responsibilities: The operator is responsible for safe operation and should understand the manual. At least one additional person should be instructed in basic operation.
• Horsepower Capacity: Do not overpower or overload the boat. Overpowering can lead to loss of control, boat breakup, serious injury, death, or boat damage.

Maintenance Features

• Pre-Operation Inspection: A thorough inspection is recommended with the selling dealer before first use, after 10-20 hours, and every three months thereafter.
• Thrust Bearing Lubrication: Lubricate every 30 hours or if the boat sits for more than 2 months, using VALVOLINE SYNTHETIC #985, SFR #2522, or equivalent. Do not use wheel bearing grease. About 4-5 pumps are recommended. Lubricate before the first outing in spring.
• Bowl Bearing Lubrication: Lubricate at winterization, summarization, and midway through the boating season using the same grease as the thrust bearing. Access is through the nozzle, requiring a long extension on the grease gun. If a Droop Snoot is present, it must be removed.
• Packing Gland Inspection (AT-309, TJ-309, 12-S, 2TD, & J120-AT):
  • The two packing gland nuts should be snug. If loose, tighten in quarter-turn increments until snug, then back off slightly less than a quarter turn.
  • After the first hour of break-in, inspect and adjust if necessary with the boat in water and engine running.
  • Excessive tightening can cause heat damage to the shaft; excessive looseness can cause air/water leakage.
• SD-309 & SD-312 Weep Hole Inspection: A weep hole indicates the condition of the mechanical seal. Water leakage suggests a failed seal or foreign debris. A blast of compressed air may clear obstructions.
• Engine Cooling Connections: Ensure all hose connections are tight.
• Transom Seals: Check for leaks at the housing seal to the boat or the housing seal to the bowl.
• Reverse Components: Inspect every 30 hours for proper function. The reverse bucket should have no play when the cable is under tension. Ensure the cable attachment to the bucket and tiller arm is secure. Adjustments can be made at the tiller arm's bulkhead fasteners.
• Hand Hole Cover: Periodically check for tightness.
• Lack of Performance: If the pump over-revs when trying to plane, it's likely due to foreign material (stick, leaf, etc.) in the impeller eye. Always remove the ignition key before placing hands inside the jet drive.
• Troubleshooting (Understanding Your Boat):
  • Tachometer: The most important instrument for performance monitoring. RPMs should remain consistent regardless of age, loading, or water conditions.
  • Normal Maximum RPM (Hull Problem): If RPMs are normal but performance is poor, check for:
    • Overload (too much weight).
    • Balance issues (weight too far aft causing nose high, or too far forward causing plowing).
    • Dragging reverse bucket.
    • Excessive hull drag (rough surface, broken keel strips, "hook" in metal hulls).
  • High RPM (Jet Unit Problem): If RPMs are higher than normal with lack of thrust, check for:
    • Blockage (weeds, stones, ski rope, fishing line, plastic bags in intake grate or around pump shaft).
    • Impeller wear (dull leading edges, increased wear-ring clearance from sand pumping).
    • Damaged bowl/stator vanes.
    • Air leaks (faulty gland seal, loose inspection cover) causing the jet unit to "slip."
  • Low RPM (Engine Problem): If RPMs are lower than usual, it's almost certainly an engine problem. Check:
    • Throttle opening.
    • Fuel supply and pressure.
    • Air supply to the carburetor (cool air).
    • Ignition system (proper spark).
    • Exhaust system (free flowing, no blockages, excessive water injection).
  • Excessive Noise:
    • Cavitation: Sounds like a rattle or loose bolts, indicating the jet unit is starved for water, often due to a blocked intake grate.
    • Moan or Whine: A new or more obvious moan/whine, especially a low-frequency grumble at idle increasing with RPM, suggests a rough/worn/water-damaged thrust bearing.
    • Periodic Vibration: Often at specific RPMs, likely torsional vibration from universal joints on the drive shaft.

The manual also includes a limited warranty section, covering defects in material and workmanship for 12 months from the date of purchase, with specific exclusions for normal wear and tear, misuse, improper installation, racing, and modifications. A warranty registration card is provided, which must be completed and mailed within 15 days of sale to validate the warranty.

American Turbine SD-312 Specifications