American Turbine SD203 User manual

SD203
OWNER MANUAL
SUPER DUTY JET
203mm Axial Flow
THE POWER IS IN THE PUMP

OWNERS MANUAL
AMERICAN TURBINE SD-203
Before Operating your jet boat
Read this manual carefully. Learn how to operate your boat properly. If you have any questions, contact your dealer.
Safety and operating information that is practiced along with using good common sense can help prevent personal injury and
product damage.
Boat Horsepower Capacity
Do not overpower or overload your boat. Using an engine that produces such power so that you have less than 8 pounds per
horsepower can 1. Cause loss of boat control 2. Cause boat to break up from excessive power. Overpowering a boat can
result in serious injury, death or boat damage.
Boater’s Responsibilities
The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public.
It is strongly recommend that each operator (driver) read and understand this entire manual before operating the boat.
Be sure at least one additional person on board is instructed in the basics or starting and operating the boat in the case the
driver is unable to operate the boat.
Check with you dealer before installation of accessories. The misuse of acceptable accessories or the use of unacceptable
accessories can result in serious injury, death, or product failure.
PRE OPERATION INSPECTION
The following inspection should be performed with the help from the SELLING DEALER prior to jet drive operation. The same
inspection should be performed by the user or selling dealer after the first 10- 20 hours of use and regularly thereafter every
three months. If any items of the inspection list do not meet inspection guidelines, they should be corrected before using the
jet drive. PLEASE NOTE, this jet is equipped reverse sense steering, which means that your boat will operate different than an
automobile when in reverse. This is easily overcome by steering in the direction you want the bow to go when in reverse.
1. Thrust Bearing Lubrication. The bearing is lubricated at the factory before shipment. Lubricate every thirty hours or if
the boat sits for more than 2 months. Lubricate before you take it out, about 4-5 pumps in the thrust bearing. Do not
force grease in the bowl bearing.
2. Hand Hole Cover. Check to make sure that the hand hole cover is tightly fastened.
3. Steering. Check the steering by rotating the wheel right and left with the engine off and verify that the nozzle turns completely
against the housing to which it is attached.
4. Reverse Shift Control. With the control in full reverse, the reverse bucket should completely cover the nozzle's discharge
opening. In full forward, the reverse bucket should clear the entire nozzle discharge opening. In neutral, the reverse
bucket should cover about 3/4 of the discharge opening. The reverse bucket should have a provision to lock it in
the forward position so that the bucket cannot fall into the water stream.
5. Throttle. Check to see that the throttle is operating smoothly.
6. Transom Seals. There should be no leaks at the housing seal to the boat or the housing seal to the bowl.
7. SD-203 Weep Hole Inspection. A weep hole is provided to indicate the condition of the mechanical seal.
Water running out the hole is an indication of a failed seal or that there is foreign debris between the seal faces i.e. fishing
line etc. A blast of compressed air in the weep hole will sometimes clear the obstruction. If it continues to leak, consult
your dealer.
8. Engine Cooling Connections. Check to make sure all hose connections are tight.
OWNERS MANUAL
1. Trailer Launching. Before launching make sure that all drain plugs are in place securely. To drive off of the trailer, the
intake part of the jet drive should be immersed in the water. Use low speed and gentle handling when driving on or off
the trailer.
2. Starting. Always start your boat in neutral. Warm up engine properly.
3. Break-In Time. The thrust bearing and the mechanical seal need break-in time to insure long life.
4. SD-203 Weep Hole Inspection. A weep hole is provided to indicate the condition of the mechanical seal.
Water running out the hole is an indication of a failed seal or that there is foreign debris between the seal faces i.e. fishing
line etc. A blast of compressed air in the weep hole will sometimes clear the obstruction. If it continues to leak, consult
your dealer.
Practice. It is a good idea to use the recommended break-in period of the engine and jet drive to get the "feel" of your new jet
drive powered boat. It should be handled in the beginning at low speeds and with gentle turns. Because of the jet drive's natural
absence of torque, steering is much more responsive than propeller driven boats. Since tighter turns can be made in a jet
drive boat, be sure to practice these carefully at lower speeds until you are completely familiar with the handling characteristics
of your boat. PLEASE NOTE, this jet is equipped reverse sense steering, which means that your boat will operate different than an
automobile when in reverse. This difference easily overcome by steering in the direction you want the bow to go when in reverse, a
little practice in a safe area is recommended.

IMPORTANT, jet boats will not steer without power to the jet. A jet drive propelled boat has the ability to brake quickly unlike
boats using a propeller that must contend with gears. At no-wake and low speeds the jet driven boat maybe halted by pulling the
control into reverse. Shifting into reverse at planing or high speed, can result in serious injury, death or boat damage.
PLEASE NOTE, this jet is equipped reverse sense steering, which means that your boat will operate different than an automobile
when in reverse. This is easily overcome by steering in the direction you want the bow to go when in reverse, a little practice in a
safe area is recommended.
GENERAL MAINTENANCE
1. Lubrication. Thrust bearing; inspect regularly, at least every thirty hours of operation or if the boat sits for more than 2
months. Grease the thrust bearing before you take it out. Lubricate the thrust bearing using VALVOLINE SYNTHETIC #
985, or the equivalent. Grease must be EXTREME PRESSURE, HIGH TEMPERATURE, and must contain MOLY. NOTE: DO NOT
USE WHEEL BEARING GREASE. Bowl bearings, lubricate at the time of winterization, summarization, and once midway through
the boating season. Use the same grease as the thrust bearing. The grease zerk is located at the discharge end of the jet drive.
Access to the grease zerk is through the nozzle, a long extension on your grease gun will be required. NOTE: Be sure to grease the
bearing before your first outing in the spring. Most thrust bearing failures occur then.
2. Reverse Components. The reverse bucket should be inspected every thirty hours for proper function. The reverse
bucket should not have any play when the cable is under tension. The cable attaches to the reverse bucket with a pivot
pin. Make sure this attachment is secure. Also make sure that the reverse cable is secure where it passes through the
bracket. Adjustments to the reverse bucket position can be made by tightening the bulkhead fasteners at the bracket
3. Steering. You should check all steering cable connections, each trip for safety. These include the transom housing
steering nut, the tiller arm-to steering tube connection, the tiller shaft set screw and the lower nozzle pin cap screw
4. Hand Hole Cover. Check the hand hole cover for tightness periodically.
5. Lack of Performance. If the pump over revs when trying to get on plane, it is probably due to a stick, leaf or something
else in the impeller eye. Remove any foreign material from the impeller. REMOVE THE IGNITION KEY BEFORE
PLACING YOUR HAND INSIDE THE JET DRIVE.
PRECAUTIONS AGAINST CORROSION
1. Salt water operation. The SD203 is designed for a trailer boats and is not intended for boats that are moored in salt or brackish
water. It can be used in salt water but must be flushed with fresh water after daily use. It is recommended that your SD203 be dis-
assembled down to the impeller and remove all signs of corrosion and coat all mating parts with an anti-corrosion compound such
as LANOCOTE. Also steering parts need to be cleaned and coated.
SAFETY
1. Retrieving Skiers. We recommend shutting off the engine when retrieving downed skiers.
2. Ski Ropes. Ski ropes should be avoided if possible to insure that they are not sucked into the pump. Should you run
over the rope turn the engine off immediately. Shut off the engine while retrieving the rope. There is a certain amount of
danger in retrieving the rope with the engine running, i.e. should the line be sucked up and a person become entangled it
could be possible for them to be drawn under water and drowned. REMOVE THE IGNITION KEY BEFORE PLACING
YOUR HAND INSIDE THE JET DRIVE.
3. Shallow Water Operation. When the boat is operated in shallow, rocky water, ingestion of small rocks can cause damage
to internal parts. No system can keep all the debris and rocks and allow enough water through to operate properly.
So, remember to be careful in rocky water.
4. Braking At Speed. Be sure to use the braking action conservatively because the effect is much the same as an emergency
stop in an automobile.
5. Engine Cooling. Do not operate the engine out of the water as severe damage to the engine and jet drive could result.
LIMITED WARRANTY
1. American Turbine, Inc. warrants, to the first original retail purchaser, each new jet drive unit manufactured by American
Turbine, Inc. to be free from defects in material and workmanship.
2. The warranty extends for 12 months from the date of purchase.
3. Claims under this warranty shall be made by returning the defective part freight prepaid to American Turbine, Inc.
4. Any jet drive or part determined to be defective in either workmanship or material during the warranty period will be repaired
or replaced at American Turbine, Inc.'s option, without charge for parts or labor. American Turbine, Inc.'s liability shall be limited
to repairing or replacing part found to be defective during the warranty period.
5. American Turbine, Inc. reserves the right to change or to improve the design of any product without assuming any obligations
to modify such units previously manufactured.
EXCLUSIONS AND LIMITATIONS
This warranty does not apply to:
1. Any part, accessory or product not manufactured by American Turbine, Inc., And for which Manufacturer warranty has been
supplied to the consumer by the respective manufacturer.
2. Normal Maintenance items such as lubrication and adjustments necessary as a result of normal wear and tear.
3. Any jet drive or part that has been modified, altered, or repaired by other than American Turbine, Inc.
4. Products damaged as a result of misuse, neglect, negligence, accident, freezing, normal wear and tear, corrosion, salt
water corrosion, improper installation, operation with lubricants which are not suitable for use with the jetdrive, failure to operate
and maintain the product in accordance with the owner's manual supplied with each new American Turbine product, products
used for racing, damage resulting from debris, or other substances entering through the jetdrive, operating the jetdrive at
RPM in excess of the maximum rated RPM as stated in the owner's manual, or any case other than a defect in the manufacture,

material, or assembly of an American Turbine, Inc.
5. American Turbine, Inc. shall not be liable for any incidental, consequential or other damages whatsoever, including but not
limited to: loss of use, loss of time, inconvenience, cost of returning the defective product to American Turbine, Inc., travel,
lodging, or damage to personal property.
6. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply to you.
7. This warranty is the only express warranty applicable to American Turbine, Inc. products, and is in lieu of any other express
or implied warranties, including warranties of merchantability and fitness
for a particular purpose. All implied warranties are limited in duration to minimum period required by State law. American Turbine,
Inc. neither assumes or authorizes any other person to assume for it any other liability or warranty in connection with its
products,
8. Some states do not allow limitations on the duration of implied warranties, so the above limitations may not apply to you.
9. This warranty gives you specific legal rights, and you may also have other rights which may vary state to state.
UNDERSTANDING YOUR BOAT
Most boat owners like to perform at least a certain amount of their boat maintenance themselves to ensure continuing good
performance and reliability.
To avoid unnecessary trips to the service center, it might be useful to have a checklist, which can be run through
systematically, in the hope of pinpointing the problem quickly. The boat can be divided into three categories - jet unit, engine,
and hull.
If something is "wrong" with the boat it is usually poor acceleration and load carrying, coupled with excessive fuel
consumption or engine RPM's. It could be unusual noise coming from the mechanicals, or possibly just poor top speed. All of
these things may be present to some degree, but the usual complaint is that the boat is just plain "gutless".
TACHOMETER
The most important single instrument on the boat when considering performance drop-off is the engine tachometer.
The great thing about jet boats is that the engine RPM's should remain the same throughout the life of the boat, regardless of
age, loading, water conditions, towing, whatever.
There is no situation where the RPM's should be different from when the boat was new, and as an owner, you will
know what these are. At any time, you should be able to open the throttle fully and get exactly the same maximum reading you
have been used to. Or perhaps you are finding it needs more RPM's to cruise your normal load? RPM's are a most important
indicator of proper operation of the boat.
It is important at this stage to feel confident that your tachometer is reading accurately.
Now we come to our check list, and determination of which major area is the problem. The simplest way is a check
on the RPM's first. They could be normal, high, or low, and this will pin point the place to look:
A. Normal maximum RPM = hull problem.
If the boat is performing poorly and the maximum RPM's are normal and what you are used to, you can look to the
hull and some of the external parts. These include:
1. Overload: Too much weight aboard.
2. Balance: Either too much weight aft, which will cause the nose to be too high and make planing difficult, or if the weight is
too far forward, it will cause the nose to plow, difficult steering, wetness, and poor top speed.
3. Reverse bucket: Is the bucket dragging in the reverse stream? Make sure the control is fully up.
4. Excessive hull drag: Is there some external hull obstruction such as rough surface, broken keel strips, or other reason impeding
the smooth flow of water over the hull bottom? A visual check on the trailer should reveal if there is. Metal hulls can
have a "hook" bashed into them forward of the transom which can cause the bow to plow. The planing surface forward of the
transom six to nine feet should be true and flat.
B. High rpm = jet unit problem.
Higher than normal RPM's, lack of thrust, slipping clutch feel, engine racing and no go?
1. Blockage: The most common problem is weeds and stones blocking the intake grate. Also be aware of ski rope, fishing line
and plastic bags winding around the pump shaft. Small sticks and stones can become lodged in the impeller affecting the
performance
dramatically, objects trapped in the impeller can cause the rotating assembly to be out of balance, causing severe
vibration. Make sure the water passage through the jet is clear.
2. Impeller wear: The heart of the jet is the impeller, and its condition. If you run in shallow gravel beds or across sandbars the
leading edges will become dull and inefficient. Pumping sand will increase the wear-ring to impeller clearance. Causing cavitations
and loss of performance.
3. Bowl / stator vanes: It's not too much of a problem, but the leading edge of the fixed stator vanes can become blunt and
damaged.
4. Air leaks: If excessive air leaks into the intake ahead of the impeller, the jet unit will "slip". Possible sources of air leaks are
through a faulty gland seal, which is usually accompanied by a static water leak into the boat when standing idle.
So if the gland is worn out and leaking into the boat with the engine off, it can also suck air when accelerating on to plane, and
if this happens, then the thrust is reduced dramatically. Air can also be introduced into the system via the inspection cover, so
you will want to make sure the cover is tight.
C. Low RPM = engine problem
There is generally no way the jet unit can overload the engine and bring the RPM's down. If the RPM's are down
from usual, it is almost certain to be an engine problem. A compression check will usually reveal leaking piston rings or valves,

but the most common reasons for reduced engine power are:
1. Throttle: Check that the throttle is opening fully.
2. Fuel: The fuel supply must be adequate for the engine size. Racing boats frequently have a fuel pressure gauge which is,
with the tachometer, probably the most important engine instrument. Sufficient fuel must be reaching the engine.
3. Air to the engine: The carburetor must be getting its full quota of cool air. If the engine has to work to get adequate air, and if
it is hot air, this will reduce power.
4. Ignition spark: Be satisfied the ignition system is operating properly. A problem here is usually indicated by a rough running
or missing engine.
5. Exhaust: Check for a free flowing exhaust system. Some silencers can become blocked, rubber hoses disintegrate internally,
or there is excessive water injection. Such things can cause excessive back pressure and reduce power.
Provided your engine is getting its full quota of air and fuel, and is getting enough spark and at the right time, the engine
will usually be OK, and maximum RPM's will result. However if the RPM's are down and you believe the tachometer, look
for an engine problem. The hull, engine, and jet unit are the three main areas to look at when your performance is down.
D. Excessive noise.
This can often be a concern even if there is not a reduction in performance. The most common causes of noise are:
1. Cavitation: The jet unit is starved for water, and usually sounds like a rattle or a can of loose bolts in the back of the boat.
Most likely a blocked intake grate.
2. Moan or whine: The jet unit can exhibit some "turbine whine" not unlike a turbocharger noise but you will know what is usual
with your boat. However, if you have a new more obvious moan/whine, especially if it is a very low frequency grumble at idle,
that increases with engine RPM's then it is likely to be a rough/worn/water damaged thrust bearing. If water has gotten into the
bearing, it is usually as a result of a flooded bilge at some time on a warm bearing, then water can be sucked in as it cools.
3. Periodic vibration: Often at specific RPM's and disappearing at other throttle openings is probably a torsional vibration emanating
most likely from the universal joints on the drive shaft.
AMERICAN TURBINE
3692 RIVERSIDE DR.
CLARKSTON, WA 99403
PHONE: [phone]
FAX: [phone]
INTERNET: WWW.AMERICANTURBINE.COM
WARRANTY REGISTRATION
1. Owners Name _______________________________________ Phone Number _______________________________
2. Address ___________________________________________________________ City ___________________________
3. State _________ ZIP _________________ E-mail ________________________________________________________
4. Dealer Name ___________________________________________ Dealer Phone Number ________________________
5. Jet Drive Model _____________________________________ Serial Number ________________
6. Engine Make _______________________________________ Size ______________________
7. Boat Make _______________________________ Model _______________________________________ Length ______
8. Primary Use - Pleasure-----Commercial------Freshwater-------Saltwater
9. Pre-Delivery Inspection Completed ______ Yes ______ No Date ___________ Inspection must be completed by Dealer
10. Date of Sale ___________________ Date Put in Service _____________________
11. Owner Signature ______________________________________________________________ Date ________________
12. Dealer Signature ______________________________________________________________ Date ________________
This Warranty Card must be completed and mailed to American Turbine. The jet drive warranty is void if registration is not mailed within 15 days of date of sale.
AMERICAN TURBINE
3692 RIVERSIDE DR.
CLARKSTON, WA 99403

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American Turbine
SD203
79

American Turbine
SD203
ITEM # DESCRIPTION PART # QTY.
1 SUCTION PIECE, SD203-312 SC1401 1
2 PUMP SHAFT, SD203, 309, 312 SH1207 1
3 THRUST BEARING (SD & FW) B1101 1
4 BEARING SLEEVE, SD203, 309, 312 SH5001 1
5 NUT, BEARING SLEEVE, SD203, 309, 312 SH5101 1
6 SNAP RING, SHAFT SH1507 1
7 SEAL FACE HOUSING, SD203, 309, 312 SH5201 ALUM 1
8 SEAL, SEAL FACE HOUSING SL1201 1
9 SEAL, MECHANICAL (SD & YJ) SL4008 1
10 5/32 X 2 COTTER PIN F03 16 CP 1
11 O-RING, BEARING HOUSING, SD203, 309, 312 O3301 2
12 O-RING, SEAL FACE HOUSING, SD203, 309, 312 O3401 1
13 BEARING HOUSING, SD203, 309, 312 SC2101 1
14 ENGINE MOUNT RING (BEARING CAP) SC4007 1
15 GREASE ZERT SC8901 2
16 SEAL, BEARING HOUSING SD203, 309, 312 SL1101 1
17 5/16-18 X 4-1/2 HEX HEAD CAP SCREW F05 18 36 HH 6
18 5/16 LOCK WASHER F05 LW 24
19 HAND HOLE COVER, SD203, 312 SC1801 1
20 O-RING, HANDHOLE COVER, BERK, SD & FW O1002 1
21 WATER TUBE, (SD203, 312) SC4201 1
22 O-RING, WATER TUBE, SD203, 312 O3801 1
23 IMPELLER KEY SH3007 1
24 5/16 CLEVIS PIN F05 CL 2
25 7/64 X 3/4 COTTER PIN F02 04 CP 2
26 3/8 EYE BOLT F06 EB 2
27 3/8 THICK WASHER (SD HAND HOLE COVER) F06 TW 2
28 3/8 LOCK WASHER F06 LW 10
29 3/8 WING NUT F06 WN 2
30 VINYL CAP, 3/8 M5001 2
31 WEAR RING, SD203AF, STAINLESS STEEL WR203SS 1
32 3/8-16 HEX NUT F06 16 HN 8
33 O-RING, SD-312 BOWL O4001 1
34 WEAR RING INSULATOR (SD203, 312) WR6005 1
35 O-RING, WEAR PLATE, SD203AF O5172 1
36 INTAKE, WELD-IN, SD-312 I1401 1
37 GRATE, INTAKE, SD203, 312 I4401 1
38 5/16-18 X 1-1/2 SET SCREW F05 18 12 SS 8
39 5/16 AN FLAT WASHER F05 AN 4
ITEM # DESCRIPTION PART # QTY.
40 5/16 -18 LOCK NUT F05 18 LN 4
41 O-RING, INTAKE, SD-312 O3901 1
42 5/16-18 X 1 HEX HEAD CAP SCREW F05 18 08 HH 2
43 5/16 FLAT WASHER F05 FW 10
44 5/16-18 X 1-1/4 HEX HEAD CAP SCREW F05 18 10 HH 8
45 STATOR, SD203 SC9312 1
46 BOWL, SNAP RING SC9201 1
47 BOWL PLUG SC9001 1
48 O-RING, BOWL PLUG O2203 1
49 BOWL BEARING, GREASE LUBE 3/4 B1502 2
50 SEAL, BOWL (AT, BERK, LATE DOM) SL2003 2
51 5/16-18 X 3/4 HEX HEAD CAP SCREW F05 18 06 HH 4
52 3/8-16 X 2 SET SCREW F06 16 16 SS 8
53 NIPPLE, WATER COOLING TUBE (SD203, 312) SC4101 1
54 IMPELLER, STAINLESS, AXIAL, SD203AF, 2.8KW IMX203-280 1
55 NOZZLE HOUSING, SDR (SD203) SR1007 1
56 NYLINER BUSHING, SPLIT (3/4) (WJ STR, HVR) B2007 4
57 SDR, NOZZLE, (AXIAL FLOW) SR1009 1
58 NOZZLE INSERT, AXIAL, SIZE 4.200 SR7420 1
59 5/16-18 X 1/2 SOCKET HEAD CAP SCREW F05 18 04 SH 1
60 5/8-11 X 1 SOCKET HEAD CAP SCREW W/ 5/8
PIVOT HEAD - TYP 304 R3702 2
61 SDR, TILLER ARM, (AXIAL) SR3009 1
62 BUCKET STOP, SDR REVERSE BUCKET SR5101 1
63 1/4-20 X 3/4 SOCKET HEAD CAP SCREW F04 20 06 SH 1
64 SDR, REVERSE BUCKET SR2101 1
65 5/8-11 X 5/8 SOCKET HEAD CAP SCREW W/
3/4 PIVOT HEAD - TYP 304 R3703 2
66 1/4-28 STAINLESS FEMALE ROD END (BEST, JET
TRIM) F04 28 FRE 1
67 1/4 CLEVIS PIN F04 CL 1
68 5/64 X 3/4 COTTER PIN F01 06 CP 1
69 3/8-24 X 1-1/4 HEX HEAD CAP SCREW F06 24 10 HH 2
70 3/8-24 LOCK NUT F06 24 LN 2
71 3/8-24 HEX NUT F06 24 HN 1
72 SDR OFF-SET STEERING EXTENSION, SS TUBING SR6101 1
73 O-RING, NOZZLE HOUSING, SD191, SD203,
TJ191 O5001 1
74 5/16-18 HEX NUT F05 18 HN 4
75 3/8-24 MALE ROD END F06 24 MRE 1
76 O-RING, TEFLON, NOZZLE, SD203 O5363T 1
77 IMPELLER NUT SH3507 1
78 SDR REVERSE CABLE BRACKET, AXIAL FLOW SR2009 REV 3 1
79 IMPELLER SHIMS SHK4007 1

American Turbine
SD203
INTAKE ADAPTER
GREASE ZERK
for THRUST BEARING
MECHANICAL SEAL
IMPELLER
GREASE ZERK for
STATOR BEARINGS
NOZZLE INSERT
ROCK GRATE

American Turbine
SD203
BEARING HOUSING
GREASE ZERK
WEEP HOLE HAND HOLE
COVER STEERING
EXTENSION
REVERSE
BUCKET
INTAKE
ADAPTER SUCTION PIECE STATOR STEERING NOZZLE
NOZZLE
HOUSING

FASTENER TORQUE
1/4" 10 FT/LBS
5/16" 15 FT/LBS
3/8" 20 FT/LBS
1/2" 40 FT/LBS
5/8" 45 FT/LBS
USE HIGH STRENGTH
LOC-TITE ON ALL
STEERING FASTENERS
SD203 SPECIFICATIONS
wear ring .045-.055"
Clearance between impeller and
IMPELLER / WEAR RING SPECIFICATIONS
Wear ring I.D. 8.005-8.000"
Impeller O.D. 7.955-7.950"
A
FROM HUB
DETAIL A
MEASURE IMPELLER
WEAR RING
TO 0.030 FORWARD FROM THE BACK
OF THE WEAR RING.
PUT STRAIGHT EDGE
ACROSS WEAR RING. SHIM IMPELLER