Electric Boats - Bumper Boats by Foster
Contents
1. Step 5 Making Electrical Plug Connections to the Prop Jet Assembly Refer to the receptacle Photo B CAUTION Be careful not to touch plugs together because it will cause a spark and blow a fuse ALWAYS work with one plug at a time leaving the ends of the plugs covered until they are ready to be installed into the receptacle Note Plugs will only go into the receptacles if the proper orientation is done to the receptacle Once the plug is properly installed and is completely into the receptacle it will be rotated slightly clockwise to lock and create a watertight connection Note When removing plugs rotate slightly counter clockwise before trying to pull out of the receptacle CAUTION As soon as one of the plugs has been removed it should have the protective cap reinstalled The same procedure of installing the protective cap should be followed when the second plug is removed Refer to Photo C Optional Squirting System If the Electric Prop Jet is set up with a squirting system it will have a second control system set up Depressing the tab over the second switch will start the water pump Release the tab and the pump will shut off The diameter suction line must be below the water line at all times Note Squirting pump is located under the motor s shroud The squirting pump is outfitted with an inline fuse to protect the pump s motor and an inline water filter is installed on the suction side of the pump 10 INSTALLIN2. Models DMR 075 E DMR 075 E6 e Operating Instructions e Preparation Safety Concerns e Maintenance WARNING Read Rules and Instructions carefully before using the Bumper Boats CAUTION READ OPERATOR S BUMPER BOAT AND BATTERY CHARGER OWNER S MANUALS THOROUGHLY BEFORE STARTING OR OPERATING BUMPER BOATS PREFACE Ride Safety Limitations Hazardous Environmental Conditions Emergency Shut Down Procedure Pool Requirements Operation and Service Manual IMPORTANT RIDE LIMITATIONS 3 Height Restrictions Operator 48 Minimum Passenger s 32 Minimum e Number Of Boat Occupants Per Boat Standard Multiple Rider 1 Operator 1 Passenger Deluxe Series Multiple Rider 1 Operator 2 Passengers e Weight Restriction Total Rider Capacity 300 Lbs Maximum e Operator Passenger Seating Operator Feet on floor and back to the seat No sitting on edge of the seat Passenger Seating cd In defined seat area Back to the seat Never on the Operator s Lap Never between Operator s Legs Never on Operator s Leg dv e Oe HAZARDOUS ENVIROMENTAL CONDITIONS THAT MANDATE THE SHUT DOWN OF THE BUMPER BOAT RIDE AND ACTIVITY Electrical Storms Never operate Bumper Boats when Lightning is present or strong potential of developing soon An unprotected electrical source is near the pool All electrical must be protected by proper G F I devices Flammables
3. Daily Inspection Required Flotation Tube Tube should be visually inspected for cuts leaks and potential leaks Tubes are made of vinyl and should be cleaned frequently and a vinyl protector applied to protect the tube and keep it from getting hard Fiberglass Boat Visual inspection should be done that all fasteners are secure Visual inspection of the fiberglass structure to identify any cracks or rough surface areas that rider s might come in contact with while they are in use of the boat Mounts and Controls Welds should be inspected i e handle bar mounting bracket and guards Fasteners should be checked for proper torque Electrical switch es plugs receptacles and bilge pump for proper functioning Inspect for proper greasing level for swivel bracket Use water resistant type grease Note Routinely inspect that all units have propeller guards in place and they are securely installed NEVER NEVER operate bumper boats without propeller guards in place 20 TROUBLE SHOOTING Problem Electric motor will not start Electrical supply cords are not correctly plugged into motor s receptacles receptacles Circuit Breakers tripped in supply cord Broken or disconnected electrical wire Defective or broken starter switch Battery charge is completely drained Problem Electrical system frequently blowing fuses Wrong size and or type of fuses slow blow fuses installed Restriction of movement a
4. Swivel Bracket Assembly and Steering Bushings 1 Routine inspection of the swivel bracket assembly Inspect the four 4 socket head cap screws making certain they are tight and secure Routinely grease the swivel bracket to avoid premature wear on the steering bushings Replace the bushings when they show excessive wear Allowing excessive wear on the bushings without replacing them will cause damage to the swivel bracket itself as well as damage and wear to the other components Inspect drive shaft housing tube bushings to make sure it is not rotating on the tube This bushing should not rotate on the tube it is intended to protect the tube from wear Note Bushing is held in place on the tube by both compression force developed by the four S H C S as well as a 5 16 18 cup point set screw on the backside Note Apply water resistant grease to the bushing and backup thrust block routinely Inspect steering bushings for proper functioning The larger outside bearing is intended to be held stationary to the swivel bracket It is held by the 7 16 O D stainless tube nipple that sticks into the sidewall of the bearing 18 The smaller inner bearing is intended to be held stationary to the motor s mounting casting It is held by the end of one of the 20 S H C S entering a hole in the bearing s flange Note Wear and pivoting is done between the two bushings when they are properly installed Note Proper pr
5. or Explosives are present or near the pool Clarity of the water is obscured or cloudy Must be able to see the bottom of the pool at all times Unsafe Water Conditions are present e Too much chemicals have been added to the water Excessive Chlorine e Polluted water Bacteria Concerns present in the pool causing unsafe conditions EMERGENCY PROCEDURE FOR SHUTDOWN FOR ALL BUMPER BOATS WITH ELECTRIC MOTORS Electric Bumper Boats have no power to the Drive Motor until the Motor s starter switch is depressed All Riders must be instructed verbally as to how the drive motor is started and stopped before the ride activity is allowed to start Procedure to shutdown an operating Electric Bumper Boat is to completely release the Normally Open Momentarily Closed contact switch After the Electric Motors have shut down and the Boats are secured to the Dock riders must be instructed and helped to leave the boat area immediately Models DMR 4G P DMR 4G P POOL REQUIREMENTS Pool Sidewall 48 Water Depth 36 IMPORTANT INFORMATION It is EXTREMELY IMPORTANT that this complete manual is read understood and instructions adhered to before and while using and installing batteries chargers and boats MANDATORY SAFETY CONCERNS AND PROCEDURES Potential explosive gases are always present and associated with batteries because they give off gases Keep flames ignited cigarettes cigars or anything that mi
6. that they should not ride bumper boats People with heart conditions should not ride bumper boats When disconnecting main electrical plugs from the motor s receptacles one plug should be removed at a time and the prongs on the plug covered before the second plug is disconnected at which time the prongs on the second plug must be covered Always record and keep complete records and accident reports when they involve personal injury No matter how slight the injury seems at the time it could be crucial at a later date 25
7. tight fit especially the first few times The fit is designed to be tight because of the nature of vinyl to stretch somewhat after initial use Lay the floatation tube on a flat surface with the valve stem facing down preferably Squirt a soapy water mixture around the inside of the tube and around the bottom of the fiberglass boat Position the boat in the center of the tube and apply equal pressure on both sides of the boat requires a minimum of two people at the same time forcing the boat down into the tube Note The straighter the boat is pushed into the tube the easier it will be to accomplish this procedure The boat should be settled into the tube until the rim rests against the tube Step 3 Installing the Batteries into the Boat It is advisable to have the tube with the boat body in the water before installing the batteries CAUTION Batteries are HEAVY approx 66 Ibs each Be careful not to strain your body It is advisable to ask for help rather than hurting yourself To install the batteries it will be necessary to carefully move the wiring harness out of the way of the batteries so as not to pinch or damage wires Lower the batteries carefully into their proper spaces Note Each battery will be wired in series and it is extremely important that the batteries are installed so that the sequence and location of the terminals is as shown in the battery compartment photo Note Wiring harness is made to fit based on proper b
8. AL SERVICE or SUPPLY near the pool is protected by PROPER GROUND FAULT protection Consult with local governing agencies Make a routine check that all nuts bolts screws and fittings are tight Never operate the motor with any of the guards missing broken or incomplete Never allow observers swimmers or by standers to be in the water while bumper boats are operating or capable of operating Never allow small riders to sit on an adult s lab or between their legs All riders must sit on the seat with the back s against the back of the seat Operators of bumper boats must be tall enough to sit completely back in the seat with their feet on the floor of the boat When a rider s height is not at least 12 greater than the water s depth a life preserver should be provided Never allow Standing or Kneeling on the bumper boats Unusual or excessive noise should be checked immediately Turn off the electric motor and review all components Maximum rider s weight capacity is 300 Ibs No food or drinks are allowed while in the bumper boats No smoking is allowed while in or around the bumper boats Signs must be posted stating that riders use the bumper boats at their own risk Propeller guards must always be in place when using bumper boats If the boats are in the general ride area they must have complete sets of proper guards installed Signs should be posted that caution person s who are pregnant or have experienced back or neck problems
9. Each operation depending on its own requirements should add to but not eliminate from this checklist 24 Rules for Safe Operation Thoroughly read and understand complete operator manuals before operating Bumper Boats Thoroughly read and understand instructions pertaining to proper and safe use of Battery Chargers Always exercise concern while working around batteries Wear safety goggles and face protection when inspecting or charging batteries Take precautions against fire and sparks Fire fighting equipment should be readily available and accessible at the bumper boat activity Handle batteries with care When replacing or removing batteries be EXTREMELY CAREFUL that loose or inappropriate wires do not come in contact with battery terminals solenoid or other connections Never charge batteries when people are in or around the boats Routinely remove corrosion from terminals and connections Periodically apply anti corrosion protection to terminals and connections Never recharge batteries in an enclosed or poorly ventilated area When an electric motor starts operating intermittently it should be immediately taken out of service until the problem can be determined There could be a chance of sparking from a short circuit Always remove inline fuses and disconnect main power to the electric motor prior to doing any work on the motor or batteries Never replace fuses with those of a greater value or type Always make sure that any ELECTRIC
10. G PROPER PLUGS INTO PROPER RECEPTACLES Plugs and receptacles have been color coded so the correct match up of the plug and receptacle is made easy Note Looking at the plug on the end of the supply cord be certain that the Green matches Green and Blue matches Blue REFER TO PHOTO B PROTECTIVE CAPS Whenever the electric supply cords are not securely installed in the proper power receptacle they should have the protective caps in place Note If the plugs of both cords were to touch each other it would cause a spark and blow a fuse REFER TO PHOTO C PROPER ROUTING OF ELECTRICAL SUPPLY CORDS TO MOTOR ASSEMBLY When the electric motor assembly is mounted in the boat the proper routing of the electrical supply cords is through the rope tie Note Be careful that proper plugs are installed in the correct receptacles Look at the color codes for proper match up REFER TO PHOTO D 11 BATTERY COMPARTMENT SHIPPED WITHOUT BATTERIES New boats are shipped from the factory without the batteries installed If the batteries were purchased from Foster Manufacturing they will be marked 1 2 3 and have color codes for proper battery terminal connections NOTE Model DMR 075 E Will have 3 12 volt batteries marked 1 2 amp 3 NOTE Model DMR 075 E Will have 6 6 volt batteries marked 1 2 3 4 5 amp 6 If the batteries are being purchased separately from others it will be necessary to follow the Battery W
11. TION MAKE CERTAIN THAT THE CHARGER IS OFF WHILE PERFORMING STEP 1 Step 1 Lift the protective cap from the charging receptacle on the back of the seat Insert the plug from the battery charger Note Plug will only go into the receptacle if proper plug orientation to the receptacle is accomplished Once the plug is properly installed and completely inserted in the receptacle it will be rotated slightly clockwise to lock and create a watertight connection When removing the plug it must be rotated slightly counter clockwise before it is pulled out of the receptacle DO NOT APPLY EXCESSIVE FORCE OR ROTATE MORE THAN SLIGHTLY Step 2 After proper connection has been made between the charge and the boat to be charged power may not be turned on for the charger Inspect the gauge on the backside of the seat to verify that the system is indeed charging Note ALWAYS VERIFY THAT POWER TO THE CHARGER HAS BEEN TURNED OFF BEFORE DISCONNECTING THE CHARGER S CORD PLUG FROM THE BOAT S CHARGING RECEPTACLE 23 Pre Opening Inspection Recorded Record for Week Ending ___ BO ATS Wednesday Thursday Friday Saturday 7 Check batten gauge very i ae T_T TO 2 Inspect omnectons to the etimo SOTTO 3 Check conifon suppy coras to moto __ f A Check battery ompariment condiion ofwires and comecions Check tor water in battery compartment bige pump working 6 applica check pump switch orsaurirgsysem _T Fappi
12. attery orientation The connection ends of the wires will be color coded so if the batteries are purchased from Foster Manufacturing they will be tagged with the proper matching colors If batteries are not purchased from Foster refer to the wiring photo for verification With the batteries in the proper location the connections can be carefully made using EXTREME CAUTION that the wire ends do not come in contact with improper terminals 9 Contact of the wrong wires with the wrong terminals will result in an arc or spark and this could present the possibility of damage or HARM After all connections have been made and verified as being correct secure terminals with the terminal wing nuts Step 4 Installing the Electric Prop Jet into the Boat Remove four 4 3 8 16 wing nuts at the mounting hole in the floor of the boat Leave the four 4 3 8 split lock washers on the mounting studs While lowering the lower unit of the Prop Jet through the floor of the boat align the four 4 holes in the mounting bracket to the studs in the floor Once in position secure the bracket to the studs using the four 4 3 8 16 wing nuts that were removed Note When lowering the Prop Jet into place be careful to properly route the two 2 cords so that they go through the rope time in the front Refer to Photo D Note The proper position of the mounting bracket will have the rope tie facing out over the front of the boat Refer to Photo D
13. cabe check for water fow from sauiring pume 8 Very complete propeller guard assembly isn place and sere o inspect fasteners and tings and ghen propery oos TTI lubricated Tec floor of the boat Make sure they are tight Inspect for proper assembly and integrity of all guards for safe Ces operating conditions n i vent caps TA Inspect and Glen any corason at batery or wing comesos 15 Ispecttubecondonforfoaaton Obseneforsignsofteakage 16 Clean motor shroud boat and ube o assure a safe rie 17 Star motorandiestridebostto very proper operating conditons al POOL AND SURROUNDINGS 1 Check water chemistry Inspect for harmful water conditions 2 Inspect the condition of rope ties for docking boats LO Lo Verify the condition and stability of handrails 4 Verify that Rules of Safe Operation are properly positioned and visible 5 Check fire extinguishers and verify proper placements oo ma Check integrity of fences and gates for proper functioning Bala If operating instructions and Rules of Safe Operation are delivered to customers via a recording verify proper functioning and clarity 8 Remove all flammable materials from ride area LO Do TT Remove all electrical cords and any potential spark generating devices Note These are basic concerns that should be addressed on a routine schedule
14. er to Top Terminal of Solenoid Switch FUSES IN THE SYSTEM 4 Fuse Set 20 amp Slow Blow 9 Fuse Set 2 amp Slow Blow 11 Fuse Set 20 amp Slow Blow SYSTEM CIRCUIT BREAKERS 5 Inside Circuit Breaker 25 amp Thermal Reset Type 17 Outside Circuit Breaker 25 amp Thermal Reset Type 17 MAINTENANCE PROCEDURES AND CONCERNS FOR ELECTRIC POWERED PROP JETS Maintaining the Performance of the Prop Jet Although the Electric Prop Jet is very simple in design it requires routine inspection The routine inspection procedure should be followed to assure good performance and minimal down time Reference Upper Unit Assembly 1 Inspect the electrical switch es to assure they are functioning properly and are in proper condition Inspect and verify that switch es are functioning properly Itis only necessary to have slight contact to actuate the control switch es Routinely check all fasteners tighten if necessary CAUTION When removing fasteners be certain to re install with a thread adhesive Loctite Routine inspection of the motor s shroud to verify it is properly installed and secured Note NEVER Operate the Electric Prop Jet without the motor s shroud in place There is the possibility of SEVER BURNS AND GREAT DANGER OF ELECTRICAL SHOCK AND HARM FROM THE ROTATING FAN BLADE 5 Routine inspection of the condition and proper installation of the electrical supply cords and waterproof plugs Reference
15. ght contribute to ignition away from batteries at all times Always wear eye and face protection when working near or around batteries During even normal battery operation hydrogen gases are being produced Batteries emit these gases through the vented caps and may form an explosive atmosphere around the battery if ventilation is poor Explosive gases may be present and continue to be present in and around the batteries for several hours after the charging cycle Despite the most modern vent cap technology an external spark may ignite the gases within or around the battery Anyone in the vicinity of an exploding battery could receive injuries from acids or flying pieces of the battery itself Never lean over a battery during testing charging or making connections Never break a LIVE CONNECTION at the terminals or receptacles because a spark will usually occur at the point where the live connection is broken ALWAYS be certain that all electrical connections are clean and tight making good connections REMEMBER a poor connection can cause an electrical arc which could ignite the gases and cause the battery to explode USING THE BATTERY CHARGER NEVER REPEAT NEVER turn the battery charger on until the plug from the charger has been properly installed into the charging receptacle ALWAYS REPEAT ALWAYS turn the charger off before disconnecting the charger s plug from the charging receptacle The room or compartmental area in wh
16. h the boat s operational functions and Ride Rules the ride is ready to start The attendant should untie and release boats from the Loading Platform when the ride cycle is started Note For safety reasons all riders should be seated completely before any boats are released Note Bumper boats must be monitored at all times by ride attendant s Step 4 When the ride cycle is completed the rider s should be directed to return to available boat slips The ride attendant s should securely tie boats to the Loading Platform Note All boats should be tied to the loading platform before any rider s are allowed to depart 22 Step 5 Ride attendant s should supervise that the departures are Orderly and Safe and that all customers that have completed their rides leave the area before starting to load the boats with new riders Note Each boat is equipped with a gauge on the back of the seat and it should be monitored throughout the operating day read the top scale for 36 volts to assure that there is an adequate charge in the batteries Procedure to Charge Batteries Note Verify and be certain that all electrical outlets and connectors meet or exceed all state and local electrical codes around and near a water environment when chargers are being used Note Thoroughly read and understand the batter charger s operating instructions NEVER repeat NEVER take a chance ELECTRICITY AND WATER DO NOT MIX CAU
17. ich the batteries are charged must be well ventilated It must always be assumed that dangerous hydrogen gases are present within the battery at all times Always wear eye and face protection when working near or starting the charging cycle READ THE COMPLETE INSTRUCTION SHEET THAT ACCOMPANIES THE CHARGER DO NOT USE THE CHARGER UNTIL COMPLETE INSTRUCTION SHEET HAS BEEN READ AND UNDERSTOOD PREPARATION PROCEDURE FOR BUMPER BOATS WITH ELECTRIC POWERED PROP JETS Step 1 Inflating Bumper Boat Tube The floatation tube is made of very durable and tuff PVC material Because of the heavy wall thickness and material hardness minimum air pressure is required The tube should be inflated so that it feels firm to the touch Never inflate the tube so that it feels rock hard Ifa low range pressure gauge is available it should be used to determine when the tube has been inflated to 2 4 3 psi NEVER INFLATE TO MORE THAN 3 psi AT ANY ONE TIME Note After the tube has been inflated pour a little water around the valve stem to verify that it is not leaking Once the valve stem is capped the tube can be placed in the water with the stem in the water instead of facing up A valve stem that is not readily accessible sometimes is better because it will not be tampered with and the chance of over inflating the tube is reduced Step 2 Assembly of Fiberglass Boat into the Tube The insertion of the boat body into the center of the PVC tube will be a
18. iring Illustration supplied in this manual NOTE For models DMR 075 E refer to the battery compartment illustration with 3 12 volt batteries NOTE For models DMR 075 E6 refer to the battery compartment illustration with 6 6 volt batteries REFER TO PHOTO E 12 Right Control Left Control Operates Drive Motor Operates Water Pump for Squirt Gun OPERATIONAL CONTROLS Photo A 2 Electrical Supply Cords POWER RECEPTACLES Photo B Rope Tie Suction Line for Squirt Gun MOTOR ASSEMBLY Photo D POWER SUPPLY CORDS Photo C 13 si BATTERY COMPARTMENT Photo E 14 gt na ke Te Le WIRING ILLUSTRATION FOR MODEL DMR 075 E KEY NO DESCRIPTION AND ROUTING 1 Battery 1 Black Wire from Charging Receptacle 2 Battery 2 White Wire from Charging Receptacle 3 Battery 1 Black Wire from Gauge 4 Battery 2 White Wire from Gauge 5 Battery 1 Black Wire to Diode bottom terminal solenoid 6 Battery 1 White Wire from Blue Cord Set 7 Battery 1 Black Wire from Blue Cord Set 8 Top Terminal of Solenoid Black Wire from Green Cord Set 9 Bottom Terminal of Solenoid Green Wire from Green Cord set 10 Battery 1 White Wire from Green Cord Se 11 Battery 2 White Wire Top Terminal of Solenoid 12 Battery 3 to Battery 2 Jumper 13 Battery 1 to Battery 3 Jumper 14 Battery 2 Black Wire of Bilge Pump 15 Battery 2 Brown Wire of Bilge Pu
19. klist for inspection prior to making the boats available to the customers Record keeping is important Step 1 Loading assistance of rider s should be offered to avoid accidents due to slipping or falling Before the ride starts the rider s must be seated completely and Rules of Safe Operation and instructions should be thoroughly reviewed with the riders If the passenger s height is less that 12 greater than the water s depth a floatation life vest should be supplied to the passenger s before they are allowed on the platform Step 2 The attendant should instruct and familiarize the rider to the operational control s The boat is powered by depressing the switch on the right of the handle assembly Refer to Photo A A Press switch and drive motor starts and will immediately come up to maximum speed As long as the switch is held the motor will run at maximum speed B Release the switch and the drive motor stops rotating immediately Note There is only one speed and there is no throttle provided Step 2a An Electric Prop Jet set up with a squirting system will have a second energizing switch located on the left side of the handle assembly Refer to Photo A A Press switch and the pump will start pumping water to the squirting nozzle and a stream of water will start coming out of the nozzle in the shroud B Release the switch and the pump will stop and so will the stream of water Step 3 After the rider is familiar wit
20. mp 16 Diode connected to Bottom Terminal of Solenoid and 5 Wire FUSES IN SYSTEM 6 20 Amp Slow Blow 11 25 Amp Slow Blow 7 20 Amp Slow Blow 15 2 Amp Slow Blow 10 20 Amp Slow Blow Note Squirting Pump has separate fuse located at the pump 15 16 WIRING ILLUSTRATION FOR MODEL DMR 075 E6 DESCRIPTION AND ROUTING Black wire from Gauge to Post Of Battery 6 Black wire Diode Connection Bottom Solenoid Terminal Post Battery 6 Black wire from Charging Receptacle Post Battery 6 Red wire Fuse Set Post Battery 6 connected with White wire of Blue Cord Set Black wire from inside Circuit Breaker Post Battery 6 Black wire from Bilge Pump Post Battery 4 White Jumper Post Battery 5 to Post Battery 6 White Jumper Post Battery 3 to Post Battery 4 Red wire Fuse Set Post Battery 3 to Brown wire of Bilge Pump White Jumper Post Battery 2 to Post Battery 3 Red wire Fuse Set Post Battery 4 connected with White wire of Green Cord Set White wire from Charging Receptacle Post Battery 1 Black wire from Inside Circuit Breaker to Black wire of Blue Cord Set White Jumper Post Battery 1 to Post Battery 2 White wire from Gauge Post Battery 1 Green wire of Green Cord Set to Bottom Terminal of Solenoid Switch White wire from Outside Circuit Breaker Post Battery 1 Black wire from Green Cord Set to Top Terminal of Solenoid Switch White wire from Outside Circuit Break
21. ocedure for greasing the steering bushings is to pivot the assembly at the same time as applying grease It is EXTREMELY IMPORTANT THAT THE MOTOR ASSEMBLY IS ROTATED WHILE APPLYING GREASE TO ASSURE PROPER DEPOSIT IN ALL OCATIONS ALWAYS USE WATER RESISTANT GREASE Reference Lower Gear Case Assembly For Model FPJ 075 P 1 Periodic inspection of the gear case is a good practice Be certain that the end caps are tightly in place and there is no leakage Note End caps are held from rotating or loosening by one cup point set screw on each end of the gear case CAUTION When removing the setscrews be certain that before they are re installed Loctite is applied to the threads CAUTION BE CAREFUL NOT TO OVERTIGHTEN SETSCREWS Note When removing end caps a 2 spanner wrench is required Be careful not to cut O rings or pinch them when reinstalling the caps Note Gear case assembly has been serviced at the factory with a premium quality S A E 80w 90w gear lube Recommended capacity is 9 ounces It is recommended that gear case lube be changed once a year Procedure to follow is as outlined A Position the engine in the upright position B Place an adequate size container under the gear case Capacity should be one 1 quart size or larger C The back gear case cap will be removed to drain the gear lube Loosen setscrew that is at the edge of the cap Using a 2 spanner wrench turn the cap counter clockwi
22. se removing it from the case Allow all the gear lube to drain out D To refill gear case position the Prop Jet on the floor Position the lower unit so that it is resting on the propeller guard Now place blocking under the guard so to support the lower unit Raise the lower unit until the drive shaft housing tube is horizontal to the floor E Fill the gear case with Premium Grade gear lube S A E 80w 90w Allow time for the gear lube to purge through bearings Raise the lower unit so it is higher than the motor causing the whole bearing cavity to fill in the drive shaft tube Return the lower unit to a level position and refill the case to the top of the backside of the driver gear Total volume of gear lube being used is approximately 13 ounces F Apply a film of grease to the O Ring on the end of the cap Re thread cap into the gear case using the 2 spanner wrench 19 CAUTION Make sure that cap is completely re installed Properly positioned the flat shoulder of the cap will stop at the flat shoulder of the gear case The end cap will be flush with the gear case G Completely remove the setscrew at the edge of the gear case Clean the setscrew and apply Loctite and re install Do Not Over Tighten 3 Inspect the propeller guard assembly to make certain it is secure to the gear case 4 Inspection of zinc anode should be done periodically Replace the anode when signs of significant deterioration are present
23. t the propeller shaft around the shaft Failed bearings in lower unit Damaged or misaligned gears in lower unit Replace or re position to proper mounting distance Defective or short circuiting drive motor If motor is drawing excessive current consult factory Problem Diminished speed or no power Possible Cause Corrective Action Very low battery charge Faulty or defective starter switch Restriction of inlet side of propeller guard Shear pin broken Worn or damaged propeller Inspect and reinstall or replace cd Key loose out of drive gears Inspect and reinstall or replace Do Short circuiting of drive motor Have a qualified electrician verify and replace if necessary d K Problem Bilge pump not functioning Possible Cause Corrective Action DI Blown fuse Replace w 2 amp slow blow Disconnected wires Reconnect wires properly Debris lodged in impeller Clean and remove debris Faulty float computer chip or defective motor Repair or replace unit 21 OPERATING PROCEDURE FOR BUMPER BOATS Note Operation can be done only after proper wiring installation has been done and batteries are adequately charged CAUTION All attendants involved in ride operation should be well informed and familiar with Rules of Safe Operation motor characteristics and control functions of the bumper boats All boats should go through a Daily Chec
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