Yanmar SD20, SD50, SD50-4T Operation Manual

Sail-Drive

OPERATION MANUAL

SD20 SD50

SD50-4T

P/N: 0ASDM-G00101

SAIL-

DRIVE

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine International.

0309

ii SD Operation Manual

TABLE OF

CONTENTS

Page

Introduction......................................................................1

Safety...............................................................................3

Safety Precautions.........................................................3

General Information ................................................. 4

Before You Operate .................................................4

During Operation and Maintenance .............................5

Product Overview..............................................................9

Overview......................................................................9

Owner / Operator Responsibilities ...............................9

New Sail-Drive Break-In: ...........................................9

Dealer / Distributor Responsibilities .............................9

Component Identification...............................................10

Galvanic Corrosion.......................................................11

Corrosion Control.........................................................11

Shore Power...............................................................12

Underwater Drive Coating..............................................13

Before You Operate..........................................................15

Propeller Selection.......................................................16

Recommended Propeller Size (Maximum) .................. 16

Fitting a Fixed Propeller (2-Blade) ............................. 17

Lubricating Oil.............................................................18

Filling With Lubricating Oil - SD20, SD50 and SD50-4T.........19

Checking the Instrument Panel Alarm System.....................20

Daily Checks...............................................................23

Visual Checks....................................................... 23

Sail-Drive Operation.........................................................25

Remote Control Device Check........................................26

SD20 .................................................................. 26

SD50 / SD50-4T.................................................... 28

Engine Cooling Water...................................................29

SD20 .................................................................. 29

SD Operation Manual iii

TABLE OF CONTENTS

SD50 / SD50-4T.................................................... 30

Periodic Maintenance.......................................................31

Tightening Fasteners....................................................33

Torque Charts.............................................................34

Standard Torque Values ......................................... 34

Standard Torque Chart ........................................... 34

Periodic Maintenance............................................. 35

Periodic Maintenance Table...........................................36

When The Vessel Is Out Of The Water, Perform The

Following:...................................................................38

Removing Deposits From The Lower Gear Case .......... 38

Repairing Damaged Coating .................................... 38

Inspecting the Anode.............................................. 38

Inspecting The Folding Propeller............................... 38

Draining Water...................................................... 38

Periodic Maintenance Procedures....................................39

After Initial 50 Hours of Operation.............................. 39

Every 100 Hours of Operation .................................. 48

Every 250 Hours of Operation .................................. 49

Every 500 Hours of Operation .................................. 49

Every Year ........................................................... 50

Every 2000 Hours of Operation................................. 51

Every 5 Years ....................................................... 51

Specifications..................................................................53

System Diagrams.............................................................55

Maintenance Log.........................................................80

iv SD Operation Manual

INTRODUCTION

This Operation Manual describes Sail-Drive Models SD20, SD50, SD50-4T. For engine handling and operation, refer to the respective operation manuals for Engine Models 1GM10C, 2YM15, 3YM20, 3YM30, 3JH4CE, 3JH5CE, 4JH4ACE, 4JH5CE and 4JH4-TCE. However, instructions for the marine gear box are not necessary as they are included.

Engines and Sail-Drive combinations are available as follows:

Engine model Sail-Drive Model

1GM10C

SD202YM15

3YM20, 3YM30

3JH4CE

3JH5CE

4JH4ACE

4JH5CE

4JH4-TCE SD50-4T

SD50

SD Operation Manual 1

INTRODUCTION

This Page Intentionally Left Blank

2 SD Operation Manual

SAFETY

!

Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual.

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

SAFETY PRECAUTIONS

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which can cause damage to the Sail-Drive, personal property and / or the environment or cause the equipment to operate improperly.

SD Operation Manual 3

SAFETY

General Information

There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.

Before You Operate

DANGER

The safety messages that follow have DANGER level hazards. These safety messages describe a hazardous situation which, if not avoided, will result in death or serious injury.

NEVER permit anyone to install or operate the SailDrive without proper training.

• Read and understand this Operation Manual before you operate or service the Sail-Drive to ensure that you follow safe operating practices and maintenance procedures.

• Safety signs and labels are additional reminders for safe operating and maintenance techniques.

• See your authorized Yanmar marine dealer or distributor for additional training.

Crush Hazard

NEVER stand under a hoisted Sail-Drive.

If the hoist mechanism fails, the Sail-Drive will fall on you.

When you need to transport a Sail-Drive for repair, have a helper assist you to attach it to a hoist and load it onto a truck.

NEVER support Sail-Drive with equipment not designed to support the weight of the Sail-Drive such as wood blocks or by only using a jack.

NEVER use the Sail-Drive lifting eye to lift the engine and Sail-Drive as an assembly. Use the engine lifting eyes to lift the engine and Sail-Drive. Only use the Sail-Drive lifting eye to lift the Sail-Drive as a separate component.

4 SD Operation Manual

SAFETY

During Operation and Maintenance

DANGER

The safety messages that follow have DANGER level hazards.

Explosion Hazard

While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily

ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area.

Fire Hazard

Ensure that appropriate fire

detection and extinguishing

equipment are installed and

checked periodically for

proper operation.

WARNING

The safety messages that follow have WARNING level hazards.

These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury.

Fire Hazard

Undersized wiring systems can cause an electrical fire.

Sever Hazard

NEVER service the Sail-Drive while under tow or if the engine is running at idle speed. The propeller may rotate under these

circumstances.

Alcohol and Drug Hazard

NEVER operate the engine while under the influence of alcohol or drugs or when feeling ill.

SD Operation Manual 5

SAFETY

WARNING

Exposure Hazard

ALWAYS wear personal

protective equipment

including appropriate

clothing, gloves, work

shoes, eye and hearing

protection as required by

the task at hand.

Entanglement Hazard

NEVER leave the key in the key switch when you are servicing the Sail-Drive. Someone may accidentally start the engine and not

realize you are servicing it.

NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

Burn Hazard

Some of the engine and SailDrive surfaces become very hot during operation and shortly after shut-down. Keep hands and other body parts

away from hot surfaces.

CAUTION

The safety messages that follow have CAUTION level hazards.

These safety messages describe a hazardous situation which, if not avoided, could result in minor to moderate injury.

Poor Lighting Hazard

Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Tool Hazard

ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.

Exposure Hazard

ALWAYS wear eye protection when servicing the Sail-Drive or when using compressed air or high-pressure water. Dust,

flying debris, compressed air, pressurized water or steam may injure your eyes.

Sudden Movement Hazard

ALWAYS stop the engine before beginning service.

Exhaust Hazard

NEVER block windows, vents, or other means of ventilation if the engine is operating in an enclosed area.

All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

6 SD Operation Manual

SAFETY

NOTICE

These notices describe a situation which, if not avoided, can cause damage to the Sail-Drive, personal property and / or the environment or cause equipment to operate improperly.

It is important to perform daily checks as listed in this Operation Manual.

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor Sail-Drive performance and can help extend the life of the Sail-Drive and engine.

ALWAYS be environmentally responsible.

Follow the guidelines of the EPA or other governmental

agencies for the proper disposal of hazardous materials such as lubrication oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

The anode of the Sail-Drive is only calculated for the Sail-Drive. Changing the material of the propeller may require additional anodes to be installed on the saildrive.

Failure to use the correct anode material may result in inadequate protection and excessive corrosion of underwater drive system components. Use only zinc or aluminum anodes in brackish and saltwater applications. In freshwater applications, use aluminum or magnesium anodes for best results. NEVER use magnesium anodes in brackish or salt water, as they will deteriorate rapidly, which will lead to severe damage to the drive system.

NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways.

NEVER attempt to modify the Sail-Drive’s design or safety features.

• NEVER release or modify the limiting

devices such as the engine speed limit, fuel injection limit, etc.

• Modification will impair the safety and

performance of the product and shorten product life.

• Modifications to the design, safety or

limiting features will void the warranty.

If the Sail-Drive oil temperature is too high, stop engine immediately and check the SailDrive oil level and check the oil cooler for proper coolant and water flow.

SD Operation Manual 7

SAFETY

This Page Intentionally Left Blank

8 SD Operation Manual

PRODUCT OVERVIEW

OVERVIEW

Owner / Operator Responsibilities

The operator must, and assumes all responsibility to:

• Read and understand the operation

manual prior to operating the sail-drive;

• Perform all safety checks as necessary to

ensure safe operation;

• Comply with and follow all lubrication and

maintenance instructions and recommendations; and

• Have an authorized Yanmar dealer /

distributor perform periodic checkups.

Conducting normal maintenance service and replacing consumable parts as necessary is the responsibility of the owner / operator and necessary to provide the best durability, performance and dependability of the Sail-Drive while keeping your overall operating expenses to a minimum. Individual operating habits and usage may increase the frequency of performing maintenance service condition. Monitor conditions frequently to determine if the maintenance intervals suggested in the manual are frequent enough for your SailDrive.

New Sail-Drive Break-In:

• On the initial engine start-up, allow the engine to idle for approximately 15 minutes while you check for proper SailDrive function and Sail-Drive oil leaks.

• During the break-in period, carefully observe Sail-Drive seal indicators for proper Sail-Drive function.

• During the break-in period, check the SailDrive oil levels frequently.

Dealer / Distributor Responsibilities

In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as:

• Ensure that the vessel is properly equipped.

• Prior to delivery, make certain that the Yanmar Sail-Drive and other equipment are in proper operating condition.

• Make all necessary adjustments for maximum efficiency.

• Familiarize the customer with the on-board equipment.

• Explain and demonstrate the operation of the Sail-Drive and vessel.

SD Operation Manual 9

PRODUCT OVERVIEW

COMPONENT IDENTIFICATION

(1)

(7)

(6)

(2)

(3)

(4)

(5)

Figure 1

1 – Dipstick 2 – Upper Gear Case 3 – Lower Gear Case

5 – Propeller 6 – Seawater Inlet 7 – Flexible Mount

4 – Lubricating Oil Drain Plug

10 SD Operation Manual

0006440

PRODUCT OVERVIEW

GALVANIC CORROSION

Galvanic corrosion results whenever two or more dissimilar metals (like those found on the sail-drive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content because a chemical reaction takes place causing electrical current to flow between the metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. If not controlled, galvanic corrosion may corrode Sail-Drive components.

CORROSION CONTROL

It is the boat designer’s responsibility and/or the re-powering engineer’s responsibility to design the proper systems and equipment to control and reduce the possibility of galvanic corrosion.

However, it is essential that the owner/ operator frequently monitor the anodes for wear, inspect the sail-drive for corrosion and replace the anodes often enough to provide a sacrificial surface for the electrical current to attack. Galvanic isolators and isolation transformers are also available from the aftermarket (not supplied by Yanmar). The Galvanic isolator is a device that is installed in series with the (AC) grounding (GREEN) conductor of the shore-power cable to effectively block low-voltage DC galvanic current flow but permit the passage of alternating current (AC) *.

The rate of corrosion depends on numerous factors, such as:

• the number, size and location of sacrificial

• the marina environment, such as stray

• improper application of marine paint or

• failure to repaint damaged areas; and

• how the vessel is bonded.

Please check with the boat builder, dealer or other professional to determine if your vessel and/or Sail-Drive is adequately protected from galvanic corrosion.

NOTICE: The anode of the Sail-Drive is only

calculated for the Sail-Drive. Changing the material of the propeller may require additional anodes to be installed on the SailDrive.

* “The Boatowner's Guide to Corrosion”, by Everett Collier.

anodes on the sail-drive and vessel;

current in the water, fresh or salt water and use and isolation of shore power;

antifouling paint;

SD Operation Manual 11

PRODUCT OVERVIEW

NOTICE: Failure to use the correct anode material may result in inadequate protection and excessive corrosion of underwater drive system components. Use only zinc or aluminum anodes in brackish and saltwater applications. In freshwater applications, use aluminum or magnesium anodes for best results. NEVER use magnesium anodes in brackish or salt water, as they will deteriorate rapidly, which will lead to severe damage to the drive system.

If sacrificial anodes erode quickly or if signs of corrosion are evident, the owner should take immediate corrective action. Yanmar recommends consulting an engineer specializing in marine electricity and corrosion control to determine the best way to correct the rapid erosion of the anodes.

SHORE POWER

Vessels that are connected to shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. Galvanic isolators are available from the aftermarket (not supplied by Yanmar) to block these currents while still providing a path to ground for dangerous shock currents.

NOTICE: If the AC shore power ground is

not isolated from the boat ground, sacrificial anodes may be unable to neutralize the increased galvanic potential. Corrosion damage that results from the improper system design or application is not covered by the Yanmar Limited Warranty.

12 SD Operation Manual

UNDERWATER DRIVE COATING

The lower gear case coating may be damaged when hit by objects in the water, or when having deposits removed from it. The underwater coating must be inspected at least once per year and when it is believed that an object was hit that may have caused damage. Repair and repaint damaged areas immediately.

Observe the following precautions when applying antifouling or marine paint to the bottom of the boat hull:

• ALWAYS follow the paint/coating manufacturer's directions for surface preparation and application.

• ALWAYS use a high quality primer and topcoat paint specifically designed for aluminum outboards, Sail-Drives or SternDrives.

• NEVER paint the sacrificial anodes installed on the Sail-Drive.

• NEVER paint the Sail-Drive with a material that contains copper or tin.

• NEVER paint over drain holes, sacrificial anodes, or other items specified by the sacrificial anode Manufacturer.

Contact your authorized Yanmar Marine dealer or distributor for assistance.

PRODUCT OVERVIEW

NOTICE: Galvanic corrosion damage, normal maintenance and consumable parts are not covered by the Yanmar Limited Warranty.

SD Operation Manual 13

PRODUCT OVERVIEW

This Page Intentionally Left Blank

14 SD Operation Manual

BEFORE YOU OPERATE

This section of the Operation Manual describes propeller selection, propeller fitting, lubricating oil specifications and how to replenish them. It also describes the daily instrument panel and remote-control device checks.

Before you operate the Sail-Drive, review the Safety section on page 3.

SD Operation Manual 15

BEFORE YOU OPERATE

PROPELLER SELECTION

Recommended Propeller Size (Maximum)

Engine Model Sail-Drive Model Folding Type

1GM10C

2YM15 14.5 in. 15 in.

3YM20 15 in. 16 in.

3YM30 16 in. 16.5 in.

3JH4CE

3JH5CE

4JH4ACE

4JH5CE

4JH4–TCE SD50-4T 18 in. 18 in.

SD20

SD50 18 in. 18 in.

NOTICE: Make sure the propeller (fixed or

folding) has a rubber bushing. If a propeller is used without a rubber bushing, the shaft, bearing and gears of the Sail-Drive will be damaged.

Diameter

14 in. 14 in.

2-Blade Fixed Type

Diameter

16 SD Operation Manual

Fitting a Fixed Propeller (2-Blade)

BEFORE YOU OPERATE

(1)

(4)

(5)

(6)

(2)

(3)

0005446

Figure 1

1 – Spacer 2 – Grease 3 – Propeller

Size Tightening Torque

*

** M8 x 75 mm 11 to 15 N·m (8 to 11 lb-ft)

M16 (SD20) M20 (SD50, SD50-4T)

4 – Washer 5 – Nut * 6 – Bolt **

60 to 70 N·m (44 to 52 lb-ft) 80 to 100 N·m (59 to 74 lb-ft)

Locking Procedure for Fixed Propeller Nut (Optional)

When tightening the nut to 60 to 70 N·m (44 to 52 lb-ft) torque for the SD20, and 80 to 100 N·m (59 to 74 lb-ft) torque for the SD50 and SD50-4T, move the shift lever to ahead and hold the crankshaft V-pulley clamp nut with a wrench to stop the propeller rotating.

SD Operation Manual 17

BEFORE YOU OPERATE

LUBRICATING OIL

The choice of lubricating oil is very important. If an unsuitable oil is used, or an oil change is neglected, it may result in damage and reduce the life of the Sail-Drive. When selecting a lubricating oil, use one of the following:

Lubricating Oil Chart

Engine series

Engine model

Sail-Drive model

Lubricating oil for the Sail-Drive

1GM10C 2YM15, 3YM20, 3YM30 3JH4E, 3JH5E, 4JH4AE, 4JH5E 4JH4-TE

SD20 SD20 SD50 SD50-4T

API CC or

greater

and SAE

10W30

Use only oil of quality GL-4 or GL-5 in the API service, and SAE No. 90 or 80W90. (Except model SD20 x 1GM10C & SD50 / SD50-4T).

Use only oil of quality CC or greater in the API service, and SAE No. 10W30. (Applicable model: SD20 x 1GM10C).

For SD20 (except if coupled with the 1GM10C)

GM, YM JH3, JH4, JH5

API GL4 or GL5 and SAE

80W90 or 90

QuickSilver® High Performance Gear Oil

Supplier Brand Name API Service SAE No.

SHELL Shell Spilax oil EP 90 GL-4 90

SHELL Shell Spilax oil HD 90 GL-5 90

CALTEX Multipurpose thuban EP GL-4/GL-59 90

MOBIL Mobilub HD 80W-90 GL-5 80W-90

ESSO Esso gear oil GP 90 GL-4 90

ESSO Esso gear oil GX 90 GL-5 90

Use QuickSilver® * High Performance Gear Oil for the SD50 / SD50-4T.

* QuickSilver® is a registered trademark of Brunswick Corporation.

18 SD Operation Manual

BEFORE YOU OPERATE

FILLING WITH LUBRICATING OIL - SD20, SD50 AND SD50-4T

Sail-Drive model

Standard unit

Long-reach unit

NOTICE: The lubricating oil capacity of the

standard unit is different from that of the long-reach unit. Confirm the capacity by means of the oil capacity nameplate.

1. Remove the dipstick (yellow cap). Fill

with approved lubricating oil.

2. Check the amount of lubricating oil by

inserting the dipstick as far as possible. Do not screw the dipstick in (Figure 3, (1)). The oil level should reach the upper mark on the dipstick (Figure 3, (2)).

NOTICE: It takes about 10 minutes to fill up

the Sail-Drive with lubricating oil. Check the oil level 15 minutes after adding the specified quantity of oil.

SD20 SD50, SD50-4T

2.2 L

(2.3 qt)

2.5 L

(2.6 qt)

2.2 L (2.3 qt)

2.35 L (2.5 qt) Extension 58

2.45 L (2.6 qt)

Extension 100

SD20

(1)

(2)

0005441

Figure 3

1 – Oil Supply Port 2 – Oil Capacity Nameplate

SD50/SD50-4T

(1)

(2)

0005574

Figure 4

1 – Oil Supply Port 2 – Oil Capacity Nameplate

Figure 2

1 – Dipstick 2 – Upper Limit 3 – Lower Limit

SD Operation Manual 19

(1)

(2)

(3)

0005573

BEFORE YOU OPERATE

CHECKING THE INSTRUMENT PANEL ALARM SYSTEM

New B-Type

(2)(3)(4)

(1)

(5)

(6)

(7)

(8)

0000472SD

Figure 5

1 – Battery Low Charge Alarm 2 – Sail-Drive Seal Warning Lamp 3 – Engine Oil Low Pressure Lamp 4 – Coolant High Temperature Alarm 5 – Hour Meter 6 – Tachometer 7 – Key Switch 8 – STOP Button

B (Keyless) - Type

(1) (2) (3) (4)

30

20

10

0

(8) (7) (5)(6)

40

50

026102-00X

Figure 6

1 – Coolant High Temperature

Indicator

2 – Engine Oil Low Pressure

Indicator 3 – Water in Sail Drive Seal Indicator 4 – Battery Low Charge Indicator 5 – ON/OFF/START Switch 6 – GLOW/STOP Switch 7 – Hourmeter 8 – Tachometer

20 SD Operation Manual

BEFORE YOU OPERATE

New C-Type

(5)

(6)

(11)

(12)

(4)

(7) (8)

(9)

0000473SD

(10)

(1)

(2)

(3)

Figure 7

1 – Battery Low Charge Alarm 2 – Sail-Drive Seal Warning Lamp 3 – Fuel Filter Warning Lamp 4 – Seawater Insufficient Flow Alarm 5 – Coolant Temperature Gauge 6 – Engine Oil Pressure Gauge 7 – Hour Meter 8 – Tachometer 9 – Key Switch 10–STOP Button 11–Coolant High Temperature

Warning Lamp

12–Engine Oil Low Pressure

Warning Lamp

C (Keyless) - Type

(2)

(1)

(12)

(10) (9)

(11) (8) (7)

(5) (6)(4)(3)

026103-00X

Figure 8

1 – Coolant High Temperature

Indicator 2 – Coolant Temperature Gauge 3 – Not Used On This Engine 4 – Water in Fuel Filter Indicator 5 – Water in Sail Drive Charge

Indicator 6 – Battery Low Charge Indicator 7 – ON/OFF/START Switch 8 – GLOW/STOP Switch 9 – Hourmeter 10–Tachometer 11–Engine Oil Pressure Gauge 12–Engine Oil Low Pressure

Indicator

SD Operation Manual 21

BEFORE YOU OPERATE

Turn the battery switch on. Turn the key to the ON position and check the lamps on the panel (Figure 5, Figure 7) with the engine off:

1. The lubricating oil warning lamp should be illuminated (Figure 5, 3, Figure 7, 6) .

2. The cooling water temperature warning lamp should be out (Figure 5, 4, Figure 7, 5) .

3. The charge warning lamp should be illuminated (Figure 5, 1, Figure 7, 1) .

4. The rubber seal warning lamp should be out (Figure 5, 2, Figure 7, 2) .

5. The warning buzzer should sound.

Note: All the above alarm signals will continue until you push the starting button or turn the key to the OFF position.

WARNING! The rubber seal alarm lamp warns of seawater entering the vessel. The watertight structure of the SailDrive is dual type. Even if the rubber diaphragm A (Figure 9, (5)) is damaged and seawater enters, the rubber diaphragm B (Figure 9, (4)) prevents it from entering the vessel. The rubber seal switch between the rubber diaphragms (Figure 9, (5)) and (Figure 9, (4)) sounds the warning buzzer and lights the rubber seal lamp on the instrument panel. If this happens, stop the engine and under sail, quickly return to the nearest port for repairs.

(1)

(2)

(5)

Figure 9

1 – ON (Rubber Seal Lamp) 2 – Rubber Seal Switch 3 – Diaphragm (B) 4 – Diaphragm (A) 5 – Seawater

22 SD Operation Manual

(3)

(4)

019410-01X

DAILY CHECKS

Before starting the Sail-Drive, make sure it is in good operating condition. Make sure you check the following items:

Visual Checks

1. Check for damaged or missing parts.

2. Check for loose, missing or damaged

fasteners.

3. Check oil level. See Filling With

Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

4. Open cooling water cock before

operation. Drain cooling water and close cooling water cock after operation. See Engine Cooling Water

on page 29

NOTICE: If any problem is noted during the visual check, the necessary corrective action should be taken before you operate the engine.

BEFORE YOU OPERATE

SD Operation Manual 23

BEFORE YOU OPERATE

This Page Intentionally Left Blank

24 SD Operation Manual

SAIL-DRIVE OPERATION

Before you operate the Sail-Drive, read the following safety information and review the Safety section on page 3.

WARNING

The safety messages that follow have WARNING level hazards.

These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury.

To prevent accidental equipment movement, NEVER start the engine in gear.

Before starting the engine, ALWAYS make sure that all bystanders are clear of the area. Keep children and pets away while the engine is operating.

Avoid unexpected equipment movement. Shift the Sail-Drive into the NEUTRAL position any time the engine is at idle.

SD Operation Manual 25

SAIL-DRIVE OPERATION

REMOTE CONTROL DEVICE CHECK

SD20

NOTICE: Before operating the engine, check Sail-Drive oil level. While cranking the

engine slowly, shift the control handle of the remote-control head (single lever control) rapidly through NEUTRAL - AHEAD NEUTRAL - ASTERN. If a shift operation is done slowly, the tip of the clutch dog is worn away by being hammered, and, consequently, the clutch fails to engage. Confirm that the operation lever of the SailDrive moves smoothly to AHEAD, ASTERN and NEUTRAL. Because the Sail-Drive SD20 uses a dog clutch, the clutch is not engaged unless the operation lever is moved to the NEUTRAL position.

NOTICE: When sailing, set the remote

control lever in neutral. Not doing so WILL introduce slippage and void your warranty (Figure 1, (2)).

(2)

(1)

(4)

Figure 1

1 – Astern 2 – Neutral 3 – Ahead 4 – Control Handle

(3)

019631-00X

26 SD Operation Manual

SAIL-DRIVE OPERATION

(5)

(7)

(6)

(10)

(1)(2)(3)

Figure 2

1 – Astern 2 – Neutral 3 – Ahead 4 – Operation Handle 5 – Cable Clamp 6 – Remote Control Cable 7 – Ahead Stop 8 – Neutral Position 9 – Astern Stop 10–Spring Joint

(8) (9)

(4)

019719-00X

(5)

(4)

(6)

(1)

(2)

(3)

D

Figure 3

1 – Astern 2 – Neutral 3 – Ahead 4 – Operation Lever 5 – Cable Clamp 6 – Remote Control Cable 7 – Pivot

D

(7)

019720-00X

SD Operation Manual 27

SAIL-DRIVE OPERATION

SD50 / SD50-4T

After starting the engine, check the shift action by using the control head to shift the AHEAD and ASTERN positions. The AHEAD / ASTERN clutch is a mechanical clutch called a cone clutch. Although a grinding noise is made when this type of clutch is engaged, it has no effect on the operation of the engine.

CAUTION! Because of the rubbing produced at the frictional face of the cone clutch, friction is decreased with use and periodic inspection and maintenance is necessary.

NOTICE: When sailing, set the remote control lever in neutral. Not doing so WILL introduce slippage and void your warranty.

NOTICE: Running for long periods at low rpm with the Sail-Drive engaged can cause slipping and premature wear of the cone clutch.

(1)

(2)

(3)

(5) (8)

(7)

(4)

(6)

003448-01X

Figure 4

1 – Mounting Plate at 90° Angle 2 – Operation Lever 3 – Cable Clamp 4 – Remote Control Cable 5 – Propeller Shaft Clockwise 6 – Pivot 7 – Neutral 8 – Propeller Shaft Counter-

Clockwise

28 SD Operation Manual

ENGINE COOLING WATER

Opening or closing the cooling water system of the engine driving the Sail-Drive is done by the cooling water cock fixed on the upper case of the Sail-Drive. Be sure to open the cock (Figure 5, (1)) and confirm that the cooling water has suction by cranking the engine before starting the vessel. The cooling water passes through the Sail-Drive case, cools the engine by the cooling water pump, and is then discharged.

SD20

SAIL-DRIVE OPERATION

(5)

(1)

1 – Cooling Water Cock 2 – Cooling Water Hose 3 – To Cooling Water Pump

(2)

(3)

(4)

0005447

Figure 5

4 – Hose Clamp 5 – Seawater Inlet

SD Operation Manual 29

SAIL-DRIVE OPERATION

SD50 / SD50-4T

(1)

1 – To Cooling Water Pump 2 – Cooling Water Cock

(3)

(2)

0005448

Figure 6

3 – Open

30 SD Operation Manual

PERIODIC MAINTENANCE

Before you perform maintenance on the Sail-Drive, read the following safety information and review the Safety section on page 3.

This section of the Operation Manual describes the procedures for proper care and maintenance of the Sail-Drive.

WARNING

The safety messages that follow have WARNING level hazards.

These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury.

Sever Hazard

NEVER wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and ALWAYS tie long hair back when

working near moving / rotating parts. Keep hands, feet and tools away from all moving parts.

Always remove any tools or shop rags used during maintenance from the area before operation.

NEVER service the Sail-Drive while under tow or if the engine is running at idle speed. The propeller may rotate under these circumstances.

ALWAYS stop the engine before you begin to service the Sail-Drive and secure the propeller so it will not turn.

SD Operation Manual 31

PERIODIC MAINTENANCE

WARNING

Electrical Shock Hazard

ALWAYS turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the Sail-Drive.

ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

CAUTION

The safety messages that follow have CAUTION level hazards.

These safety messages describe a hazardous situation which, if not avoided, could result in minor or moderate injury.

Slipping and Tripping Hazard

Ensure that adequate floor space is set aside for servicing Sail-Drive. The floor space must be clean, flat and free of spilled liquids and

debris to prevent slipping or tripping.

32 SD Operation Manual

PERIODIC MAINTENANCE

NOTICE

These notices describe a situation which, if not avoided, can cause damage to the SailDrive, personal property and / or the environment, or cause equipment to operate improperly.

Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly.

Only use replacement parts specified. Other replacement parts may affect warranty coverage.

NEVER attempt to modify the Sail-Drive’s design or safety features. Failure to comply may impair the marine gear’s safety and performance characteristics and shorten the Sail-Drive’s life. Any alterations to this Sail-Drive may affect the warranty coverage of your Sail-Drive.

TIGHTENING FASTENERS

Use the correct amount of torque when tightening fasteners. Applying excessive torque may damage the fastener or component and too little torque may cause a leak or component failure.

The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7” head. (JIS strength classification: 7T).

Apply 60% torque to bolts that are not listed.

Apply 80% torque when tightened to aluminum alloy.

SD Operation Manual 33

PERIODIC MAINTENANCE

TORQUE CHARTS

Standard Torque Values

M6 x 1.0 M8 x 1.25 M10 x 1.25

Cast Iron or Steel

Aluminum 8.8 ± 1.0

10.8 ± 1.0 N·m

8.0 ± 0.8 lb-ft

N·m

6.5 ± 0.8 lb-ft

25.5 ± 2.0 N·m

18.8 ± 1.5 lb-ft

20.6 ± 2.0 N·m

15.2 ± 1.5 lb-ft

or 1.5

49.1 ± 4.9 N·m

36.2 ± 3.6 lb-ft

39.2 ± 2.0 N·m

28.9 ± 1.5 lb-ft

M12 x 1.25 or 1.5

88.3 ± 10.0 N·m

65.1 ± 7.4 lb-ft

70.6 ± 4.9 N·m

52.1 ± 3.6 lb-ft

M14 x 1.5 M16 x 1.5

137.2 ± 4.9 N·m

101.2 ± 3.6 lb-ft

109.8 ± 4.9 N·m

81.0 ± 3.6 lb-ft

225.4 ± 10.0 N·m

166.2 ± 7.4 lb-ft

180.3 ± 10.0 N·m

133.0 + 7.4 lb-ft

Standard Torque Chart

Thread size × PitchmmM6×1.0 M8×1.25 M10×1.5 M12×1.75 M14×1.5 M16×1.5

Tightening

Torque

lb-in. 96.0 ± 9.0 - - - - -

lb-ft - 19.0 ± 2.0 36.0 ± 4.0 65.0 ± 7.0 101.0 ± 7.0 167.0 ± 7.0

N·m 10.8 ± 1.0 25.5 ± 2.9 49.0 ± 4.9 88.3 ± 9.8 137.0 ± 9.8 226.0 ± 9.8

kgf-m 1.1 ± 0.1 2.6 ± 0.3 5.0 ± 0.5 9.0 ± 1.0 14.0 ± 1.5 23.0 ± 2.0

34 SD Operation Manual

PERIODIC MAINTENANCE

Periodic Maintenance

CAUTION! Establish a periodic maintenance plan according to the Sail-Drive

application and make sure you perform the required periodic maintenance at intervals indicated. Failure to follow these guidelines will impair the Sail-Drive’s safety and performance characteristics, shorten the Sail-Drive's life and may affect the warranty coverage on your Sail-Drive.

The Importance of Periodic Maintenance

Sail-Drive deterioration and wear occur in proportion to the length of time the Sail-Drive has been in service and the conditions it is subjected to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor Sail-Drive performance and helps extend the life of the Sail-Drive.

The Importance of Daily Checks

The Periodic Maintenance Table assumes that the daily checks are performed on a regular basis. Make a habit of performing daily checks before the start of each operating day. See

Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19, Checking the Instrument Panel Alarm System on page 20 and Engine Cooling Water on page 29, and refer to the Operation Manual for your engine.

Keep a Log of Sail-Drive Hours and Daily Checks

Keep a log of the number of hours the Sail-Drive is run each day and a log of the daily checks performed. Also note the date, type of repair (e.g., replaced bearings), and parts used for any service needed between the periodic maintenance intervals. Failure to perform periodic maintenance will shorten the life of the Sail-Drive.

Yanmar Replacement Parts

Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed. Genuine replacement parts help ensure long Sail-Drive life.

Tools Required

Before you start any periodic maintenance procedure, make sure you have the tools you need to perform all of the required tasks.

Ask Your Authorized Yanmar Marine Dealer or Distributor For Help

Our professional service technicians have the expertise and skills to help you with any maintenance or service related procedures.

Daily and periodic maintenance is important to keep the Sail-Drive in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on Sail-Drive application and are hard to establish definitively. The following should be treated only as a general guideline.

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

SD Operation Manual 35

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE TABLE

◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

Daily

Lubricating Oil

Check Oil

Level, Fill If Necessary

Change

Lubricating Oil

Cooling Water

Open/Close

Cooling Water Cock

Clean Cooling

Water Suction Hole

Drain Cooling

Water

Remote Control System

Inspect

Remote Control Device

Cone Clutch and Shifter

Inspect /

replace or lap

Replace the

cone-clutch

Anode

Inspect And

Replace Anode

Lower Case

Repair Case

Coating

Boat Hull Water-Tightness

Inspect

Rubber Diaphragm

Inspect Seal

Sensor

(See Daily Checks on

page 23.)

Before

operation

Before / after

operation

After

operation

◯

●

◊

●

50

Hours

Or

After 1

Month

First

◊

Every

100

Hours

SD20

◊

Every

250

Hours

SD50, SD50-

4T

◊

Every

500

hours

Every

Year

◯

Every

Hours

2000

◊

Every

5

Years

36 SD Operation Manual

PERIODIC MAINTENANCE

◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

Daily

Flexible Mount

Inspect and/or

replace the flexible mount, mounting height

Replace the

flexible mount

(See Daily

Checks on

page 23.)

●

50

Hours

Or

After 1

Month

Every

100

Hours

Every

250

Hours

Every

500

hours

Every

Year

Every

2000

Hours

Every

5

Years

SD Operation Manual 37

PERIODIC MAINTENANCE

WHEN THE VESSEL IS OUT OF THE WATER, PERFORM THE FOLLOWING:

Removing Deposits From The Lower Gear Case

Remove seaweed, seashells and other marine growth from the lower gear case. Completely remove deposits around the cooling water intake (Figure 1, (2)) since the engine may overheat if the cooling water intake amount is insufficient.

Repairing Damaged Coating

The lower gear case coating may be damaged when hit by objects in the water, or when having deposits removed from it. NEVER use paint containing copper or tin. This will damage the drive and void the warranty. Use a high quality primer and topcoat paint specifically designed for aluminum outboards or stern-drives. Follow the manufacturer's directions for surface preparation and application. Contact your authorized Yanmar Marine dealer or distributor for assistance.

Inspecting the Anode

See Inspecting and Replacing the Anode on page 48.

Draining Water

Drain the engine cooling water, together with the water in the Sail-Drive case. If this water is not drained, freezing may cause the engine block and / or the Sail-Drive case to crack.

(1)

(2)

0005464

Figure 1

1 – Lower Gear Case 2 – Seawater Inlet

Inspecting The Folding Propeller

Confirm that the blade of the folding propeller opens smoothly. Inspect for wear on the blade-fixing pins, replacing them when wear is excessive. Apply seawaterproof grease to the pins in the blade gear and propeller shaft.

38 SD Operation Manual

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE PROCEDURES

After Initial 50 Hours of Operation

Perform the following procedures after the first 50 hours of operation.

• Draining and Replacing Lubricating Oil

• Inspecting and Replacing the Clutch

Shifter

Draining and Replacing Lubricating Oil - SD20

When the vessel is out of the water, drain the oil by removing the lower gear case drain plug, and the upper gear case oil dipstick.

CAUTION! Let the drive unit cool at least 5 minutes after operation before removing the oil drain plug. Hot oil could spurt out forcefully if the drain plug is removed from the drive unit immediately after operation.

SD20

(1)

(2)

(3)

(4)

0005450

Figure 2

1 – Dipstick 2 – Upper Gear Case 3 – Lower Gear Case 4 – Lubricating Oil Drain Plug

Inspecting and Replacing the Clutch Shifter

See your authorized Yanmar dealer or distributor for procedure.

SD Operation Manual 39

PERIODIC MAINTENANCE

Draining and Replacing Lubricating Oil - SD50 / SD50-4T

Lubricating oil should be changed while the engine is still warm. CAUTION! Let the

drive unit cool at least 5 minutes after operation before removing the oil drain plug. Hot oil could spurt out forcefully if the drain plug is removed from the drive unit immediately after operation.

SD50 / SD50–4T

(1)

(2)

1 – Dipstick 2 – Plug 3 – Drain Plug

(3)

Figure 3

0005451

40 SD Operation Manual

PERIODIC MAINTENANCE

Equipment Used

Description Part Code Quantity Remarks

Bottle of Quicksilver High Performance Gear Lube from MerCruiser

Market pump from MerCruiser® on bottle

®

MerCruiser® Part code 92-850743A1

®

MerCruiser® Part code 91-85729A1

2 Each bottle contains

1

0.946 L (1 qt) of oil. Mandatory for SD50, SD50-4T. For other models see p. 7.

-

Adapter joint 196311-92960 1* Thread std. M10 x 1.5

O-ring for adapter 24311-000100

Stiff rubber hoses

-

Compressor set

Hand pump 28210-000080 1 Optional parts

* When vessel is out of the water, 2 are required.

- 1 -

*

1

2 Inner diameter 14 to 16

maximum length 12 mm.

-

mm (0.5 to 0.625 in.) plus hose clamps (If Yanmar part is used, part code is 196440-92970).

SD Operation Manual 41

PERIODIC MAINTENANCE

When Vessel Is In The Water

Preparing the Sail-Drive

(1)

(2)

(3)

(4)

0005452

Figure 4

1 – O-Ring 2 – Adapter Joint 3 – Oil Changing Plug 4 – Thread M10x1.5

1. Remove the oil changing plug located under the shift lever.

2. Screw in an adapter joint with an O-ring. When using your own adapter joint, the maximum length of thread should be 12 mm.

3. Attach a stiff rubber hose (inner diameter 14 to 16 mm [0.5 to 0.625 in.]) with hose clamps to the adapter joint at the oil changing position (Figure 4, (2)). The hose must be long enough to reach the bucket or pump. If a Yanmar original rubber hose is to be used, the part number is 196440-92970.

Removing Oil

(2)

(1)

(3)

0005453

Figure 5

1 – Plug 2 – Air Pressure Hose 3 – Adapter Joint

Fastest Way: Blowing Out by using Air Pressure

Note: Use Compressed Air (0.5 to 1 Bar [7.25 to 14.5 psi]) from main system, 12 V portable compressor or from portable hand pump or foot pump.WARNING! ALWAYS

wear safety glasses when using compressed air.

1. Take out the plug from the upper case cover.

2. Screw in a second adapter joint with an O-ring at the oil inlet position. Screw in the oil plug at the dipstick position.

3. Connect the air pressure hose with hose clamps.

42 SD Operation Manual

PERIODIC MAINTENANCE

Option 1: Using Compressed air from main system or 12 V portable compressor.

1. Connect a hose to the top adapter joint and to a compressed air source (Figure 5, (2)). Within 10 to 15 minutes almost all oil will be blown out.

(1)

(2)

(3)

0005454

Figure 6

1 – One-Way (Non-Return) Valve 2 – Adapter Joint Screwed Into

Cover

3 – Foot Pump

Option 2: Using Compressed air with help from a portable hand pump or foot pump

1. Install a one-way (non-return) valve (Figure 6, (1)) into the pressure line. This is done to maintain pressure during use of the pump.

2. Connect the hand pump or foot pump with pressure line to the adapter joint (Figure 6, (2)).

3. Pump out the oil until empty. The first 0.9 L (1 qt) will take approximately 3 minutes. The second part takes more time as mostly air will be pumped out; this will take approximately 12 minutes.

Using Yanmar Pump

Refer to Preparing the Sail-Drive on page 42 and Fastest Way: Blowing Out by using Air Pressure on page 42.

0005455

Figure 7

Connect the hand pump with hoses as shown above (Figure 7), and start pumping. Be aware that oil has to flow down through restricted parts of the casing and then back up again, so pressure will initially be high and pumping will be difficult. Pausing for a few minutes will help. After pumping out about 0.9 L (1 qt) of oil, mostly you will be pumping out air, but continuous pumping is necessary. Though approximately 100 to 200 ml (0.1 to 0.2 qt) of old oil will remain in the drive unit, it will not cause a problem when mixed with clean oil.

The hand pump and rubber hose are available from Yanmar, and are optional parts for SD50 / SD50-4T. Any type of hand pump or rubber hose (inner diameter 14 to 16 mm [0.5 to 0.625 in.]) available from your local supplier can be used.

SD Operation Manual 43

PERIODIC MAINTENANCE

Replacing Oil

Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

Fastest way: By using MerCruiser pump or simple market pump

Refer to Preparing the Sail-Drive on page

42.

(1)

0005575

Figure 8

1 – Plug

1.

Use a MerCruiser® pump like the one shown (Figure 8) or use a similar pump available locally.

2. Attach the pump to a new bottle of Quicksilver® High Performance Gear Lube from MerCruiser®.

3. Connect the hose with a hose clip to the adapter joint below the shift lever.

4. Remove the plug from the upper case cover (Figure 8, (1)).

5. Operate the pump to fill the Sail-Drive with oil. After bottle is empty, change the bottle while the pump and hose remain connected to the adapter joint.

6. After filling, first screw in and tighten the plug at the top cover (Figure 8, (1)). Then remove the oil bottle, pump, hose and adapter joint and screw in the oil plug with a gasket.

Using Yanmar Hand Pump

(1)

0005456

Figure 9

1 – Plug

44 SD Operation Manual

PERIODIC MAINTENANCE

1. Connect the hoses as shown above

(Figure 9).

2. Remove the plug from the upper case

cover (Figure 9, (1)).

3. Operate the pump to fill the Sail-Drive

with oil. Be aware that oil has to flow down through restricted parts of the casing and then back up again, so pressure will initially be high and pumping will be difficult. Pausing for a few minutes will help. The hand pump and rubber hose are available from Yanmar, and are optional parts for SD50 / SD50-4T. Any type of hand pump or rubber hose (inner diameter 14 to 16 mm [0.5 to 0.625 in.]) available locally can be used.

4. After filling, first screw in and tighten the

plug at the top cover. Then remove the hand pump, hose and adapter joint and screw in the oil plug with a gasket.

Not Using Pump

Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

When The Vessel Is Out Of The Water

Preparing The Sail-Drive

(1)

0005457

Figure 10

1 – Plug

1. Remove the bottom drain plug.

2. Screw in the adapter joint with the O-ring. When using own adapter joint, maximum length of thread is 12 mm.

3. Attach a stiff rubber hose with an inner diameter of 14 to 16 mm (0.5 to 0.625 in.) with hose clamps to the adapter joint at the oil drain position. The hose must be long enough to drain to the bucket.

4. Remove the dipstick and oil inlet plug from the upper case cover.

SD Operation Manual 45

PERIODIC MAINTENANCE

Removing Oil By Draining

Refer to Preparing The Sail-Drive on page

45.

Oil draining is possible when the vessel is out of the water but will take a greater amount of time.

1. After approximately 0.6 L (0.6 qt) has been drained, remove the oil changing plug. If you remove the plug before this, oil may spill out because maximum oil level is higher than the plug.

(2)

(1)

0005458

Figure 11

1 – Thread M10x1.5 2 – Oil Changing Plug

Fastest way: Blowing out by using Air pressure

Refer to Preparing the Sail-Drive on page 42, then to Fastest Way: Blowing Out by using Air Pressure on page 42. Be aware

that oil is divided into two channels connected by the lower gear and lower drain port.

Replacing Oil

Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

Using MerCruiser® Pump or simple market pump

Refer to Preparing The Sail-Drive on page

45.

(1)

(2)

(3)

0005459

Figure 12

1 – Plug 2 – O-Ring 3 – Adapter Joint

1.

Use a MerCruiser® pump with like the one shown above (Figure 12), or use a similar pump available locally.

2. Attach the pump to a new bottle of Quicksilver® High Performance Gear Lube from MerCruiser®.

3. Remove the oil changing plug from below the shift lever.

4. Connect the hose with a hose clip to the adapter joint at the drain position.

5. Take out the plug from the upper case cover.

46 SD Operation Manual

PERIODIC MAINTENANCE

6. Pump the oil into the drive. After the first bottle is empty, screw in the oil changing plug.

7. Change the bottle while the pump and hose remain connected to the adapter joint.

8. After filling, first screw in and tighten the plug at the top cover. Then remove the oil bottle, pump, hose and adapter joint and screw in the oil drain plug.

Using Yanmar Hand Pump

Refer to Preparing The Sail-Drive on page

45.

(1)

3. Pump the oil into the drive. Be aware that oil has to flow up through restricted parts of the drive, so pumping will be hard. Waiting a few minutes will help. After pumping in about 1 L (1.1 qt) of oil, screw in the oil changing plug. Be aware that the drain hose can easily slip out of the bucket and cause oil spilling. The hand pump and rubber hose are available from Yanmar, and are optional parts for SD50 / SD50-4T. Any type of hand pump or rubber hose of inner diameter 14 to 16 mm (0.5 to 0.625 in.) available locally can be used.

0005461

Figure 14

4. After filling, first screw in and tighten the plug at the top cover. Then remove the pump, hose and adapter joint and screw in the oil drain plug.

By not using pump

Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

0005460

Figure 13

1 – Plug

1. Connect the hose from the bottom and a suction hose to the Yanmar pump with hose clip (Figure 13).

2. Take out the plug from the upper case cover (Figure 13, (1)).

SD Operation Manual 47

PERIODIC MAINTENANCE

Every 100 Hours of Operation

Perform the following maintenance every 100 hours of operation.

• Changing the Lubricating Oil (SD20)

• Inspecting and Replacing the Anode

Changing the Lubricating Oil (SD20)

See Draining and Replacing Lubricating Oil

- SD20 on page 39.

Inspecting and Replacing the Anode

To prevent corrosion of the Sail-Drive body by sea or lake water, replace the anode every 100 hours of operation, once every six months or when it has reduced to half of the original volume (size).

NOTICE: The anode of the Sail-Drive is only

calculated for the Sail-Drive. Changing the material of the propeller may require additional anodes to be installed on the saildrive.

SD20

(4)

(2)

SD50/SD50–4T

(1)

(2)

0005463

Figure 16

1 – Lower Gear Case 2 – Anode

An anode is provided on the lower gear case. To inspect and replace the anode on the lower gear case, the vessel must be removed from the water.

Note: An optional two-part anode is available from Yanmar for the lower gear

(1)

-

0

2

4

6

9

1

while the boat

in the water

ANODE

1 – Safety Label 2 – Anode

4

1

Figure 15

(5)

(3)

019416-01X

case. This option may allow the anode in the lower gear case to be changed without removing the vessel from the water, or by an underwater diver.

Optional Two-Part Anode Information

Part Number Description Qty.

196440-02660 anode 2

196440-02690 mounting

plate

196440-02700 flat head bolt 4

26453-080202 8 X 20 bolt 2

3 – Anode 4 – Upper Gear Case 5 – Lower Gear Case

48 SD Operation Manual

2

PERIODIC MAINTENANCE

Every 250 Hours of Operation

Perform the following maintenance every 250 hours of operation.

• Changing the Lubricating Oil (SD50,

SD50-4T)

• Inspecting and Replacing the Clutch

Shifter

Changing the Lubricating Oil (SD50, SD50-4T)

See Draining and Replacing Lubricating Oil

- SD50 / SD50-4T on page 40.

Inspecting and Replacing the Clutch Shifter

See your authorized Yanmar dealer or distributor for procedure.

Every 500 Hours of Operation

• Inspecting and / or Replacing the Cone-Clutch

Inspecting and / or Replacing the Cone-Clutch

See your authorized Yanmar dealer or distributor for procedure.

SD Operation Manual 49

PERIODIC MAINTENANCE

Every Year

Perform the following maintenance every year of operation.

• Cleaning Cooling Water Suction Hole

• Inspecting Remote Control Device

• Repairing Case Coating

• Inspecting and Replacing Rubber

Diaphragm Seal Ring

• Inspecting Seal Sensor

• Inspecting and / or Replacing the

Flexible Mount

Cleaning Cooling Water Suction Hole

See Removing Deposits From The Lower Gear Case on page 38.

Inspecting Remote Control Device

See Remote Control Device Check on page

26.

Repairing Case Coating

See Repairing Damaged Coating on page

38.

Inspecting and / or Replacing the Flexible Mount

Replace if clearance is less than 1 mm (Figure 17, (1)). See your authorized Yanmar Marine dealer or distributor for procedure.

(1)

0005449

Figure 17

Inspecting and Replacing Rubber Diaphragm Seal Ring

Rubber diaphragms (A) and (B) (SD20 & SD50, SD50-4T)

The rubber diaphragms (A) and (B) of the Sail-Drive are important parts for the hull and crew safety. Since rubber degenerates during use, be sure to inspect them every two years. The vessel must be lifted onto a block for this procedure. To replace, consult your Yanmar Marine dealer.

Inspecting Seal Sensor

See (Figure 9) on page 22. See your authorized Yanmar Marine dealer or distributor for inspection procedure.

50 SD Operation Manual

PERIODIC MAINTENANCE

Every 2000 Hours of Operation

• Replacing the Flexible Mount

• Replacing the Cone-Clutch

Replacing the Flexible Mount

See your authorized Yanmar dealer or distributor for procedure. Flexible Mount must be replaced every 2000 hours.

Replacing the Cone-Clutch

See your authorized Yanmar dealer or distributor for procedure.

Every 5 Years

• Replacing Rubber Diaphragm Seal Ring

Replacing Rubber Diaphragm Seal Ring

To replace, consult your Yanmar Marine dealer.

SD Operation Manual 51

PERIODIC MAINTENANCE

This Page Intentionally Left Blank

52 SD Operation Manual

SPECIFICATIONS

Model

Reduction Gear System Constant mesh

Direction Of Rotation Input Shaft Counterclockwise viewed from stern

Propeller Shaft Counter-clock-

Reduction Ratio Ahead 2.64 2.32

Astern 2.64 2.32

Propeller Speed (rpm) 1364 1293 1337

Lubrication System Oil bath type

Lubricating Oil Capacity

Dry Weight 30 kg (66 lb) 39 kg (86 lb) 41 kg (90 lb)

Remote-Control Device

Applicable Engine Model (Maximum Rated Output Power At Crankshaft)

Standard Unit 2.2 L (2.3 qt) 2.2 L (2.3 qt), SD40: 1.8L (1.9 qt)

Long-Reach Unit 2.5 L (2.4 qt) 2.35 L (Extension 58) [2.5 qt], 2.45 L

Control Head Single control lever

Cable MORSE 33C (equivalent)

SD20 SD50 SD50-4T

gear with dog clutch

wise viewed from stern

1GM10C:

6.7 kW (9.1 hp) / 3600 rpm 2YM15:

10.3 kW (14 hp) / 3600 rpm 3YM20:

16.2 kW (22 hp) / 3600 rpm 3YM30:

22.1 kW (30 hp) / 3600 rpm

Counter-clockwise or clockwise viewed from stern

(Extension 100) [2.6 qt]

3JH4CE:

28.7 kW (39 hp) / 3000 rpm

4JH4ACE

39.6 kW (53 hp) / 3000 rpm 3JH5CE:

28.7 kW (39 hp) / 3000 rpm 4JH5CE:

39.6 kW (53 hp) / 3000 rpm

Cone clutch

4JH4-TCE:

55.2 kW (75 hp) / 3200 rpm

Note: A propeller with rubber bushing must be used in all SD series Sail-Drives.

Note: 1 hp metric = 0.7355 kW

SD Operation Manual 53

SPECIFICATIONS

This Page Intentionally Left Blank

54 SD Operation Manual

SYSTEM DIAGRAMS

Color coding for wiring diagrams

R Red

B Black

W White

Y Yellow

L Blue

O Orange

L/B Blue/Black

W/L White/Blue

Y/W Yellow/White

W/R White/Red

L/R Blue/Red

W/B White/Black

R/B Red/Black

Allowable length by cross sectional area of battery cable

Section of cable

mm2 (in.2)

15 (0.023) < 0.86 (0.26)

20 (0.031) < 1.3 (0.40)

30 (0.046) < 2.3 (0.70)

40 (0.062) < 2.8 (0.85)

50 (0.077) < 3.5 (1.07)

60 (0.093) < 4.1 (1.25)

Allowable length

L = 1 + 2 + 3 m (ft)

SD Operation Manual 55

SYSTEM DIAGRAMS

A-Type Instrument Panel

(21)(20)

30 AC

(18)

(22)

R/B

W

(23)

R/B

(24)

R/B

(25)

0005465

R/B

(26)

W/R

L/B

W/L

Y/W

W

R

R/B

W/R

(16)

R

L/B

W/L

W

Y/W

R/B

L/R

O

L

B

(17)

(15)

(13)

(14)

B

W/RBO

L/R

W/B

L/B

W/L

W

R

Y/W

W/R

B

(6)

(1)

(4)

(5)

(2)

(10)

Y/W

(11)

L/B

R

W

B

S

(7)

B

(3)

R

E

B

(8)

W/L

L

R/B

R

L

(9)

O

(12)

Figure 1

56 SD Operation Manual

L/R

SYSTEM DIAGRAMS

A-Type Instrument Panel

Applicable Engine Model: 1GM10C

1 Cable, battery to switch

2 Cable, switch to starter

3 Cable, battery to starter

4 Battery Recommended capacity GM,

12V-70AH 1GM,12V-100AH (Minimum)

5 Battery switch

6 FUSE

7 Starter motor

8 Alternator

9 Not used

10 Cooling Water temp. switch

11 Engine Oil pressure switch

12 Spare connector

13 Extension cable 3 m [9.8 ft] (Standard)

14 The total length extension cable must

be less than 6 m (19.7 ft)

15 Rubber seal switch (Sail-Drive)

16 Amplifier

17 Ground

18 Sail-Drive extension cable 0.3 m (1 ft)

19 Not used (Except 1GMC)

20 Key switch

21 Push button switch

22 Charge lamp

23 Cooling Water temp. lamp

24 Engine Oil pressure lamp

25 Rubber seal lamp (Sail-Drive)

26 Buzzer

Note: If the cross-sectional area of the wire being used is equal to or less than 20 mm (approximately AWG 4), the combined lengths of items 1, 2 and 3 must be less than

2.5 m (8.2 ft).

If the cross-sectional area of the wire being used is equal to or less than 40 mm

2

(approximately AWG 1), the combined lengths of items 1, 2 and 3 must be less than 5 m (16.4 ft).

Note: Battery, battery switch and cables are not supplied by Yanmar.

2

SD Operation Manual 57

SYSTEM DIAGRAMS

22

30 AC

21

W/L

B

20

R/B

B-Type Instrument Panel

23

24

25

R/B

W/L

R/B

Y/W

W/R

R/B

L/B

W

L/B

W

R

W/L

Y/W

B

W/R

26

R/B

R/B W/L Y/W

W/R R/B

B O L/B

B R

003877-00E

27

P

28

P

18

W

R

L/B

W/L

Y/W

R/B

BOL/R

L

16

17

15

14

W/R

W/B

13

W/R

B

W/R

B

19

W

L/B

W/L

Y/W

R

BOL/R

6

1

2

5

R

W

B

S

B

7

L/B

R/B

L

R

E

B

W/L

L

R

Y/W

O

L/R

P

4

3

8

9

10

11

12

Figure 2

58 SD Operation Manual

SYSTEM DIAGRAMS

B-Type Instrument Panel

Applicable Engine Model: 1GM10C

1 Cable, battery to switch

2 Cable, switch to starter

3 Cable, battery to starter

4 Battery Recommended capacity GM,

12V-70AH 1GM, 12V-100AH (Mini.)

5 Battery switch

6 FUSE

7 Starter motor

8 Alternator

9 Not used

10 Cooling Water temp. switch

11 Engine Oil pressure switch

12 Tachometer sender

13 Extension cable 3 m. (Standard)

14 The total length extension cable must

be less than 6 m.

15 Rubber seal switch (Sail-Drive)

16 Amplifier

17 Ground

18 Sail-Drive extension cable 0.3 m.

19 Not used (Except 1GMC)

20 Light switch

21 Key switch

22 Push button switch

23 Charge lamp

24 Cooling Water temp. lamp

25 Engine Oil pressure lamp

26 Rubber seal lamp (Sail-Drive)

27 Buzzer

28 Tachometer

Note: If the cross-sectional area of the wire being used is equal to or less than 20 mm (approximately AWG 4), the combined lengths of items 1, 2 and 3 must be less than

2.5 m (8.2 ft).

If the cross-sectional area of the wire being used is equal to or less than 40 mm

2

(approximately AWG 1), the combined lengths of items 1, 2 and 3 must be less than 5 m (16.4 ft).

Note: Battery, battery switch and cables are not supplied by Yanmar.

2

SD Operation Manual 59

SYSTEM DIAGRAMS

4JH4-TE with B x B Type Panel

12V

20 20

12V

19

< 1.3(m)

< 0.86(m)

L=1+2+3(m)

Allowable length

)

2

(mm

Allowable length by

cross sectional area

of battery cable

15(mm

20(mm

section of cable

-

+

1

-

+

1

< 2.3(m)

)

2

30(mm

< 2.8(m)

< 3.5(m)

)

2

40(mm

50(mm

3R

3

2

21

3

2

< 4.1(m)

)

2

60(mm

31

B

S

27

2W

B

2R

26

3R

B

W/Y

10B

10R

BLE

R

P

BLE

LB

RB

LB

RB

R

YG

Y

O

RB LB

32

30 30

24

25

2R

WBr

YW

22

23

24

5R

WL

29

28

16

5R

3L

2B

17

G2

G1

AC

30

GLOW

Key switch

33

+

-

B

L

RB

YG

OFF

008433-00E

ON

START

GR

WR

G

Y

GB

YR

WB

YB

B

YG

WG

WL

LB O

YW

RB

3W

3L

3R

18

16

15

WBr

9

1

R

30

L

G1G2

L

W

17 AC

R

11

O

P

-

B

12

+

WBr

9

R

30

L

G1

AC

R

W

G2

17

B

L

11

13

YW WL YG LB

4 5 6 7 8

2

3

10

2

YW WL YG LB

4 5 6 7 8

3

10

Figure 3

60 SD Operation Manual

O

15 17

P

-

+

0004506

12

14

SYSTEM DIAGRAMS

4JH4-TE with B x B Type Panel

Color Coding Engine Harness

R Red +

B Black -

W White Ignition

L Blue Air heater / glow (op-

RB Red / Black Alternator exciter

LB Blue / Black Alternator charge

YW Yellow /

White

YB Yellow /

Black

YG Yellow /

Green

WL White / Blue Water temperature

WB White /

Black

WG White /

Green

GR Green / Red Fuel filter alarm

O Orange Pulse for tachometer

WBr White /

Brown

tion)

alarm

Engine oil pressure alarm

Engine oil pressure

Sail-drive seal

alarm

Water temperature

Seawater flow alarm

Electric stop

1 Option

2 Alarm Lamps

3 Buzzer

4 Engine Oil Pressure

5 Coolant Temperature

6 Sail-Drive Seal

7 Battery Low Charge Alarm

8 Fuse (3A)

9 Stop Switch

10 Diodes

11 Key Switch

12 Tachometer / Hour Meter

13 Instrument panel (sub station) (Op-

tion)

14 Instrument panel (main station) (Op-

tion)

15 Wire Harness

16 Relay

17 Wire Harness for Sub Panel

18 Amplifier (Sail-Drive Only)

19 Procured by Customer

20 Battery

21 Battery Switch

22 Engine Stop Solenoid with VE Pump

23 Air Heater

24 Option

25 Stop Relay

26 Starter Relay

27 Starter

28 Coolant Temperature Switch

29 Engine Oil Pressure Switch

30 Alternator

31 Ground Bolt

32 Sail-Drive Only

33 Details of Coupler (View from A-A)

SD Operation Manual 61

SYSTEM DIAGRAMS

4JH4-TE with C x B Type Panel

12V

20 20

12V

19

< 1.3(m)

< 0.86(m)

L=1+2+3(m)

Allowable length

)

2

(mm

Allowable length by

cross sectional area

of battery cable

15(mm

20(mm

section of cable

-

+

1

-

+

1

< 2.3(m)

)

2

30(mm

< 2.8(m)

< 3.5(m)

)

2

40(mm

50(mm

3R

3

2

21

3

2

< 4.1(m)

)

2

60(mm

31

B

S

27

2W

B

2R

26

3R

B

W/Y

10B

10R

BLE

R

P

BLE

Y

LB

RB

LB

RB

R

YG

O

RB LB

30 30

32

WB

24

25

2R

WBr

YW

22

23

24

5R

WL

29

28

YB

16

5R

3L

2B

39 40

17

G2

G1

AC

30

GLOW

Key switch

33

GR B

+

-

B

L

RB

YG

OFF

38

008434-00E

ON

START

GR

WR

G

Y

GB

YR

WB

YB

B

YG

WG

WL

LB O

YW

RB

3W

3L

3R

18

16

15

WBr

9

1

R

30

L

G1G2

L

W

17 AC

R

11

O

P

-

B

12

+

13

YW WL YG LB

4 5 6 7 8

2

3

10

WBr

9

34 35 6 7 8

2

3

R

30

L

G1G2

AC

L

W

17

R

WG G YG LB

11

10

O

WB

YB

B

Figure 4

62 SD Operation Manual

15 17

P

-

+

-

+

-

+

0004507

123736

14

WL

YW

SYSTEM DIAGRAMS

4JH4-TE with C x B Type Panel

Color Coding Engine Harness

R Red +

B Black -

W White Ignition

L Blue Air heater / glow (op-

RB Red / Black Alternator exciter

LB Blue / Black Alternator charge

YW Yellow /

White

YB Yellow /

Black

YG Yellow /

Green

WL White / Blue Water temperature

WB White /

Black

WG White /

Green

GR Green / Red Fuel filter alarm

O Orange Pulse for tachometer

WBr White /

Brown

tion)

alarm

Engine oil pressure alarm

Engine oil pressure

Sail-drive seal

alarm

Water temperature

Seawater flow alarm

Electric stop

1 Option

2 Alarm Lamps

3 Buzzer

4 Engine Oil Pressure

5 Coolant Temperature

6 Sail-Drive Seal

7 Battery Low Charge Alarm

8 Fuse (3A)

9 Stop Switch

10 Diodes

11 Key Switch

12 Tachometer / Hour Meter

13 Instrument Panel (sub station) (Op-

tion)

14 Instrument panel (main station) (Op-

tion)

15 Wire Harness

16 Relay

17 Wire Harness for Sub Panel

18 Amplifier (Sail-Drive Only)

19 Procured by Customer

20 Battery

21 Battery Switch

22 Engine Stop Solenoid with VE Pump

23 Air Heater

24 Option

25 Stop Relay

26 Starter Relay

27 Starter

28 Coolant Temperature Switch

29 Engine Oil Pressure Switch

30 Alternator

31 Ground Bolt

32 Sail-Drive Only

33 Details of Coupler (View from A-A)

34 Seawater

35 Fuel Filter

36 Engine Oil Pressure Meter / Alarm

37 Water Temperature Meter / Alarm

38 Fuel Filter Switch

39 Engine Oil Pressure Sender

40 Coolant Temperature Sender

SD Operation Manual 63

SYSTEM DIAGRAMS

B-Type Instrument Panel for 3YM30, 3YM20 and 2YM15

-

3

21

12V

1

+

<0.86(m)

<2.8(m)

<3.5(m)

<1.3(m)

<2.3(m)

)

2

15(mm

)

2

20(mm

)

2

30(mm

)

2

40(mm

)

2

50(mm

<4.1(m)

)

60(mm

19 20

L=1+2+3(m)

Allowable Length

)

2

(mm

Section of cable

27

0.85B

24

S

2W

B 5R 2R

W/Y

B

2B

2

23

120270

-77511

2W

10B

3R

28

0.85YG

R

BLE

Y

10R

0.85RB

0.85LB

18

22

119247-77100

WBr

2R

+

0.85B

2B

-

17

16

119717

-77800

2B 2B

3BR

15

5R

128990-77910

2L

2B

0.85YW

25 26

0.85WL

0.85WBr

0.85 O

A

29

30 AC G1 G2 17

GLOW

Key switch

-

B

L

003880-00E

START

OFF

ON

30

RB LB O YG

YW WL WG B

3L

3R 3W

+

14

RB

YG

A

12 13

Figure 5

WBr

7

R

30

L

AC

G1

W

R

L

17

G2

O

9

B

11

+ -P

10

5 6

1

YW WL YG LB

2 3 4

8

64 SD Operation Manual

SYSTEM DIAGRAMS

B-Type Instrument Panel for 3YM30, 3YM30, 3YM20 and 2YM15

Color Coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YG Yellow / Green

WL White / Blue

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

1 Alarm Lamps

2 Buzzer Oil Pressure

3 Coolant Temperature

4 Sail-Drive Seal

5 Charge

6 Fuse (3A)

7 Stop Switch

8 Diodes

9 Key Switch

10 Instrument Panel

11 Tachometer Hour Meter

12 Wire Harness Option (L=3M)

13 Wire Harness Option (L=6M)

14 Amplifier (only for Sail-Drive)

15 Relay

16 Glow Plug

17 Engine Stop Solenoid

18 Battery Switch

19 Allowable Length by Cross Sectional

Area of Battery Cable

20 Procured by Customer

21 Battery

22 Stop Relay

23 Starter Relay

24 Starter

25 Coolant Temperature Switch

26 Engine Oil Pressure Switch

27 Ground Bolt

28 Alternator

29 Sail-Drive Only

30 Coupler (View from A-A)

SD Operation Manual 65

SYSTEM DIAGRAMS

B-Type Instrument Panel for 3JH4E

48

B

S

2W

B

25

3

2

1

33

12V

2R

3R

24

B

W/Y

47

46

12V

3

2

1

32

2R

2B

22

23

WBr

21

5R

10B

Option

YW

R

L

29

B

E

Y

10R

RBYGLB

RB LB

RB

LB

B

E

R

L

28

27

WL

26

30

O

17

49

G1 G2

30 AC

Key switch

GLOW

OFFONSTART

WB YR Y WR

YW WL WG B

3R 3W

003881-00E

YB GB G GR

RB LB O YG

3L

44 45

5R

3L

2B

3R

A

BLYG

RB

43

A

31

9

19

36

WBr

R

2

30

LL

G1

W

17 AC

R

10

G2

LB

O

P

B

1

3

WBr

R

30

12

R

W

L

G1G2

L

17 AC

11

35

LB

41

O

P

B

40

13

WL YG

20

YW

5 6 7 8

4

34

WL YG

37 38

YW

15 16 17 18

14

39

Figure 6

66 SD Operation Manual

SYSTEM DIAGRAMS

B-Type Instrument Panel for 3JH4E

Color Coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

1 Starter Switch

2 Stop Switch

3 Tachometer / Hour Meter

4 Buzzer

5 Lubricating Oil Low Pressure Alarm

6 Coolant High Temperature Alarm

7 Water in Sail-Drive Seal Alarm

8 Battery Low Charge Alarm

9 Relay (for 2 Station: Option)

10 Fuse (3A)

11 Starter Switch

12 Stop Switch

13 Tachometer / Hour Meter

14 Buzzer

15 Engine Oil Low Pressure Alarm

16 Coolant High Temperature Alarm

17 Water in Sail-Drive Seal Alarm

18 Battery Low Charge Alarm

19 Option

20 Alarm Lamps

21 Air Heater (Option)

22 Engine Stop Solenoid

23 Stop Relay

24 Starter Relay

25 Starter

26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch

28 Alternator (Option)

29 Alternator

30 Water in Sail-Drive Seal Sensor (on

Sail-Drive)

31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

32 Battery (Option)

33 Battery

34 Diodes

35 Instrument Panel (Sub Station) (Op-

tion)

36 Wire Harness

37 Alarm Lamps

38 Fuse (3A)

39 Diodes

40 Instrument Panel (Main Station) (Op-

tion)

41 Wire Harness

42 Wire Harness for Sub Panel

43 Only for Sail-Drive

44 Relay

45 Option

46 Procured by Customer

47 Battery Switch

48 Ground Bolt

49 Only for Sail-Drive

SD Operation Manual 67

SYSTEM DIAGRAMS

3

3332

1

12V

50

12V

3

1

3R

9

C-Type Instrument Panel for 3JH4E

52

B

S

2W

25

B

2R

3R

2

24

B

W/Y

51

2

23

2R

2B

22

WBr

21

5R

48 49

5R

3L

2B

R

L

B

E

10B

29

Y

10R

LB

B

E

L

53

O

RBYGLB

RB LB

RB

R

WB

28

YB

YW

27

WL

26

A

54

30

30 AC G1 G2 17

Key switch

GLOW

OFFONSTART

35

34

BLYG

YB GB G GR

WB YR Y WR

YW WL WG B

3R 3W

RB

A

003882-00E

RB LB O YG

3L

47

31

40

WBr

R

30

2

36

W

R

10

37

LL

G1G2

17 AC

1

LB

WL YG

YW

5 6 7 8

4

O

P

B

3

39

38

WBrR

R

30

12

W

L

G1G2

L

17 AC

11

42

LB

G YG

YG

41

15 16 17 18

43

14

45 46

O

P

13

WB

YB

B

44

20

WL

19

YW

Figure 7

68 SD Operation Manual

SYSTEM DIAGRAMS

C-Type Instrument Panel for 3JH4E

Color Coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

1 Starter Switch

2 Stop Switch

3 Tachometer / Hour Meter

4 Buzzer

5 Lubricating Oil Low Pressure Alarm

6 Coolant High Temperature Alarm

7 Water in Sail-Drive Seal Alarm

8 Battery Low Charge Alarm

9 Relay (for 2 Station: Option)

10 Fuse (3A)

11 Starter Switch

12 Stop Switch

13 Tachometer / Hour Meter

14 Buzzer

15 Lubricating Oil Low Pressure Alarm

16 Coolant High Temperature Alarm

17 Water in Sail-Drive Seal Alarm

18 Battery Low Charge Alarm

19 Engine Oil Pressure Meter

20 Coolant Temperature Meter

21 Air Heater (Option)

22 Engine Stop Solenoid

23 Stop Relay

24 Starter Relay

25 Starter

26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch

28 Alternator (Option)

29 Alternator

30 Water in Sail-Drive Seal Sensor (on

Sail-Drive)

31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

32 Battery (Option)

33 Battery

34 Engine Oil Pressure Sensor (Option)

35 Coolant Temperature Sensor (Option)

36 Option

37 Alarm Lamps

38 Diodes

39 Instrument Panel (Sub Station) (Op-

tion)

40 Wire Harness

41 Alarm Lamps

42 Fuse (3A)

43 Diodes

44 Instrument Panel (Main Station) (Op-

tion)

45 Wire Harness

46 Wire Harness for Sub Panel

47 Only for Sail-Drive

48 Relay

49 Option

50 Procured by Customer

51 Battery Switch

52 Ground Bolt

53 Option

54 Only for Sail-Drive

SD Operation Manual 69

SYSTEM DIAGRAMS

3

3332

12V

+

2

1

Battery switch

-

3

12V

+

2

Procured by customer

1

2R

+

-

B-Type Instrument Panel for 4JH4AE

Earth bolt

S

2W

25

B

2R

3R

24

B

W/Y

10B

Option

R

BLE

10R

LB

RB

LB

RB

B

E

L

R

23

2B

WBr

YW

22

21

5R

Relay

5R

3L

2B

WL

B

YG

29

O

Y

RB

LB

B

R

28

27

26

A

30

only for sail drive

P

36

(4JH4AE only)

17

G2

G1

AC

30

GLOW

OFF

ON

START

WR

GR

Y

G

GB

YR

YB

WB

B

YG

WG

LB O

WL

RB

YW

3W

3L

3R

+

-

B

31

L

RB

YG

only for sail drive

A

3R

9

WBr

Option

2

W

R

10

Alarm lamps

5 6 7 8

4

Wire harness

for sub panel

Wire

harness

WBr

R

30

L

G1G2

AC

17

YW WL YG LB

L

diodes

1

O

P-

B

3

+

12

Instrument panel (sub station) (Option)

Alarm lamps

R

Fuse(3A)

14

R

30

L

AC

G1

L

W

17

YW WL YG LB

15 16 17 18

11

G2

diodes

harness

O

- P

B

13

+

Instrument panel (main station) (Option)

0004594

Figure 8

70 SD Operation Manual

SYSTEM DIAGRAMS

B-Type Instrument Panel for 4JH4AE

Color coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

Description

1 Starter Switch

2 Stop Switch

3 Tachometer / Hour Meter

4 Buzzer

5 Engine Oil Low Pressure Alarm

6 Coolant High Temperature Alarm

7 Water in Sail-Drive Seal Alarm

8 Battery Low Charge Alarm

9 Relay (for 2 station - Optional)

10 Fuse (3A)

11 Starter Switch

12 Stop Switch

13 Tachometer / Hour Meter

14 Buzzer

15 Lubricating Oil Low Pressure Alarm

16 Coolant High Temperature Alarm

17 Water in Sail-Drive Seal Alarm

18 Battery Low Charge Alarm

19 -

20 -

21 Air Heater

22 Engine Stop Solenoid

23 Stop Relay

24 Starter Relay

25 Starter

26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch

28 Alternator (Optional)

29 Alternator

30 Water in Sail-Drive Seal Sensor Am-

plifier (on Sail-Drive)

31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

32 Battery (Optional)

33 Battery

34 -

35 -

36 Fuel Feed Pump (4JH4AE Only)

SD Operation Manual 71

SYSTEM DIAGRAMS

3

3332

12V

+

2

1

Battery switch

3

12V

+

2

Procured by customer

1

2R

+

-

C-Type Instrument Panel for 4JH4AE

Earth bolt

S

2W

25

B

2R

3R

24

B

W/Y

R

BLE

10B

10R

RB

LB

RB

LB

BLE

R

23

2B

WBr

YW

22

21

5R

Relay

5R

3L

2B

WL

B

YG

29

Y

O

B

R

WB

YB

28

RB

LB

27

26

A

30

only for sail drive

P

36

(4JH4AE Only)

34 35

17

G2

G1

AC

30

GLOW

OFF

ON

START

WR

GR

Y

G

GB

YR

YB

WB

B

YG

WG

LB O

WL

RB

YW

3W

3L

3R

+

-

B

L

31

RB

YG

A

only for sail drive

3R

9

WBr

2

Option

W

R

10

Alarm lamps

5 6 7 8

4

Wire harness

for sub panel

Wire

harness

WBr

R

30

L

AC

G1

1

L

17

G2

YW WL YG LB

diodes

O

P-

B

3

+

12

Instrument panel (sub station) (Option)

Alarm lamps

R

Fuse(3A)

14

R

30

L

AC

G1G2

L

diodes

11

B

W

17

WG G YG LB

15 16 17 18

harness

O

- P

132019

+

WB

-

+

WL

YB

-

+

Instrument panel (main station) (Option)

YW

0004595

Figure 9

72 SD Operation Manual

SYSTEM DIAGRAMS

C-Type Instrument Panel for 4JH4AE

Color coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

Description

1 Starter Switch

2 Stop Switch

3 Tachometer / Hour Meter

4 Buzzer

5 Engine Oil Low Pressure Alarm

6 Coolant High Temperature Alarm

7 Water in Sail-Drive Seal Alarm

8 Battery Low Charge Alarm

9 Relay (for 2 station - Optional)

10 Fuse (3A)

11 Starter Switch

12 Stop Switch

13 Tachometer / Hour Meter

14 Buzzer

15 Seawater

16 Fuel Filter

17 Water in Sail-Drive Seal Alarm

18 Battery Low Charge Alarm

19 Engine Oil Pressure Meter / Alarm

20 Coolant Temperature Meter / Alarm

21 Air Heater

22 Engine Stop Solenoid

23 Stop Relay

24 Starter Relay

25 Starter

26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch

28 Alternator (Optional)

29 Water in Sail-Drive Seal Sensor (on

Sail-Drive)

30 Water in Sail-Drive Seal Sensor Am-

plifier (on Sail-Drive)

31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

32 Battery (Optional)

33 Battery

34 Engine Oil Pressure Sensor (Optional)

35 Coolant Temperature Sensor (Option-

al)

36 Fuel Feed Pump (4JH4AE Only)

SD Operation Manual 73

026375-00X

(18)

(19)

(25)

(26)

(30)

(29)

(31)

(32)

(20)

(28)(27)

(24)

(17)

(13)

(14)

(15) (16)

(7)

(8)

(6)

(5)

(4)

(3)

(2)

(1)

(9) (10)

(11)

(12)

(22)

(21)

(23)

-

+

S

B

L

E

3R

0.85LB

0.85RB

0.85YW

0.85WL

0.85 O

0.85YG

R

2L

12V

1

3

2

10R

10B

0.85B

2B

2R

WBr

2B

5R

+

-

W/Y

B

3BR

B

Y

+

-

B

L

YG

RB

2W

2B

5R

2W

2B

0.85B

119717

119247-77100

120270

-77511

128990

-77910

-77800

0.85WBr

2R

A

3R 3W

Y

W WL

WG B

R

B LB

O YG

3L

+

-

P

O

0

47Ω/3W

1N4007

L

WBr

W

R

L

YW

R

B

YW

WL

YG

LB

RB

B

RB

II

IIII

SYSTEM DIAGRAMS

2YM15, 3YM20, 3YM30 - B (Keyless) - Type Instrument Panel (optional)

Figure 10

74 SD Operation Manual

2YM15, 3YM20, 3YM30 - B (Keyless) Type Instrument Panel (optional)

1 Optional

2 Diodes

3 Buzzer

4 Engine Oil Low Pressure Alarm

5 Coolant High Temperature Alarm

6 Water in Sail-Drive Seal Alarm

7 Battery Low Charge Alarm

8 Fuse (3A)

9 SWITCH GLOW (I) / OFF (0) / STOP

(II)

10 SWITCH START (II) / ON (I) / OFF (0)

11 Diode

12 Switch

13 Tachometer / Hourmeter

14 Instrument Panel (Main Station) (Op-

tion)

15 Wire Harness

16 Wire Harness for Sub Panel

17 Water in Sail-Drive Seal Sensor

Amplifier (Sail-Drive Only)

18 Procured by Customer

19 Battery

20 Battery Switch

21 Engine Stop Solenoid

22 Relay

23 Glow Plug

24 Stop Relay

25 Starter Relay

26 Starter

27 Coolant High Temperature Switch

28 Engine Oil Pressure Switch

29 Alternator

30 Ground Bolt

31 Sail-Drive Only for Sail-Drive

32 Coupler (View from A-A)

SYSTEM DIAGRAMS

SD Operation Manual 75

SYSTEM DIAGRAMS

3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (optional)

(32)

2B

(20)

B

S

2W

(27)

B

5R

3

12V

+

2

1

(21)

2R

3R

(26)

B

W/Y

2B

(22)

3

12V

+

2

1

(21)

L

R

B

E

10B

10R

LB

RB

LB

B

E

L

R

(30)

YG

(31)

Y

O

RB

LB

(31)

(33)

B

P

R

(34)

(35)

WR

GR

Y

G

YR

GB

WB

YB

B

YG

WG

LB O

WL

RB

YW

3W

3L

3R

(25)

2R

2B

+

-

WBr

YW

(23)

(24)

5R

WL

(16)

5R

2L

0.85B

3R

(16)

(17)

L

R

W

WBr

III

0

(10)

(1)

(11)

1N4007

(9)

II I

0

RB

YW

(12)(12)

B

L

RB

(8)

RB

O

- P

B

RB

(13)

+

R

(14)

(10)

(9)

(29)

(28)

R

W

2L

WBr

YB

WB

RB

LB

O

YG

B

WL YW

+

-

B

L

RB

YG

(19)

(18)

(17)

B

L

R

W

WBr

III

0

(11)

1N4007

II I

0

RB

YW

(12)(12)

B

L

O

- P

B

(13)

RB

+

RB

(8)

RB

R

(15)

47Ω/3W

(4)

(5)

(3)

(6)

(2)

LB

(7)

YG WL

YW

(4)

(5)

(6)

(3)

(7)

(2)

47Ω/3W

LB

YG

WL

YW

Figure 11

76 SD Operation Manual

026112-00X

SYSTEM DIAGRAMS

3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (optional)

Color

coding

R Red +

B Black -

W White Ignition

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green Sail-Drive Seal

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red Fuel Filter Alarm

O Orange

WBr White / Brown Electric Stop

Description

Engine Har-

ness

Air Heater / Glow

(option)

Alternator Excit-

er

Alternator

Charge Alarm

Engine Oil Pres-

sure Alarm

Engine Oil Pres-

sure

Water Tempera-

ture Alarm

Water Tempera-

ture

Seawater Flow

Alarm

Pulse For Tach-

ometer

1 Option

2 Diodes

3 Buzzer

4 Engine Oil Low Pressure Alarm

5 Coolant High Temperature Alarm

6 Water in Sail-Drive Seal Alarm

7 Battery Low Charge Alarm

8 Fuse (3A)

9 SWITCH GLOW (I) / OFF (0) / STOP

(II)

10 SWITCH START (II) / ON (I) / OFF (0)

11 Diodes

12 Switch

13 Tachometer / Hourmeter

14 Instrument Panel (Sub Station) (Op-

tion)

15 Instrument Panel (Main Station) (Op-

tion)

16 Relay

17 Wire Harness

18 Wire Harness for Sub Panel

19 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

20 Procured by Customer

21 Battery

22 Battery Switch

23 Engine Stop Solenoid

24 Air Heater

25 Stop Relay

26 Starter Relay

27 Starter

28 Coolant High Temperature Switch

29 Engine Oil Pressure Switch

30 Option

31 Alternator

32 Ground Bolt

33 Water in Sail-Drive Seal Sensor (Sail-

Drive Only)

34 Fuel Feed Pump

35 Details of Coupler (View from A-A)

SD Operation Manual 77

026113-00X

-+

S

B

L

E

3R

LB

RB

YW

WL

O

YG

R

2L

12V

1

3

2

10R

10B

B

2B

2R

WBr

0.85B

5R

+

-

B

L

E

LB

RB

R

LB

RB

W/Y

B

5R

B

Y

-+

12V

1

3

2

3R

+

-

B

L

YG

RB

2W

2R

5R

2B

+

-

P

O

0

47Ω/3W

1N4007

+

-

P

O

0

47Ω/3W

1N4007

WBr

W

L

WBr

W

R

L

R

L

YW

R

WG

G

YG

LB

YW

WL

YG

LB

R

RB R

RB

L

B

YG

O

LB

RB

WB

YB

WBr

2L

W

R

YW

WL

R

WL

+

-

+

-

WB

YW

R

WL

YW

B

R

B

WB

YB

RB

R

P

B

3W

3L

3R

YW

RB

WL

LB O

WG

B

YG

WB

YB

GB

G

YR

GR

WR

Y

III

II I

(21) (21)

(23)

(25)

(26)

(27)

(32)

(31) (31)

(19)

(13)

(14)

(15)

(16)

(20)

(17)

(17) (18)

(3)

(9)

(10)

(11)

(12)

(8)

(1)

(2)

(4)

(5)

(6)

(7)

(13)

(3)

(9) (10)

(11)

(12)(12)

(8)

(2)

(36)

(37)

(6)

(7)

(40)

(34)

(41)

(35)

(28)

(24)

(33)

(29)

(30)

(22)

(38) (39)

SYSTEM DIAGRAMS

3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (optional)

78 SD Operation Manual

Figure 12

SYSTEM DIAGRAMS

3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (optional)

Color

coding

R Red +

B Black -

W White Ignition

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YB Yellow / Black

YG Yellow / Green Sail-Drive Seal

WL White / Blue

WB White / Black

WG White / Green

GR Green / Red Fuel Filter Alarm

O Orange

WBr White / Brown Electric Stop

1 Option

2 Diodes

3 Buzzer

4 Engine Oil Low Pressure Alarm

5 Coolant High Temperature Alarm

6 Water in Sail-Drive Seal Alarm

7 Battery Low Charge Alarm

8 Fuse (3A)

9 SWITCH GLOW (I) / OFF (0) / STOP

Description

(II)

Engine Har-

ness

Air Heater / Glow

(option)

Alternator Excit-

er

Alternator

Charge Alarm

Engine Oil Pres-

sure Alarm

Engine Oil Pres-

sure

Water Tempera-

ture Alarm

Water Tempera-

ture

Seawater Flow

Alarm

Pulse For Tach-

ometer

10 SWITCH START (II) / ON (I) / OFF (0)

11 Diodes

12 Switch

13 Tachometer / Hourmeter

14 Instrument Panel (Sub Station) (Op-

tion)

15 Instrument Panel (Main Station) (Op-

tion)

16 Relay

17 Wire Harness

18 Wire Harness for Sub Panel

19 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)

20 Procured by Customer

21 Battery

22 Battery Switch

23 Engine Stop Solenoid

24 Air Heater

25 Stop Relay

26 Starter Relay

27 Starter Relay

28 Coolant High Temperature Switch

29 Engine Oil Pressure Switch

30 Option

31 Alternator

32 Ground Bolt

33 Water in Sail-Drive Seal Sensor (Sail-

Drive Only)

34 Fuel Feed Pump

35 Details of Coupler (View from A-A)

36 Seawater Flow

37 Fuel Filter

38 Engine Oil Pressure Meter / Alarm

39 Water Temperature Meter / Alarm

40 Engine Oil Pressure Sender

41 Coolant Temperature Sender

SD Operation Manual 79

SYSTEM DIAGRAMS

MAINTENANCE LOG

Date Operating

Hours

Maintenance Performed Dealer Name Stamp or Signa-

ture

80 SD Operation Manual

SYSTEM DIAGRAMS

Date Operating

Hours

Maintenance Performed Dealer Name Stamp or Signa-

ture

SD Operation Manual 81

SYSTEM DIAGRAMS

This Page Intentionally Left Blank

82 SD Operation Manual

Yanmar SD20, SD50, SD50-4T Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

SAFETY

SAFETY PRECAUTIONS

General Information

Before You Operate

During Operation and Maintenance

PRODUCT OVERVIEW

OVERVIEW

Owner / Operator Responsibilities

New Sail-Drive Break-In:

Dealer / Distributor Responsibilities

COMPONENT IDENTIFICATION

GALVANIC CORROSION

CORROSION CONTROL

SHORE POWER

UNDERWATER DRIVE COATING

BEFORE YOU OPERATE

PROPELLER SELECTION

Recommended Propeller Size (Maximum)

Fitting a Fixed Propeller (2-Blade)

LUBRICATING OIL

FILLING WITH LUBRICATING OIL - SD20, SD50 AND SD50-4T

CHECKING THE INSTRUMENT PANEL ALARM SYSTEM

DAILY CHECKS

Visual Checks

SAIL-DRIVE OPERATION

REMOTE CONTROL DEVICE CHECK

SD20

SD50 / SD50-4T

ENGINE COOLING WATER

SD20

SD50 / SD50-4T

PERIODIC MAINTENANCE

TIGHTENING FASTENERS

TORQUE CHARTS

Standard Torque Values

Standard Torque Chart

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE TABLE

WHEN THE VESSEL IS OUT OF THE WATER, PERFORM THE FOLLOWING:

Removing Deposits From The Lower Gear Case

Repairing Damaged Coating

Inspecting the Anode

Draining Water

Inspecting The Folding Propeller

PERIODIC MAINTENANCE PROCEDURES

After Initial 50 Hours of Operation

Every 100 Hours of Operation

Every 250 Hours of Operation

Every 500 Hours of Operation

Every Year

Every 2000 Hours of Operation

Every 5 Years

SPECIFICATIONS

SYSTEM DIAGRAMS

MAINTENANCE LOG