Yanmar SD20, SD50, SD50-4T Operation Manual

Download

Page 1

OPERATION MANUAL

SD20,SD50/SD50-4T

Page 2

SD-Series

SAIL-DRIVE

MODEL: SD20, SD50/SD50-4T

OPERATION MANUAL

Applicable Engine Model:

1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E 4JH3-TCE

without the written permission of YANMAR CO., LTD.

Page 3

Introduction ................................................... 3

1. For Your Safety ........................................ 4

1.1 Safety Precautions For Inspection .... 4

2. Specifications ........................................... 7

3. Selecting Lubricating Oil ........................... 8

3.1 Choice of lube oil .............................. 8

3.2 Kind of lube oil .................................. 8

3.3 Lube oil viscosity ............................... 9

4. Starting the New Sail-Drive for the First

Time ..................................................10

4.1 Filling with lubricating oil ................. 10

4.1.1 SD20 and SD50/-4T ..............10

4.2 Check of instrument panel alarm sys-

tem: 11

4.3 Remote-Control Device Check ........ 12

4.4 Fitting for Fixed Propeller (2-blade) . 14

4.5 Recommended Propeller Size (Max.) . 14

7. Electrical Wiring Diagrams ......................31

5. Method of Operation ..............................16

5.1 Engine Cooling Water ..................... 16

5.1.1 SD20 .....................................16

5.1.2 SD50/SD50-4T ......................17

6. Periodic Inspections and Maintenance ... 18

6.1 Lubricating oil system ...................... 19

6.1.1 SD20 .....................................19

6.1.2 SD50/-4T ...............................20

6.2 Procedure for filling and removing oil in the Sail-Drive; SD50/-4T 21

6.2.1 When the boat is in the water 22

6.2.2 When the boat is out of the water

6.3 Anticorrosive zinc ............................ 29

6.3.1 SD20 and SD50/ SD50-4T .... 29

6.4 Rubber diaphragms (A) and (B) (SD20 and SD50/-4T) 29

6.5 When the boat hull is raised onto a block, inspect the following: 30

Page 4

Introduction

This Installation and 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, 3JH4E, 4JH4E and 4JH3-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 SD20

2YM15

3YM20, 3YM30

3JH4E SD50

4JH4E

4JH3-TCE SD50-4T

Page 5

1. For Your Safety

1.1 Safety Precautions For Inspection

DANGER

WARNING

Battery Never smoke or permit sparks near the battery, because it may emit ex-

plosive hydrogen gas. Place the battery in a well-ventilated place.

Fuel Use only diesel fuel. Never use other fuels, including gasoline, kero-

sene, etc., because they could cause a fire. The wrong fuel could also cause the fuel injection pump and injector to fail due to lack of proper lubrication. Be sure to check that you have selected the correct diesel fuel before filling the fuel tank.

Do not use starting fluids or sprays. Their use may cause explosion, serious injury and engine damage.

Fire Prevention Be sure to stop the engine and confirm that there are no open flames in

the vicinity before fueling. If you do spill fuel, wipe such spillage carefully and dispose of the wiping materials properly. Wash your hands thoroughly with soap and water.

Never place oil or other flammable material in the engine room. Install a fire extinguisher near the engine room, and familiarize yourself

with its use.

WARNING

Exhaust Gas Exhaust gas contains poisonous carbon monoxide and should not be

inhaled. Be sure to install ventilation ports or ventilators in the engine room and

ensure good ventilation during engine operation.

Moving Parts Do not touch or let your clothing get caught in the moving parts of the

engine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured.

Never operate the engine without covers on the moving parts.

Page 6

1. For Your Safety

CAUTION

WARNING

DANGER

WARNING

Burns The whole engine is hot during operation and immediately after

shut-down. The exhaust manifold, exhaust pipe and high pressure fuel lines are very hot. Never touch these parts with your body or clothing.

Alcohol Never operate the engine while you are under the influence of alcohol. Never operate the engine when you are ill or not feeling well.

Battery Fluid Battery fluid is dilute sulphuric acid. It can blind you if it gets in your

eyes, or burn your skin. Keep the fluid away from your body. If you touch it, wash it off immediately with a large quantity of fresh wa-

ter and call your doctor for treatment.

Fire by Electric Short-Circuits Always turn off the battery switch before inspecting the electrical sys-

tem. Failure to do so could cause short-circuiting and fires.

WARNING

CAUTION

Stop the engine before you service it. Turn the battery switch off. If you must inspect while the engine is in op-

eration, never touch moving parts. Keep your body and clothing well clear of all moving parts.

Scalds When extracting oil from the engine while it is still hot, don't let the oil

splash on you. Wait until the temperature has dropped before extracting cooling water

from the engine. Don't let it splash on you.

Page 7

1. For Your Safety

DANGER

Forbidden Modifications. Never release 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. Also note that any troubles arising from modification are not covered by

our warranty.

Precautions for Treating Waste. Never dispose of waste oil or other fluid in a field, sewer, river, or the

sea. Treat waste matters safely observing regulations or laws. Ask a waste recovery company to collect it.

Page 8

2. Specifications

Model SD20 SD50 SD50-4T

Reduction gear system Constant mesh gear with

dog clutch use

Direction of rotation

Reduction ratio Ahead 2.64 2.32

Propeller speed (min-1) 1364 1293 1638

Lubrication system Oil bath type

Lubrication oil capacity

Dry weight 30 Kg 39 kg 41 kg

Remote-control device

Applicable engine model (Fuel stop power at crankshaft)

Input shaft Counter-clockwise viewed from stern

Propeller shaft Counter-clockwise viewed

from stern

Astern 2.64 2.32

Standard unit 2.2 L 2.2 L

Long-reach unit

Control head Single control lever

Cable "MORSE" 33C (equivalent)

1GM10C (6.7kW/3600

2YM15 (10.3kW/3600 min-1) 3YM20 (16.2kW/3600 min-1) 3YM30 (22.1kW/3600 min-1)

2.5 L 2.35 L (Extension 58), 2.45 L (Extension

min-1)

Counter-clockwise or clockwise viewed from

3JH4E

(29.4 kW/3000 min-1)

4JH4E

(40.5 kW/3000 min-1)

Cone clutch

stern

100)

4JH3-TCE

(55.2kW/3800min-1)

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

Page 9

3. Selecting Lubricating Oil

3.1 Choice of lube oil

The choice of lube oil is very important to a Sail-Drive. If an unsuitable oil is used, or oil change is neglected, it may result in

damage, and a shorter Sail-Drive life. When selecting the lube oil, it must be one of the following:

3.2 Kind of lube oil

Engine series GM, YM JH3, JH4

Engine model 1GM10C 2YM15 3YM20 3YM30 3JH4E 4JH4E 4JH3-TCE

Sail-drive model SD20 SD50 SD50 SD50-4T

Lubrication oil for the sail-drive

API CC or

greater and

SAE 10W30

API GL4 or GL5 and SAE

80W90 or 90

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 and SD50/-4T)

For SD20 (except if coupled with the 1GM10C) and SD50/-4T

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 only oil of quality "cc" or greater in the API service, and SAE no. 10W30.

(Applicable model: SD20 x 1GM10C)

API GL4 or GL5 and SAE

80W90 or 90 or Quicksil-

ver High Performance Gear

Lube

Quicksilver High Performance Gear

Lube

Use "Quicksilver High Performance Gear Lube" for the SD50/-4T.

This lube oil is available through all MerCruiser, Mercury, Mariner and Force outlets in their Quicksilver accessories program.

Page 10

3. Selecting Lubricating Oil

This High Performance Gear Lube is available in the following sizes:

Volume Part number Package

300 ml 92-802851Q1 case of 24 tubes

1 L 92-802854Q1 case of 12 plastic

bottles

10 L 92-802856Q1 case of 2 cans

60.5 L 92-802857Q1 single drum

208 L 92-802858Q1 single drum

3.3 Lube oil viscosity

The viscosity of the lube oil greatly influences Sail-Drive performance

Page 11

4. Starting the New Sail-Drive for the First Time

4.1 Filling with lubricating oil

4.1.1 SD20 and SD50/-4T

(1) Remove the dipstick (yellow cap)

and supply approved lube oil.

(2) Check the amount of lube oil by in-

serting the dipstick as far as possible. Do not screw the dipstick in. (see the illustration below). The oil level should reach the upper mark on the dipstick.

CAUTION

Since it takes about 10 minutes to fill up the Sail-Drive with lube oil, owing to its

construction, check the supplied oil quantity again by using the dipstick 15 minutes after completion of supply of the specified quantity of oil.

Sail-Drive Model:SD20 & SD50/-4T

Lube oil capacity:

Sail-drive model

Standard unit 2.2 L 2.2 L

Long-reach unit

SD20 SD50/-4T

2.5 L 2.35 L (Extension 58)

2.45 L (Extension 100)

CAUTION

The lube 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.

SD20 SD50/SD50-4T

A Dipstick D Oil level B Upper limit E Oil supply port C Lower limit F Oil capacity nameplate

003443-00E

Page 12

4. Starting the New Sail-Drive for the First Time

4.2 Check of instrument panel alarm system:

Turn on the battery switch. Then the key in the "ON" position and check the lamps on the panel (with the engine off).

(A-type) (B-Type)

1 Rubber seal (Sail-Drive) 4 LO press 7 Push button 2 CW temp 5 Key switch 8 Tachometer 3 Charge 6 Warning Buzzer 9 Check switch

(1) Lube oil warning lamp should be lit.

(2) Cooling water temperature warning

lamp should be out. (For small type panel: A-type only)

For the large type panel (B-type), raise the CHECK switch "ON" to see if the cooling water temperature warning lamp lights.

(3) Charging warning lamp should be

lit.

(4) Rubber seal lamp should be out.

(5) The warning buzzer should sound.

WARNING

The rubber seal alarm lamp warns of seawater entering the boat. The watertight structure of the Sail-Drive is the dual type. Even if the rubber diaphragm (A) is damaged and seawater enters, the rubber diaphragm (B) prevents it from entering the inboard. The rubber seal switch between the rubber diaphragms (A) and (B) works 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.

CAUTION

All the above alarm signs will continue until you push the starting button or turn the key off.

003446-00E

A ON (Rubber seal lamp) BBuzzer C Rubber seal switch D Diaphragm (B) E Diaphragm (A) F Seawater

OFF

5976

Page 13

4. Starting the New Sail-Drive for the First Time

4.3 Remote-Control Device Check

4.3.0.1 SD20

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 Sail-Drive moves smoothly to Ahead, Astern and Stopper. Because the Sail-Drive SD20 uses a dog clutch, the clutch is not engaged unless the operation lever is moved to the stopper position.

Serial No. 0001-2128 for SD10

Old type :

Serial No. 2129 and after for SD20

New type :

New type: Serial No. 2129 and after for SD20 Old type: Serial No. 0001-2128 for SD10 A Control handle L Ahead stopper B Astern M Neutral position C Neutral N Astern stopper D Ahead O Cable clamp E Operation lever P Remote control cable F Cable clamp Q Spring joint G Remote control cable R Operation lever HPivot SAstern I Astern T Neutral J Neutral U Ahead K Ahead

003447-00E

Page 14

4. Starting the New Sail-Drive for the First Time

4.3.0.2 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, gripping action is lessened with use and periodic inspection and maintenance is necessary.

A When attaching the cable mounting plate at a 90º

angle handle B Operation lever C Cable clamp D Remote control cable E Propeller shaft clockwise FPivot G Neutral H Propeller shaft counter-clockwise

003448-00E

Page 15

4. Starting the New Sail-Drive for the First Time

4.4 Fitting for Fixed Propeller (2-blade)

A Spacer

003449-00E

BGrease C Washer D Propeller E Nut Tightening torque 60-70 Nm (M16,

SD20) 80-100 Nm (M20, SD50/-4T)

F Bolt M8x75mm

Tightening torque11-15 Nm

Locking Procedure for Fixed Propeller Nut (Optional). When tightening the nut at 60-70 Nm torque for the SD20, and 80-100 Nm torque for the SD50/-4T, move the shift lever to ahead and hold the crankshaft V-pulley clamp nut with a wrench to stop the rotation.

4.5 Recommended Propeller Size (Max.)

Engine model Sail-Drive Model Folding type Dia. mm

1GM10C SD20 355 (14) 380 (15)

2YM15 368 (14.5) 380 (15)

3YM20 380 (15) 405 (16)

3YM30 405 (16) 420 (16.5)

3JH4E SD50 457 (18) 457 (18)

4JH4E 457 (18) 457 (18)

4JH3-TCE SD50-4T 457 (18) 457 (18)

CAUTION

Rubber bushing (Folding propeller)

For the sail-drive, be sure to use the folding propeller which is provided with a rubber bushing. If a propeller is used without rubber bushing, the shaft, bearing, and gears of the sail-drive are surely damaged.

2-blade, fixed type-

(inch)

Dia. mm (inch)

CAUTION

Precautions on matching of the propeller

(1) Be sure to confirm a matching of

the propeller in a sea trial.

(2) Execute a propeller matching on

the basis of the propeller shaft rated output (continuous rating at propeller shaft). 95% of the engine rated output (continuous rating at crankshaft) becomes the propeller shaft rated output (continuous rating at propeller shaft).

Page 16

4. Starting the New Sail-Drive for the First Time

Note: The propeller shaft output becomes 95% of the engine rated output (continuous rating at crankshaft) in consideration of mechanical efficiency 95% of the sail-drive.

(3) In the case of propeller calculation,

further add 5%, at minimum, as the sea margin to the aforementioned matching point. That is, 95% of the propeller shaft rated output (Continuous rating at propeller shaft) becomes the best propeller matching. Note about sea margin: In actu-

al navigation, there is an increase in resistance due to the waves, wind and fouling of the hull and, moreover, a drop in the efficiency due to fouling of the propeller. Consequently, in the case of propeller calculation, it is necessary to allow the engine output to have some margin. For that reason, it is necessary to add the sea margin of 5%, at minimum.

Page 17

5. Method of Operation

5.1 Engine Cooling Water

Opening or closing the cooling water system of the Sail-Drive Set Engine is done by the cooling water cock fixed on the upper case of the Sail-Drive. Be sure to open the cock and confirm that the C.W. has suction by cranking the engine before starting the boat. The cooling water passes through the Sail-Drive case, cools the engine by the cooling water pump, and is then discharged.

5.1.1 SD20

Note: For other items, refer to the engine operation manual.

Note: When sailing, set the remote control lever in neutral.

Old type:

Serial No.0001-2128 for Model SD20

New type:

Serial No.2129 and after for Model SD20

A Atern D Neutral G To C.W. pump B Neutral E Cock, C.W. H Hose clamp C Ahead F C.W. hose I Seawater inlet

003442-00E

Page 18

5. Method of Operation

5.1.2 SD50/SD50-4T

A Open C Cock C.W. E Neutral B To C.W. pump D Propeller shaft Clockwise F Propeller shaft Counter-clockwise

003450-00E

Page 19

6. Periodic Inspections and Maintenance

Lubricating Oil

(1) Check oil level: fill

(2) Change lube oil

Cooling Water

(1) Open/close cooling wa-

ter cock

(2) Clean cooling water suc-

tion hole

(3) Drain cooling water

Remote Control System

(1) Inspect remote control

device

(2) Inspect and replace

clutch shifter

Anti-Corrosive Zinc

(1) Inspect and replace an-

ti-corrosive zinc

Lower Case

(1) Repair case coating

Boat Bottom Water- tightness

(1) Inspect and replace rub-

ber diaphragm seal ring

(2) Inspect seal sensor

Flexible mount

(1) Inspect and replace

mounting height.

Every day

Before opera-

tion

Before/after

operation

After opera-

tion

50 hrs. or after

1 month

First

Every 100 hrs.

SD20OSD50/-4T

Replace if

wear is

more than

50%

Every 250

hrs.

Every 1 year Every 2 years

Replace if the

thickness is less than 10

mm.

Replace if

clearance is

less than 1 mm.

Serial No.

2129 and

after for

SD20

Inspect and

replace, if

there is

cracking

003451-00E

A: Clearance

Page 20

6. Periodic Inspections and Maintenance

6.1 Lubricating oil system

6.1.1 SD20

(1) Check the oil level before every op-

eration.

(2) Change the oil after the first 50

hours of operation or after long storage and every 100 hours of operation thereafter. Lube oil should be changed while the engine is still warm.

Change oil in the following manner:

(1) Put the boat hull on a block.

Drain the oil by removing the lower gear case drain plug, and the upper gear case oil dipstick.

WARNING

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

A Dipstick B Upper gear case C Lower gear case D Lube oil drain plug

003440-00E

Page 21

6. Periodic Inspections and Maintenance

6.1.2 SD50/-4T

(1) Check the oil level before every op-

eration.

(2) Change the oil after the first 50

hours of operation or after long storage, and every 250 hours of operation thereafter. Lube oil should be changed while the engine is still warm.

WARNING

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

A Dipstick B Plug C Drain plug

003441-00E

Page 22

6. Periodic Inspections and Maintenance

6.2 Procedure for filling and removing oil in the Sail-Drive; SD50/-4T

When the boat is (6.2.1) in the water and (6.2.2) out of the water

Used equipment:

Description Part code Quantity Remarks

Bottle of Quicksilver High Performance Gear Lube from MerCruiser

Market pump from MerCruiser on bottle

Adapter joint 196311-92960 1 (2) Thread std. M10 x 1.5 max. length 12

O-ring for adapter 24311-000100 1 (2)

Stiff rubber hoses 2 Inner diameter ø14-16 mm + hose

Compressor set - 1

Hand pump 28210-000080 1 Option parts

MerCruiser Part code

92-850743A1

MerCruiser Part code

91-85729A1

2 Each bottle contains 0.946 liter of oil.

Mandatory for SD50/-4T. For other

models see page 8.

mm.

clips (If Yanmar part is used, part code

is 196440-92970)

Page 23

6. Periodic Inspections and Maintenance

6.2.1 When the boat is in the water

6.2.1.1 Preparing the sail-drive:

AO-ring B Adapter joint C Oil changing plug D Tread M10 x 1.5

(1) Take out the oil changing plug lo-

cated under the shift lever.

(2) Screw in the adapter joint (196311-

92960) with the O-ring (24311-000100). When using own adapter joint, max. length of thread is 12 mm.

(3) Attach a stiff rubber hose with inner

diameter ø14~16 mm with hose clips to the adapter joint at the oil changing position. Hose must be long enough to drain to bucket or pump. (If Yanmar original rubber hose is used, part code is 196440-92970)

003452-00E

6.2.1.2 Removing oil (total quantity

2.2 liter)

003453-00E

APlug

6.2.1.3 Fastest way: Blowing out by using Air pressure

First follow steps (1), (2), (3) on page 22

(1) Take out the plug from the upper

case cover.

(2) Screw in a second adapter joint (P/

N 196311-92960) with an O-ring (P/N 24311-000100) at the oil inlet position. Screw in the oil plug at the dipstick position.

(3) Connect the air pressure hose with

hose clips.

(4) Option 1: Using Compressed air

from main system or 12 V portable compressor.

1. Connect hose at top adapter joint to compressed air and within 10 to 15 minutes almost all oil will be blown out.

Page 24

6. Periodic Inspections and Maintenance

A One-way valve B Adapter joint screwed in cover C Simple foot pump

003454-00E

Use Compressed Air (0.5~1 Bar) from main system, 12 V portable compressor or from portable hand pump or 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

in the pressure line (connected to the top cover). This is done to maintain the pressure during use of the pump.

(2) Connect the hand pump or foot

pump with the pressure line to the adapter joint on the top as shown above.

(3) With the system now connected,

pump out the oil until empty. The first 0.9 liter will take approx. 3 minutes. The second part takes more time as mostly air will be pumped out; this will take approx. 12 minutes.

6.2.1.4 Using Yanmar Pump

First follow steps (1), (2), (3) on page 22 and step (1) on page 22

Connect the hand pump with hoses as shown above, and start pumping.

Be aware that oil has to flow down through narrow parts and then up again.

Therefore, during this procedure, at first suction pressure will be high and pumping will be hard. A few minutes waiting in between will help. After taking out about 0.9 liter of oil, mostly you will pump out air, but continuous pumping is necessary.

Though approx. 100-200 ml of old oil will remain in the drive unit, in this case, it is no problem to fill-up with the new oil for maintenance.

The hand pump (p/#:28210-000080) and rubber hose (p/#:196440-92970) are available from Yanmar, and are optional parts for SD50/-4T. Or any type of hand pump or rubber hose (Inner diameter ø14-16 mm) available from the hardware shop, are usable.

Page 25

6. Periodic Inspections and Maintenance

APlug

003455-00E

6.2.1.5 Filling oil (total quantity 2.2

liter)

The following methods of filling with lube oil are in addition to the way mentioned in page 10.

6.2.1.6 Fastest way: By using MerCruiser pump or simple market pump

First follow steps (1) and (2) on page 22

(1) Use a MerCruiser pump with Part

number 91-85729A1 like the one shown above or use a similar pump available on the market.

(2) Screw the pump on a new bottle of

Quicksilver High Performance Gear Lube Part number 92-850743A1 (0.946 liter) from MerCruiser.

(3) Connect the hose with a hose clip

to the adapter joint below the shift lever.

(4) Take out the plug from the upper

case cover.

(5) Fill the oil by pushing the upper

part of the pump. After bottle is empty, change the bottle while the pump and hose remains connected with the adapter joint.

(6) After filling, first screw in and tight-

en the plug at the top cover. Then remove the oil bottle, pump, hose and adapter joint and screw in the oil plug (don't forget the gasket).

Page 26

6. Periodic Inspections and Maintenance

6.2.1.7 By using Yanmar Hand Pump

First follow steps (3) and (4) on page 24.

(2) Take out the plug from the upper

case cover.

(3) Fill in the oil moved by the hand

pump. Be aware that oil has to flow down through narrow parts and then up again. Therefore, during this procedure, at first suction pressure will be high and pumping will be hard. A few minutes waiting in between will help. The hand pump (p/#: 28210-000080) and rubber hose (p/#: 196440-92970) are available from Yanmar, and are optional parts for SD50/-4T. Or any type of hand pump or rubber hose (Inner diameter ø14-16 mm) available from the hardware shop, are usable.

(4) After filling, first screw in and tight-

en the plug at the top cover. Then remove the hand pump, hose and adapter joint and screw in the oil plug (don't forget the gasket).

003456-00E

APlug

(1) Connect the hoses as shown above

at the top adapter joint to the hand pump by using the rubber hose.

6.2.1.8 By not using pump

For the oil filling procedure by not using pump, see the explanation on chapter 4., page 10.

Page 27

6. Periodic Inspections and Maintenance

6.2.2 When the boat is out of the water

6.2.2.1 Preparing the sail-drive:

(4) Take out the dipstick and oil inlet

plug from the upper case cover.

6.2.2.2 Removing oil (total quantity

2.2 liter)

6.2.2.3 By draining

First follow steps (1), (2), (3), (4) on page

26.

Oil drain is possible from this point but will take much time.

(1) After approx. 0.6 liter has been

drained, remove the oil changing plug. If you remove sooner, oil may spill out of this position (because max. oil level is higher than this position).

003457-00E

APlug

(1) Remove the bottom drain plug

(2) Screw in the adapter joint (P/N

196311- 92960) with the O-ring (P/N 24311- 000100).

When using own adapter joint, max. length of thread is 12 mm.

(3) Attach a stiff rubber hose with inner

diameter ø14~16 mm with hose clips to the adapter joint at the oil drain position. The hose must be long enough to drain to bucket.

003458-00E

A Tread M10 x 1.5 B Oil changing plug

6.2.2.4 Fastest way: Blowing out by using Air pressure

First follow steps (1), (2), (3) on page 22, then follow the procedures on page 22. Be aware that oil is divided in two channels connected by the lower gear and lower drain port.

Page 28

6. Periodic Inspections and Maintenance

6.2.2.5 Filling oil (total quantity 2.2 liter)

6.2.2.6 By using MerCruiser pump or simple market pump

First follow steps (1), (2), (4) on page 26.

003870-00E

APlug BO-ring C Adapter joint

(1) Use a MerCruiser pump with Part

number 91-85729A1 like the one shown on p. 24, 6.2.1.4, or use a similar pump available on the market.

(2) Screw the pump on a new bottle of

Quicksilver High Performance Gear Lube Part number 92-850743A1 (0.946 liter) from MerCruiser.

(3) Remove the oil changing plug be-

low 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.

(6) Fill the oil by pushing the upper

part of the pump. After the first bottle is empty, screw in the oil changing plug (don't forget the gasket).

(7) Change the bottle while the pump

and hose remain connected with the adapter joint.

(8) After filling, first screw in and tight-

en the plug at the top cover. Then remove the oil bottle, pump, hose and adapter joint and screw in the oil drain plug (don't forget the gasket).

Page 29

6. Periodic Inspections and Maintenance

6.2.2.7 By using Yanmar hand pump

First follow steps (1), (2), (3), (4) on page

26.

pumping will be hard. A few minutes waiting in between will help. After pumping in about 1 liter of oil, screw in the oil changing plug (do not forget to insert the gasket). Please be aware that the drain hose can easily slip out of the bucket and cause oil spilling. The hand pump (p/#: 28210-000080) and rubber hose (p/#:196440-92970) are available from Yanmar, and are optional parts for SD50/-4T. Or any type of hand pump or rubber hose (Inner diameter ø14-16 mm) available from the hardware shop, are usable.

003871-00E

APlug

(1) Connect the hose from the bottom

and a suction hose to Yanmar pump with hose clip like shown above.

(2) Take out the plug from the upper

case cover.

(3) Fill oil by pumping it into drive. Be

aware that oil has to flow up through narrow parts. Therefore,

003872-00E

(4) After filling, first screw in and tight-

en the plug at the top cover. Then remove the pump, hose and adapter joint and screw in the oil drain plug (do not forget to insert the gasket).

6.2.2.8 By not using pump

For the oil filling procedure by not using pump, see the explanation on chapter 4., page 10.

Page 30

6. Periodic Inspections and Maintenance

6.3 Anticorrosive zinc

6.3.1 SD20 and SD50/ SD50-4T

To prevent corrosion of the sail-Drive body by sea (lake) water, replace the anticorrosive zinc at the earliest time of every 100

SD20

M10 x 11

ZINC

Don't remove

while the boat

in the water

M20 x 50

hours of operation, once every six months or when it becomes half of the original volume (size).

A Safety label C Upper gear case B Anticorrosive zinc D Lower gear case

Anticorrosive zinc is provided on the upper and lower gear case. To inspect and replace the anticorrosive zinc on the lower gear case, the boat hull must be put on a block.

WARNING

Do not remove the plug (including Anticorrosive Zinc) while the boat is in the water.

6.4 Rubber diaphragms (A) and (B) (SD20 and 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 replace them

every two years. (Boat hull must be lifted onto a block). To replace, consult your Yanmar dealer.

003873-00E

Page 31

6. Periodic Inspections and Maintenance

SD50/-4T

A Lower gear case B Upper gear case

6.5 When the boat hull is raised onto a block, inspect the following:

003874-00

(3) Inspecting anticorrosive zinc

Since anticorrosive zinc can not be inspected except when the boat hull is raised onto a block, be sure not to forget to inspect it.

(4) Inspecting the folding propeller

Inspect whether or not the blade of the folding propeller opens smoothly. Also inspect for wear on the blade-fixing pins. Replace them when wear is excessive. Apply seawater-proof grease to the pins blade gear and propeller shaft.

(5) Draining water

When the boat hull is on a block, drain the engine cooling water, and the water in the Sail-Drive case. (If this water is not drained, freezing may cause cracks)

(1) Remove deposit from the lower

gear case.

Remove seaweed, seashells, and marine growth from the lower gear case. Be sure to remove deposit completely around the cooling water intake since the engine may overheat if the intake amount is insufficient.

(2) Repairing damaged membrane

The membrane of the lower gear case which is always in seawater may be damaged when hitting floating objects in the sea, or when having deposit removed from it. Do not use paint containing copper derivatives.

003875-00E

A Lower gear case B Seawater inlet

Page 32

7. Electrical Wiring Diagrams

See Appendix B. at the back of this manual.

Color coding

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

A-type Instrument Panel

Applicable Engine Model: 1GM10C

4 Battery Recommended capacity

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

5 Battery switch

6FUSE

7 Starter motor

8 Alternator

9 Not used

10 C.W. temp. switch

11 L.O. pressure switch

12 Spare connector

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 Earth

18 Sail-drive extension cable 0.3 m.

19 Not used (Except 1GMC)

20 Key switch

21 Push button switch

22 Charge lamp

23 C.W. temp. lamp

24 L.O. pressure lamp

25 Rubber seal lamp (Sail-drive)

26 Buzzer

Note: 1 + 2 + 3 < 2,5 m - 20 mm2

(Cross sectional area)

1 + 2 + 3 < 5 m - 40 mm2

(Cross sectional area)

B-type Instrument Panel

Applicable Engine Model:

3YM30, 3YM20 and 2YM15

(See A-5)

3JH4E, 4JH4E (See A-6)

B-type Instrument Panel

Applicable Engine Model: 1GM10C

4 Battery Recommended capacity

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

5 Battery switch

6FUSE

7 Starter motor

8Alternator

9 Not used

10 C.W. temp. switch

11 L.O. 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 Earth

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 C.W. temp. lamp

25 L.O. pressure lamp

26 Rubber seal lamp (Sail-drive)

27 Buzzer

28 Tachometer

Note: 1 + 2 + 3 < 2,5 m - 20 mm2

(Cross sectional area)

1 + 2 + 3 < 5 m - 40 mm2

(Cross sectional area)

C-type Instrument Panel

Applicable Engine Model:

3JH4E, 4JH4E (See A-7)

Page 33

7. Electrical Wiring Diagrams

B x B-type Instrument Panel

Applicable Engine Model: 4JH3-TCE

1 Procured by customer

2 Battery

3 Battery switch

4Relay

5 Eng. stop solenoid

6 Air heater

7 Starter relay

8Starter

9 C.W. Temp. switch

10 Eng. oil pressure switch

11 Alternator

12 Earth bolt

13 C.W. Temp. sender

14 Tacho sensor

15 Sail-drive

16 Amplifier

17 Wire harness for 2 panel

18 Option

19 Wire harness

20 Starter switch

21 Stop switch

22 Fuse

23 Buzzer stop illumination

24 Buzzer

25 Tachometer with hour meter

26 Charge

27 Eng. oil pressure

28 C.W. Temp.

29 Sail-drive

30 Exhaust

31 Fuel emplacement

32 Instrument panel no. 2 station; Option

C x B-type Instrument Panel

Applicable Engine Model: 4JH3-TCE

1 Procured by customer

2 Battery

3 Battery switch

4 Relay

5 Eng. stop solenoid

6 Air heater

7 Starter relay

8Starter

9 C.W. Temp. switch

10 Eng. oil pressure switch

11 Alternator

12 Earth bolt

13 C.W. Temp. sender

14 Tacho sensor

15 Sail-drive

16 Eng. oil pressure sender

17 Wire harness for 2 panel

18 Option

19 Wire harness

20 Starter switch

21 Stop switch

22 Fuse

23 Buzzer stop illumination

24 Buzzer

25 Tachometer with hour meter

26 C.W. Temp. meter

27 Eng. oil pressure meter

28 Charge

29 Eng. oil pressure

30 C.W. Temp.

31 Sail-drive

32 Exhaust

33 Fuel filter

34 Fuel emplacement

35 Instrument panel no. 2 station; Option

Yanmar SD20, SD50, SD50-4T Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

1. For Your Safety

1.1 Safety Precautions For Inspection

2. Specifications

3. Selecting Lubricating Oil

3.1 Choice of lube oil

3.2 Kind of lube oil

3.3 Lube oil viscosity

4. Starting the New Sail-Drive for the First Time

4.1 Filling with lubricating oil

4.1.1 SD20 and SD50/-4T

4.2 Check of instrument panel alarm system:

4.3 Remote-Control Device Check

4.4 Fitting for Fixed Propeller (2-blade)

5. Method of Operation

5.1 Engine Cooling Water

5.1.1 SD20

5.1.2 SD50/SD50-4T

6. Periodic Inspections and Maintenance

6.1 Lubricating oil system

6.1.1 SD20

6.1.2 SD50/-4T

6.2 Procedure for filling and removing oil in the Sail-Drive; SD50/-4T

6.2.1 When the boat is in the water

6.2.2 When the boat is out of the water

6.3 Anticorrosive zinc

6.3.1 SD20 and SD50/ SD50-4T

6.4 Rubber diaphragms (A) and (B) (SD20 and SD50/-4T)

7. Electrical Wiring Diagrams