SD40/SD40-4T SD50/SD50-4T
YANMAR CO.,LTD.
History of Correction | Document No. | M2215-04E140 | |||
---|---|---|---|---|---|
mistory of correction | Page No. | 1 | |||
Manual Name: | YANMAR SERVICE MANUAL FOR SAIL DRIVE UNIT SD40/SD40-4T & SD50/SD50-4T | SD50/SD50-4T | |||
UNIT Model: | SD40/ | SD40-4T, SD50/SD | )50-4T | ||
No.of
Correction |
Date of
Correction |
Cause for
Correction |
Outline of
Correction |
Corrected Item
Number |
Corrected
by: |
- | Mar. 2005 | Added SD50/-4T |
|
- |
Quality Control
Dept. Marine factory |
1 General | 1 |
---|---|
1.1 Specifications | 1 |
1.2 Exterior view | 2 |
1.3 Sectional view | 3 |
1.4 Criteria for replacing parts | 4 |
1.5 Route of cooling water and lubricating oil | 5 |
1.6 Lubricating oil | 6 |
1.7 Disassembly and reassembly | 7 |
1.8 Special tools | 14 |
1.9 Notes on disassembly, inspection and reassembly | 19 |
2 Disassembly | 20 |
2.1 Disassembling the upper case | |
2.1.1 Removal of the unit | 20 |
2.1.2 Disassembling the unit | 27 |
2.2 Disassembling the lower case | |
2.2.1 Removal of unit | |
3 Reassembly | |
3.1 Reassembling the bearing for lower case | |
3.1.1 Needle bearing | |
3.1.2 Taper roller bearing outer race | |
3.2 Reassembling the bearings of shaft | 39 |
3.2.1 Propeller shaft | 39 |
3.2.2 Drive shaft | 39 |
4 Shim adjustment (Gear backlash adjustment) | 40 |
4.1 Location of adjustment shims | 40 |
4.2 Measurement of the dimensions of the cases | 41 |
4.2.1 Upper case | 41 |
4.2.2 Lower case | |
4.3 Shim selection method for the clutch shaft | 42 |
4.3.1 Measurement of the dimensions (L1, L2, L3) of the gear | 42 |
4.3.2 Calculation of the shim thickness | 43 |
4.4 Shim selection method for the pinion shaft | 44 |
4.4.1 Measurement of the pinion dimensions | 44 |
4.4.2 Calculation of the shim thickness | 44 |
4.5 Shim selection method for the drive shaft | 45 |
4.5.1 Measurement of the dimensions (M1) of the pinion | 45 |
4.5.2 Calculation of the shim thickness | 45 |
4.6 Shim selection method for the propeller shaft | 46 |
---|---|
4.6.1 Measurement of the dimensions (M3) of the gear | 46 |
4.6.2 Calculation of the shim thickness | 46 |
5 Adjustment of bearing assembly gap | 47 |
5.1 Upper gear bearing | 47 |
5.1.1 Measurement of the dimension (L6) of the bearing | 47 |
5.1.2 Calculation of the shim thickness | 47 |
5.2 Pinion shaft bearing | 48 |
5.2.1 Measurement of the dimension (L4) of the bearing | 48 |
5.2.2 Calculation of the shim thickness | 48 |
5.3 Pinion drive shaft bearing | 49 |
5.3.1 Measurement of the dimension (M2) of the bearing | 49 |
5.3.2 Calculation of the shim thickness | 49 |
5.4 Propeller shaft bearing | 50 |
5.4.1 Measurement of the dimension (M4) of the bearing | 50 |
5.4.2 Calculation of the shim thickness | 50 |
6 Adjustment of the gear backlash | 51 |
6.1 Upper gear | 51 |
6.2 Lower gear | 52 |
7 Adjustment of the gear dye pattern | 53 |
7.1 Upper gear | 53 |
7.2 Propeller shaft | 54 |
8 Adjustment of the shift lever | 55 |
8.1 Measurement of the dimensions (H, A) | 55 |
8.1.1 Shift Lever bolt | 55 |
8.1.2 Shifter pin position | 55 |
8.2 Calculation of the shim thickness | 56 |
8.3 Caution of reassembly | 56 |
9 Tightening torque for nuts and bolts | 57 |
Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consideration for safety is required in addition to the matters marked A CAUTION . Especially for safety precautions in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable leader.
• Safety marks used in this manual and their meanings are as follows:
DANGER -indicates an imminent hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING -indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION -indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• NOTICE - indicates that if not observed, the product performance or quality may not be guaranteed.
Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas.
The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip" or "trip and fall" type accidents.
No dust, mud, oil or parts should be left on the floor surface. [Failure to Observe] An unexpected accident may be caused.
The work area should be well lit or illuminated in a safe manner. For work in enclosed or dark areas, a "drop cord" should be utilized. The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances.
Fire extinguisher(s), first aid kit and eye wash / shower station should be close at hand (or easily accessible) in case of an emergency.
Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness', clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery.
When lifting an engine, use only a lifting device (crane, jack, etc.) with sufficient lifting capacity. Do not overload the device. Use only a chain, cable, or lifting strap as an attaching device. Do not use rope, serious injury may result.
To hold or support an engine, secure the engine to a support stand, test bed or test cart designed to carry the weight of the engine. Do not overload this device, serious injury may result.
Never run an engine without being properly secured to an engine support stand, test bed or test cart, serious injury may result.
Always use tools that are designed for the task at hand. Incorrect usage of tools may result in damage to the engine and or serious personal injury.
Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.
Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury.
Always disconnect the (-) Negative battery cable before working on the electrical system. An accidental "short circuit" may cause damage, fire and or personal injury. Remember to connect the (-) Negative battery cable (back onto the battery) LAST
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is extremely explosive. Keep sparks, open flame and any other form of ignition away. Explosion may occur causing severe personal injury.
Batteries contain sulfuric acid. Do NOT allow it to come in contact with clothing, skin and or eyes, severe burns will result.
Observe the following instructions with regard to hazardous waste disposal. Negligence of these will have a serious impact on environmental pollution concerns.
Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result
Do NOT touch the engine (or any of its components) during running or shortly after shutting it down. Scalding / serious burns may result. Allow the engine to cool down before attempting to approach the unit.
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or tools may become entangled causing damage to the engine and or severe personal injury.
Pay attention to the product safety label. A safety label (caution plate) is affixed on the product for calling special attention to safety.
If it is missing or illegible, always affix a new one.
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
Inspect and measure parts to be used again as required to determine whether they are reusable or not.
Use measuring instruments for adjustment to the specified service standards.
lt | em | Unit | Contents | |||||
---|---|---|---|---|---|---|---|---|
Model | SD40-3, | SD50-3 | SD40-4, | SD50-4 | SD40-4T, SD50-4T | |||
Clutch system | Cone | clutch | ||||||
Reduction gear syst | tem | Beve | l gear | |||||
Direction of rotation | Input shaft | Counte | er-clockwise | viewed fro | m stern | |||
Direction of fotation | Propeller shaft | С | ounter-cloc | kwise or clo | ckwise viev | ved from stern | ||
Reduction ratio | Ahead | 2. | 32 | |||||
Reduction fatio | Astern | 2. | 32 | |||||
Lubrication system | Splash lubrication | |||||||
Lub.oil capacity | L | 2.2 (SD40 old type 1.8) | ) | |||||
Dry mass | kg | 39 | 41 | |||||
Model | 3JH3CE | 3JH4CE | 4JH3CE | 4JH4CE | 4JH3-TCE | |||
Output (DIN6270B) | kW (PS) | 29.4(40)/3800 | 29.4(40)/3000 | 41.2(56)/3800 | 40.5(55)/3000 | 55.2(75)/3800 | ||
Allowable torque | N•m (kgf•m) | 129( | 13.1) | 140(14.3) | ||||
Allowable speed at | Input shaft | min -1 (rpm) | 40 | 000 | ||||
Lube oil |
API service grade GL4 or higher,SAE80W-90 Quicksilver high
or 90(High performance gear lube, as shown on the right, is also acceptable.) Quicksilver high performance gear lube. |
Quicksilver high
performance gear lube. |
||||||
Max. propeller dia. | mm (inch) | 457(18) | ||||||
Mounting size | SAE #5 SAE #4 | SAE #4 | ||||||
Sealing method for bottom of ship | Double | |||||||
Engine installation of | lirection | 180° Acceptable |
Quicksilver® is registered trademark of Brunswick Corporation.
Criteria for replacement | ||||
---|---|---|---|---|
Standard value | Standard service life | |||
Desting |
Needle bearing (A)
(K24 x 28 x 17) |
Every 1500 hours | ||
beaning | Needle bearing (B) | |||
Anti-corrosive zinc | Weight : ≦400 g (with plug) | A half year or less than 1/2 of its original size | ||
Oil seals |
|
Every 1000 hours or 2 years | ||
O-ring | Disassembly | |||
Diaphragms (A) & (B) | Hair cracks | 2 years | ||
Steel band | Disassembly |
(1) Choice of lube oil
The selection 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 follow-ing.
(2) Kind of lube oil
See 1.2 specifications.
(3) Lube oil viscosity
The viscosity of the lube oil greatly influences Sail-drive performance.
SD40, SD50 | |||
---|---|---|---|
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-5 | 90 |
MOBIL | Mobilub HD 80W-90 | GL-5 | 80W-90 |
ESSO | Esso gear oil GP 90 | GL-4 | 90 |
ESSO | Esso gear oil GP 90 | GL-5 | 90 |
SD40-4T, SD50-4T | |||
Quicksilver ® | High performance gear lube |
Quicksilver® is registered trademark of Brunswick Corporation.
The following tools are necessary when disassembling and reassembling the sail drive unit. These tools must be used according to disassembly process and location.
Name | Illustration | Remarks |
---|---|---|
Spanner | 001385-00X |
10 x 13
12 x 14 17 x 19 21 x 23 21 x 24 |
Screwdriver for +
(Cross recessed head) screws |
002952-00X | |
Screwdriver for –
(Philips head) screws |
002953-00X | |
Steel hammer | 001389-00X | |
Copper hammer | 001390-00X | |
Mallet | 001391-00X |
Name | Illustration | Accuracy & range | Ref. |
---|---|---|---|
Vernier calipers |
1/20 mm,
0-150 mm |
||
Micrometer | о01424-00Х |
1/100 mm,
0-25 mm, 25-50 mm, 100-125 mm |
|
Thickness gauge | 001426-00X | 0.05-2 mm | |
Torque wrench | 001427-00X |
0-147 N-m
(0-15 kgf-m) |
|
Dial depth gauge | 002955-00X |
1/100 mm,
0-150 mm |
8.1.2 |
Name | Illustration | Accuracy & range | Ref. |
---|---|---|---|
Lever type
dial test indicator |
003042-00X |
1/100 mm,
0-0.8 mm |
6.1 |
Magnetic base | OC 256-OX | ||
Clamp type
box block |
100 mm (K-type) |
The surface to be coated must be thoroughly cleaned with thinner or benzene and completely dry. Moreover, coating must be thin and uniform.
Liquid gasket
(1) For needle bearingUse when reassembling the needle bearing to the lower case.
(2) For taper roller bearing at drive shaftUse when reassembling thetaper roller bearing at the driveshaft.Press it as striking it with a hammer strongly.
(3) For outer race of taper roller bearing at propeller shaft Use when reassembling the outer race of the taper roller bearing to the lower case. Press it as striking it with a hammer strongly.
(4) For taper roller bearing at propeller shaft
Use when reassembling the
taper roller bearing at the propeller shaft.
Press it as striking it with a hammer strongly.
(1) For taper roller bearing at pinion shaft Use when measuring the dimension of L4(Refer to 5.2.1(1)).
(2) For taper roller bearing at drive shaft Use when measuring the dimension of M2(Refer to 5.3.1(1)).
(4) For bevel gear on propeller shaft Use when measuring the dimension of M3(Refer to 4.6.1).
(2) Special tool B
blv.
1) Use when disassembling the pinion shaft assembly.
2) Use when disassembling the gear (upper) assem-
2) Upper case separated from lower case.
3) Lower case separated from upper case.
2) Removal of mounting flange.
3) Upper case removed from mounting flange.
2) Remove the support.
3) Shift lever assembly after removal.
2) Remove the pinion shaft assembly from the upper case.
3) Pinion shaft assembly after removal.
2) Remove the upper cover.
003031-00E
003032-00E
Clutch shaft edge face screw hole
003033-00E
003034-00E
4) Gear (upper) assembly after removal.
1) Remove the damper rubber mounting nut (M12) from the upper case.
2) Remove the diaphragm A which was installed on the back of the upper case seal flange.
3) Diaphragm A after removal.
2) Remove the seal flange band.
3) Remove the upper case and the seal flange.
4) Remove the diaphragm B from the upper case.
5) Diaphragm B after removal.
Tightening bolt
2) Insert the pinion shaft to the fixed special tool B (for stopping gear movement).
3) Remove the tightening bolt (M10).
4) Pinion shaft assembly after removal.
. Tightening bolt
. Pinion shaft assembly
5) Push out the pinion by using the press to separate the pinion from bearing housing.
6) Pinion and taper roller bearing separated from bearing housing.
2) The edge of the clutch shaft end nut (M16 x 1.5 left-hand screw) is caulked to the clutch shaft.
3) Lift up the caulking.
6) Gear, clutch ring and bearing as a unit after removal.
7) Gear (upper) assembly after disassembly.
(3) Disassembling the shift lever assembly
1) Disassemble in the order shown in the illustrations below.
Spray with liquid detergent for easy removal.
(1) Removal of anti-corrosive zinc
1) Remove the tightening bolts (M6) and take off anti-corrosive zinc.
(2) Removal of the propeller shaft assembly
2) Lower case removed from propeller shaft assembly.
2) Insert the drive shaft to the fixed special tool A (for stopping the gear).Loosen the end nut (M14).
3) Remove the end nut (M14).
Reassemble parts in the reverse order from disassembly. Refer to Chapter 9 for tightening torque.
1) Reattach the needle bearing using the special tool.
2) Fix the needle to the outer race with grease.
1) Reattach using the special tool.
1) Reattach the taper roller bearing using the special tool.
1) Reattach the taper roller bearing using the special tool.
mm | ||
---|---|---|
Standard value | ||
А | 78.5 | |
С | 100 |
The actual dimension A is engraved on the part (A).
Example " A - 3 "
That shows A = 78.5 - 0.03 = 78.47
mm | ||
---|---|---|
Standard value | ||
D | 49 | |
В | 343 |
The actual dimension B is engraved on the part (B).
That shows B = 343 - 0.03 = 342.97
Calculate the thickness of the shim T1, shim T2 shown at the right with the following procedure.
Standard value | ||
---|---|---|
L1 | 68.2 | |
Lз | 55.0 |
(2) Upper gear (A)
mm | ||
---|---|---|
Standard value | ||
L2 | 35.5 |
(1) Under gear (B)
Formula
T1=(A-L1-10)
Standard value | ||
А | See 4.2.1 | |
L1 | See 4.3.1(1) | |
T1 | 0.3 |
Make the thickness for the shim T1-0.025~T1+0.025.
(2) Upper gear (A)
Formula T2=(L2+20-L3)
Standard value | ||
L2 | See 4.3.1(2) | |
Lз | See 4.3.1(1) | |
T2 | 0.5 |
Make the thickness for the shim T2-0.025~T2+0.025.
Formula T4=(L5+32-C)
mm | ||
---|---|---|
Standard value | ||
L5 | See 4.4.1 | |
В | See 4.2.2 | |
T4 | 0.6 |
Make the thickness for the shim T4-0.025~T4+0.025.
Formula
S3=(M1+57-B)
Standard value | |
M1 | See 4.5.1 |
В | See 4.2.2 |
S3 | 0.5 |
Make the thickness for the shim S3-0.025~S3+0.025.
(1) Measurement of bearing lug
mm | ||
---|---|---|
Standard value | ||
L6 | 16.2 |
(2) Measurement of bearing case
mm | ||
---|---|---|
Standard value | ||
H6 | 16.5 |
mm | ||
---|---|---|
Standard value | ||
T5 | 0.30 |
(1) Measurement of the bearing position
mm | ||
---|---|---|
Standard value | ||
L4 | 15.0 |
(2) Measurement of oil seal case
mm | ||
---|---|---|
Standard value | ||
H4 | 15.5 |
Formula T3=(H4-L4)
mm | ||
---|---|---|
Standard value | ||
H4 | See 5.2.1(2) | |
L4 | See 5.2.1(1) | |
Тз | 0.5 |
Make the thickness for the shim T3-0.1~T3.
(1) Measurement of the bearing position
mm | ||
---|---|---|
Standard value | ||
M2 | 3.50 |
(2) Measurement of middle plate
mm | ||
---|---|---|
Standard value | ||
J2 | 4.0 |
Formula S1=(J2-M2)
mm | ||
---|---|---|
Standard value | ||
J2 | See 5.3.1(2) | |
M2 | See 5.3.1(1) | |
S1 | 0.5 |
Make the thickness for the shim S1-0.075~S1-0.025.
(1) Measurement of the bearing position
mm | ||
---|---|---|
Standard value | ||
M4 | 3.75 |
mm | ||
---|---|---|
Standard value | ||
J4 | 3.0 |
Formula S2=(M4-J4)
Standard value | ||
M4 | See 5.4.1(1) | |
J4 | See 5.4.1(2) | |
S2 | 0.75 |
Make the thickness for the shim S2-0.075~S2-0.025.
The measurement for the backlash of the upper gear is shown in the figure to the right.
2) Use special tool (Part No. 196440-92300) Stop the moving of the gear one and another by the bolt. (Part No. 26116-060302)
Dial gauge reading | Conversion value at gear |
---|---|
0.031~0.062 | 0.10~0.20 |
mm
Find the gear conversion value at the dial gauge on the shaft.
The measurement for the backlash of the lower gear is shown in the figure to the right.
Reading of backla | ash | mm |
---|---|---|
Dial gauge reading | Conversion value at | gear |
0.056~0.113 0.14~0.28 Find the gear conversion value at the
dial gauge on the shaft.
1) After deciding the shim thickness T1, T2 and T4 in accordance with the section 4.2, 4.3 and 4.4 check the dye pattern of the gear faces and then adjust it.
2) After checking the dye pattern, adjust according to the table.
Check pinion dye patern and follow the table below
GEAR, UPPER | ||
---|---|---|
DYE PATTERN | ADJUST | |
A |
GOOD
NO ADJUSTING |
|
B |
INCLEASE THE SHIM
THICKNESS "T1" DECLEASE THE SHIM THICKNESS "T2" INCLEASE THE SHIM THICKNESS "T4" |
|
C |
DECLEASE THE SHIM
THICKNESS "T1" INCLEASE THE SHIM THICKNESS "T2" DECLEASE THE SHIM THICKNESS "T4" |
1) After deciding the shim thickness S3 and S4 in accordance with the section 4.5 and 4.6 check the dye pattern of the gear faces and then adjust it.
2) After checking the dye pattern, adjust according to the table.
GEAR, LOWER | ||
---|---|---|
DYE PATTERN | ADJUST | |
A |
GOOD
NO ADJUSTING |
|
B |
DECLEASE THE SHIM
THICKNESS "S3" INCLEASE THE SHIM THICKNESS "S4" |
|
C |
INCLEASE THE SHIM
THICKNESS "S3" DECLEASE THE SHIM THICKNESS "S4" |
Adjust the operation of the shift lever with the thickness of shim T.
mm | ||
---|---|---|
Standard value | ||
Н | 17.0 |
1) The measurement figure for the shifter pin position (A
dimension) is shown in the figure on the right.
mm | ||
---|---|---|
Standard value | ||
А | 16.35 |
Keep the shift lever 10~15° from neutral position.
Formula
T = (H - A) +0.3
111111 | ||
---|---|---|
Standard value | ||
Н | See 8.1.1 | |
А | See 8.1.2 | |
Т | 0.9 |
Calculation of the shim thickness make the thickness for the shim T-0.1~T+0.1.
SD40/SD40-4T/SD50/SD50-4T SERVICE MANUAL
Code No. M2215-04E140 First Edition : March 2005
Published by : Quality Control Dept. Marine Factory Large Power Products Operations Division. Edited by : YANMAR TECHNICAL SERVICE CO., LTD.
All Right Reserved, Copyright, © 2005
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