Yanmar SD40, SD40-4T, SD50, SD50-4T Service Manual

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SD40/SD40-4T SD50/SD50-4T

YANMAR CO.,LTD.

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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
  • (1) Added SD50 series.
  • (2) Changed document number.
  • M9961-H13030 ↓
  • M2215-04E140
- Quality Control
Dept.
Marine factory
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CONTENTS

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
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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
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FOR SAFETY

1. SAFETY LABELS

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.

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2. Safety Precautions

(1) SERVICE AREA

Sufficient Ventilation

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.

• Safe / Adequate Work Area

The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip" or "trip and fall" type accidents.

Clean, orderly arranged place

No dust, mud, oil or parts should be left on the floor surface. [Failure to Observe] An unexpected accident may be caused.

Bright, Safely Illuminated Area

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.

Safety Equipment

Fire extinguisher(s), first aid kit and eye wash / shower station should be close at hand (or easily accessible) in case of an emergency.

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(2) WORK - WEAR (GARMENTS)

(3) TOOLS

Safe Work Clothing Appropriate safety wear (glo

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.

Appropriate Lifting / Holding

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.

Appropriate Tools

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.

(4) GENUINE PARTS and MATERIALS

Genuine Parts

Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.

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(5) FASTENER TORQUE

Torquing Fasteners

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.

(6) Electrical

Short Circuits

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 Batteries

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.

Battery Electrolyte

Batteries contain sulfuric acid. Do NOT allow it to come in contact with clothing, skin and or eyes, severe burns will result.

(7) WASTE MANAGEMENT

Observe the following instructions with regard to hazardous waste disposal. Negligence of these will have a serious impact on environmental pollution concerns.

  • 1) Waste fluids such as lube oil, fuel and coolant shall be carefully put into separate sealed containers and disposed of properly.
  • 2) Do NOT dispose of waste materials irresponsibly by dumping them into the sewer, overland or into natural waterways.
  • 3) Waste materials such as oil, fuel, coolant, solvents, filter elements and batteries, must be disposed of properly according to local ordinances. Consult the local authorities or reclamation facility.
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(8) FURTHER PRECAUTIONS

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

Hot Surfaces

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.

Rotating Parts

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.

Preventing burns from scalding

  • 1) Never open the filler cap shortly after shutting the engine down. Steam and hot water will spurt out and seriously burn you. Allow the engine to cool down before attempt to open the filler cap.
  • 2) Securely tighten the filler cap after checking the cooling water. Steam can spurt out during engine running, if tightening loose.

Safety Label Check

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.

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3. Precautions for Service Work

(1) Precautions for Safety

Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.

(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.

  • Preceding service date
  • Period/operation hours after preceding service
  • Problems and actions in preceding service
  • Replacement parts expected to be required for service
  • Recording form/check sheet required for service
(3) Preparation before Disassembly

  • Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts, and parts expected to be required for replacement.
  • When disassembling complicated portions, put match-marks and other marks at places not adversely affecting the function for easy reassembly.

(4) Precautions in Disassembly

  • Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface defect, etc.
  • Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again.
  • Parts to be used again shall be washed and cleaned sufficiently.
  • Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump.
(5) Precautions for Inspection and Measurement

Inspect and measure parts to be used again as required to determine whether they are reusable or not.

(6) Precautions for Reassembly

  • Reassemble correct parts in correct order according to the specified standards (tightening torques, and adjustment standards). Apply oil important bolts and nuts before tightening when specified.
  • Always use genuine parts for replacement.
  • Always use new oil seals, O-rings, packing and cotter pins.
  • Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact portions, and apply grease to oil seal lips.

(7) Precautions for Adjustment and Check

Use measuring instruments for adjustment to the specified service standards.

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1 General

1.1 Specifications

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.

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1.2 Exterior view

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1.3 Sectional view

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1.4 Criteria for replacing parts

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
  1. Lip hardening or hair cracks
  2. Disassembly
Every 1000 hours or 2 years
O-ring Disassembly
Diaphragms (A) & (B) Hair cracks 2 years
Steel band Disassembly
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1.5 Route of cooling water and lubricating oil

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1.6 Lubricating oil

(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.

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1.7 Disassembly and reassembly

The following tools are necessary when disassembling and reassembling the sail drive unit. These tools must be used according to disassembly process and location.

General hand tools
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
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Measuring instruments
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
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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)
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Others
Supplementary packing agent

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

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1.8 Special tools

Reassembly tools

(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.

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(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.

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Tools for measuring dimensions

(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)).

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  • (3) For taper roller bearing at propeller shaftUse when measuring the dimen-
  • sion of M4(Refer to 5.4.1(1)).

(4) For bevel gear on propeller shaft Use when measuring the dimension of M3(Refer to 4.6.1).

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Disassembly tools

  • (1) Special tool A
  • 1) Use when removing the drive pinion end nut.

(2) Special tool B

blv.

1) Use when disassembling the pinion shaft assembly.

2) Use when disassembling the gear (upper) assem-

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1.9 Notes on disassembly, inspection and reassembly

  • (1) Carefully note the correct mounting position before removing or disassembling the unit.
  • (2) To avoid mix-ups when disassembling, keep the parts in order.
  • (3) Use liquid gasket wherever necessary to prevent oil or water leakage.
  • (4) When the tightening torque is specified, tighten the bolt to the specified torque with a torque wrench.
  • (5) Always use new gaskets, packing, and o-rings when reassembling.
  • (6) Always use genuine YANMAR replacement parts.
  • (7) Some repairs require special tools in fully equipped workshops. These repairs should be made with the proper tools and in the proper facilities.
  • (8) Disassemble in the order specified in this Service Manual.
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2 Disassembly

2.1 Disassembling the upper case

2.1.1 Removal of the unit

  • (1) Separation from the lower case
  • 1) Remove the tightening bolts (M10) from the lower case.

2) Upper case separated from lower case.

3) Lower case separated from upper case.

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  • (2) Removal of the mounting flange
  • 1) Remove the tightening bolts (M8) from the mounting flange and the upper case.

2) Removal of mounting flange.

3) Upper case removed from mounting flange.

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  • (3) Removal of the Shift Lever and Support
  • 1) Remove the support tightening bolt (M8).

2) Remove the support.

3) Shift lever assembly after removal.

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  • (4) Removal of the pinion shaft assembly
  • 1) Remove the pinion shaft assembly nuts.

2) Remove the pinion shaft assembly from the upper case.

3) Pinion shaft assembly after removal.

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2) Remove the upper cover.

  • (5) Removal of the gear (upper) assembly
  • 1) Remove the upper cover tightening bolts (M8).
  • Tightening bolt

003031-00E

003032-00E

Clutch shaft edge face screw hole

003033-00E

  • Screw the gear (upper) assembly raising tool into the thread (M8) of the clutch shaft edge face and lift out the assembly.
  • Raising tool Gear (upper) assembly

003034-00E

4) Gear (upper) assembly after removal.

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  • (6) Removal of the diaphragm
  • Diaphragm A

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.

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  • Diaphragm B
  • 1) Remove the upper case bend.

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.

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Tightening bolt

2.1.2 Disassembling the unit

  • (1) Disassembling the pinion shaft assembly
  • 1) Remove the tightening bolt (M10) for pinion gear and the pinion shaft assembly to disassemble.

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

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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.

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  • (2) Disassembling the gear (upper) assembly
  • Insert the clutch shaft to the fixed special tool A (for stopping gear movement)

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.

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6) Gear, clutch ring and bearing as a unit after removal.

7) Gear (upper) assembly after disassembly.

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(3) Disassembling the shift lever assembly

1) Disassemble in the order shown in the illustrations below.

Spray with liquid detergent for easy removal.

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2.2 Disassembling the lower case

2.2.1 Removal of unit

(1) Removal of anti-corrosive zinc

1) Remove the tightening bolts (M6) and take off anti-corrosive zinc.

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(2) Removal of the propeller shaft assembly

2) Lower case removed from propeller shaft assembly.

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  • (3) Removal of the drive pinion end nut
  • 1) The drive pinion is positioned to the drive shaft with the end nut.

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).

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  • (4) Removal of the mid plate
  • Remove the two M8 bolts. Remove the mid plate.

  • (5) Removal of the drive pinion shaft assembly
  • 1) Remove the drive pinion shaft assembly.
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  • (6) Removal of the needle bearing
  • 1) Remove the needle bearing with the tool shown in the illustration below.

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  • (7) Removal of the taper roller bearing outer race
  • Remove the taper roller bearing outer race with the tool shown in the illustration below.

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3 Reassembly

Reassemble parts in the reverse order from disassembly. Refer to Chapter 9 for tightening torque.

3.1 Reassembling the bearing for lower case

3.1.1 Needle bearing

1) Reattach the needle bearing using the special tool.

2) Fix the needle to the outer race with grease.

3.1.2 Taper roller bearing outer race

1) Reattach using the special tool.

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3.2 Reassembling the bearings of shaft

3.2.1 Propeller shaft

1) Reattach the taper roller bearing using the special tool.

3.2.2 Drive shaft

1) Reattach the taper roller bearing using the special tool.

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4 Shim adjustment (Gear backlash adjustment)

4.1 Location of adjustment shims

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4.2 Measurement of the dimensions of the cases

4.2.1 Upper case

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

4.2.2 Lower case
mm
Standard value
D 49
В 343

The actual dimension B is engraved on the part (B).

Example " B - 3 "

That shows B = 343 - 0.03 = 342.97

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4.3 Shim selection method for the clutch shaft

Calculate the thickness of the shim T1, shim T2 shown at the right with the following procedure.

4.3.1 Measurement of the dimensions (L1, L2, L3) of the gear
(1) Under gear (B)
Standard value
L1 68.2
55.0

(2) Upper gear (A)

mm
Standard value
L2 35.5

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4.3.2 Calculation of the shim thickness

(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)
See 4.3.1(1)
T2 0.5

Make the thickness for the shim T2-0.025~T2+0.025.

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4.4 Shim selection method for the pinion shaft

4.4.1 Measurement of the pinion dimensions

4.4.2 Calculation of the shim thickness

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.

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4.5 Shim selection method for the drive shaft

4.5.1 Measurement of the dimensions (M1) of the pinion

4.5.2 Calculation of the shim thickness

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.

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4.6 Shim selection method for the propeller shaft

4.6.1 Measurement of the dimensions (M3) of the gear

4.6.2 Calculation of the shim thickness

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5 Adjustment of bearing assembly gap

5.1 Upper gear bearing

5.1.1 Measurement of the dimension (L6) of the bearing

(1) Measurement of bearing lug

mm
Standard value
L6 16.2

(2) Measurement of bearing case

mm
Standard value
H6 16.5

5.1.2 Calculation of the shim thickness
mm
Standard value
T5 0.30

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5.2 Pinion shaft bearing

5.2.1 Measurement of the dimension (L4) of the bearing

(1) Measurement of the bearing position

mm
Standard value
L4 15.0

(2) Measurement of oil seal case

mm
Standard value
H4 15.5

5.2.2 Calculation of the shim thickness

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.

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5.3 Pinion drive shaft bearing

5.3.1 Measurement of the dimension (M2) of the bearing

(1) Measurement of the bearing position

mm
Standard value
M2 3.50

(2) Measurement of middle plate

mm
Standard value
J2 4.0

5.3.2 Calculation of the shim thickness

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.

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5.4 Propeller shaft bearing

5.4.1 Measurement of the dimension (M4) of the bearing

(1) Measurement of the bearing position

mm
Standard value
M4 3.75

(2) Measurement of bearing case
mm
Standard value
J4 3.0

5.4.2 Calculation of the shim thickness

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.

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6 Adjustment of the gear backlash

6.1 Upper gear

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)

Reading of backlash
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.

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6.2 Lower gear

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.

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7 Adjustment of the gear dye pattern

7.1 Upper gear

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"
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7.2 Propeller shaft

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.

Check pinion dye patern and follow the table below
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"
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8 Adjustment of the shift lever

Adjust the operation of the shift lever with the thickness of shim T.

8.1 Measurement of the dimensions (H, A)
8.1.1 Shift Lever bolt
mm
Standard value
Н 17.0
8.1.2 Shifter pin position

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.

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8.2 Calculation of the shim thickness

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.

8.3 Caution of reassembly

  • Fasten the shift lever bolt (Part No. 196440-06070) with "Threebond 1104".
  • Check the smooth rotation of propeller shaft when change shift lever ± 15° from neutral position.
Page 67

9 Tightening torque for nuts and bolts

Page 68

SAIL DRIVE UNIT

SD40/SD40-4T/SD50/SD50-4T SERVICE MANUAL

Code No. M2215-04E140 First Edition : March 2005

YANMAR CO.,LTD.

Published by : Quality Control Dept. Marine Factory Large Power Products Operations Division. Edited by : YANMAR TECHNICAL SERVICE CO., LTD.

All Right Reserved, Copyright, © 2005

Page 69

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