Yanmar SD20, SD50, SD50-4T Sail-Drive Operation Manual

SailDrive
OPERATION MANUAL
SD20
SD50
SD50-4T
P/N: 0ASDM-G00100
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
are
the right to make any change at any time without notice. Yanmar and
registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other
countries.
All Rights Reserved:
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.
© 2007 Yanmar Marine International
1107
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SD Operation Manual
© 2007 Yanmar Marine International
TABLE OF
CONTENTS
Page
Introduction .............................................................. 1
Safety ....................................................................... 3
Safety Precautions .................................................
General Information .........................................
Before You Operate .........................................
During Operation and Maintenance .....................
3
4
4
5
Product Overview ...................................................... 9
Overview .............................................................
Owner / Operator Responsibilities .......................
New Sail-Drive Break-In: ...................................
Dealer / Distributor Responsibilities .....................
9
9
9
9
Component Identification ........................................ 10
Galvanic Corrosion ................................................ 11
Corrosion Control ................................................. 11
Shore Power ........................................................ 12
Underwater Drive Coating ....................................... 12
Before You Operate .................................................. 13
Propeller Selection ................................................ 14
Recommended Propeller Size (Maximum) ........... 14
Fitting a Fixed Propeller (2-Blade) ...................... 15
Lubricating Oil ...................................................... 16
Filling With Lubricating Oil - SD20, SD50 and
SD50-4T ............................................................. 17
Checking the Instrument Panel Alarm System ............. 18
Daily Checks ....................................................... 20
Visual Checks ............................................... 20
Sail-Drive Operation .................................................. 21
SD Operation Manual
© 2007 Yanmar Marine International
iii
TABLE OF CONTENTS
Remote Control Device Check ................................. 22
SD20 ........................................................... 22
SD50 / SD50-4T ............................................ 24
Engine Cooling Water ............................................ 25
SD20 ........................................................... 25
SD50 / SD50-4T ............................................ 26
Maintenance ............................................................ 27
Tightening Fasteners ............................................. 30
Torque Charts ...................................................... 31
Standard Torque Values .................................. 31
Standard Torque Chart .................................... 31
Periodic Maintenance ..................................... 32
Periodic Maintenance Table .................................... 34
When The Vessel Is Out Of The Water, Perform The
Following: ........................................................... 36
Removing Deposits From The Lower Gear
Case ........................................................... 36
Repairing Damaged Coating ............................. 36
Inspecting the Zinc Anode ................................ 36
Inspecting The Folding Propeller ....................... 36
Draining Water .............................................. 36
Periodic Maintenance Procedures ............................ 37
After Initial 50 Hours of Operation ...................... 37
Every 100 Hours of Operation ........................... 46
Every 250 Hours of Operation ........................... 47
Every 500 Hours of Operation ........................... 47
Every Year .................................................... 48
Every 2 Years ................................................ 48
Every 2000 Hours of Operation ......................... 49
Specifications .......................................................... 51
System Diagrams ..................................................... 53
iv
SD Operation Manual
© 2007 Yanmar Marine International
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, 4JH4AE and 4JH4-TE. 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
2YM15
SD20
3YM20, 3YM30
3JH4E
SD50
4JH4AE
4JH4-TE
SD50-4T
SD Operation Manual
© 2007 Yanmar Marine International
1
INTRODUCTION
This Page Intentionally Left Blank
2
SD Operation Manual
© 2007 Yanmar Marine International
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
© 2007 Yanmar Marine International
3
SAFETY
General Information
Before You Operate
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.
! 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 marine gear with
equipment not designed to support the
weight of the marine gear 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
© 2007 Yanmar Marine International
SAFETY
During Operation and
Maintenance
! WARNING
The safety messages that follow have
WARNING level hazards.
! 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.
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
© 2007 Yanmar Marine International
5
SAFETY
Exhaust Hazard
! 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.
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.
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.
Sudden Movement Hazard
ALWAYS stop the engine before beginning
service.
6
SD Operation Manual
© 2007 Yanmar Marine International
SAFETY
NOTICE
! 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
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.
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.
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.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground
or into ground water or waterways.
SD Operation Manual
© 2007 Yanmar Marine International
7
SAFETY
NOTICE
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.
8
SD Operation Manual
© 2007 Yanmar Marine International
PRODUCT OVERVIEW
OVERVIEW
New Sail-Drive Break-In:
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 Sail-Drive.
• 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 indicators (if any) 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 onboard equipment.
• Explain and demonstrate the operation of
the Sail-Drive and vessel.
SD Operation Manual
© 2007 Yanmar Marine International
9
PRODUCT OVERVIEW
COMPONENT
IDENTIFICATION
(2)
(1)
(7)
(3)
(6)
(4)
(5)
0006440
1–
2–
3–
4–
10
Dipstick
Upper Gear Case
Lower Gear Case
Lubricating Oil Drain Plug
Figure 1
5 – Propeller
6 – Seawater Inlet
7 – Flexible Mount
SD Operation Manual
© 2007 Yanmar Marine International
PRODUCT OVERVIEW
GALVANIC CORROSION
CORROSION CONTROL
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
stern-drive components.
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 are also
available from the aftermarket (not supplied
by Yanmar) to block stray current while still
providing a path to ground for dangerous
shock currents.
The rate of corrosion depends on numerous
factors, such as:
• the number, size and location of sacrificial
anodes on the sail drive and vessel;
• the marina environment, such as stray
current in the water, fresh or salt water and
use and isolation of shore power;
• improper application of marine paint or
antifouling paint;
• 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.
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.
SD Operation Manual
© 2007 Yanmar Marine International
11
PRODUCT OVERVIEW
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.
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
transom 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
Stern-Drives.
• 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.
NOTICE: Galvanic corrosion damage,
normal maintenance and consumable
parts are not covered by the Yanmar
Limited Warranty.
12
SD Operation Manual
© 2007 Yanmar Marine International
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
© 2007 Yanmar Marine International
13
BEFORE YOU OPERATE
PROPELLER SELECTION
Recommended Propeller Size (Maximum)
Engine Model
Folding Type
Diameter
2-Blade Fixed Type
Diameter
1GM10C
14 in.
14 in.
2YM15
14.5 in.
15 in.
15 in.
16 in.
3YM30
16 in.
16.5 in.
3JH4E
18 in.
18 in.
18 in.
18 in.
18 in.
18 in.
3YM20
4JH4AE
4JH4–TE
Sail-Drive Model
SD20
SD50
SD50-4T
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.
14
SD Operation Manual
© 2007 Yanmar Marine International
BEFORE YOU OPERATE
Fitting a Fixed Propeller (2-Blade)
(1)
(4)
(5)
(6)
(3)
(2)
0005446
Figure 1
4 – Washer
5 – Nut *
6 – Bolt **
1 – Spacer
2 – Grease
3 – Propeller
Size
Tightening Torque
*
M16 (SD20)
M20 (SD50, SD50-4T)
60 to 70 N·m (44 to 52 lb-ft)
80 to 100 N·m (59 to 74 lb-ft)
**
M8 x 75 mm
11 to 15 N·m (8 to 11 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
© 2007 Yanmar Marine International
15
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
GM, YM
Engine
model
1GM10C
Sail-Drive
model
Lubricating
oil for the
Sail-Drive
2YM15
3YM20
JH3, JH4
3YM30
3JH4E
SD20
API CC or
greater
and SAE
10W30
API GL4 or GL5 and SAE 80W90
or 90
4JH4AE
4JH4-TE
SD50
SD50-4T
API GL4 or GL5 and
SAE 80W90 or 90 or
Quicksilver® High
Performance Gear
Lube
Quicksilver®
High
Performance
Gear Lube
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) and SD50, SD50-4T
Supplier
Brand Name
SHELL
Shell Spilax oil EP 90
SHELL
Shell Spilax oil HD 90
CALTEX
Multipurpose thuban EP
MOBIL
ESSO
ESSO
API Service
SAE No.
GL-4
90
GL-5
90
GL-4/GL-59
90
Mobilub HD 80W-90
GL-5
80W-90
Esso gear oil GP 90
GL-4
90
Esso gear oil GX 90
GL-5
90
Use QuickSilver®1 High Performance Gear Lube for the SD50 / SD50-4T.
This lubricating oil is available through all MerCruiser, Mercury, Mariner and Force outlets in
their “QuickSilver®” accessories program.
1
16
QuickSilver® is a registered trademark of Brunswick Corporation.
SD Operation Manual
© 2007 Yanmar Marine International
BEFORE YOU OPERATE
FILLING WITH
LUBRICATING OIL - SD20,
SD50 AND SD50-4T
Sail-Drive
model
SD20
SD50, SD50-4T
Standard
unit
2.2 L
(2.3 qt)
2.2 L (2.3 qt)
Long-reach
unit
2.5 L
(2.6 qt)
2.35 L (2.5 qt)
Extension 58
2.45 L (2.6 qt)
Extension 100
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.
2.
Remove the dipstick (yellow cap). Fill
with approved lubricating oil.
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
(1)
(2)
0005441
Figure 3
1 – Oil Supply Port
2 – Oil Capacity Nameplate
SD50/SD50-4T
(1)
(2)
Figure 4
0005574
1 – Oil Supply Port
2 – Oil Capacity Nameplate
(1)
(2)
(3)
0005573
Figure 2
1 – Dipstick
2 – Upper Limit
3 – Lower Limit
SD Operation Manual
© 2007 Yanmar Marine International
17
BEFORE YOU OPERATE
CHECKING THE INSTRUMENT PANEL ALARM SYSTEM
New B-Type
(4) (3) (2) (1)
(5)
(6)
New C-Type
(4) (3) (2) (1)
(7)
(8)
(9) (10)
0000473SD
(5)
Figure 6
(6)
(7) (8)
0000472SD
Figure 5
1–
2–
3–
4–
5–
6–
7–
8–
18
Battery Low Charge Alarm
Sail-Drive Seal Warning Lamp
Engine Oil Low Pressure Lamp
Coolant High Temperature Alarm
Hour Meter
Tachometer
Key Switch
STOP Button
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
SD Operation Manual
© 2007 Yanmar Marine International
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 6) with the engine
off:
1.
2.
3.
4.
5.
The lubricating oil warning lamp should
be illuminated ((Figure 5, (3)),
(Figure 6, (6))) .
The cooling water temperature warning
lamp should be out ((Figure 5, (4)),
(Figure 6, (5))) .
The charge warning lamp should be
illuminated ((Figure 5, (1)),
(Figure 6, (1))) .
The rubber seal warning lamp should
be out ((Figure 5, (2)),
(Figure 6, (2))) .
The warning buzzer should sound.
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 7, (5)) is damaged
and seawater enters, the rubber
diaphragm B (Figure 7, (4)) prevents it
from entering the vessel. The rubber
seal switch between the rubber
diaphragms (Figure 7, (5)) and
(Figure 7, (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)
Note: All the above alarm signals will
continue until you push the starting button or
turn the key to the OFF position.
(3)
(2)
(4)
(5)
019410-01X
Figure 7
1–
2–
3–
4–
5–
ON (Rubber Seal Lamp)
Rubber Seal Switch
Diaphragm (B)
Diaphragm (A)
Seawater
SD Operation Manual
© 2007 Yanmar Marine International
19
BEFORE YOU OPERATE
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.
2.
3.
4.
Check for damaged or missing parts.
Check for loose, missing or damaged
fasteners.
Check oil level. See Filling With
Lubricating Oil - SD20, SD50 and
SD50-4T on page 17.
Open cooling water cock before
operation. Drain cooling water and
close cooling water cock after
operation. See Engine Cooling Water
on page 25
NOTICE: If any problem is noted during
the visual check, the necessary
corrective action should be taken before
you operate the engine.
20
SD Operation Manual
© 2007 Yanmar Marine International
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
© 2007 Yanmar Marine International
21
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.
22
NOTICE: When sailing, set the remote
control lever in neutral. Not doing so
WILL introduce slippage and void your
warranty (Figure 1, (2)).
(2)
(3)
(1)
(4)
019631-00X
Figure 1
1–
2–
3–
4–
Astern
Neutral
Ahead
Control Handle
SD Operation Manual
© 2007 Yanmar Marine International
SAIL-DRIVE OPERATION
(8)
(9)
(7)
(5)
D
(4)
(6)
(10)
(4)
(5)
(6)
(1)
(2)
(3)
(1)(2)(3)
(7)
D
019720-00X
019719-00X
Figure 3
Figure 2
1–
2–
3–
4–
5–
6–
7–
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
Astern
Neutral
Ahead
Operation Lever
Cable Clamp
Remote Control Cable
Pivot
SD Operation Manual
© 2007 Yanmar Marine International
23
SAIL-DRIVE OPERATION
SD50 / SD50-4T
(1)
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.
(2)
(3)
(5)
(7)
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.
24
(8)
(4)
(6)
003448-01X
Figure 4
1–
2–
3–
4–
5–
6–
7–
8–
Mounting Plate at 90° Angle
Operation Lever
Cable Clamp
Remote Control Cable
Propeller Shaft Clockwise
Pivot
Neutral
Propeller Shaft Counter-Clockwise
SD Operation Manual
© 2007 Yanmar Marine International
SAIL-DRIVE OPERATION
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
(5)
(2)
(1)
(3)
(4)
0005447
Figure 5
1 – Cooling Water Cock
2 – Cooling Water Hose
3 – To Cooling Water Pump
4 – Hose Clamp
5 – Seawater Inlet
SD Operation Manual
© 2007 Yanmar Marine International
25
SAIL-DRIVE OPERATION
SD50 / SD50-4T
(3)
(1)
(2)
0005448
1 – To Cooling Water Pump
2 – Cooling Water Cock
26
Figure 6
3 – Open
SD Operation Manual
© 2007 Yanmar Marine International
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
© 2007 Yanmar Marine International
27
MAINTENANCE
! WARNING
! CAUTION
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.
28
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.
SD Operation Manual
© 2007 Yanmar Marine International
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.
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.
Only use replacement parts specified. Other
replacement parts may affect warranty
coverage.
SD Operation Manual
© 2007 Yanmar Marine International
29
MAINTENANCE
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.
Apply 60% torque to bolts that are not listed.
Apply 80% torque when tightened to
aluminum alloy.
The tightening torque in the
Standard Torque Chart should be
applied only to the bolts with a “7”
head. (JIS strength classification:
7T).
30
SD Operation Manual
© 2007 Yanmar Marine International
MAINTENANCE
TORQUE CHARTS
Standard Torque Values
M6 x 1.0
M8 x 1.25
M10 x 1.25
or 1.5
M12 x 1.25
or 1.5
M14 x 1.5
M16 x 1.5
Cast Iron
or Steel
10.8 ± 1.0
N·m
8.0 ± 0.8
lb-ft
25.5 ± 2.0
N·m
18.8 ± 1.5
lb-ft
49.1 ± 4.9
N·m
36.2 ± 3.6
lb-ft
88.3 ± 10.0
N·m
65.1 ± 7.4
lb-ft
137.2 ± 4.9
N·m
101.2 ± 3.6
lb-ft
225.4 ± 10.0
N·m
166.2 ± 7.4
lb-ft
Aluminum
8.8 ± 1.0
N·m
6.5 ± 0.8
lb-ft
20.6 ± 2.0
N·m
15.2 ± 1.5
lb-ft
39.2 ± 2.0
N·m
28.9 ± 1.5
lb-ft
70.6 ± 4.9
N·m
52.1 ± 3.6
lb-ft
109.8 ± 4.9
N·m
81.0 ± 3.6
lb-ft
180.3 ± 10.0
N·m
133.0 + 7.4
lb-ft
Standard Torque Chart
Thread size × Pitch
mm
Tightening
Torque
M6×1.0
M8×1.25
M10×1.5
M12×1.75
M14×1.5
M16×1.5
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
SD Operation Manual
© 2007 Yanmar Marine International
31
MAINTENANCE
Periodic Maintenance
CAUTION! Establish a periodic
maintenance plan according to the SailDrive 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.
Keep a Log of Sail-Drive Hours and
Daily Checks
Keep a log of the number of hours the SailDrive 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.
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 17,
Checking the Instrument Panel Alarm
System on page 18 and Engine Cooling
Water on page 25, and refer to the Operation
Manual for your engine.
32
SD Operation Manual
© 2007 Yanmar Marine International
MAINTENANCE
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.
Note: These procedures are considered
normal maintenance and are performed at
the owner’s expense.
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.
SD Operation Manual
© 2007 Yanmar Marine International
33
MAINTENANCE
PERIODIC MAINTENANCE TABLE
◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor
Daily
50
Hours
Or
After 1
Month
Every
100
Hours
Every
250
Hours
First
◊
SD20
◊
SD50,
SD504T
◊
Every
500
hours
Every
Year
Every
2
Years
Every
2000
Hours
Lubricating Oil
Check Oil
Level, Fill If
Necessary
Before
operation
◯
Change
Lubricating Oil
Cooling Water
Open/Close
Cooling Water
Cock
Before /
after
operation
◯
Clean Cooling
Water Suction
Hole
Drain Cooling
Water
◯
After
operation
◯
Remote Control System
Inspect
Remote
Control Device
◯
Cone Clutch and Shifter
Inspect /
replace or lap
●
Replace the
cone-clutch
●
Zinc Anode
Inspect And
Replace Zinc
Anode
◊
Lower Case
Repair Case
Coating
34
●
SD Operation Manual
© 2007 Yanmar Marine International
MAINTENANCE
◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor
Daily
50
Hours
Or
After 1
Month
Every
100
Hours
Every
250
Hours
Every
500
hours
Every
Year
Every
2
Years
Every
2000
Hours
Boat Hull Water-Tightness
Inspect
Rubber
Diaphragm
◯
Inspect Seal
Sensor
◯
Flexible Mount
Inspect and/or
replace the
flexible mount,
mounting
height
●
Replace the
flexible mount
●
SD Operation Manual
© 2007 Yanmar Marine International
35
MAINTENANCE
WHEN THE VESSEL IS OUT
OF THE WATER, PERFORM
THE FOLLOWING:
Removing Deposits From The
Lower Gear Case
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.
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.
(1)
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 Zinc Anode
See Inspecting and Replacing the Zinc
Anode on page 46.
(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.
36
SD Operation Manual
© 2007 Yanmar Marine International
MAINTENANCE
PERIODIC MAINTENANCE
PROCEDURES
SD20
(1)
(2)
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
(3)
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.
(4)
Figure 2
1–
2–
3–
4–
0005450
Dipstick
Upper Gear Case
Lower Gear Case
Lubricating Oil Drain Plug
Inspecting and Replacing the Clutch
Shifter
See your authorized Yanmar dealer or
distributor for procedure.
SD Operation Manual
© 2007 Yanmar Marine International
37
MAINTENANCE
Draining and Replacing Lubricating
Oil - SD50 / SD50-4T
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.
(1)
(2)
(3)
Figure 3
1 – Dipstick
2 – Plug
3 – Drain Plug
38
SD Operation Manual
© 2007 Yanmar Marine International
0005451
MAINTENANCE
Equipment Used
Description
Part Code
Quicksilver®
Quantity
Bottle of
High Performance Gear
Lube from MerCruiser®
Part code
92-850743A1
2
Market pump from
MerCruiser® on bottle
MerCruiser® Part code
91-85729A1
1
-
Adapter joint
196311-92960
1*
Thread std. M10 x 1.5
maximum length 12 mm.
O-ring for adapter
24311-000100
1*
-
2
Inner diameter 14 to 16
mm (0.5 to 0.625 in.) plus
hose clips (If Yanmar part
is used, part code is
196440-92970).
1
-
Stiff rubber hoses
Compressor set
Hand pump
*
Remarks
MerCruiser®
28210-000080
1
Each bottle contains
0.946 L (1 qt) of oil.
Mandatory for SD50,
SD50-4T. For other
models see p. 7.
Optional parts
When vessel is out of the water, 2 are required.
SD Operation Manual
© 2007 Yanmar Marine International
39
MAINTENANCE
When Vessel Is In The Water
Removing Oil
Preparing the Sail-Drive
(1)
(2)
(1)
(2)
(3)
(3)
(4)
0005452
Figure 4
1–
2–
3–
4–
O-Ring
Adapter Joint
Oil Changing Plug
Thread M10x1.5
1.
Remove the oil changing plug located
under the shift lever.
Screw in an adapter joint with an O-ring.
When using your own adapter joint, the
maximum length of thread should be
12 mm.
Attach a stiff rubber hose (inner
diameter 14 to 16 mm [0.5 to 0.625 in.])
with hose clips 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.
2.
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.
2.
3.
40
Take out the plug from the upper case
cover.
Screw in a second adapter joint with an
O-ring at the oil inlet position. Screw in
the oil plug at the dipstick position.
Connect the air pressure hose with
hose clips.
SD Operation Manual
© 2007 Yanmar Marine International
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.
Using Yanmar Pump
Refer to Preparing the Sail-Drive on page
40 and Fastest Way: Blowing Out by using
Air Pressure on page 40.
(1)
(2)
0005455
(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.
2.
3.
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.
Connect the hand pump or foot pump
with pressure line to the adapter joint
(Figure 6, (2)).
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.
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
© 2007 Yanmar Marine International
41
MAINTENANCE
Replacing Oil
Refer to Filling With Lubricating Oil - SD20,
SD50 and SD50-4T on page 17.
Using Yanmar Hand Pump
(1)
Fastest way: By using MerCruiser pump
or simple market pump
Refer to Preparing the Sail-Drive on page
40.
(1)
0005575
Figure 8
Figure 9
1 – Plug
1.
2.
3.
4.
5.
6.
42
Use a MerCruiser® pump like the one
shown (Figure 8) or use a similar pump
available locally.
Attach the pump to a new bottle of
Quicksilver® High Performance Gear
Lube from MerCruiser®.
Connect the hose with a hose clip to the
adapter joint below the shift lever.
Remove the plug from the upper case
cover (Figure 8, (1)).
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.
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.
1 – Plug
SD Operation Manual
© 2007 Yanmar Marine International
0005456
MAINTENANCE
1.
2.
3.
4.
Connect the hoses as shown above
(Figure 9).
Remove the plug from the upper case
cover (Figure 9, (1)).
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.
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.
When The Vessel Is Out Of The
Water
Preparing The Sail-Drive
(1)
Not Using Pump
Refer to Filling With Lubricating Oil - SD20,
SD50 and SD50-4T on page 17.
Figure 10
0005457
1 – Plug
1.
2.
3.
4.
Remove the bottom drain plug.
Screw in the adapter joint with the
O-ring. When using own adapter joint,
maximum length of thread is 12 mm.
Attach a stiff rubber hose with an inner
diameter of 14 to 16 mm
(0.5 to 0.625 in.) with hose clips to the
adapter joint at the oil drain position.
The hose must be long enough to drain
to the bucket.
Remove the dipstick and oil inlet plug
from the upper case cover.
SD Operation Manual
© 2007 Yanmar Marine International
43
MAINTENANCE
Removing Oil By Draining
Refer to Preparing The Sail-Drive on page
43.
Replacing Oil
Refer to Filling With Lubricating Oil - SD20,
SD50 and SD50-4T on page 17.
Oil draining is possible when the vessel is
out of the water but will take a greater
amount of time.
Using MerCruiser® Pump or simple
market pump
Refer to Preparing The Sail-Drive on page
43.
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.
(1)
(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
40, then to Fastest Way: Blowing Out by
using Air Pressure on page 40. Be aware
that oil is divided into two channels
connected by the lower gear and lower drain
port.
(2)
0005459
Figure 12
1 – Plug
2 – O-Ring
3 – Adapter Joint
1.
2.
3.
4.
44
(3)
Use a MerCruiser® pump with like the
one shown above (Figure 12), or use
a similar pump available locally.
Attach the pump to a new bottle of
Quicksilver® High Performance Gear
Lube from MerCruiser®.
Remove the oil changing plug from
below the shift lever.
Connect the hose with a hose clip to the
adapter joint at the drain position.
SD Operation Manual
© 2007 Yanmar Marine International
MAINTENANCE
5.
6.
7.
8.
Take out the plug from the upper case
cover.
Pump the oil into the drive. After the first
bottle is empty, screw in the oil
changing plug.
Change the bottle while the pump and
hose remain connected to the adapter
joint.
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.
3.
Using Yanmar Hand Pump
Refer to Preparing The Sail-Drive on page
43.
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.
(1)
0005461
4.
Figure 14
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 17.
0005460
Figure 13
1 – Plug
1.
2.
Connect the hose from the bottom and
a suction hose to the Yanmar pump with
hose clip (Figure 13).
Take out the plug from the upper case
cover (Figure 13, (1)).
SD Operation Manual
© 2007 Yanmar Marine International
45
MAINTENANCE
SD50/SD50–4T
Every 100 Hours of Operation
Perform the following maintenance every
100 hours of operation.
• Changing the Lubricating Oil (SD20)
• Inspecting and Replacing the Zinc
Anode
Changing the Lubricating Oil (SD20)
See Draining and Replacing Lubricating Oil
- SD20 on page 37.
(1)
Inspecting and Replacing the Zinc
Anode
(2)
To prevent corrosion of the Sail-Drive body
by sea or lake water, replace the zinc anode
every 100 hours of operation, once every six
months or when it has reduced to half of the
original volume (size).
0005463
SD20
(4)
Figure 16
1 – Lower Gear Case
2 – Zinc Anode
(2)
A zinc anode is provided on the lower gear
case. To inspect and replace the zinc anode
on the lower gear case, the vessel must be
removed from the water.
(1)
(5)
19
642
0-024
Note: An optional two-part zinc anode is
available from Yanmar for the lower gear
case. This option may allow the zinc anode
in the lower gear case to be changed without
removing the vessel from the water.
41
Don't remove
while the boat
in the water
ZINC
(3)
019416-01X
Figure 15
1–
2–
3–
4–
5–
46
Safety Label
Zinc Anode
Zinc Anode
Upper Gear Case
Lower Gear Case
Optional Two-Part Zinc Anode
Information
Part Number
Description
196440-02660
anode
2
196440-02690
mounting
plate
2
196440-02700
flat head bolt
4
26453-080202
8 X 20 bolt
2
SD Operation Manual
© 2007 Yanmar Marine International
Qty.
MAINTENANCE
Every 250 Hours of Operation
Every 500 Hours of Operation
Perform the following maintenance every
250 hours of operation.
• Inspecting and / or Replacing the
Cone-Clutch
• Changing the Lubricating Oil (SD50,
SD50-4T)
• Inspecting and Replacing the Clutch
Shifter
Inspecting and / or Replacing the
Cone-Clutch
See your authorized Yanmar dealer or
distributor for procedure.
Changing the Lubricating Oil (SD50,
SD50-4T)
See Draining and Replacing Lubricating Oil
- SD50 / SD50-4T on page 38.
Inspecting and Replacing the Clutch
Shifter
See your authorized Yanmar dealer or
distributor for procedure.
SD Operation Manual
© 2007 Yanmar Marine International
47
MAINTENANCE
Every Year
Every 2 Years
Perform the following maintenance every
year of operation.
• Inspecting and Replacing Rubber
Diaphragm Seal Ring
•
•
•
•
•
Inspecting and Replacing Rubber
Diaphragm Seal Ring
Cleaning Cooling Water Suction Hole
Inspecting Remote Control Device
Repairing Case Coating
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 36.
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 replace them every
two years. The vessel must be lifted onto a
block for this procedure. To replace, consult
your Yanmar Marine dealer.
Inspecting Remote Control Device
See Remote Control Device Check on page
22.
Repairing Case Coating
See Repairing Damaged Coating on page
36.
Inspecting Seal Sensor
See Figure 7 on page 15. See your
authorized Yanmar Marine dealer or
distributor for inspection procedure.
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
48
SD Operation Manual
© 2007 Yanmar Marine International
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.
SD Operation Manual
© 2007 Yanmar Marine International
49
MAINTENANCE
This Page Intentionally Left Blank
50
SD Operation Manual
© 2007 Yanmar Marine International
SPECIFICATIONS
Model
SD20
Reduction Gear System
Direction Of Rotation
Reduction Ratio
Constant mesh
gear with dog
clutch
Counterclockwise viewed from stern
Propeller Shaft
Counterclockwise
viewed from
stern
Counter-clockwise or clockwise
viewed from stern
Ahead
2.64
2.32
Astern
2.64
2.32
1364
1293
Lubrication System
1337
Oil bath type
Standard Unit
2.2 L (2.3 qt)
2.2 L (2.3 qt)
Long-Reach Unit
2.5 L (2.4 qt)
2.35 L (Extension 58) [2.5 qt], 2.45 L
(Extension 100) [2.6 qt]
30 kg (66 lb)
39 kg (86 lb)
Dry Weight
Remote-Control
Device
SD50-4T
Input Shaft
Propeller Speed (rpm)
Lubricating Oil
Capacity
SD50
Cone clutch
Control Head
Single control lever
Cable
MORSE 33C (equivalent)
Applicable Engine Model (Maximum Rated
Output Power At Crankshaft)
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
41 kg (90 lb)
3JH4E
29.4 kW (40 hp) / 3000 rpm
4JH4AE
39.6 kW (53 hp) / 3000 rpm
4JH4-TE
55.2 kW 75.1 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
© 2007 Yanmar Marine International
51
SPECIFICATIONS
This Page Intentionally Left Blank
52
SD Operation Manual
© 2007 Yanmar Marine International
SYSTEM DIAGRAMS
Color coding for wiring diagrams
Color coding for wiring diagrams
R
Red
B
Black
W
White
Y
Yellow
L
Blue
O
Orange
L/B
W/L
White/Blue
Y/W
Yellow/White
W/R
White/Red
L/R
Blue/Red
W/B
White/Black
R/B
Red/Black
Blue/Black
SD Operation Manual
© 2007 Yanmar Marine International
53
© 2007 Yanmar Marine International
(11)
(10)
(9)
(8)
(3)
E
B
L
R
(12)
B
B
(7)
B
S
R
R
W
Figure 1
SD Operation Manual
L/R
O
Y/W
W/L
L/B
R/B
L
(2)
(5)
(6)
B
(1)
B
W/R
R
W
L/B
W/L
Y/W
W/R
B
O
L/R
W/B
(14)
(13)
(15)
(17)
(16)
R
W
L/B
W/L
Y/W
R/B
B
O
L/R
L
(18)
W/R
54
R
W
L/B
W/L
Y/W
R/B
W/R
AC
(26)
30
(20)
R/B
(4)
W
(21)
R/B
R/B
R/B
R/B
0005465
(25)
(24)
(23)
(22)
SYSTEM DIAGRAMS
A-Type Instrument Panel
W/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
Note: If the cross-sectional area of the wire
being used is equal to or less than 20 mm2
(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 mm2
(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.
9
Not used
10
Cooling Water temp. switch
11
L.O. 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
L.O. pressure lamp
25
Rubber seal lamp (Sail-Drive)
26
Buzzer
SD Operation Manual
© 2007 Yanmar Marine International
55
© 2007 Yanmar Marine International
Figure 2
SD Operation Manual
12
11
10
9
8
B
B
7
P
P
E
B
L
R
B
S
L/B
R/B
L
O
L/R
Y/W
W/L
R
R
W
2
6
W/R
B
R
W
L/B
W/L
Y/W
B
O
L/R
W/R
W/B
14
13
19
15
18
17
16
R
W
L/B
W/L
Y/W
B
O
L/R
R/B
L
R
W
L/B
W/L
Y/W
B
P
28
P
L/B
O
R
B
5
20
R/B
21
W/L
R/B
W/R
B
B
R/B
1
30
27
AC
R/B
56
W/R
Y/W
W/L
3
4
W
W
L/B
25
26
W/R
R/B
24
23
Y/W
R/B
W/L
R/B
R/B
003877-00E
22
SYSTEM DIAGRAMS
B-Type Instrument Panel
B
W/R
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
Note: If the cross-sectional area of the wire
being used is equal to or less than 20 mm2
(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 mm2
(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.
9
Not used
10
Cooling Water 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
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
L.O. pressure lamp
26
Rubber seal lamp (Sail-Drive)
27
Buzzer
28
Tachometer
SD Operation Manual
© 2007 Yanmar Marine International
57
10
3
2
10
YW
4
YW
4
WL
5
WL
5
YG
6
YG
6
LB
7
LB
7
14
8
13
8
W
© 2007 Yanmar Marine International
L
Figure 3
SD Operation Manual
+
B
12
11
O
- P
L
O
30
AC
R
12
- P
G2 G1
17
W
+
B
L
11
G1
L
30
AC
G2
17
R
R
9
R
9
WBr
WBr
15
15
17
3R
2B
5R
18
B
L
YG
RB
3L
+
-
16
24
5R
28
WL
23
3R
33
22
3L
3W
25
+
20
12V
24
0004506
RB LB O YG
YW WL WG B
29
YW
WBr
2R
19
1
2
3
16
section of cable Allowable length
L=1+2+3(m)
(mm2)
15(mm2)
< 0.86(m)
2
20(mm )
< 1.3(m)
30(mm2)
< 2.3(m)
40(mm2)
< 2.8(m)
2
50(mm )
< 3.5(m)
2
60(mm )
< 4.1(m)
-
L
R
E
B
LB
RB
21
YB GB G GR
WB YR Y WR
30
3
2
1
20
12V
+
1
LB
RB
W/Y
B
LB
RB
-
3R
10B
2R
L
R
P
B
30
27
2W
S
GLOW
OFF
ON
START
B
32
YG
31
008433-00E
30 AC G1 G2 17
Key switch
O
Y
E
10R B
26
3
58
2
Allowable length by
cross sectional area
of battery cable
SYSTEM DIAGRAMS
4JH4-TE with B x B Type Panel
SYSTEM DIAGRAMS
4JH4-TE with B x B Type Panel
Color Coding
1
Option
Engine Harness
2
Alarm Lamps
R
Red
+
3
Buzzer
B
Black
-
4
Oil Pressure
W
White
Ignition
5
Coolant Temperature
L
Blue
Air heater / glow
(option)
6
Sail Drive Seal
7
Battery Low Charge Alarm
8
Fuse (3A)
RB
Red / Black
Alternator exciter
LB
Blue / Black
Alternator charge
alarm
YW
Yellow /
White
Engine oil pressure
alarm
YB
Yellow /
Black
Engine oil pressure
YG
Yellow /
Green
WL
9
Stop Switch
10
Diodes
11
Key Switch
12
Tachometer / Hour Meter
Sail drive seal
13
Instrument panel (sub station)
(Option)
White / Blue
Water temperature
alarm
14
Instrument panel (main station)
(Option)
WB
White /
Black
Water temperature
15
Wire Harness
WG
White /
Green
Seawater flow alarm
16
Relay
17
Wire Harness for Sub Panel
GR
Green / Red
Fuel filter alarm
18
Amplifier (Sail Drive Only)
Procured by Customer
O
Orange
Pulse for tachometer
19
WBr
White /
Brown
Electric stop
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
Earth bolt (ground)
32
Sail Drive Only
33
Details of Coupler (View from A-A)
SD Operation Manual
© 2007 Yanmar Marine International
59
YW
3
2
10
WL
5
© 2007 Yanmar Marine International
Figure 4
SD Operation Manual
+
36
B
10
WG
-
YB
G
34 35
YW
4
WL
YG
6
YG
6
+
LB
7
LB
7
-
37
14
WB
8
13
8
W
W
+
L
- P
12
11
L
O
O
30
AC
12
- P
G2 G1
17
R
+
B
L
11
G1
L
30
AC
G2
17
R
R
9
R
9
WBr
WBr
15
15
17
3R
2B
5R
18
B
L
YG
RB
3L
+
-
16
38
28
WL
23
GR
24
5R
22
B
3R
33
3L
25
39
YB
3W
29
YW
WBr
2R
19
20
12V
+
1
WB
30
-
0004507
RB LB O YG
YW WL WG B
24
2
3
16
section of cable Allowable length
L=1+2+3(m)
(mm2)
15(mm2)
< 0.86(m)
20(mm2)
< 1.3(m)
2
30(mm )
< 2.3(m)
40(mm2)
< 2.8(m)
50(mm2)
< 3.5(m)
2
60(mm )
< 4.1(m)
3
2
1
40
L
R
E
B
LB
RB
21
20
12V
+
1
YB GB G GR
WB YR Y WR
LB
RB
W/Y
B
LB
RB
-
3R
10B
2R
L
R
P
B
30
27
2W
S
GLOW
OFF
ON
START
B
32
YG
31
008434-00E
30 AC G1 G2 17
Key switch
O
Y
E
10R B
26
3
60
2
Allowable length by
cross sectional area
of battery cable
SYSTEM DIAGRAMS
4JH4-TE with C x B Type Panel
SYSTEM DIAGRAMS
4JH4-TE with C x B Type Panel
Color Coding
10
Diodes
Engine Harness
11
Key Switch
Tachometer / Hour Meter
R
Red
+
12
B
Black
-
13
W
White
Ignition
Instrument Panel (sub station)
(Option)
L
Blue
Air heater / glow
(option)
14
Instrument panel (main station)
(Option)
RB
Red / Black
Alternator exciter
15
Wire Harness
LB
Blue / Black
Alternator charge
alarm
16
Relay
17
Wire Harness for Sub Panel
YW
Yellow /
White
Engine oil pressure
alarm
18
Amplifier (Sail Drive Only)
YB
Yellow /
Black
Engine oil pressure
19
Procured by Customer
20
Battery
YG
Yellow /
Green
Sail drive seal
21
Battery Switch
22
Engine Stop Solenoid with VE Pump
23
Air Heater
Option
WL
White / Blue
Water temperature
alarm
WB
White /
Black
Water temperature
24
25
Stop Relay
WG
White /
Green
Seawater flow alarm
26
Starter Relay
GR
Green / Red
27
Starter
O
Orange
Pulse for tachometer
28
Coolant Temperature Switch
WBr
White /
Brown
Electric stop
29
Engine Oil Pressure Switch
30
Alternator
31
Earth bolt (ground)
32
Sail Drive Only
33
Details of Coupler (View from A-A)
34
Seawater
35
Fuel Filter
36
Oil Pressure Meter / Alarm
37
Water Temperature Meter / Alarm
38
Fuel Filter Switch
39
Oil Pressure Sender
40
Coolant Temperature Sender
Fuel filter alarm
1
Option
2
Alarm Lamps
3
Buzzer
4
Oil Pressure
5
Coolant Temperature
6
Sail Drive Seal
7
Battery Low Charge Alarm
8
Fuse (3A)
9
Stop Switch
SD Operation Manual
© 2007 Yanmar Marine International
61
8
3
YW WL
2
5
YG LB
4
1
10
6
© 2007 Yanmar Marine International
+
Figure 5
SD Operation Manual
B
L
O
-P
9
11
L
G2 G1
30
17 AC
R
W
R
7
WBr
12
13
15
A
A
14
B
L
YG
RB
+
-
3BR
128990-77910
2L
5R
2B
0.85WBr
2B
2B
16
22
26
3L
3R 3W
119247-77100
WBr
0.85YW
119717
-77800
25
0.85WL
2B
17
+
-
2R
0.85B
18
+
2W
21
12V
30
RB LB O YG
YW WL WG B
20
1
2
19
-
3
0.85YG
GLOW
OFF
ON
START
29
0.85B
27
003880-00E
30 AC G1 G2 17
Key switch
0.85 O
28
24
2W
S
B
E
10R B
L
R
Y
10B
2R 5R
23
120270
-77511
3R
W/Y
B
2B
0.85LB
0.85RB
62
Section of cable Allowable Length
L=1+2+3(m)
(mm2)
15(mm2)
<0.86(m)
2
20(mm )
<1.3(m)
2
30(mm )
<2.3(m)
40(mm2)
<2.8(m)
50(mm2)
<3.5(m)
2
60(mm )
<4.1(m)
SYSTEM DIAGRAMS
B-Type Instrument Panel for 3YM30, 3YM20 and 2YM15
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
WBr
Orange
White / Brown
1
Alarm Lamps
2
Buzzer Oil Pressure
3
CFW 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
C.W. Temperature Switch
26
Engine Oil Pressure Switch
27
Earth Bolt
28
Alternator
29
Sail Drive Only
30
Coupler (View from A-A)
SD Operation Manual
© 2007 Yanmar Marine International
63
34
37
YW WL
5 6 7
YG LB
8
© 2007 Yanmar Marine International
39
YW WL
YG LB
14 15 16 17 18
4
38
35
10
13
12
30
L
B
O
P
L
G2 G1
40
11
R
O
P
L
17 AC
W
3
B
1
L
G2 G1
30
17 AC
W
R
R
R
WBr
WBr
41
36
3R
Figure 6
SD Operation Manual
31
A
A
2B
43
B
L
YG
RB
3L
5R
44
5R
26
WL
3L
27
23
RB LB O YG
YW WL WG B
WBr
YW
2B
3R 3W
21 45
22
2R
LB
RB
YB GB G GR
WB YR Y WR
L
R
E
B
47
Option
28
32
1
2
20
9
3
46
3R
O
Y
10R
GLOW
OFF
ON
START
2W
S
L
R
YG
49
B
48
003881-00E
30 AC G1 G2 17
30
25
B
29
E
B
10B
2R
Key switch
LB
RB
W/Y
B
3
24
33
12V
1
12V
LB
2
64
RB
2
19
SYSTEM DIAGRAMS
B-Type Instrument Panel for 3JH4E
SYSTEM DIAGRAMS
B-Type Instrument Panel for 3JH4E
18
Battery Low Charge Alarm
Color Coding
19
Option
Alarm Lamps
R
Red
20
B
Black
21
Air Heater (Option)
W
White
22
Engine Stop Solenoid
L
Blue
23
Stop Relay
RB
Red / Black
24
Starter Relay
LB
Blue / Black
25
Starter
YW
Yellow / White
26
Coolant High Temperature Switch
YB
Yellow / Black
27
Lubricating Oil Low Pressure Switch
YG
Yellow / Green
28
Alternator (Option)
WL
White / Blue
29
Alternator
WB
White / Black
30
WG
White / Green
Water in Sail Drive Seal Sensor (on
Sail Drive)
GR
Green / Red
31
Water in Sail Drive Seal Sensor
Amplifier (Sail Drive Only)
Orange
32
Battery (Option)
White / Brown
33
Battery
34
Diodes
35
Instrument Panel (Sub Station)
(Option)
O
WBr
1
Starter Switch
2
Stop Switch
3
Tachometer / Hour Meter
36
Wire Harness
4
Buzzer
37
Alarm Lamps
5
Lubricating Oil Low Pressure Alarm
38
Fuse (3A)
6
Coolant High Temperature Alarm
39
Diodes
7
Water in Sail Drive Seal Alarm
40
8
Battery Low Charge Alarm
Instrument Panel (Main Station)
(Option)
9
Relay (for 2 Station: Option)
41
Wire Harness
10
Fuse (3A)
42
Wire Harness for Sub Panel
11
Starter Switch
43
Only for Sail Drive
12
Stop Switch
44
Relay
13
Tachometer / Hour Meter
45
Option
14
Buzzer
46
Procured by Customer
15
Lubricating Oil Low Pressure Alarm
47
Battery Switch
16
Coolant High Temperature Alarm
48
Ground Bolt
17
Water in Sail Drive Seal Alarm
49
Only for Sail Drive
SD Operation Manual
© 2007 Yanmar Marine International
65
38
YW WL
5 6 7
YG LB
8
© 2007 Yanmar Marine International
Figure 7
SD Operation Manual
20
19
YG LB
WL
YB
G
YW
B
43
YG
41
14 15 16 17 18
4
42
2
B
12
30
O
P
L
G2 G1
L
O
P
L
17 AC
W
R
L
G2 G1
30
17 AC
R
W
11
3
1
13
44
WB
39
10
R
R
WBr
WBr
45
40
46
3R
31
A
A
2B
5R
47
B
L
YG
RB
3L
48
WL
49
3L
3R 3W
21
26
5R
22
WBr
34
YB
23
RB LB O YG
YW WL WG B
27
YW
2B
2R
32
1
35
L
R
53
WB
3
E
B
51
YB GB G GR
WB YR Y WR
28
2
37
9
50
LB
RB
O
GLOW
OFF
ON
START
E
B
L
R
2W
S
30
54
YG
25
B
B
52
003882-00E
30 AC G1 G2 17
29
Y
10R
10B
2R
Key switch
LB
RB
3R
24
W/Y
B
33
12V
1
2
12V
LB
3
66
RB
36
SYSTEM DIAGRAMS
C-Type Instrument Panel for 3JH4E
SYSTEM DIAGRAMS
C-Type Instrument Panel for 3JH4E
20
Coolant Temperature Meter
Color Coding
21
Air Heater (Option)
Engine Stop Solenoid
R
Red
22
B
Black
23
Stop Relay
W
White
24
Starter Relay
L
Blue
25
Starter
RB
Red / Black
26
Coolant High Temperature Switch
LB
Blue / Black
27
Lubricating Oil Low Pressure Switch
YW
Yellow / White
28
Alternator (Option)
YB
Yellow / Black
29
Alternator
YG
Yellow / Green
30
Water in Sail Drive Seal Sensor (on
Sail Drive)
31
Water in Sail Drive Seal Sensor
Amplifier (Sail Drive Only)
WL
White / Blue
WB
White / Black
WG
White / Green
32
Battery (Option)
GR
Green / Red
33
Battery
Orange
34
Oil Pressure Sensor (Option)
White / Brown
35
Coolant Temperature Sensor (Option)
36
Option
37
Alarm Lamps
38
Diodes
39
Instrument Panel (Sub Station)
(Option)
O
WBr
1
Starter Switch
2
Stop Switch
3
Tachometer / Hour Meter
4
Buzzer
5
Lubricating Oil Low Pressure Alarm
40
Wire Harness
6
Coolant High Temperature Alarm
41
Alarm Lamps
7
Water in Sail Drive Seal Alarm
42
Fuse (3A)
8
Battery Low Charge Alarm
43
Diodes
9
Relay (for 2 Station: Option)
44
10
Fuse (3A)
Instrument Panel (Main Station)
(Option)
11
Starter Switch
45
Wire Harness
12
Stop Switch
46
Wire Harness for Sub Panel
13
Tachometer / Hour Meter
47
Only for Sail Drive
14
Buzzer
48
Relay
15
Lubricating Oil Low Pressure Alarm
49
Option
16
Coolant High Temperature Alarm
50
Procured by Customer
17
Water in Sail Drive Seal Alarm
51
Battery Switch
18
Battery Low Charge Alarm
52
Ground Bolt
19
Oil Pressure Meter
53
Option
54
Only for Sail Drive
SD Operation Manual
© 2007 Yanmar Marine International
67
5
YW
6
YG
© 2007 Yanmar Marine International
diodes
YW
LB
WL
YG
W
0004594
Figure 8
SD Operation Manual
+
3
B
- P
O
+
13
B
- P
L
11
G1
L
O
30
AC
G2
17
W
R
R
12
Instrument panel (main station) (Option)
LB
Fuse(3A)
WBr
Wire
harness
Wire harness
for sub panel
2B
5R
Wire
harness
Relay
31
B
L
YG
RB
+
-
only for sail drive
A
A
3L
5R
21
26
WL
3L
WBr
2R
32
12V
+
1
2
RB LB O YG
YW WL WG B
23
27
YW
2B
3R 3W
L
1
22
G1
L
R
3R
G2
30
AC
WBr
9
+
-
17
R
Instrument panel (sub station) (Option)
8
Alarm lamps
WL
7
14 15 16 17 18
diodes
4
10
2
-
28
L
R
B
E
+
33
P
B
(4JH4AE only)
36
R
LB
RB
YB GB G GR
O
Y
L
R
25
S
2W
OFF
ON
START
B
30 AC G1 G2 17
30
YG
Earth bolt
only for sail drive
29
B
GLOW
E
10B
2R
10R B
-
3R
24
W/Y
B
WB YR Y WR
LB
RB
Battery switch
Option
3
12V
Procured by customer
3
Option
LB
1
2
68
RB
Alarm lamps
SYSTEM DIAGRAMS
B-Type Instrument Panel for 4JH4AE
SYSTEM DIAGRAMS
B-Type Instrument Panel for 4JH4AE
Color
coding
Description
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
WBr
Orange
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 - 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
Lubricating Oil Low Pressure Switch
28
Alternator (Optional)
29
Alternator
30
Water in Sail Drive Seal Sensor
Amplifier (on Sail Drive)
31
Water in Sail Drive Seal Sensor
Amplifier (Sail Drive Only)
32
Battery (Optional)
33
Battery
34
-
35
-
36
Fuel Feed Pump (4JH4AE Only)
SD Operation Manual
© 2007 Yanmar Marine International
69
5
YW
6
YG
© 2007 Yanmar Marine International
Figure 9
SD Operation Manual
YW
+
-
19
B
diodes
WG
LB
YB
G
W
+
3
B
- P
L
1
G1
L
O
30
AC
G2
17
R
+
-
20
LB
WB
Fuse(3A)
W
+
13
- P
L
11
G1
L
O
30
AC
G2
17
R
Instrument panel (main station) (Option)
WL
YG
10
R
R
12
Instrument panel (sub station) (Option)
8
Alarm lamps
WL
7
14 15 16 17 18
diodes
4
2
WBr
WBr
Wire
harness
Wire
harness
Wire harness
for sub panel
9
3R
5R
31
B
L
YG
RB
3L
+
-
Relay
only for sail drive
A
A
2B
5R
26
WL
21
2B
3L
3R 3W
22
+
-
23
1
2
RB LB O YG
YW WL WG B
34
YB
27
YW
WBr
2R
+
32
12V
3
WB
28
-
35
R
L
LB
RB
YB GB G GR
10B
2R
R
L
2W
S
OFF
ON
START
B
30 AC G1 G2 17
30
YG
Earth bolt
only for sail drive
29
25
B
GLOW
O
Y
E
10R B
(4JH4AE Only)
P
B
36
R
LB
RB
-
3R
24
W/Y
B
WB YR Y WR
E
B
Battery switch
33
12V
+
1
RB
Alarm lamps
Procured by customer
LB
3
70
2
Option
SYSTEM DIAGRAMS
C-Type Instrument Panel for 4JH4AE
0004595
SYSTEM DIAGRAMS
C-Type Instrument Panel for 4JH4AE
Color
coding
Description
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
WBr
Orange
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 - 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
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
Lubricating Oil Low Pressure Switch
28
Alternator (Optional)
29
Water in Sail Drive Seal Sensor (on
Sail Drive)
30
Water in Sail Drive Seal Sensor
Amplifier (on Sail Drive)
31
Water in Sail Drive Seal Sensor
Amplifier (Sail Drive Only)
32
Battery (Optional)
33
Battery
34
Oil Pressure Sensor (Optional)
35
Coolant Temperature Sensor
(Optional)
36
Fuel Feed Pump (4JH4AE Only)
SD Operation Manual
© 2007 Yanmar Marine International
71
SYSTEM DIAGRAMS
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72
SD Operation Manual
© 2007 Yanmar Marine International
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