Yanmar SD50-4T Operation Manual

OPERATION MANUAL

SD20,SD50/SD50-4T

SD-Series

SAIL-DRIVE

MODEL: SD20, SD50/SD50-4T

OPERATION MANUAL

EN

Applicable Engine Model:

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

All rights reserved. This manual may not be reproduced or copied, in whole or in part, without the written permission of YANMAR CO., LTD.

Copyright © 2004 Yanmar CO., LTD

Introduction ................................................... 3 7. Electrical Wiring Diagrams ......................31

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

1.1 Safety Precautions For Inspection .... 4

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

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

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

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

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

EN

4. Starting the New Sail-Drive for the First

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

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

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

4.2 Check of instrument panel alarm system: 11

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

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

4.5 Recommended Propeller Size (Max.) .

14

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

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

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

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

6. Periodic Inspections and Maintenance ... 18

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

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

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

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

6.2.1 When the boat is in the water 22

6.2.2 When the boat is out of the water

26

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

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

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

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

Introduction

This Installation and Operation Manual describes Sail-Drive Models SD20, SD50,

SD50-4T.

For engine handling and operation, refer to the respective operation manuals for Engine

Models 1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E and 4JH3-TCE. However, instructions for the marine gear box are not necessary as they are included.

Engines and sail-drive combinations are available as follows:

Engine model

1GM10C

2YM15

3YM20, 3YM30

3JH4E

4JH4E

4JH3-TCE

Sail-drive model

SD20

SD50

SD50-4T

EN

3

1. For Your Safety


1.1 Safety Precautions For Inspection

DANGER

Battery

Never smoke or permit sparks near the battery, because it may emit explosive hydrogen gas. Place the battery in a well-ventilated place.

EN

DANGER

WARNING

WARNING

Fuel

Use only diesel fuel. Never use other fuels, including gasoline, kerosene, etc., because they could cause a fire. The wrong fuel could also cause the fuel injection pump and injector to fail due to lack of proper lubrication. Be sure to check that you have selected the correct diesel fuel before filling the fuel tank.

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

Fire Prevention

Be sure to stop the engine and confirm that there are no open flames in the vicinity before fueling. If you do spill fuel, wipe such spillage carefully and dispose of the wiping materials properly. Wash your hands thoroughly with soap and water.

Never place oil or other flammable material in the engine room.

Install a fire extinguisher near the engine room, and familiarize yourself with its use.

Exhaust Gas

Exhaust gas contains poisonous carbon monoxide and should not be inhaled.

Be sure to install ventilation ports or ventilators in the engine room and ensure good ventilation during engine operation.

WARNING

Moving Parts

Do not touch or let your clothing get caught in the moving parts of the engine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured.

Never operate the engine without covers on the moving parts.

4


CAUTION

Burns

The whole engine is hot during operation and immediately after shut-down. The exhaust manifold, exhaust pipe and high pressure fuel lines are very hot. Never touch these parts with your body or clothing.

WARNING

Alcohol

Never operate the engine while you are under the influence of alcohol.

Never operate the engine when you are ill or not feeling well.

DANGER

Battery Fluid

Battery fluid is dilute sulphuric acid. It can blind you if it gets in your eyes, or burn your skin. Keep the fluid away from your body.

If you touch it, wash it off immediately with a large quantity of fresh water and call your doctor for treatment.

EN

WARNING

Fire by Electric Short-Circuits

Always turn off the battery switch before inspecting the electrical system.

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

WARNING

Stop the engine before you service it.

Turn the battery switch off. If you must inspect while the engine is in operation, never touch moving parts. Keep your body and clothing well clear of all moving parts.

CAUTION

Scalds

When extracting oil from the engine while it is still hot, don't let the oil splash on you.

Wait until the temperature has dropped before extracting cooling water from the engine. Don't let it splash on you.

5

EN


DANGER

DANGER

Forbidden Modifications.

Never release the limiting devices such as the engine speed limit, fuel injection limit, etc.

Modification will impair the safety and performance of the product and shorten product life.

Also note that any troubles arising from modification are not covered by our warranty.

Precautions for Treating Waste.

Never dispose of waste oil or other fluid in a field, sewer, river, or the sea.

Treat waste matters safely observing regulations or laws.

Ask a waste recovery company to collect it.

6

2. Specifications

2. Specifications

Model

Reduction gear system

SD20

Constant mesh gear with dog clutch use

SD50 SD50-4T

Cone clutch

Direction of rotation

Propeller speed (min-1)

Lubrication system

Lubrication oil capacity

Input shaft Counter-clockwise viewed from stern

Propeller shaft Counter-clockwise viewed from stern

Counter-clockwise or clockwise viewed from stern

Reduction ratio Ahead

Astern

Standard unit

Long-reach unit

2.64

2.64

1364

2.2 L

2.5 L

1293

Oil bath type

2.32

2.32

2.2 L

2.35 L (Extension 58), 2.45 L (Extension

100)

1638

Dry weight

Remote-control device

Control head

Cable

Applicable engine model (Fuel stop power at crankshaft)

30 Kg 39 kg

Single control lever

"MORSE" 33C (equivalent)

1GM10C (6.7kW/3600 min-1)

2YM15 (10.3kW/3600 min-1)

3YM20 (16.2kW/3600 min-1)

3YM30 (22.1kW/3600 min-1)

3JH4E

(29.4 kW/3000 min-1)

4JH4E

(40.5 kW/3000 min-1)

41 kg

4JH3-TCE

(55.2kW/3800min-1)

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

EN

7

3. Selecting Lubricating Oil


3.1 Choice of lube oil

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

When selecting the lube oil, it must be one of the following:

3.2 Kind of lube oil

Engine series GM, YM JH3, JH4

Engine model

Sail-drive model

1GM10C

Lubrication oil for the sail-drive

API CC or greater and

SAE 10W30

2YM15 3YM20 3YM30

SD20

3JH4E

SD50

4JH4E

SD50

API GL4 or GL5 and SAE

80W90 or 90

API GL4 or GL5 and SAE

80W90 or 90 or Quicksilver High Performance Gear

Lube

4JH3-TCE

SD50-4T

Quicksilver

High Performance Gear

Lube

EN

Use only oil of quality “GL-4" or "GL-5" in the API service, and SAE No. 90 or

80W90.

Use only oil of quality "cc" or greater in the

API service, and SAE no. 10W30.

(Applicable model: SD20 x 1GM10C)

(Except model SD20 x 1GM10C and

SD50/-4T)

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

Supplier

SHELL

SHELL

CALTEX

MOBIL

ESSO

ESSO

Brand Name

Shell Spilax oil EP 90

Shell Spilax oil HD 90

Multipurpose thuban EP

Mobilub HD 80W-90

Esso gear oil GP 90

Esso gear oil GX 90

Use "Quicksilver High Performance Gear

Lube" for the SD50/-4T.

API Service

GL-4

GL-5

GL-4/GL-59

GL-5

GL-4

GL-5

SAE No.

90

90

90

80W-90

90

90

This lube oil is available through all Mer-

Cruiser, Mercury, Mariner and Force outlets in their Quicksilver accessories program.

8


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

Volume Part number Package

300 ml

1 L

10 L

60.5 L

208 L

92-802851Q1 case of 24 tubes

92-802854Q1 case of 12 plastic bottles

92-802856Q1 case of 2 cans

92-802857Q1 single drum

92-802858Q1 single drum

3.3 Lube oil viscosity

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

EN

9

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


4.1 Filling with lubricating oil

4.1.1 SD20 and SD50/-4T

(1) Remove the dipstick (yellow cap) and supply approved lube oil.

(2) Check the amount of lube oil by inserting the dipstick as far as possible. Do not screw the dipstick in.

(see the illustration below). The oil level should reach the upper mark on the dipstick.

EN

CAUTION

Since it takes about 10 minutes to fill up the Sail-Drive with lube oil, owing to its construction, check the supplied oil quantity again by using the dipstick 15 minutes after completion of supply of the specified quantity of oil.

A

B

C

D

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

Lube oil capacity:

Sail-drive model

Standard unit

Long-reach unit

SD20 SD50/-4T

2.2 L

2.5 L

2.2 L

2.35 L (Extension 58)

2.45 L (Extension 100)

CAUTION

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

A

B

C

D

E

E

F

F

A Dipstick

B Upper limit

C Lower limit

SD20 SD50/SD50-4T

003443-00E

D Oil level

E Oil supply port

F Oil capacity nameplate

10


4.2 Check of instrument panel alarm system:

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

(A-type)

2 3 4 8

(B-Type)

1

2

4

3

1

OFF

ON

7

1 Rubber seal (Sail-Drive)

2 CW temp

3 Charge

6

5

4 LO press

5 Key switch

6 Warning Buzzer

(1) Lube oil warning lamp should be lit.

(2) Cooling water temperature warning lamp should be out. (For small type panel: A-type only)

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

(3) Charging warning lamp should be lit.

(4) Rubber seal lamp should be out.

(5) The warning buzzer should sound.

WARNING

The rubber seal alarm lamp warns of seawater entering the boat. The watertight structure of the Sail-Drive is the dual type. Even if the rubber diaphragm

(A) is damaged and seawater enters, the rubber diaphragm (B) prevents it from entering the inboard. The rubber seal switch between the rubber diaphragms (A) and (B) works the warning buzzer and lights the rubber seal lamp

6 7

7 Push button

8 Tachometer

9 Check switch

9 5 on the instrument panel. If this happens, stop the engine and, under sail, quickly return to the nearest port for repairs.

CAUTION

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

A

A ON (Rubber seal lamp)

B Buzzer

C Rubber seal switch

D Diaphragm (B)

E Diaphragm (A)

F Seawater

B

C

D

E

F

003446-00E

EN

11


4.3 Remote-Control Device Check

EN

4.3.0.1 SD20

While cranking the engine slowly, shift the control handle of the remote-control head

(single lever control) rapidly through Neutral - Ahead - Neutral - Astern. If a shift operation is done slowly, the tip of the clutch dog is worn away by being hammered,

B

A

C

F

D

E and, consequently, the clutch fails to engage. Confirm that the operation lever of the Sail-Drive moves smoothly to Ahead,

Astern and Stopper. Because the

Sail-Drive SD20 uses a dog clutch, the clutch is not engaged unless the operation lever is moved to the stopper position.

M

L N

O

R

P

Q

S

T

U

Old type :

Serial No. 0001-2128 for SD10

G

D

H

I

J

K

New type :

Serial No. 2129 and after for SD20

New type: Serial No. 2129 and after for SD20

A Control handle

B Astern

C Neutral

D Ahead

E Operation lever

F Cable clamp

G Remote control cable

H Pivot

I Astern

J Neutral

K Ahead

Old type: Serial No. 0001-2128 for SD10

L Ahead stopper

M Neutral position

N Astern stopper

O Cable clamp

P Remote control cable

Q Spring joint

R Operation lever

S Astern

T Neutral

U Ahead

003447-00E

12


4.3.0.2 SD50 & SD50-4T

After starting the engine, check the shift action by using the control head to shift the

Ahead and Astern positions. The Ahead/

Astern clutch is a mechanical clutch called a cone clutch. Although a grinding noise is made when this type of clutch is engaged, it has no effect on the operation of the engine.

CAUTION

Because of the rubbing produced at the frictional face of the cone clutch, gripping action is lessened with use and periodic inspection and maintenance is necessary.

C

B

A

D

E

F

G

H

003448-00E

A When attaching the cable mounting plate at a 90º angle handle

B Operation lever

C Cable clamp

D Remote control cable

E Propeller shaft clockwise

F Pivot

G Neutral

H Propeller shaft counter-clockwise

EN

13


4.4 Fitting for Fixed Propeller (2-blade)

A

B

C

D

E

F

003449-00E

A Spacer

B Grease

C Washer

D Propeller

E Nut Tightening torque 60-70 Nm (M16,

SD20)

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

F Bolt M8x75mm

Tightening torque11-15 Nm

EN

Locking Procedure for Fixed Propeller Nut

(Optional). When tightening the nut at

60-70 Nm torque for the SD20, and 80-100

Nm torque for the SD50/-4T, move the shift lever to ahead and hold the crankshaft V-pulley clamp nut with a wrench to stop the rotation.

CAUTION

Rubber bushing (Folding propeller)

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

4.5 Recommended Propeller Size (Max.)

Engine model

1GM10C

2YM15

3YM20

3YM30

3JH4E

4JH4E

4JH3-TCE

CAUTION

Sail-Drive Model

SD20

SD50

SD50-4T

Precautions on matching of the propeller

(1) Be sure to confirm a matching of the propeller in a sea trial.

Folding type Dia. mm

(inch)

355 (14)

368 (14.5)

380 (15)

405 (16)

457 (18)

457 (18)

457 (18)

2-blade, fixed type-

Dia. mm (inch)

380 (15)

380 (15)

405 (16)

420 (16.5)

457 (18)

457 (18)

457 (18)

(2) Execute a propeller matching on the basis of the propeller shaft rated output (continuous rating at propeller shaft). 95% of the engine rated output (continuous rating at crankshaft) becomes the propeller shaft rated output (continuous rating at propeller shaft).

14


Note: The propeller shaft output becomes

95% of the engine rated output (continuous rating at crankshaft) in consideration of mechanical efficiency 95% of the sail-drive.

(3) In the case of propeller calculation, further add 5%, at minimum, as the sea margin to the aforementioned matching point. That is, 95% of the propeller shaft rated output (Continuous rating at propeller shaft) becomes the best propeller matching. Note about sea margin: In actual navigation, there is an increase in resistance due to the waves, wind and fouling of the hull and, moreover, a drop in the efficiency due to fouling of the propeller. Consequently, in the case of propeller calculation, it is necessary to allow the engine output to have some margin. For that reason, it is necessary to add the sea margin of 5%, at minimum.

EN

15

EN

5. Method of Operation


5.1 Engine Cooling Water

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

5.1.1 SD20

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

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

Old type:

Serial No.0001-2128 for Model SD20

New type:

Serial No.2129 and after for Model SD20

E

A

B

C

D

F

G

H

D

I

A Atern

B Neutral

C Ahead

16

D Neutral

E Cock, C.W.

F C.W. hose

G To C.W. pump

H Hose clamp

I Seawater inlet

003442-00E


5.1.2 SD50/SD50-4T

A

B

C

D

40

E

40

F

A Open

B To C.W. pump

C Cock C.W.

D Propeller shaft Clockwise

003450-00E

E Neutral

F Propeller shaft Counter-clockwise

EN

17

6. Periodic Inspections and Maintenance

EN


Every day

50 hrs. or after

1 month

Every 100 hrs.

Every 250 hrs.

Lubricating Oil

(1) Check oil level: fill

Before operation

O

First

O

SD20

O

SD50/-4T

O

(2) Change lube oil

Cooling Water

(1) Open/close cooling water cock

Before/after operation

O

(2) Clean cooling water suction hole

After operation

O

(3) Drain cooling water

Remote Control System

(1) Inspect remote control device

(2) Inspect and replace clutch shifter

First

O O

Anti-Corrosive Zinc

(1) Inspect and replace anti-corrosive zinc

Replace if wear is more than

50%

O

Lower Case

(1) Repair case coating

Boat Bottom Water- tightness

(1) Inspect and replace rubber diaphragm seal ring

Every 1 year

O

Replace if the thickness is less than 10 mm.

O

O

(2) Inspect seal sensor

Flexible mount

(1) Inspect and replace mounting height.

O

Replace if clearance is less than 1 mm.

O

Every 2 years

Serial No.

2129 and after for

SD20

Inspect and replace, if there is cracking

O

003451-00E

A: Clearance

A

18


6.1 Lubricating oil system

6.1.1 SD20

(1) Check the oil level before every operation.

(2) Change the oil after the first 50 hours of operation or after long storage and every 100 hours of operation thereafter. Lube oil should be changed while the engine is still warm.

Change oil in the following manner:

(1) Put the boat hull on a block.

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

WARNING

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

SD20

A

B

C

EN

D

003440-00E

A Dipstick

B Upper gear case

C Lower gear case

D Lube oil drain plug

19


EN

6.1.2 SD50/-4T

(1) Check the oil level before every operation.

(2) Change the oil after the first 50 hours of operation or after long storage, and every 250 hours of operation thereafter. Lube oil should be changed while the engine is still warm.

WARNING

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

SD50/SD50-4T

A

B

A Dipstick B Plug

C

003441-00E

C Drain plug

20


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

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

Used equipment:

Description Part code

Bottle of Quicksilver High Performance Gear Lube from

MerCruiser

MerCruiser Part code

92-850743A1

Market pump from MerCruiser on bottle

MerCruiser Part code

91-85729A1

Adapter joint 196311-92960

Quantity

2

1

1 (2)

Remarks

Each bottle contains 0.946 liter of oil.

Mandatory for SD50/-4T. For other models see page 8.

Thread std. M10 x 1.5 max. length 12 mm.

O-ring for adapter

Stiff rubber hoses

24311-000100 1 (2)

2 Inner diameter ø14-16 mm + hose clips (If Yanmar part is used, part code is 196440-92970)

Compressor set

Hand pump

-

28210-000080

1

1 Option parts

EN

21


6.2.1 When the boat is in the water

6.2.1.1 Preparing the sail-drive:

A

B

C

6.2.1.2 Removing oil (total quantity

2.2 liter)

A

D

EN

003453-00E

003452-00E

A O-ring

B Adapter joint

C Oil changing plug

D Tread M10 x 1.5

(1) Take out the oil changing plug located under the shift lever.

(2) Screw in the adapter joint (196311-

92960) with the O-ring

(24311-000100). When using own adapter joint, max. length of thread is 12 mm.

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

196440-92970)

A Plug

6.2.1.3 Fastest way: Blowing out by using Air pressure

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

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

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

N 196311-92960) with an O-ring (P/N

24311-000100) at the oil inlet position. Screw in the oil plug at the dipstick position.

(3) Connect the air pressure hose with hose clips.

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

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

22


A

B

C

A One-way valve

B Adapter joint screwed in cover

C Simple foot pump

003454-00E

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

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

(1) Install a one-way (non return) valve in the pressure line (connected to the top cover). This is done to maintain the pressure during use of the pump.

(2) Connect the hand pump or foot pump with the pressure line to the adapter joint on the top as shown above.

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

6.2.1.4 Using Yanmar Pump

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

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

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

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

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

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

EN

23


A

003455-00E

A Plug

EN

6.2.1.5 Filling oil (total quantity 2.2 liter)

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

6.2.1.6 Fastest way: By using Mer-

Cruiser pump or simple market pump

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

(1) Use a MerCruiser pump with Part number 91-85729A1 like the one shown above or use a similar pump available on the market.

(2) Screw the pump on a new bottle of

Quicksilver High Performance Gear

Lube Part number 92-850743A1

(0.946 liter) from MerCruiser.

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


(5) Fill the oil by pushing the upper part of the pump. After bottle is empty, change the bottle while the pump and hose remains connected with the adapter joint.

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

24


6.2.1.7 By using Yanmar Hand

Pump

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

A

003456-00E

A Plug

(1) Connect the hoses as shown above at the top adapter joint to the hand pump by using the rubber hose.


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

(Inner diameter ø14-16 mm) available from the hardware shop, are usable.

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

EN

6.2.1.8 By not using pump

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

25

EN


6.2.2 When the boat is out of the water

6.2.2.1 Preparing the sail-drive:

A

(4) Take out the dipstick and oil inlet plug from the upper case cover.

6.2.2.2 Removing oil (total quantity

2.2 liter)

6.2.2.3 By draining

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

26.

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

(1) After approx. 0.6 liter has been drained, remove the oil changing plug. If you remove sooner, oil may spill out of this position (because max. oil level is higher than this position).

A

B

003458-00E

003457-00E

A Plug

(1) Remove the bottom drain plug

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

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

24311- 000100).

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

(3) Attach a stiff rubber hose with inner diameter ø14~16 mm with hose clips to the adapter joint at the oil drain position. The hose must be long enough to drain to bucket.

A Tread M10 x 1.5

B Oil changing plug

6.2.2.4 Fastest way: Blowing out by using Air pressure

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

26


6.2.2.5 Filling oil (total quantity 2.2 liter)

6.2.2.6 By using MerCruiser pump or simple market pump

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

A

B

C

A Plug

B O-ring

C Adapter joint

003870-00E

(1) Use a MerCruiser pump with Part number 91-85729A1 like the one shown on p. 24, 6.2.1.4, or use a similar pump available on the market.

(2) Screw the pump on a new bottle of

Quicksilver High Performance Gear

Lube Part number 92-850743A1

(0.946 liter) from MerCruiser.

(3) Remove the oil changing plug below the shift lever.

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


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

(7) Change the bottle while the pump and hose remain connected with the adapter joint.

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

EN

27

EN


6.2.2.7 By using Yanmar hand pump

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

26.

A

pumping will be hard. A few minutes waiting in between will help.

After pumping in about 1 liter of oil, screw in the oil changing plug (do not forget to insert the gasket).

Please be aware that the drain hose can easily slip out of the bucket and cause oil spilling. The hand pump

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

003871-00E

A Plug

(1) Connect the hose from the bottom and a suction hose to Yanmar pump with hose clip like shown above.


(3) Fill oil by pumping it into drive. Be aware that oil has to flow up through narrow parts. Therefore,

003872-00E

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

6.2.2.8 By not using pump

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

28


6.3 Anticorrosive zinc

6.3.1 SD20 and SD50/ SD50-4T

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

SD20

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

B

M10 x 11

A

19

6420-02441

Don't remove while the boat in the water

ZINC

M20 x 50

C

EN

D

003873-00E

A Safety label

B Anticorrosive zinc

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

C Upper gear case

D Lower gear case

WARNING

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

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

The rubber diaphragms (A) and (B) of the

Sail-Drive are important parts for the hull and crew safety. Since rubber degenerates during use, be sure to replace them every two years. (Boat hull must be lifted onto a block). To replace, consult your

Yanmar dealer.

29


SD50/-4T

A

B

EN

A Lower gear case

B Upper gear case

003874-00E

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

(1) Remove deposit from the lower gear case.

Remove seaweed, seashells, and marine growth from the lower gear case.

Be sure to remove deposit completely around the cooling water intake since the engine may overheat if the intake amount is insufficient.

(2) Repairing damaged membrane

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

A Lower gear case

B Seawater inlet

(3) Inspecting anticorrosive zinc

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

(4) Inspecting the folding propeller

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

(5) Draining water

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

A

B

003875-00E

30

7. Electrical Wiring Diagrams


See Appendix B. at the back of this manual.

Color coding

R

Red

B

W

Black

White

Y

L

Yellow

Blue

O

L/B

Orange

Blue/Black

W/L

White/Blue

Y/W

Yellow/White

W/R

White/Red

L/R

Blue/Red

W/B

White/Black

R/B

Red/Black

A-type Instrument Panel

Applicable Engine Model: 1GM10C

4 Battery Recommended capacity

GM,12V-70AH

1GM,12V-100AH

(Mini.)

5 Battery switch

6 FUSE

7 Starter motor

8 Alternator

9 Not used

10 C.W. temp. switch

11 L.O. pressure switch

12 Spare connector

13 Extension cable 3 m. (Standard)

14 The total length extension cable must be less than 6 m.

15 Rubber seal switch (Sail-drive)

16 Amplifier

17 Earth

18 Sail-drive extension cable 0.3 m.

19 Not used (Except 1GMC)

20 Key switch

21 Push button switch

22 Charge lamp

23 C.W. temp. lamp

24 L.O. pressure lamp

25 Rubber seal lamp (Sail-drive)

26 Buzzer

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

(Cross sectional area)

1 + 2 + 3 < 5 m - 40 mm2


B-type Instrument Panel


3YM30, 3YM20 and 2YM15

(See A-5)

3JH4E, 4JH4E (See A-6)

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


1 + 2 + 3 < 5 m - 40 mm2


C-type Instrument Panel


3JH4E, 4JH4E (See A-7)

B-type Instrument Panel

Applicable Engine Model: 1GM10C

4 Battery Recommended capacity

GM,12V-70AH

1GM,12V-100AH

(Mini.)

5 Battery switch

6 FUSE

7 Starter motor

8 Alternator

9 Not used

10 C.W. temp. switch

11 L.O. pressure switch

12 Tachometer sender

13 Extension cable 3 m. (Standard)

14 The total length extension cable must be less than 6 m.

15 Rubber seal switch (Sail-drive)

16 Amplifier

17 Earth

18 Sail-drive extension cable 0.3 m.

19 Not used (Except 1GMC)

20 Light switch

21 Key switch

22 Push button switch

23 Charge lamp

24 C.W. temp. lamp

25 L.O. pressure lamp

26 Rubber seal lamp (Sail-drive)

27 Buzzer

28 Tachometer

EN

31

EN

B x B-type Instrument Panel

6

7

4

5

2

3

Applicable Engine Model: 4JH3-TCE

1 Procured by customer

Battery

Battery switch

Relay

Eng. stop solenoid

Air heater

Starter relay

8

9

Starter

C.W. Temp. switch

10 Eng. oil pressure switch

11 Alternator

12 Earth bolt

13 C.W. Temp. sender

14 Tacho sensor

15 Sail-drive

16 Amplifier

17 Wire harness for 2 panel

18 Option

19 Wire harness

20 Starter switch

21 Stop switch

22 Fuse

23 Buzzer stop illumination

24 Buzzer

25 Tachometer with hour meter

26 Charge

27 Eng. oil pressure

28 C.W. Temp.

29 Sail-drive

30 Exhaust

31 Fuel emplacement

32 Instrument panel no. 2 station; Option


C x B-type Instrument Panel

6

7

4

5

2

3

Applicable Engine Model: 4JH3-TCE

1 Procured by customer

Battery

Battery switch

Relay

Eng. stop solenoid

Air heater

Starter relay

8

9

Starter

C.W. Temp. switch

10 Eng. oil pressure switch

11 Alternator

12 Earth bolt

13 C.W. Temp. sender

14 Tacho sensor

15 Sail-drive

16 Eng. oil pressure sender

17 Wire harness for 2 panel

18 Option

19 Wire harness

20 Starter switch

21 Stop switch

22 Fuse

23 Buzzer stop illumination

24 Buzzer

25 Tachometer with hour meter

26 C.W. Temp. meter

27 Eng. oil pressure meter

28 Charge

29 Eng. oil pressure

30 C.W. Temp.

31 Sail-drive

32 Exhaust

33 Fuel filter

34 Fuel emplacement

35 Instrument panel no. 2 station; Option

32

Yanmar SD50-4T Operation Manual

OPERATION MANUAL

OPERATION MANUAL

Introduction

1.1 Safety Precautions For Inspection

3.1 Choice of lube oil

3.2 Kind of lube oil

3.3 Lube oil viscosity

4.1 Filling with lubricating oil

4.2 Check of instrument panel alarm system:

4.3 Remote-Control Device Check

4.4 Fitting for Fixed Propeller (2-blade)

4.5 Recommended Propeller Size (Max.)

5.1 Engine Cooling Water

6.1 Lubricating oil system

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

6.3 Anticorrosive zinc

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

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

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