Yanmar SD20 User manual

SD20,SD50/SD50-4T
OPERATION MANUAL

EN
SD-Series
SAIL-DRIVE
MODEL: SD20, SD50/SD50-4T
OPERATION MANUAL
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

EN
Introduction ................................................... 3
1. For Your Safety ........................................ 4
1.1 Safety Precautions For Inspection .... 4
2. Specifications ........................................... 7
3. Selecting Lubricating Oil ........................... 8
3.1 Choice of lube oil .............................. 8
3.2 Kind of lube oil .................................. 8
3.3 Lube oil viscosity ............................... 9
4. Starting the New Sail-Drive for the First
Time .................................................. 10
4.1 Filling with lubricating oil ................. 10
4.1.1 SD20 and SD50/-4T .............. 10
4.2 Check of instrument panel alarm sys-
tem: 11
4.3 Remote-Control Device Check ........ 12
4.4 Fitting for Fixed Propeller (2-blade) . 14
4.5 Recommended Propeller Size (Max.) .
14
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
7. Electrical Wiring Diagrams ......................31

3
EN
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, in-
structions for the marine gear box are not necessary as they are included.
Engines and sail-drive combinations are available as follows:
Engine model Sail-drive model
1GM10C SD20
2YM15
3YM20, 3YM30
3JH4E SD50
4JH4E
4JH3-TCE SD50-4T

4
1. For Your Safety
EN
1. For Your Safety
1.1 Safety Precautions For Inspection
Battery
Never smoke or permit sparks near the battery, because it may emit ex-
plosive hydrogen gas. Place the battery in a well-ventilated place.
Fuel
Use only diesel fuel. Never use other fuels, including gasoline, kero-
sene, etc., because they could cause a fire. The wrong fuel could also
cause the fuel injection pump and injector to fail due to lack of proper
lubrication. Be sure to check that you have selected the correct diesel
fuel before filling the fuel tank.
Do not use starting fluids or sprays. Their use may cause explosion, se-
rious 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 careful-
ly and dispose of the wiping materials properly. Wash your hands thor-
oughly 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.
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 en-
gine operation. You will be injured.
Never operate the engine without covers on the moving parts.
DANGER
DANGER
WARNING
WARNING
WARNING

1. For Your Safety
5
EN
Burns
The whole engine is hot during operation and immediately after
shut-down. The exhaust manifold, exhaust pipe and high pressure fuel
lines are very hot. Never touch these parts with your body or clothing.
Alcohol
Never operate the engine while you are under the influence of alcohol.
Never operate the engine when you are ill or not feeling well.
Battery Fluid
Battery fluid is dilute sulphuric acid. It can blind you if it gets in your
eyes, or burn your skin. Keep the fluid away from your body.
If you touch it, wash it off immediately with a large quantity of fresh wa-
ter and call your doctor for treatment.
Fire by Electric Short-Circuits
Always turn off the battery switch before inspecting the electrical sys-
tem.
Failure to do so could cause short-circuiting and fires.
Stop the engine before you service it.
Turn the battery switch off. If you must inspect while the engine is in op-
eration, never touch moving parts. Keep your body and clothing well
clear of all moving parts.
Scalds
When extracting oil from the engine while it is still hot, don't let the oil
splash on you.
Wait until the temperature has dropped before extracting cooling water
from the engine. Don't let it splash on you.
CAUTION
WARNING
DANGER
WARNING
WARNING
CAUTION

6
1. For Your Safety
EN
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.
DANGER
DANGER

2. Specifications
7
EN
2. Specifications
Note: A propeller with rubber bushing must be used in all SD series sail-drives.
Model SD20 SD50 SD50-4T
Reduction gear system Constant mesh gear with
dog clutch use
Cone clutch
Direction of
rotation
Input shaft Counter-clockwise viewed from stern
Propeller shaft Counter-clockwise viewed
from stern
Counter-clockwise or clockwise viewed from
stern
Reduction ratio Ahead 2.64 2.32
Astern 2.64 2.32
Propeller speed (min-1) 1364 1293 1638
Lubrication system Oil bath type
Lubrication oil
capacity
Standard unit 2.2 L 2.2 L
Long-reach
unit
2.5 L 2.35 L (Extension 58), 2.45 L (Extension
100)
Dry weight 30 Kg 39 kg 41 kg
Remote-con-
trol device
Control head Single control lever
Cable "MORSE" 33C (equivalent)
Applicable engine model (Fuel
stop power at crankshaft)
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)
4JH3-TCE
(55.2kW/3800min-1)

8
3. Selecting Lubricating Oil
EN
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
Use only oil of quality “GL-4" or "GL-5" in
the API service, and SAE No. 90 or
80W90.
(Except model SD20 x 1GM10C and
SD50/-4T)
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/-4T
Use "Quicksilver High Performance Gear
Lube" for the SD50/-4T.
This lube oil is available through all Mer-
Cruiser, Mercury, Mariner and Force out-
lets in their Quicksilver accessories
program.
Engine series GM, YM JH3, JH4
Engine model 1GM10C 2YM15 3YM20 3YM30 3JH4E 4JH4E 4JH3-TCE
Sail-drive model SD20 SD50 SD50 SD50-4T
Lubrication oil for
the sail-drive
API CC or
greater and
SAE 10W30
API GL4 or GL5 and SAE
80W90 or 90
API GL4 or GL5 and SAE
80W90 or 90 or Quicksil-
ver High Performance Gear
Lube
Quicksilver
High Perfor-
mance Gear
Lube
Supplier Brand Name API Service SAE No.
SHELL Shell Spilax oil EP 90 GL-4 90
SHELL Shell Spilax oil HD 90 GL-5 90
CALTEX Multipurpose thuban EP GL-4/GL-59 90
MOBIL Mobilub HD 80W-90 GL-5 80W-90
ESSO Esso gear oil GP 90 GL-4 90
ESSO Esso gear oil GX 90 GL-5 90

3. Selecting Lubricating Oil
9
EN
This High Performance Gear Lube is avail-
able in the following sizes:
3.3 Lube oil viscosity
The viscosity of the lube oil greatly influ-
ences Sail-Drive performance
Volume Part number Package
300 ml 92-802851Q1 case of 24 tubes
1 L 92-802854Q1 case of 12 plastic
bottles
10 L 92-802856Q1 case of 2 cans
60.5 L 92-802857Q1 single drum
208 L 92-802858Q1 single drum

10
4. Starting the New Sail-Drive for the First Time
EN
4. Starting the New Sail-Drive for the First Time
4.1 Filling with lubricating oil
4.1.1 SD20 and SD50/-4T
(1) Remove the dipstick (yellow cap)
and supply approved lube oil.
(2) Check the amount of lube oil by in-
serting the dipstick as far as possi-
ble. Do not screw the dipstick in.
(see the illustration below). The oil
level should reach the upper mark
on the dipstick.
Since it takes about 10 minutes to fill up
the Sail-Drive with lube oil, owing to its
construction, check the supplied oil
quantity again by using the dipstick 15
minutes after completion of supply of
the specified quantity of oil.
Sail-Drive Model:SD20 & SD50/-4T
Lube oil capacity:
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.
CAUTION
Sail-drive
model
SD20 SD50/-4T
Standard unit 2.2 L 2.2 L
Long-reach
unit
2.5 L 2.35 L (Extension 58)
2.45 L (Extension 100)
CAUTION
A Dipstick D Oil level
B Upper limit E Oil supply port
C Lower limit F Oil capacity nameplate
A
B
C
D
E
F
F
E
SD20 SD50/SD50-4T
003443-00E
A
B
C
D

4. Starting the New Sail-Drive for the First Time
11
EN
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).
(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.
The rubber seal alarm lamp warns of
seawater entering the boat. The water-
tight 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 dia-
phragms (A) and (B) works the warning
buzzer and lights the rubber seal lamp
on the instrument panel. If this hap-
pens, stop the engine and, under sail,
quickly return to the nearest port for re-
pairs.
All the above alarm signs will continue
until you push the starting button or
turn the key off.
(A-type) (B-Type)
1 Rubber seal (Sail-Drive) 4 LO press 7 Push button
2 CW temp 5 Key switch 8 Tachometer
3 Charge 6 Warning Buzzer 9 Check switch
OFF ON
1
233
6
7
44
5976
5
2
1
8
WARNING
A ON (Rubber seal lamp)
BBuzzer
C Rubber seal switch
D Diaphragm (B)
E Diaphragm (A)
F Seawater
CAUTION
A
B
C
D
E
F
003446-00E

12
4. Starting the New Sail-Drive for the First Time
EN
4.3 Remote-Control Device Check
4.3.0.1 SD20
While cranking the engine slowly, shift the
control handle of the remote-control head
(single lever control) rapidly through Neu-
tral - Ahead - Neutral - Astern. If a shift op-
eration is done slowly, the tip of the clutch
dog is worn away by being hammered,
and, consequently, the clutch fails to en-
gage. 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.
New type: Serial No. 2129 and after for SD20 Old type: Serial No. 0001-2128 for SD10
A Control handle L Ahead stopper
B Astern M Neutral position
C Neutral N Astern stopper
D Ahead O Cable clamp
E Operation lever P Remote control cable
F Cable clamp Q Spring joint
G Remote control cable R Operation lever
HPivot SAstern
I Astern T Neutral
J Neutral U Ahead
K Ahead
D
A
D
F
O
E
G
P
Q
H
New type :
Serial No. 2129 and after for SD20
Old type :
Serial No. 0001-2128 for SD10
B
C
STU
N
R
M
L
I
J
K
003447-00E

4. Starting the New Sail-Drive for the First Time
13
EN
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 en-
gine.
Because of the rubbing produced at the
frictional face of the cone clutch, grip-
ping action is lessened with use and
periodic inspection and maintenance is
necessary.
CAUTION
A When attaching the cable mounting plate at a 90º
angle handle
B Operation lever
C Cable clamp
D Remote control cable
E Propeller shaft clockwise
FPivot
G Neutral
H Propeller shaft counter-clockwise
B
C
G
EFH
A
003448-00E
D

14
4. Starting the New Sail-Drive for the First Time
EN
4.4 Fitting for Fixed Propeller (2-blade)
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 crank-
shaft V-pulley clamp nut with a wrench to
stop the rotation.
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, bear-
ing, and gears of the sail-drive are sure-
ly damaged.
4.5 Recommended Propeller Size (Max.)
Precautions on matching of the propel-
ler
(1) Be sure to confirm a matching of
the propeller in a sea trial.
(2) Execute a propeller matching on
the basis of the propeller shaft rat-
ed output (continuous rating at pro-
peller shaft). 95% of the engine
rated output (continuous rating at
crankshaft) becomes the propeller
shaft rated output (continuous rat-
ing at propeller shaft).
A Spacer
BGrease
C Washer
D Propeller
E Nut Tightening torque 60-70 Nm (M16,
SD20)
80-100 Nm (M20, SD50/-4T)
F Bolt M8x75mm
Tightening torque11-15 Nm
AC
D
E
F
B
003449-00E
CAUTION
Engine model Sail-Drive Model Folding type Dia. mm
(inch)
2-blade, fixed type-
Dia. mm (inch)
1GM10C SD20 355 (14) 380 (15)
2YM15 368 (14.5) 380 (15)
3YM20 380 (15) 405 (16)
3YM30 405 (16) 420 (16.5)
3JH4E SD50 457 (18) 457 (18)
4JH4E 457 (18) 457 (18)
4JH3-TCE SD50-4T 457 (18) 457 (18)
CAUTION

4. Starting the New Sail-Drive for the First Time
15
EN
Note: The propeller shaft output becomes
95% of the engine rated output (continuous
rating at crankshaft) in consideration of me-
chanical 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 (Con-
tinuous rating at propeller shaft)
becomes the best propeller match-
ing. Note about sea margin: In actu-
al navigation, there is an increase
in resistance due to the waves,
wind and fouling of the hull and,
moreover, a drop in the efficiency
due to fouling of the propeller. Con-
sequently, in the case of propeller
calculation, it is necessary to allow
the engine output to have some
margin. For that reason, it is neces-
sary to add the sea margin of 5%, at
minimum.

16
5. Method of Operation
EN
5. Method of Operation
5.1 Engine Cooling Water
Opening or closing the cooling water sys-
tem 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 dis-
charged.
Note: For other items, refer to the engine opera-
tion 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
5.1.1 SD20
A Atern D Neutral G To C.W. pump
B Neutral E Cock, C.W. H Hose clamp
C Ahead F C.W. hose I Seawater inlet
D
D
A
B
C
EF
G
H
I
003442-00E

5. Method of Operation
17
EN
5.1.2 SD50/SD50-4T
A Open C Cock C.W. E Neutral
B To C.W. pump D Propeller shaft Clockwise F Propeller shaft Counter-clockwise
D
F
E
40
40
C
B
A
003450-00E

18
6. Periodic Inspections and Maintenance
EN
6. Periodic Inspections and Maintenance
Every day 50 hrs. or after
1 month Every 100 hrs. Every 250 hrs. Every 1 year Every 2 years
Lubricating Oil
(1) Check oil level: fill
(2) Change lube oil
Before opera-
tion
O
First
O
SD20
O
SD50/-4T
O
Cooling Water
(1) Open/close cooling wa-
ter cock
(2) Clean cooling water suc-
tion hole
(3) Drain cooling water
Before/after
operation
O
After opera-
tion
O
O
Remote Control System
(1) Inspect remote control
device
(2) Inspect and replace
clutch shifter
First
OO
Replace if the
thickness is
less than 10
mm.
O
Serial No.
2129 and
after for
SD20
Anti-Corrosive Zinc
(1) Inspect and replace an-
ti-corrosive zinc
Replace if
wear is
more than
50%
O
Lower Case
(1) Repair case coating O
Boat Bottom Water- tightness
(1) Inspect and replace rub-
ber diaphragm seal ring
(2) Inspect seal sensor O
Inspect and
replace, if
there is
cracking
O
Flexible mount
(1) Inspect and replace
mounting height.
Replace if
clearance is
less than 1 mm.
O
A: Clearance
A
003451-00E

6. Periodic Inspections and Maintenance
19
EN
6.1 Lubricating oil system
6.1.1 SD20
(1) Check the oil level before every op-
eration.
(2) Change the oil after the first 50
hours of operation or after long
storage and every 100 hours of op-
eration 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.
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.
WARNING
SD20
A Dipstick
B Upper gear case
C Lower gear case
D Lube oil drain plug
A
B
C
D
003440-00E