Yanmar SD25 User manual

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English
SAIL-DRIVE
OPERATION MANUAL
SD25

MODEL
OPERATION MANUAL CODE
All Rights Reserved, Copyright
SD25
0ASDM-EN0030
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 the right to make any change at any time without notice.
Yanmar and are 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 CO., LTD.

SD25 Operation Manual i
TABLE OF
CONTENTS
Page
Introduction..................................................................... 1
Safety............................................................................... 3
Safety Precautions ..................................................... 4
General Information ............................................. 4
Before You Operate............................................. 4
During Operation and Maintenance..................... 5
Product Overview ........................................................... 9
Overview .................................................................... 9
Owner/Operator Responsibilities ......................... 9
New Sail-Drive Break-In: ..................................... 9
Dealer/Distributor Responsibilities....................... 9
Component Identification ......................................... 10
Galvanic Corrosion................................................... 11
Corrosion Control .................................................... 11
Shore Power ............................................................ 12
Underwater Drive Coating........................................ 13
Before You Operate...................................................... 15
Propeller Selection ................................................... 16
Recommended Propeller Size (Maximum) ........ 16
Fitting a Fixed Propeller (2-Blade) ..................... 17
Lubricating Oil .......................................................... 18
Lubricating Oil Chart.......................................... 18
For SD25 (Except if coupled with the 1GM10C) .. 18
Filling with Lubricating Oil ........................................ 19
Checking The Instrument Panel Alarm System ....... 20
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TABLE OF CONTENTS
ii SD25 Operation Manual
Daily Checks............................................................. 22
Visual Checks .................................................... 22
Sail-Drive Operation...................................................... 23
Remote Control Device Check ................................. 24
Engine Cooling Water............................................... 26
Periodic Maintenance .................................................. 27
Tightening Fasteners................................................ 28
Torque Charts........................................................... 28
Standard Torque Values .................................... 28
Standard Torque Chart ...................................... 28
Periodic Maintenance......................................... 29
Periodic Maintenance Table ..................................... 30
When the Vessel is Out of the Water,
Perform the Following:.............................................. 31
Removing Deposits from the Lower Gear Case... 31
Repairing Damaged Coating.............................. 31
Inspecting the Anode ......................................... 31
Inspecting the Folding Propeller......................... 31
Draining Water ................................................... 31
Periodic Maintenance Procedures............................ 32
After Initial 50 Hours of Operation...................... 32
Every 100 Hours of Operation............................ 33
Every 250 Hours of Operation............................ 34
Every Year ......................................................... 34
Every 2000 Hours of Operation.......................... 35
Every 5 Years..................................................... 36
Specifications................................................................ 37
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SD25 Operation Manual 1
INTRODUCTION
This Operation Manual describes Sail-Drive Model SD25. For engine handling and
operation, refer to the respective operation manuals for Engine Models 1GM10C, 2YM15,
3YM20, 3YM30 and 3YM30AE.
However, instructions for the marine gear box are not necessary as they are included.
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INTRODUCTION
2SD25 Operation Manual
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SD25 Operation Manual 3
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.
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.
A
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.
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SAFETY
4SD25 Operation Manual
SAFETY PRECAUTIONS
General Information
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.
Before You Operate
DANGER
• Never permit anyone to
install or operate the
Sail-Drive 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.
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SAFETY
SD25 Operation Manual 5
12/05
During Operation and
Maintenance
DANGER
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.
WARNING
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.
• 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.
Alcohol and Drug Hazard
Never operate the engine
while under the influence
of alcohol or drugs or
when feeling ill.
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SAFETY
6SD25 Operation Manual
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.
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
Sail-Drive 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.
WARNING
Exhaust Hazard
• 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.
• 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.
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.
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SAFETY
SD25 Operation Manual 7
12/05
CAUTION
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. Always install wire cages
on portable safety lamps.
To o l H a z a rd
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.
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.
NOTICE
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.
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.
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.
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SAFETY
8SD25 Operation Manual
NOTICE
If the Sail-Drive oil temperature is too high,
stop engine immediately and check the
Sail-Drive oil level.
The anode of the Sail-Drive is only
calculated for the Sail-Drive. Using the
different material propeller may require
additional anodes to be installed on the
propeller itself.
Failure to use the correct anode material
may result in inadequate protection and
excessive corrosion of underwater drive
system components. Use only aluminum
anodes in brackish and saltwater
applications. In freshwater applications,
use aluminum or magnesium anodes for
best results. Never use magnesium
anodes in brackish or salt water, as they
will deteriorate rapidly, which will lead to
severe damage to the drive system.
Always tighten components to the
specified torque. Loose parts can cause
equipment damage or cause it to operate
improperly.
Only use replacement parts specified.
Other replacement parts may affect
warranty coverage.
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.
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SD25 Operation Manual 9
PRODUCT
OVERVIEW
OVERVIEW
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 your
Sail-Drive.
New Sail-Drive Break-In:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
Sail-Drive function and Sail-Drive oil
leaks.
• During the break-in period, carefully
observe Sail-Drive seal indicators for
proper Sail-Drive function.
• During the break-in period, check the
Sail-Drive 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
on-board equipment.
• Explain and demonstrate the operation
of the Sail-Drive and vessel.
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PRODUCT OVERVIEW
10 SD25 Operation Manual
COMPONENT IDENTIFICATION
1 – Dipstick
2 – Upper gear case
3 – Lower gear case
4 – Lubricating oil drain plug
5 – Propeller
6 – Seawater inlet
7 – Flexible mount
Figure 1
1
2
3
4
K0006440
5
6
7
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PRODUCT OVERVIEW
SD25 Operation Manual 11
12/05
GALVANIC CORROSION
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 Sail-Drive components.
CORROSION CONTROL
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 and isolation transformers are
also available from the aftermarket (not
supplied by Yanmar). The Galvanic
isolator is a device that is installed in series
with the (AC) grounding (GREEN)
conductor of the shore-power cable to
effectively block low-voltage DC galvanic
current flow but permit the passage of
alternating current (AC)*.
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.
* “The Boatowner’s Guide to Corrosion”, by Everett Collier.
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PRODUCT OVERVIEW
12 SD25 Operation Manual
NOTICE
The anode of the Sail-Drive is only
calculated for the Sail-Drive. Changing the
material of the propeller may require
additional anodes to be installed on the
Sail-Drive.
NOTICE
Failure to use the correct anode material
may result in inadequate protection and
excessive corrosion of underwater drive
system components. Use only aluminum
anodes in brackish and saltwater
applications. In freshwater applications,
use aluminum or magnesium anodes for
best results. Never use magnesium
anodes in brackish or salt water, as they
will deteriorate rapidly, which will lead to
severe damage to the drive system.
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.
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.
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PRODUCT OVERVIEW
SD25 Operation Manual 13
12/05
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
bottom 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.
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PRODUCT OVERVIEW
14 SD25 Operation Manual
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SD25 Operation Manual 15
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.
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BEFORE YOU OPERATE
16 SD25 Operation Manual
PROPELLER SELECTION
Recommended Propeller Size (Maximum)
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.
Engine model Folding type diameter 2-Blade fixed type diameter
1GM10C 14 in. 14 in.
2YM15 14.5 in. 15 in.
3YM20 15 in. 16 in.
3YM30 16 in. 16.5 in.
3YM30AE 16 in. 16.5 in.
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