Yanmar SD20 User manual

SAIL-
DRIVE
Sail-Drive
OPERATION MANUAL
SD20
SD50
SD50-4T
P/N: 0ASDM-G00101

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 Marine International.
© 2009 Yanmar Marine International
0309
ii SD Operation Manual
© 2009 Yanmar Marine International

TABLE OF
CONTENTS
Page
Introduction......................................................................1
Safety...............................................................................3
Safety Precautions.........................................................3
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
Filling With Lubricating Oil - SD20, SD50 and SD50-4T.........19
Checking the Instrument Panel Alarm System.....................20
Daily Checks...............................................................23
Visual Checks....................................................... 23
Sail-Drive Operation.........................................................25
Remote Control Device Check........................................26
SD20 .................................................................. 26
SD50 / SD50-4T.................................................... 28
Engine Cooling Water...................................................29
SD20 .................................................................. 29
SD Operation Manual iii
© 2009 Yanmar Marine International

SD50 / SD50-4T.................................................... 30
Periodic Maintenance.......................................................31
Tightening Fasteners....................................................33
Torque Charts.............................................................34
Standard Torque Values ......................................... 34
Standard Torque Chart ........................................... 34
Periodic Maintenance............................................. 35
Periodic Maintenance Table...........................................36
When The Vessel Is Out Of The Water, Perform The
Following:...................................................................38
Removing Deposits From The Lower Gear Case .......... 38
Repairing Damaged Coating .................................... 38
Inspecting the Anode.............................................. 38
Inspecting The Folding Propeller............................... 38
Draining Water...................................................... 38
Periodic Maintenance Procedures....................................39
After Initial 50 Hours of Operation.............................. 39
Every 100 Hours of Operation .................................. 48
Every 250 Hours of Operation .................................. 49
Every 500 Hours of Operation .................................. 49
Every Year ........................................................... 50
Every 2000 Hours of Operation................................. 51
Every 5 Years ....................................................... 51
Specifications..................................................................53
System Diagrams.............................................................55
Maintenance Log.........................................................80
TABLE OF CONTENTS
iv SD Operation Manual
© 2009 Yanmar Marine International

INTRODUCTION
This 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, 3JH4CE, 3JH5CE, 4JH4ACE, 4JH5CE and 4JH4-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 Sail-Drive Model
1GM10C
SD202YM15
3YM20, 3YM30
3JH4CE
SD50
3JH5CE
4JH4ACE
4JH5CE
4JH4-TCE SD50-4T
SD Operation Manual 1
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INTRODUCTION
2 SD Operation Manual
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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 3
© 2009 Yanmar Marine International

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
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 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 Sail-Drive with equipment
not designed to support the weight of the
Sail-Drive 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.
SAFETY
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© 2009 Yanmar Marine International

During Operation and
Maintenance
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.
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.
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.
SAFETY
SD Operation Manual 5
© 2009 Yanmar Marine International

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.
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.
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
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.
SAFETY
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© 2009 Yanmar Marine International

NOTICE
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.
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.
If the Sail-Drive oil temperature is too high,
stop engine immediately and check the Sail-
Drive oil level and check the oil cooler for
proper coolant and water flow.
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.
Failure to use the correct anode material
may result in inadequate protection and
excessive corrosion of underwater drive
system components. Use only zinc or
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.
SAFETY
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SAFETY
8 SD Operation Manual
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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.
SD Operation Manual 9
© 2009 Yanmar Marine International

COMPONENT IDENTIFICATION
(1)
(2)
(3)
(4)
0006440
(5)
(6)
(7)
Figure 1
1 – Dipstick
2 – Upper Gear Case
3 – Lower Gear Case
4 – Lubricating Oil Drain Plug
5 – Propeller
6 – Seawater Inlet
7 – Flexible Mount
PRODUCT OVERVIEW
10 SD Operation Manual
© 2009 Yanmar Marine International

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.
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.
* “The Boatowner's Guide to Corrosion”, by Everett Collier.
PRODUCT OVERVIEW
SD Operation Manual 11
© 2009 Yanmar Marine International

NOTICE: Failure to use the correct anode
material may result in inadequate protection
and excessive corrosion of underwater drive
system components. Use only zinc or
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.
PRODUCT OVERVIEW
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© 2009 Yanmar Marine International

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.
PRODUCT OVERVIEW
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PRODUCT OVERVIEW
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© 2009 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 15
© 2009 Yanmar Marine International

PROPELLER SELECTION
Recommended Propeller Size (Maximum)
Engine Model Sail-Drive Model Folding Type
Diameter
2-Blade Fixed Type
Diameter
1GM10C
SD20
14 in. 14 in.
2YM15 14.5 in. 15 in.
3YM20 15 in. 16 in.
3YM30 16 in. 16.5 in.
3JH4CE
SD50 18 in. 18 in.
3JH5CE
4JH4ACE
4JH5CE
4JH4–TCE SD50-4T 18 in. 18 in.
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.
BEFORE YOU OPERATE
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© 2009 Yanmar Marine International