Yanmar SD60 User manual

English
en English
OPERATION
MANUAL
SAIL-DRIVE
SD60

MODEL
OPERATION MANUAL CODE
SD60
0ASDM-EN0022
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.
Please review and comply with the applicable laws and regulations of the interna-
tional export control regimes at the territory or country where the product and
manual are intended to be imported and used.
All Rights Reserved, Copyright YANMAR CO., LTD.

SD60 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
Galvanic Corrosion................................................... 10
Corrosion Control .................................................... 10
Electrical Connections and Regulations
According to International Rules
ISO 60092-507 IEC:2008 .................................. 11
Shore Power ............................................................ 11
Painting the Boat...................................................... 12
Check Under-Water Metallic Parts .......................... 12
Gear Identification .................................................... 13
Before You Operate...................................................... 15
Lubricating Oil .......................................................... 16
SD60_OPM.book i ページ ２０１７年１２月８日 金曜日 午後３時６分

TABLE OF CONTENTS
ii SD60 Operation Manual
Sail-Drive Operation...................................................... 17
Operation.................................................................. 18
Boat Sailing, Moving in Tow or Anchoring ......... 18
Direction of Rotation........................................... 19
Gear Shift Operation .......................................... 20
Periodic Maintenance .................................................. 21
Maintenance ............................................................. 22
Routine Maintenance ......................................... 22
Scheduled Maintenance..................................... 22
Maintenance Procedures.......................................... 23
Oil Level Check .................................................. 23
Oil Change ......................................................... 24
Removing Propeller............................................ 27
Installing Propeller.............................................. 28
Corrosion Protection .......................................... 30
Anode Replacement........................................... 31
Electric Installation ....................................................... 33
Troubleshooting............................................................ 35
Specifications................................................................ 37
SD60_OPM.book ii ページ ２０１７年１２月８日 金曜日 午後３時６分

SD60 Operation Manual 1
INTRODUCTION
This Operation Manual describes
Sail-Drive Models SD60. For engine
handling and operation, refer to the
respective Operation Manuals for Engine
Models JH series in the below table.
However, instructions for the marine gear
box are not necessary as they are
included.
Engine Model Sail Drive Model
3JH5E
SD60-5
3JH5AE
4JH5E
3JH40
4JH45
4JH57
4JH4-TE SD60-4
4JH80
SD60_OPM.book 1 ページ ２０１７年１２月８日 金曜日 午後３時６分

INTRODUCTION
2SD60 Operation Manual
This Page Intentionally Left Blank
SD60_OPM.book 2 ページ ２０１７年１２月８日 金曜日 午後３時６分

SD60 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.
SD60_OPM.book 3 ページ ２０１７年１２月８日 金曜日 午後３時６分

SAFETY
4SD60 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.
SD60_OPM.book 4 ページ ２０１７年１２月８日 金曜日 午後３時６分

SAFETY
SD60 Operation Manual 5
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.
SD60_OPM.book 5 ページ ２０１７年１２月８日 金曜日 午後３時６分

SAFETY
6SD60 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.
SD60_OPM.book 6 ページ ２０１７年１２月８日 金曜日 午後３時６分

SAFETY
SD60 Operation Manual 7
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 r d
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.
SD60_OPM.book 7 ページ ２０１７年１２月８日 金曜日 午後３時６分

SAFETY
8SD60 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 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.
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.
SD60_OPM.book 8 ページ ２０１７年１２月８日 金曜日 午後３時６分

SD60 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.
SD60_OPM.book 9 ページ ２０１７年１２月８日 金曜日 午後３時６分

PRODUCT OVERVIEW
10 SD60 Operation Manual
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.
SD60_OPM.book 10 ページ ２０１７年１２月８日 金曜日 午後３時６分

PRODUCT OVERVIEW
SD60 Operation Manual 11
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.
Electrical Connections and
Regulations According to
International Rules ISO
60092-507 IEC:2008
It is recommended to perform the boat
electric system in conformity with the
regulation ISO 60092-507 IEC 2008, or
equal local and international rules or laws.
To protect the boat from galvanic current
when it is connected to the power source
located on the dry land (wharf), it is
recommended to install on the boat a
galvanic isolator on the ground conductor
of the AC power line.
This will prevent the flow of galvanic
current with low voltage but will allow a
normal supply.
For more information about or to find
different solutions of the power system
from the dry land, refer to the instructions
of ABYC (American Boat and Yacht
Council) in chapter E-11 or ISO 60092-507
IEC 2008.
At the same purpose can also be used an
isolating transformer with the relevant
characteristics of the circuit. Even in this
case, refer to the applicable ABYC E-11 or
ISO 60092-507 IEC 2008 for more
information and suggestions.
Note: We advise you to install an isolating
transformer for the electrical power
supply from pier.
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.
SD60_OPM.book 11 ページ ２０１７年１２月８日 金曜日 午後３時６分

PRODUCT OVERVIEW
12 SD60 Operation Manual
PAINTING THE BOAT
When painting the boat hull with
anti-fouling paint, observe the following
rules:
• Use high-quality, anti-fouling paint
designed for marine use.
• Avoid using anti-fouling paint that
contains copper material, which could
conduct electrical current.
• Avoid using anti-fouling paint that
contains copper material on the
sail-drive foot in any case.
• If using copper-based or tin-based paints
is necessary, ensure that they comply
with all local and federal laws prohibiting
their use.
• Do not paint drain holes or items as
specified by the boat manufacturer.
• Do not paint any anodes.
CHECK UNDER-WATER
METALLIC PARTS
Check the status of corrosion protection
(boat dry) of the lower part of the hull
before that the boat enters in the water.
Make sure all metallic parts over-hanging
from the hull underneath the seawater line
have to have the same potential.
Contact your local Yanmar dealer for
advice.
This way will assure:
• All metallic parts will have same potential
and will avoid having current/tension
circulation when the boat is in the water.
This create corrosion.
• All metallic parts are properly connected
to the ground of the boat and they are,
therefore, having the same potential.
SD60_OPM.book 12 ページ ２０１７年１２月８日 金曜日 午後３時６分

PRODUCT OVERVIEW
SD60 Operation Manual 13
GEAR IDENTIFICATION
Name Plate:
The name plate is fixed onto the sail drive
A – Sail drive type
B – Sail drive ratio
C – Sail drive serial number
D – Sail drive part number
E – Lubricating oil specifications
Figure 1
/1&'.
20
/#&'+0'7
)'#44#6+1
/()01
1+.6;2'
#
$
%
&
'
053143-00X00
SD60_OPM.book 13 ページ ２０１７年１２月８日 金曜日 午後３時６分

PRODUCT OVERVIEW
14 SD60 Operation Manual
This Page Intentionally Left Blank
SD60_OPM.book 14 ページ ２０１７年１２月８日 金曜日 午後３時６分

SD60 Operation Manual 15
BEFORE YOU
OPERATE
This section of the Operation Manual
describes lubricating oil specifications and
how to replenish them.
Before you operate the Sail-Drive, review
the Safety section on page 3.
SD60_OPM.book 15 ページ ２０１７年１２月８日 金曜日 午後３時６分

BEFORE YOU OPERATE
16 SD60 Operation Manual
LUBRICATING OIL
The selection of lubricating oil is very important. If an inappropriate oil is used, or an oil
change is neglected, it may result in damage and reduce the life of the Sail-Drive. When
selecting a lubricating oil, use one of the following:
1. Lubricating oil type: API Service Categories CD or higher, SAE Viscosity 15W-40
2. Lubricating oil quantity: Figure 1
3. Loosen dipstick (1, Figure 1) by turning the grip counterclockwise.
4. Wipe dipstick with a clean and dustfree cloth.
5. Insert dipstick do not screw. Remove dipstick and check lubricating oil level:
Lubricating oil level has to be between minimum and maximum marks on the dipstick.
6. Check O-ring (2, Figure 1) for damage, replace if necessary.
7. Insert the dipstick and lock it by turning the grip clockwise.
Figure 1
Quantity (l)
Standard (S) 2.8
with extension (L) 3
1–Dipstick 2–O-ring
Housing surface
Oil level max. Dipstick
1
2
Oil level min.
050440-00EN01
SD60_OPM.book 16 ページ ２０１７年１２月８日 金曜日 午後３時６分