Yanmar Sd20 Saildrive Operations

Engine Model1GM10C 2YM15 3YM20 3YM30 3JH4E 4JH4E 4JH3TCEAll rights reserved This manual may not be reproduced or copied in whole or in part without the written permission of YANMAR CO LTDCopyright 2004 Yanmar CO LTD2 Introduction 31For Your Safety 411Safety Precautions For Inspection 73Selecting Lubricating Oi831Choice of lube oil 832Kind of lube oil 833Lube oil viscosity 94Starting the New SailDrive for the First Time 1041Filling with lubricating oil 10411SD20 and SD504T 1042Check of instrument panel alarm system Device Check 1244Fitting for Fixed Propeller Propeller Size Max5Method of Operation 1651Engine Cooling Water 16511SD20 176Periodic Inspections and Maintenance oil system 19611SD20 19612SD504T 2062Procedure for filling and removing oil in the SailDrive SD504T 21621When the boat is in the water 22622When the boat is out of the water zinc 29631SD20 and SD50 SD504T 2964Rubber diaphragms Aand BSD20 and SD504T2965When the boat hull is raised onto a block inspect the following 307Electrical Wiring Diagrams 31This Installation and Operation Manual describes SailDrive Models SD20 SD50 For engine handling and operation refer to the respective operation manuals for Engine Models 1GM10C 2YM15 3YM20 3YM30 3JH4E 4JH4E and 4JH3TCE However instructions for the marine gear box are not necessary as they are and saildrive combinations are available as followsEngine modelSaildrive Your Safety1 For Your Safety11 Safety Precautions For smoke or permit sparks near the battery because it may emit explosive hydrogen gas Place the battery in a wellventilated placeFuelUse 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 tankDo not use starting fluids or sprays Their use may cause explosion serious injury and engine damageFire PreventionBe 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 waterNever place oil or other flammable material in the engine roomInstall a fire extinguisher near the engine room and familiarize yourself with its useExhaust GasExhaust gas contains poisonous carbon monoxide and should not be inhaledBe sure to install ventilation ports or ventilators in the engine room and ensure good ventilation during engine PartsDo not touch or let your clothing get caught in the moving parts of the engine such as the front drive shaft Vbelt or propeller shaft during engine operation You will be injuredNever operate the engine without covers on the moving Your SafetyThe whole engine is hot during operation and immediately after shutdown The exhaust manifold exhaust pipe and high pressure fuel lines are very hot Never touch these parts with your body or clothingNever operate the engine while you are under the influence of alcoholNever operate the engine when you are ill or not feeling wellBattery FluidBattery 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 bodyIf you touch it wash it off immediately with a large quantity of fresh water and call your doctor for treatmentFire by Electric turn off the battery switch before inspecting the electrical systemFailure to do so could cause and firesStop the engine before you service itTurn 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 partsWhen extracting oil from the engine while it is still hot dont let the oil splash on youWait until the temperature has dropped before extracting cooling water from the engine Dont let it splash on youRR1For Your release the limiting devices such as the engine speed limit fuel injection limit will impair the safety athe product and shorten product lifeAlso note that any troubles arising from modification are not covered by our for Treating WasteNever dispose of waste oil or other fluid in a field sewer river or the Treat waste matters safely observing regulations or lawsAsk a waste recovery company to collect A propeller with rubber bushing must be used in all SD series gear systemConstant mesh gear with dog clutch useCone of Input viewed from sternPropeller viewed or clockwise viewed from sternReduction speed systemOil bath oil unit22 L22 L25 L235 L Extension 58Extension Dry weight30 Kg39 kg41 kg headSingle control 33C engine model Fuel stop power at 67kW3600 min12YM15 103kW3600 min13YM20 162kW3600 min13YM30 221kW3600 Lubricating OilThe choice of lube oil is very important to a SailDrive If an unsuitable oil is used or oil change is neglectedamage and a shorter SailDrive life When selecting the lube oil it must be one of the followingUse only oil of quality GL4 or GL5 in the API service and SAE No 90 or 80W90Except model SD20 x 1GM10C and SD504TUse only oil of quality cc or greater in the API service and SAE no model SD20 x 1GM10CFor SD20 except if coupled with the 1GM10C and SD504TUse Quicksilver High Performance Gear Lube for the SD504TThis lube oil is available through all MerCruiser Mercury Mariner and Force outlets in their Quicksilver accessories programEngine seriesGM YMJH3 JH4Engine oil for the saildriveAPI CC or greater and API GL4 or GL5 and SAE API GL4 or GL5 and SAE 80W90 or 90 or Quicksilver High Performance Gear Quicksilver mance Gear SupplierBrand NameAPI ServiceSAE NoSHELLShell Spilax oil EP Spilax oil HD thuban HD gear oil GP gear oil GX Lubricating OilThis High Performance Gear Lube is available in the following sizes33 Lube oil viscosityThe viscosity of the lube oil greatly influences SailDrive of 24 tubes1 of 12 plastic 10 of 2 cans605 drum208 the New SailDrive for the First Time4 Starting the New SailDrive for the First Time411 SD20 and SD504T1Remove the dipstick yellow capand supply approved lube oil2Check 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 dipstickSince it takes about 10 minutes to fill up the SailDrive 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 oilSailDrive ModelSD20 SD504TLube oil capacityThe lube oil capacity of the standard unit is different from that of the longreach unit Confirm the capacity by means of the oil capacity unit22 L22 L25 L235 L Extension 58245 L Extension levelBUpper limitEOil supply portCLower limitFOil capacity the New SailDrive for the First Time panel alarm systemTurn on the battery switch Then the key in the ON position and check the lamps on the panel with the engine off1Lube oil warning lamp should be lit 2Cooling water temperature warning lamp should be out For small type panel Atype only For the large type panel Btype raise the CHECK switch ON to see if the cooling water temperature warning 3Charging warning lamp should be 4Rubber seal lamp should be out 5The warning buzzer should soundThe rubber seal alarm lamp warns of seawater entering the boat The watertight structure of the SailDrive is the dual type Even if the rubber diaphragm A is damaged and seawater enters the rubber diaphragm Bvents 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 on the instrument panel If this happens stop the engine and under sail quickly return to the nearest port for repairsAll the above alarm signs will continue until you push the starting button or turn the key seal SailDrive4LO press7Push button2CW temp5Key Buzzer9Check switchAON Rubber seal seal BEDiaphragm the New SailDrive for the First Time43 RemoteControl Device Check 4301 SD20While cranking the engine slowly shift the control handle of the remotecontrol head single lever controlpidly through Neutral Ahead Neutral Astern If a shift operation is done slowly the tip of the clutch dog is worn away by being hammered and consequently the clutch fails to engage Confirm that the operation lever of the SailDrive moves smoothly to Ahead Astern and Stopper Because the SailDrive SD20 uses a dog clutch the clutch is not engaged unless the operation lever is moved to the stopper positionNew type Serial No 2129 and after for SD20Old type Serial No 00012128 for SD10AControl handleLAhead leverPRemote control cableFCable clampQSpring jointGRemote control the New SailDrive for the First Time4302 SD50 SD504TAfter starting the engine check the shift action by using the control head to shift the Ahead and Astern positions The AheadAstern 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 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 necessaryAWhen attaching the cable mounting plate at a 90 BOperation leverCCable clampDRemote control shaft shaft the New SailDrive for the First TimePropeller 2bladeLocking Procedure for Fixed Propeller Nut Optionalen tightening the nut at 6070 Nm torque for the SD20 and 80100 Nm torque for the SD504T move the shift lever to ahead and hold the crankshaft Vpulley clamp nut with a wrench to stop the rotationRubber bushing Folding propellerFor the saildrive 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 saildrive are surely damagedller Size MaxPrecautions on matching of the propel1Be sure to confirm a matching of the propeller in a sea trial2Execute 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 the propeller shaft rated output continuous rating at propeller Tightening torque 6070 Nm M16 SD20 80100 Nm M20 SD504TFBolt torque1115 NmEngine modelSailDrive ModelFolding type Dia mm inch2blade fixed typeDia mm 14380 152YM15368 145380 153YM20380 15405 163YM30405 16420 18457 184JH4E457 18457 18457 184Starting the New SailDrive for the First TimeNote The propeller shaft output becomes 95 of the engine rated output continuous rating at crankshaft in consideration of mechanical efficiency 95 of the saildrive3In 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 of Operation51 Engine Cooling Water Opening or closing the cooling water system of the SailDrive Set Engine is done by the cooling water cock fixed on the upper case of the SailDrive Be sure to open the cock and confirm that the CW has suction by cranking the engine before starting the boat The cooling water passes through the SailDrive case cools the engine by the cooling water pump and is then discharged Note For other items refer to the engine operation manualNote When sailing set the remote control lever in neutral Old type Serial No00012128 for Model SD20 Serial No2129 and after for Model SD20511 CW CWHHose clampCAheadFCW hoseISeawater inletR5Method of Operation512 CWENeutralBTo CW pumpDPropeller shaft shaft Inspections and Maintenance6 Periodic Inspections and day50 hrs or after 1 monthEvery 100 hrsEvery 250 Every 1 yearEvery 2 Oil1Check oil level fill2Change lube oilBefore cooling water cock2Clean cooling water suc3Drain cooling operationAfter Control System1Inspect remote control device2Inspect and replace clutch shifterReplace if the thickness is less than 10 mmSerial No 2129 and after for Zinc1Inspect and replace anticorrosive zincReplace if wear is more than 50Lower Case1Repair case coatingBoat Bottom Water and replace rubber diaphragm seal ring2Inspect seal sensorInspect and replace if there is cracking or at least every 6 Flexible mount1Inspect and replace mounting heightReplace if clearance is less than 1 A Inspections and Maintenance61 Lubricating oil system611 SD201Check the oil level before every 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 1Put the boat hull on a blockDrain the oil by removing the lower gear case drain plug and the upper gear case oil dipstickLet 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 gear caseCLower gear caseDLube oil drain Inspections and Maintenance612 SD504T1Check the oil level before every 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 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 plug6Periodic Inspections and Maintenance62 Procedure for filling and removiWhen the boat is 621 in the water and 622t of the waterUsed of Quicksilver High Performance Gear Lube from Part code bottle contains 0946 liter of oil Mandatory for SD504T For other models see page 8Market pump from MerCruiser on Part code 2Thread std M10 x 15 max length 12 Oring for 2Stiff rubber hoses2Inner diclips If Yanmar part is used part code is set1Hand Inspections and Maintenance621 When the boat is in the water 6211 Preparing the saildrive 1Take out the oil changing plug located under the shift lever2Screw in the adapter joint 196311 92960 with the Oring 24311000100 When using own adapter joint max length of thread is 12 mm3Attach a stiff rubber hose with inner diameter 1416 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 Removing oil total quantity 22 liter6213 Fastest way Blowing out by using Air pressure First follow steps 12 3 on page 221Take out the plug from the upper case cover2Screw in a second adapter joint PN 19631192960h an Oring PN 24311000100 the oil inlet position Screw in the oil plug at the dipstick the air pressure hose with hose clips 4Option 1 Using Compressed air from main system or 12 V portable hose at top adapter joint tocompressed air and within 10 to 15minutes almost all oil will be blown out AOringBAdapter jointCOil changing plugDTread M10 x Inspections and MaintenanceUse Compressed Air 051 Barommain system 12 V portable compressor or from portable hand pump or footpumpOption 2 Using Compressed air with help from a portable hand pump or foot pump 1Install a oneway non returnlve in the pressure line connected to the top cover This is done to maintain the pressure during use of the pump 2Connect the hand pump or foot pump with the pressure line to the adapter joint on the top as shown above3With the system now connected pump out the oil until empty The first 09 liter will take approx 3 minutes The second part takes more time as mostly air will be pumped out this will take approx 12 minutes6214 Using Yanmar Pump First follow steps 12 3 on page 22 and step 1 page 22Connect 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 09 liter of oil mostly you will pump out air but continuous pumping is necessary 100200 ml of old oil will remain in the drive unit in this case it is no problem to fillup with the new oil for maintenance The hand pump p28210000080 and rubber hose p19644092970 are available from Yanmar and are optional parts for SD504T Or any type of hand pump or rubber hose Inner diameter 1416 mmavailable from the hardware shop are usableAOneway valveBAdapter joint screwed in coverCSimple foot pumpR6Periodic Inspections and Filling oil total quantity 22 literof filling with lube oil are in addition to the way mentioned in page 10 6216 Fastest way By using MerCruiser pump or simple market pumpFirst follow steps 1 and 2 on page 221Use a MerCruiser pump with Part number 9185729A1 like the one shown above or use a similar pump available on the market 2Screw the pump on a new bottle of Quicksilver High Performance Gear Lube Part number 92850743A1 0946 liter from MerCruiser 3Connect the hose with a hose clip to the adapter joint below the shift 4Take out the plug from the upper case cover5Fill 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 joint6After 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 dont forget the Inspections and By using Yanmar Hand First follow steps 3 and 4 on page 241Connect the hoses as shown above at the top adapter joint to the hand pump by using the rubber hose2Take out the plug from the upper case cover 3Fill 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 28210000080 and rubber hose p 19644092970 are available from Yanmar and are optional parts for SD504T Or any type of hand pump or rubber hose Inner diameter 1416 mm available from the hardware shop are usable4After 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 dont forget the gasket6218 By not using pumpFor the oil filling procedure by not using pump see the explanation on chapter 4 page 10 Inspections and Maintenance622 When the boat is out of the 6221 Preparing the the bottom drain plug2Screw in the adapter joint PN 196311 92960 with the Oring PN 24311 000100When using own adapter joint max length of thread is 12 mm3Attach a stiff rubber hose with inner diameter 1416 mm with hose clips to the adapter joint at the oil drain position The hose must be long enough to drain to bucket4Take out the dipstick and oil inlet plug from the upper case cover6222 Removing oil total quantity 22 liter6223 By draining First follow steps 12 3 4 on page 26Oil drain is possible from this point but will take much time1After approx 06 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 position6224 Fastest way Blowing out by using Air pressure First follow steps 12 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 M10 x 15BOil changing plugR6Periodic Inspections and Filling oil total quantity 22 liter6226 By using MerCruiser pump or simple market pumpFirst follow steps 12 4on page 26 1Use a MerCruiser pump with Part number 9185729A1 like the one shown on p 24 6214 or use a similar pump available on the market2Screw the pump on a new bottle of Quicksilver High Performance Gear Lube Part number 92850743A1 0946 liter from MerCruiser 3Remove the oil changing plug below the shift lever 4Connect the hose with a hose clip to the adapter joint at the drain position 5Take out the plug from the upper case cover 6Fill the oil by pushing the upper part of the pump After the first bottle is empty screw in the oil changing plug dont forget the gasket7Change the bottle while the pump and hose remain connected with the adapter joint8After 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 dont forget the gasket Inspections and By using Yanmar hand pump First follow steps 12 3 4 on page 261Connect the hose from the bottom and a suction hose to Yanmar pump with hose clip like shown above 2Take out the plug from the upper case cover 3Fill oil by pumping it into drive Be aware that oil has to flow up through narrow parts Therefore 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 28210000080d rubber hose p19644092970 are available from Yanmar and are optional parts for SD504T Or any type of hand pump or rubber hose Inner diameter 1416 mm available from the hardware shop are usable4After 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 gasket6228 By not using pumpFor the oil filling procedure by not using pump see the explanation on chapter 4 page Inspections and Maintenance631 SD20 and SD50 SD504TTo prevent corrosion of the sailDrive body by sea lake water replace the anticorrosive zinc at the earliest time of every 100 hours of operation once every six months or when it becomes half of the original volume 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 blockDo not remove the plug including Anticorrosive Zinchile the boat is in the waterThe rubber diaphragms A and Bf the SailDrive are important parts for the hull and crew safety Since rubber degenerates during use be sure to replace them at ASafety labelCUpper gear zincDLower gear caseM10 x 11RR6Periodic Inspections and every six years see the table Periodic Inspections and Maintenance on page 18 Boat hull must be lifted onto a block To replace consult your Yanmar dealer65 When the boat hull is raised ect the deposit from the lower gear caseRemove 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 2Repairing damaged membraneThe 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 3Inspecting anticorrosive zincSince anticorrosive zinc can not be inspected except when the boat hull is raised onto a block be sure not to forget to inspect it4Inspecting the folding whether or not the blade of the folding propeller opens smoothly Also inspect for wear on the bladefixing pins Replace them when wear is excessive Apply seawaterproof grease to the pins blade gear and propeller shaft 5Draining waterWhen the boat hull is on a block drain the engine cooling water and the water in the SailDrive case If this water is not drained freezing may cause cracksALower gear caseBUpper gear caseALower gear caseBSeawater Wiring Diagrams7 Electrical Wiring DiagramsSee Appendix B at the back of this manualNote 1 2 3 25 m 20 mm2Cross sectional area1 2 3 5 m 40 mm2 Cross sectional areaBtype Instrument Panel Applicable Engine Model 3YM30 3YM20 and 2YM15 See A5 3JH4E 4JH4E See A6Note 1 2 3 25 m 20 mm2Cross sectional area1 2 3 5 m 40 mm2 Cross sectional areaCtype Instrument Panel Applicable Engine Model 3JH4E 4JH4E See A7Color Instrument Engine Model 1GM10C4Battery Recommended used10CW temp switch11LO pressure switch12Spare cable 3 m Standard14The total length extension cable must be less than 6 m 15Rubber seal switch extension cable 03 m19Not used Except 1GMC20Key switch21Push button switch22Charge lamp23CW temp lamp24LO pressure lamp25Rubber seal lamp Instrument Engine Model 1GM10C4Battery Recommended used10CW temp switch11LO pressure cable 3 m Standard14The total length extension cable must be less than 6 m 15Rubber seal switch extension cable 03 m19Not used Except 1GMC20Light switch21Key switch22Push button switch23Charge lamp24CW temp lamp25LO pressure lamp26Rubber seal lamp Wiring DiagramsB x Btype Instrument Engine Model by stop solenoid6Air heater7Starter Temp switch10Eng oil pressure bolt13CW Temp sender 14Tacho harness for 2 switch21Stop stop with hour oil pressure28CW panel no 2 station OptionC x Btype Instrument Engine Model by stop solenoid6Air heater7Starter Temp switch10Eng oil pressure bolt13CW Temp sender 14Tacho oil pressure sender17Wire harness for 2 switch21Stop stop with hour meter26CW Temp meter27Eng oil pressure oil pressure30CW filter34Fuel panel no 2 station n2b b YXRU uEeE bch aeueDD 1EeE bch XEeE bch aeeDXD AEeE bch Trust Inc10UVeriSign Time Stamping Service Root1402UNO LIABILITY ACCEPTED cc EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EEadPQXEDYCcbB ECDCCe ia D QXDzzYYFFaHKS XYXY EDEDEeE j Bhja RyE TXYaDRy E I c a a CC5vAp AE PXaYddbQXdd EDYKTX FH FHYYCXddadQX FH and date issued Y Sugita Manager Quality Assurance Dept Power System Operation Div 1332 BS Almerede Vaart The Netherlands Nagahama Japan Sept 21 1997 IMPORTER IN THE EU YANMAR MARINE INTERNATIONAL BV Brugplein 11 BE INCORPORATED HAS BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THE DIRECTIVE THIS MACHINERY PART MUST NOT BE PUT INTO SERVICE UNTIL THE MACHINERY INTO WHICH IT IS TO OF THE MACHINERY PARTS CATEGORY Diesel engine 1 MAKE YANMAR 2336EEC MANUFACTURER YANMAR CO LTD 132 Chayamachi Kitaku Osaka Japan DESCRIPTION DECLARATION FOR MACHINERY PARTS ACCORDING TO 9425EECANNEX15 89