SD-Series

SAIL-DRIVE
MODEL: SD20, SD50/SD50-4T

OPERATION MANUAL
EN

Applicable Engine Model:

1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E 4JH3-TCE

All rights reserved. This manual may not be reproduced or copied, in whole or in part,
without the written permission of YANMAR CO., LTD.
Copyright © 2004 Yanmar CO., LTD
 Introduction ................................................... 3 7. Electrical Wiring Diagrams ......................31

1. For Your Safety ........................................ 4

1.1 Safety Precautions For Inspection .... 4

2. Specifications ........................................... 7

3. Selecting Lubricating Oil ........................... 8

3.1 Choice of lube oil .............................. 8
3.2 Kind of lube oil .................................. 8
3.3 Lube oil viscosity ............................... 9

4. Starting the New Sail-Drive for the First

Time .................................................. 10
4.1 Filling with lubricating oil ................. 10
4.1.1 SD20 and SD50/-4T .............. 10
4.2 Check of instrument panel alarm sys-
EN tem: 11
4.3 Remote-Control Device Check ........ 12
4.4 Fitting for Fixed Propeller (2-blade) . 14
4.5 Recommended Propeller Size (Max.) .
14

5. Method of Operation .............................. 16

5.1 Engine Cooling Water ..................... 16
5.1.1 SD20 ..................................... 16
5.1.2 SD50/SD50-4T ...................... 17

6. Periodic Inspections and Maintenance ... 18

6.1 Lubricating oil system ...................... 19
6.1.1 SD20 ..................................... 19
6.1.2 SD50/-4T ............................... 20
6.2 Procedure for filling and removing oil in
the Sail-Drive; SD50/-4T 21
6.2.1 When the boat is in the water 22
6.2.2 When the boat is out of the water
26
6.3 Anticorrosive zinc ............................ 29
6.3.1 SD20 and SD50/ SD50-4T .... 29
6.4 Rubber diaphragms (A) and (B) (SD20
and SD50/-4T) 29
6.5 When the boat hull is raised onto a
block, inspect the following: 30
Introduction
This Installation and Operation Manual describes Sail-Drive Models SD20, SD50,
SD50-4T.
For engine handling and operation, refer to the respective operation manuals for Engine
Models 1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E and 4JH3-TCE. However, in-
structions for the marine gear box are not necessary as they are included.
Engines and sail-drive combinations are available as follows:

Engine model Sail-drive model

1GM10C SD20

2YM15
3YM20, 3YM30

3JH4E SD50

4JH4E

4JH3-TCE SD50-4T

EN

3
 1. For Your Safety

1. For Your Safety

1.1 Safety Precautions For Inspection

DANGER Battery
Never smoke or permit sparks near the battery, because it may emit ex-
plosive hydrogen gas. Place the battery in a well-ventilated place.

DANGER Fuel
Use only diesel fuel. Never use other fuels, including gasoline, kero-
sene, etc., because they could cause a fire. The wrong fuel could also
cause the fuel injection pump and injector to fail due to lack of proper
lubrication. Be sure to check that you have selected the correct diesel
fuel before filling the fuel tank.
EN Do not use starting fluids or sprays. Their use may cause explosion, se-
rious injury and engine damage.

WARNING Fire Prevention

Be sure to stop the engine and confirm that there are no open flames in
the vicinity before fueling. If you do spill fuel, wipe such spillage careful-
ly and dispose of the wiping materials properly. Wash your hands thor-
oughly with soap and water.
Never place oil or other flammable material in the engine room.
Install a fire extinguisher near the engine room, and familiarize yourself
with its use.

WARNING Exhaust Gas

Exhaust gas contains poisonous carbon monoxide and should not be
inhaled.
Be sure to install ventilation ports or ventilators in the engine room and
ensure good ventilation during engine operation.

WARNING Moving Parts

Do not touch or let your clothing get caught in the moving parts of the
engine, such as the front drive shaft, V-belt or propeller shaft, during en-
gine operation. You will be injured.
Never operate the engine without covers on the moving parts.

4
1. For Your Safety

CAUTION Burns
The whole engine is hot during operation and immediately after
shut-down. The exhaust manifold, exhaust pipe and high pressure fuel
lines are very hot. Never touch these parts with your body or clothing.

WARNING Alcohol
Never operate the engine while you are under the influence of alcohol.
Never operate the engine when you are ill or not feeling well.

DANGER Battery Fluid

Battery fluid is dilute sulphuric acid. It can blind you if it gets in your
eyes, or burn your skin. Keep the fluid away from your body.
If you touch it, wash it off immediately with a large quantity of fresh wa-
ter and call your doctor for treatment. EN

WARNING Fire by Electric Short-Circuits

Always turn off the battery switch before inspecting the electrical sys-
tem.
Failure to do so could cause short-circuiting and fires.

WARNING Stop the engine before you service it.

Turn the battery switch off. If you must inspect while the engine is in op-
eration, never touch moving parts. Keep your body and clothing well
clear of all moving parts.

CAUTION Scalds
When extracting oil from the engine while it is still hot, don't let the oil
splash on you.
Wait until the temperature has dropped before extracting cooling water
from the engine. Don't let it splash on you.

5
 1. For Your Safety

DANGER Forbidden Modifications.

Never release the limiting devices such as the engine speed limit, fuel
injection limit, etc.
Modification will impair the safety and performance of the product and
shorten product life.
Also note that any troubles arising from modification are not covered by
our warranty.

DANGER Precautions for Treating Waste.

Never dispose of waste oil or other fluid in a field, sewer, river, or the
sea.
Treat waste matters safely observing regulations or laws.
Ask a waste recovery company to collect it.

EN

6
 2. Specifications

2. Specifications
Model SD20 SD50 SD50-4T
Reduction gear system Constant mesh gear with Cone clutch
dog clutch use
Direction of Input shaft Counter-clockwise viewed from stern
rotation Propeller shaft Counter-clockwise viewed Counter-clockwise or clockwise viewed from
from stern stern
Reduction ratio Ahead 2.64 2.32
Astern 2.64 2.32
Propeller speed (min-1) 1364 1293 1638
Lubrication system Oil bath type
Lubrication oil Standard unit 2.2 L 2.2 L
capacity Long-reach 2.5 L 2.35 L (Extension 58), 2.45 L (Extension
unit 100)
Dry weight 30 Kg 39 kg 41 kg
Remote-con- Control head Single control lever
trol device Cable "MORSE" 33C (equivalent)
Applicable engine model (Fuel 1GM10C (6.7kW/3600 3JH4E 4JH3-TCE
stop power at crankshaft) min-1) (29.4 kW/3000 min-1) (55.2kW/3800min-1) EN
2YM15 (10.3kW/3600 min-1) 4JH4E
3YM20 (16.2kW/3600 min-1) (40.5 kW/3000 min-1)
3YM30 (22.1kW/3600 min-1)

Note: A propeller with rubber bushing must be used in all SD series sail-drives.

7
 3. Selecting Lubricating Oil

3. Selecting Lubricating Oil

3.1 Choice of lube oil

The choice of lube oil is very important to damage, and a shorter Sail-Drive life.
a Sail-Drive. If an unsuitable oil is used, or When selecting the lube oil, it must be one
oil change is neglected, it may result in of the following:

3.2 Kind of lube oil

Engine series GM, YM JH3, JH4

Engine model 1GM10C 2YM15 3YM20 3YM30 3JH4E 4JH4E 4JH3-TCE
Sail-drive model SD20 SD50 SD50 SD50-4T

Lubrication oil for API CC or API GL4 or GL5 and SAE API GL4 or GL5 and SAE Quicksilver
the sail-drive greater and 80W90 or 90 80W90 or 90 or Quicksil- High Perfor-
SAE 10W30 ver High Performance Gear mance Gear
Lube Lube
EN
Use only oil of quality “GL-4" or "GL-5" in Use only oil of quality "cc" or greater in the
the API service, and SAE No. 90 or API service, and SAE no. 10W30.
80W90.
(Applicable model: SD20 x 1GM10C)
(Except model SD20 x 1GM10C and
SD50/-4T)
For SD20 (except if coupled with the 1GM10C) and SD50/-4T

Supplier Brand Name API Service SAE No.

SHELL Shell Spilax oil EP 90 GL-4 90

SHELL Shell Spilax oil HD 90 GL-5 90

CALTEX Multipurpose thuban EP GL-4/GL-59 90

MOBIL Mobilub HD 80W-90 GL-5 80W-90

ESSO Esso gear oil GP 90 GL-4 90

ESSO Esso gear oil GX 90 GL-5 90

Use "Quicksilver High Performance Gear This lube oil is available through all Mer-
Lube" for the SD50/-4T. Cruiser, Mercury, Mariner and Force out-
lets in their Quicksilver accessories
program.

8
 3. Selecting Lubricating Oil

This High Performance Gear Lube is avail-

able in the following sizes:

Volume Part number Package

300 ml 92-802851Q1 case of 24 tubes

1L 92-802854Q1 case of 12 plastic

bottles

10 L 92-802856Q1 case of 2 cans

60.5 L 92-802857Q1 single drum

208 L 92-802858Q1 single drum

3.3 Lube oil viscosity

The viscosity of the lube oil greatly influ-
ences Sail-Drive performance

EN

9
 4. Starting the New Sail-Drive for the First Time

4. Starting the New Sail-Drive for the First Time

4.1 Filling with lubricating oil

4.1.1 SD20 and SD50/-4T

(1) Remove the dipstick (yellow cap) Sail-Drive Model:SD20 & SD50/-4T
and supply approved lube oil.
Lube oil capacity:
(2) Check the amount of lube oil by in-
serting the dipstick as far as possi-
ble. Do not screw the dipstick in. Sail-drive SD20 SD50/-4T
model
(see the illustration below). The oil
level should reach the upper mark Standard unit 2.2 L 2.2 L
on the dipstick. Long-reach 2.5 L 2.35 L (Extension 58)
unit 2.45 L (Extension 100)
CAUTION
CAUTION
Since it takes about 10 minutes to fill up
EN the Sail-Drive with lube oil, owing to its The lube oil capacity of the standard
construction, check the supplied oil unit is different from that of the
quantity again by using the dipstick 15 long-reach unit. Confirm the capacity
minutes after completion of supply of by means of the oil capacity nameplate.
the specified quantity of oil.
A A
B B
C C
D D

E E

F
F

SD20 SD50/SD50-4T
003443-00E

A Dipstick D Oil level

B Upper limit E Oil supply port
C Lower limit F Oil capacity nameplate

10
 4. Starting the New Sail-Drive for the First Time

4.2 Check of instrument panel alarm system:

Turn on the battery switch. Then the key in the "ON" position and check the lamps on the
panel (with the engine off).
(A-type) (B-Type)

2 3 4 8 1 2 4 3
1

OFF
ON

7 6 5 6 7 9 5
1 Rubber seal (Sail-Drive) 4 LO press 7 Push button
2 CW temp 5 Key switch 8 Tachometer
3 Charge 6 Warning Buzzer 9 Check switch

(1) Lube oil warning lamp should be lit. on the instrument panel. If this hap-
pens, stop the engine and, under sail,
EN
(2) Cooling water temperature warning
lamp should be out. (For small type quickly return to the nearest port for re-
panel: A-type only) pairs.
For the large type panel (B-type), raise
CAUTION
the CHECK switch "ON" to see if the
cooling water temperature warning All the above alarm signs will continue
lamp lights. until you push the starting button or
(3) Charging warning lamp should be turn the key off.
lit.
A A ON (Rubber seal lamp)
(4) Rubber seal lamp should be out. B Buzzer
(5) The warning buzzer should sound. C Rubber seal switch
D Diaphragm (B)
WARNING E Diaphragm (A)
F Seawater
The rubber seal alarm lamp warns of B
seawater entering the boat. The water-
C
tight structure of the Sail-Drive is the
D
dual type. Even if the rubber diaphragm
(A) is damaged and seawater enters,
the rubber diaphragm (B) prevents it E
from entering the inboard. The rubber
F
seal switch between the rubber dia-
003446-00E
phragms (A) and (B) works the warning
buzzer and lights the rubber seal lamp

11
 4. Starting the New Sail-Drive for the First Time

4.3 Remote-Control Device Check

4.3.0.1 SD20 and, consequently, the clutch fails to en-

gage. Confirm that the operation lever of
While cranking the engine slowly, shift the the Sail-Drive moves smoothly to Ahead,
control handle of the remote-control head Astern and Stopper. Because the
(single lever control) rapidly through Neu- Sail-Drive SD20 uses a dog clutch, the
tral - Ahead - Neutral - Astern. If a shift op- clutch is not engaged unless the operation
eration is done slowly, the tip of the clutch lever is moved to the stopper position.
dog is worn away by being hammered,
B M
A C
L N

O
D R
P
E
Q

S T U
EN F
Old type :
Serial No. 0001-2128 for SD10
G
D

H
I
J
K

New type :
Serial No. 2129 and after for SD20

003447-00E

New type: Serial No. 2129 and after for SD20 Old type: Serial No. 0001-2128 for SD10
A Control handle L Ahead stopper
B Astern M Neutral position
C Neutral N Astern stopper
D Ahead O Cable clamp
E Operation lever P Remote control cable
F Cable clamp Q Spring joint
G Remote control cable R Operation lever
H Pivot S Astern
I Astern T Neutral
J Neutral U Ahead
K Ahead

12
 4. Starting the New Sail-Drive for the First Time

4.3.0.2 SD50 & SD50-4T A

After starting the engine, check the shift

action by using the control head to shift the
Ahead and Astern positions. The Ahead/
Astern clutch is a mechanical clutch called
a cone clutch. Although a grinding noise is
made when this type of clutch is engaged, B
it has no effect on the operation of the en-
gine. C

CAUTION

Because of the rubbing produced at the

frictional face of the cone clutch, grip-
ping action is lessened with use and
periodic inspection and maintenance is
D
necessary. E F G H
003448-00E

A When attaching the cable mounting plate at a 90º

angle handle EN
B Operation lever
C Cable clamp
D Remote control cable
E Propeller shaft clockwise
F Pivot
G Neutral
H Propeller shaft counter-clockwise

13
 4. Starting the New Sail-Drive for the First Time

4.4 Fitting for Fixed Propeller (2-blade)

A Spacer
B Grease
E
C Washer
D Propeller
A C E Nut Tightening torque 60-70 Nm (M16,
F
SD20)
80-100 Nm (M20, SD50/-4T)
B F Bolt M8x75mm
D Tightening torque11-15 Nm
003449-00E

Locking Procedure for Fixed Propeller Nut

CAUTION
(Optional). When tightening the nut at
60-70 Nm torque for the SD20, and 80-100 Rubber bushing (Folding propeller)
Nm torque for the SD50/-4T, move the
shift lever to ahead and hold the crank- For the sail-drive, be sure to use the
shaft V-pulley clamp nut with a wrench to folding propeller which is provided with
stop the rotation. a rubber bushing. If a propeller is used
EN without rubber bushing, the shaft, bear-
ing, and gears of the sail-drive are sure-
ly damaged.

4.5 Recommended Propeller Size (Max.)

Engine model Sail-Drive Model Folding type Dia. mm 2-blade, fixed type-
(inch) Dia. mm (inch)
1GM10C SD20 355 (14) 380 (15)
2YM15 368 (14.5) 380 (15)

3YM20 380 (15) 405 (16)

3YM30 405 (16) 420 (16.5)

3JH4E SD50 457 (18) 457 (18)

4JH4E 457 (18) 457 (18)

4JH3-TCE SD50-4T 457 (18) 457 (18)

(2) Execute a propeller matching on

CAUTION
the basis of the propeller shaft rat-
Precautions on matching of the propel- ed output (continuous rating at pro-
ler peller shaft). 95% of the engine
rated output (continuous rating at
(1) Be sure to confirm a matching of crankshaft) becomes the propeller
the propeller in a sea trial. shaft rated output (continuous rat-
ing at propeller shaft).

14
 4. Starting the New Sail-Drive for the First Time

Note: The propeller shaft output becomes al navigation, there is an increase

95% of the engine rated output (continuous in resistance due to the waves,
rating at crankshaft) in consideration of me-
chanical efficiency 95% of the sail-drive.
wind and fouling of the hull and,
moreover, a drop in the efficiency
(3) In the case of propeller calculation, due to fouling of the propeller. Con-
further add 5%, at minimum, as the sequently, in the case of propeller
sea margin to the aforementioned calculation, it is necessary to allow
matching point. That is, 95% of the the engine output to have some
propeller shaft rated output (Con- margin. For that reason, it is neces-
tinuous rating at propeller shaft) sary to add the sea margin of 5%, at
becomes the best propeller match- minimum.
ing. Note about sea margin: In actu-

EN

15
 5. Method of Operation

5. Method of Operation

5.1 Engine Cooling Water

Opening or closing the cooling water sys- Note: For other items, refer to the engine opera-
tem of the Sail-Drive Set Engine is done by tion manual.
the cooling water cock fixed on the upper Note: When sailing, set the remote control lever
case of the Sail-Drive. Be sure to open the in neutral.
cock and confirm that the C.W. has suction Old type:
by cranking the engine before starting the
boat. The cooling water passes through Serial No.0001-2128 for Model SD20
the Sail-Drive case, cools the engine by New type:
the cooling water pump, and is then dis-
charged. Serial No.2129 and after for Model SD20

5.1.1 SD20

EN

E F
D

A G
B H
C

003442-00E

A Atern D Neutral G To C.W. pump

B Neutral E Cock, C.W. H Hose clamp
C Ahead F C.W. hose I Seawater inlet

16
 5. Method of Operation

5.1.2 SD50/SD50-4T

40 40
B

D E

F EN
C

003450-00E

A Open C Cock C.W. E Neutral

B To C.W. pump D Propeller shaft Clockwise F Propeller shaft Counter-clockwise

17
 6. Periodic Inspections and Maintenance

6. Periodic Inspections and Maintenance

50 hrs. or after Every 250
Every day Every 100 hrs. Every 1 year Every 2 years
1 month hrs.
Lubricating Oil
Before opera-
(1) Check oil level: fill
tion
First SD20 SD50/-4T
(2) Change lube oil O O O O
Cooling Water
Before/after
(1) Open/close cooling wa-
operation
ter cock
O
O
(2) Clean cooling water suc-
tion hole After opera-
tion
(3) Drain cooling water O

Remote Control System Replace if Serial No. 2129

the thick- and after for
(1) Inspect remote control
ness is less SD20
device
than 10 mm.
First O
(2) Inspect and replace O O
clutch shifter
Replace if
Anti-Corrosive Zinc
EN (1) Inspect and replace an-
wear is
more than
ti-corrosive zinc 50%
O
Lower Case
O
(1) Repair case coating
Inspect and
Boat Bottom Water- tightness
replace, if there
(1) Inspect and replace rub- is cracking, or at
ber diaphragm seal ring least every 6
years
O
(2) Inspect seal sensor
O
Replace if
Flexible mount clearance is
(1) Inspect and replace less than 1
mounting height. mm.
O

003451-00E

A: Clearance

18
 6. Periodic Inspections and Maintenance

6.1 Lubricating oil system

6.1.1 SD20
(1) Check the oil level before every op- forcefully if the drain plug is removed
eration. from the drive unit immediately after
(2) Change the oil after the first 50 operation.
hours of operation or after long SD20
storage and every 100 hours of op-
A
eration thereafter. Lube oil should
be changed while the engine is still
B
warm.
Change oil in the following manner:
(1) Put the boat hull on a block.
Drain the oil by removing the lower
gear case drain plug, and the upper
gear case oil dipstick.

WARNING EN
Let the drive unit cool at least 5 minutes
after operation before removing the oil
drain plug. Hot oil could spurt out
C

003440-00E

A Dipstick
B Upper gear case
C Lower gear case
D Lube oil drain plug

19
 6. Periodic Inspections and Maintenance

6.1.2 SD50/-4T
(1) Check the oil level before every op- SD50/SD50-4T
eration.
(2) Change the oil after the first 50
hours of operation or after long
storage, and every 250 hours of op-
eration thereafter. Lube oil should
be changed while the engine is still
warm. A

WARNING
B
Let the drive unit cool at least 5 minutes
after operation before removing the oil
drain plug. Hot oil could spurt out
forcefully if the drain plug is removed
from the drive unit immediately after
operation.

EN

C
003441-00E

A Dipstick B Plug C Drain plug

20
 6. Periodic Inspections and Maintenance

6.2 Procedure for filling and removing oil in the Sail-Drive; SD50/-4T
When the boat is (6.2.1) in the water and (6.2.2) out of the water
Used equipment:

Description Part code Quantity Remarks

Bottle of Quicksilver High Per- MerCruiser Part code 2 Each bottle contains 0.946 liter of oil.
formance Gear Lube from 92-850743A1 Mandatory for SD50/-4T. For other
MerCruiser models see page 8.
Market pump from MerCruiser MerCruiser Part code 1
on bottle 91-85729A1

Adapter joint 196311-92960 1 (2) Thread std. M10 x 1.5 max. length 12
mm.

O-ring for adapter 24311-000100 1 (2)

Stiff rubber hoses 2 Inner diameter ø14-16 mm + hose

clips (If Yanmar part is used, part code
is 196440-92970)

Compressor set - 1

Hand pump 28210-000080 1 Option parts

EN

21
 6. Periodic Inspections and Maintenance

6.2.1 When the boat is in the water

6.2.1.1 Preparing the sail-drive: 6.2.1.2 Removing oil (total quantity

2.2 liter)
A
B

C
A

EN 003453-00E

003452-00E
A Plug

A O-ring
B Adapter joint 6.2.1.3 Fastest way: Blowing out by
C Oil changing plug
using Air pressure
D Tread M10 x 1.5
First follow steps (1), (2), (3) on page 22
(1) Take out the oil changing plug lo-
cated under the shift lever. (1) Take out the plug from the upper
case cover.
(2) Screw in the adapter joint (196311-
92960) with the O-ring (2) Screw in a second adapter joint (P/
(24311-000100). When using own N 196311-92960) with an O-ring (P/N
adapter joint, max. length of thread 24311-000100) at the oil inlet posi-
is 12 mm. tion. Screw in the oil plug at the dip-
stick position.
(3) Attach a stiff rubber hose with inner
diameter ø14~16 mm with hose (3) Connect the air pressure hose with
clips to the adapter joint at the oil hose clips.
changing position. Hose must be (4) Option 1: Using Compressed air
long enough to drain to bucket or from main system or 12 V portable
pump. (If Yanmar original rubber compressor.
hose is used, part code is 1. Connect hose at top adapter joint to
196440-92970) compressed air and within 10 to 15
minutes almost all oil will be blown out.

22
 6. Periodic Inspections and Maintenance

(3) With the system now connected,

A
pump out the oil until empty. The
B first 0.9 liter will take approx. 3 min-
utes. The second part takes more
time as mostly air will be pumped
out; this will take approx. 12 min-
utes.

6.2.1.4 Using Yanmar Pump

First follow steps (1), (2), (3) on page 22
and step (1) on page 22
C 003454-00E Connect the hand pump with hoses as
A One-way valve shown above, and start pumping.
B Adapter joint screwed in cover
C Simple foot pump Be aware that oil has to flow down through
narrow parts and then up again.
Use Compressed Air (0.5~1 Bar) from Therefore, during this procedure, at first
main system, 12 V portable compres- suction pressure will be high and pumping
sor or from portable hand pump or foot will be hard. A few minutes waiting in be- EN
pump. tween will help. After taking out about 0.9
Option 2: Using Compressed air liter of oil, mostly you will pump out air, but
with help from a portable hand continuous pumping is necessary.
pump or foot pump
Though approx. 100-200 ml of old oil will
(1) Install a one-way (non return) valve remain in the drive unit, in this case, it is no
in the pressure line (connected to problem to fill-up with the new oil for main-
the top cover). This is done to main- tenance.
tain the pressure during use of the
The hand pump (p/#:28210-000080) and
pump.
rubber hose (p/#:196440-92970) are avail-
(2) Connect the hand pump or foot able from Yanmar, and are optional parts
pump with the pressure line to the for SD50/-4T. Or any type of hand pump or
adapter joint on the top as shown rubber hose (Inner diameter ø14-16 mm)
above. available from the hardware shop, are us-
able.

23
 6. Periodic Inspections and Maintenance

003455-00E

A Plug

EN 6.2.1.5 Filling oil (total quantity 2.2 (2) Screw the pump on a new bottle of
liter) Quicksilver High Performance Gear
Lube Part number 92-850743A1
The following methods of filling with lube (0.946 liter) from MerCruiser.
oil are in addition to the way mentioned in (3) Connect the hose with a hose clip
page 10. to the adapter joint below the shift
lever.
6.2.1.6 Fastest way: By using Mer- (4) Take out the plug from the upper
Cruiser pump or simple market case cover.
pump (5) Fill the oil by pushing the upper
part of the pump. After bottle is
First follow steps (1) and (2) on page 22 empty, change the bottle while the
(1) Use a MerCruiser pump with Part pump and hose remains connected
number 91-85729A1 like the one with the adapter joint.
shown above or use a similar pump (6) After filling, first screw in and tight-
available on the market. en the plug at the top cover. Then
remove the oil bottle, pump, hose
and adapter joint and screw in the
oil plug (don't forget the gasket).

24
 6. Periodic Inspections and Maintenance

6.2.1.7 By using Yanmar Hand (2) Take out the plug from the upper
Pump case cover.
(3) Fill in the oil moved by the hand
First follow steps (3) and (4) on page 24. pump. Be aware that oil has to flow
down through narrow parts and
A 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/#: 28210-000080) and rub-
ber hose (p/#: 196440-92970) are
available from Yanmar, and are op-
tional parts for SD50/-4T. Or any
type of hand pump or rubber hose
(Inner diameter ø14-16 mm) avail-
able from the hardware shop, are
usable.
(4) After filling, first screw in and tight-
en the plug at the top cover. Then EN
remove the hand pump, hose and
adapter joint and screw in the oil
plug (don't forget the gasket).

003456-00E 6.2.1.8 By not using pump

A Plug
For the oil filling procedure by not using
pump, see the explanation on chapter 4.,
(1) Connect the hoses as shown above page 10.
at the top adapter joint to the hand
pump by using the rubber hose.

25
 6. Periodic Inspections and Maintenance

6.2.2 When the boat is out of the (4) Take out the dipstick and oil inlet
water plug from the upper case cover.

6.2.2.1 Preparing the sail-drive: 6.2.2.2 Removing oil (total quantity

2.2 liter)
A

6.2.2.3 By draining
First follow steps (1), (2), (3), (4) on page
26.
Oil drain is possible from this point but will
take much time.
(1) After approx. 0.6 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 po-
sition).
EN

A B

003458-00E

A Tread M10 x 1.5

003457-00E B Oil changing plug
A Plug

6.2.2.4 Fastest way: Blowing out by

(1) Remove the bottom drain plug using Air pressure
(2) Screw in the adapter joint (P/N
196311- 92960) with the O-ring (P/N First follow steps (1), (2), (3) on page 22,
24311- 000100). then follow the procedures on page 22. Be
When using own adapter joint, max. aware that oil is divided in two channels
length of thread is 12 mm. connected by the lower gear and lower
drain port.
(3) Attach a stiff rubber hose with inner
diameter ø14~16 mm with hose
clips to the adapter joint at the oil
drain position. The hose must be
long enough to drain to bucket.

26
 6. Periodic Inspections and Maintenance

6.2.2.5 Filling oil (total quantity 2.2 (1) Use a MerCruiser pump with Part
liter) number 91-85729A1 like the one
shown on p. 24, 6.2.1.4, or use a
similar pump available on the mar-
6.2.2.6 By using MerCruiser pump ket.
or simple market pump
(2) Screw the pump on a new bottle of
First follow steps (1), (2), (4) on page 26. Quicksilver High Performance Gear
Lube Part number 92-850743A1
A (0.946 liter) from MerCruiser.
(3) Remove the oil changing plug be-
low the shift lever.
(4) Connect the hose with a hose clip
to the adapter joint at the drain po-
sition.
(5) Take out the plug from the upper
case cover.
(6) Fill the oil by pushing the upper
part of the pump. After the first bot-
tle is empty, screw in the oil chang- EN
ing plug (don't forget the gasket).
(7) Change the bottle while the pump
and hose remain connected with
the adapter joint.
B
(8) After filling, first screw in and tight-
C en the plug at the top cover. Then
remove the oil bottle, pump, hose
003870-00E
and adapter joint and screw in the
oil drain plug (don't forget the gas-
A Plug
ket).
B O-ring
C Adapter joint

27
 6. Periodic Inspections and Maintenance

6.2.2.7 By using Yanmar hand pumping will be hard. A few min-

pump utes waiting in between will help.
After pumping in about 1 liter of oil,
First follow steps (1), (2), (3), (4) on page screw in the oil changing plug (do
26. not forget to insert the gasket).
Please be aware that the drain hose
A
can easily slip out of the bucket and
cause oil spilling. The hand pump
(p/#: 28210-000080) and rubber
hose (p/#:196440-92970) are avail-
able from Yanmar, and are optional
parts for SD50/-4T. Or any type of
hand pump or rubber hose (Inner
diameter ø14-16 mm) available
from the hardware shop, are us-
able.

EN

003872-00E

003871-00E
(4) After filling, first screw in and tight-
A Plug
en the plug at the top cover. Then
remove the pump, hose and adapt-
er joint and screw in the oil drain
(1) Connect the hose from the bottom
plug (do not forget to insert the gas-
and a suction hose to Yanmar
ket).
pump with hose clip like shown
above.
(2) Take out the plug from the upper 6.2.2.8 By not using pump
case cover.
For the oil filling procedure by not using
(3) Fill oil by pumping it into drive. Be pump, see the explanation on chapter 4.,
aware that oil has to flow up page 10.
through narrow parts. Therefore,

28
 6. Periodic Inspections and Maintenance

6.3 Anticorrosive zinc

6.3.1 SD20 and SD50/ SD50-4T

To prevent corrosion of the sail-Drive body hours of operation, once every six months
by sea (lake) water, replace the anticorro- or when it becomes half of the original vol-
sive zinc at the earliest time of every 100 ume (size).
SD20
B

M10 x 11

A
M20 x 50
0-024
642 41
19

C
EN
Don't remove
while the boat
in the water
ZINC

003873-00E

A Safety label C Upper gear case

B Anticorrosive zinc D Lower gear case

Anticorrosive zinc is provided on the upper

WARNING
and lower gear case. To inspect and re-
place the anticorrosive zinc on the lower Do not remove the plug (including Anti-
gear case, the boat hull must be put on a corrosive Zinc) while the boat is in the
block. water.

6.4 Rubber diaphragms (A) and (B) (SD20 and SD50/-4T)

The rubber diaphragms (A) and (B) of the ates during use, be sure to replace them at
Sail-Drive are important parts for the hull
and crew safety. Since rubber degener-

29
 6. Periodic Inspections and Maintenance

least every six years (see the table: Peri- in the sea, or when having deposit re-
odic Inspections and Maintenance on moved from it. Do not use paint con-
page 18.) (Boat hull must be lifted onto a taining copper derivatives.
block.) To replace, consult your Yanmar (3) Inspecting anticorrosive zinc
dealer. Since anticorrosive zinc can not be in-
SD50/-4T spected except when the boat hull is
raised onto a block, be sure not to for-
get to inspect it.
(4) Inspecting the folding propeller
Inspect whether or not the blade of the
folding propeller opens smoothly. Also
inspect for wear on the blade-fixing
pins. Replace them when wear is ex-
cessive. Apply seawater-proof grease
to the pins blade gear and propeller
A
shaft.
(5) Draining water
B When the boat hull is on a block, drain
EN the engine cooling water, and the wa-
ter in the Sail-Drive case. (If this water
is not drained, freezing may cause
cracks)
A
003874-00E

A Lower gear case

B Upper gear case

6.5 When the boat hull is raised

onto a block, inspect the follow-
ing:
(1) Remove deposit from the lower
gear case.
Remove seaweed, seashells, and ma-
rine 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.
B
(2) Repairing damaged membrane
003875-00E
The membrane of the lower gear case
A Lower gear case
which is always in seawater may be
B Seawater inlet
damaged when hitting floating objects

30
 7. Electrical Wiring Diagrams

7. Electrical Wiring Diagrams

See Appendix B. at the back of this manual.

Color coding A-type Instrument Panel B-type Instrument Panel

R Red Applicable Engine Model: 1GM10C Applicable Engine Model: 1GM10C

B Black 4 Battery Recommended capacity 4 Battery Recommended capacity

GM,12V-70AH GM,12V-70AH
W White 1GM,12V-100AH 1GM,12V-100AH
(Mini.) (Mini.)
Y Yellow
5 Battery switch 5 Battery switch
L Blue
6 FUSE 6 FUSE
O Orange
7 Starter motor 7 Starter motor
L/B Blue/Black 8 Alternator 8 Alternator
W/L White/Blue 9 Not used 9 Not used
Y/W Yellow/White 10 C.W. temp. switch 10 C.W. temp. switch
W/R White/Red 11 L.O. pressure switch 11 L.O. pressure switch
L/R Blue/Red 12 Spare connector 12 Tachometer sender

W/B White/Black 13 Extension cable 3 m. (Standard) 13 Extension cable 3 m. (Standard)

R/B Red/Black 14 The total length extension cable 14 The total length extension cable
must be less than 6 m. must be less than 6 m.
EN
15 Rubber seal switch (Sail-drive) 15 Rubber seal switch (Sail-drive)
16 Amplifier 16 Amplifier
17 Earth 17 Earth
18 Sail-drive extension cable 0.3 m. 18 Sail-drive extension cable 0.3 m.
19 Not used (Except 1GMC) 19 Not used (Except 1GMC)
20 Key switch 20 Light switch
21 Push button switch 21 Key switch
22 Charge lamp 22 Push button switch
23 C.W. temp. lamp 23 Charge lamp
24 L.O. pressure lamp 24 C.W. temp. lamp
25 Rubber seal lamp (Sail-drive) 25 L.O. pressure lamp
26 Buzzer 26 Rubber seal lamp (Sail-drive)
27 Buzzer
Note: 1 + 2 + 3 < 2,5 m - 20 mm2
28 Tachometer
(Cross sectional area)
1 + 2 + 3 < 5 m - 40 mm2 Note: 1 + 2 + 3 < 2,5 m - 20 mm2
(Cross sectional area) (Cross sectional area)
B-type Instrument Panel 1 + 2 + 3 < 5 m - 40 mm2
Applicable Engine Model: (Cross sectional area)
3YM30, 3YM20 and 2YM15 C-type Instrument Panel
(See A-5) Applicable Engine Model:
3JH4E, 4JH4E (See A-6) 3JH4E, 4JH4E (See A-7)

31
 7. Electrical Wiring Diagrams

B x B-type Instrument Panel C x B-type Instrument Panel

Applicable Engine Model: 4JH3-TCE Applicable Engine Model: 4JH3-TCE
1 Procured by customer 1 Procured by customer
2 Battery 2 Battery
3 Battery switch 3 Battery switch
4 Relay 4 Relay
5 Eng. stop solenoid 5 Eng. stop solenoid
6 Air heater 6 Air heater
7 Starter relay 7 Starter relay
8 Starter 8 Starter
9 C.W. Temp. switch 9 C.W. Temp. switch
10 Eng. oil pressure switch 10 Eng. oil pressure switch
11 Alternator 11 Alternator
12 Earth bolt 12 Earth bolt
13 C.W. Temp. sender 13 C.W. Temp. sender
14 Tacho sensor 14 Tacho sensor

EN 15 Sail-drive 15 Sail-drive
16 Amplifier 16 Eng. oil pressure sender
17 Wire harness for 2 panel 17 Wire harness for 2 panel
18 Option 18 Option
19 Wire harness 19 Wire harness
20 Starter switch 20 Starter switch
21 Stop switch 21 Stop switch
22 Fuse 22 Fuse
23 Buzzer stop illumination 23 Buzzer stop illumination
24 Buzzer 24 Buzzer
25 Tachometer with hour meter 25 Tachometer with hour meter
26 Charge 26 C.W. Temp. meter
27 Eng. oil pressure 27 Eng. oil pressure meter
28 C.W. Temp. 28 Charge
29 Sail-drive 29 Eng. oil pressure
30 Exhaust 30 C.W. Temp.
31 Fuel emplacement 31 Sail-drive
32 Instrument panel no. 2 station; Option 32 Exhaust
33 Fuel filter
34 Fuel emplacement
35 Instrument panel no. 2 station; Option

32
• MANUFACTURER’S DECLARATION FOR MACHINERY PARTS ACCORDING TO 94/25/EEC(ANNEX-15) & 89/336/EEC
• MANUFACTURER: YANMAR CO., LTD.
1-32, Chayamachi, Kita-ku, Osaka, Japan
• DESCRIPTION OF THE MACHINERY PARTS
• CATEGORY: Diesel engine
1. MAKE: YANMAR
2. THIS MACHINERY PART MUST NOT BE PUT INTO SERVICE UNTIL THE MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS
BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THE DIRECTIVE.
• IMPORTER IN THE EU: YANMAR MARINE INTERNATIONAL B.V.
Brugplein 11
1332 BS Almere-de Vaart, The Netherlands

Nagahama, Japan, Sept. 21, 1997

Place and date issued Y. Sugita
Manager
Quality Assurance Dept.
Power System Operation Div.