SD-Series SAIL-DRIVE MODEL: SD20, SD50/SD50-4T
SD-SeriesSAIL-DRIVEMODEL: SD20, SD50/SD50-4TOPERATION MANUALENApplicable Engine Model:1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E 4JH3-TCEAll 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 . 31. For Your Safety . 41.1 Safety Precautions For Inspection . 42. Specifications . 73. Selecting Lubricating Oil . 83.1 Choice of lube oil . 83.2 Kind of lube oil . 83.3 Lube oil viscosity . 9EN4. Starting the New Sail-Drive for the FirstTime . 104.1 Filling with lubricating oil . 104.1.1 SD20 and SD50/-4T . 104.2 Check of instrument panel alarm system: 114.3 Remote-Control Device Check . 124.4 Fitting for Fixed Propeller (2-blade) . 144.5 Recommended Propeller Size (Max.) .145. Method of Operation . 165.1 Engine Cooling Water . 165.1.1 SD20 . 165.1.2 SD50/SD50-4T . 176. Periodic Inspections and Maintenance . 186.1 Lubricating oil system . 196.1.1 SD20 . 196.1.2 SD50/-4T . 206.2 Procedure for filling and removing oil inthe Sail-Drive; SD50/-4T 216.2.1 When the boat is in the water 226.2.2 When the boat is out of the water266.3 Anticorrosive zinc . 296.3.1 SD20 and SD50/ SD50-4T . 296.4 Rubber diaphragms (A) and (B) (SD20and SD50/-4T) 296.5 When the boat hull is raised onto ablock, inspect the following: 307. Electrical Wiring Diagrams .31
IntroductionThis Installation and Operation Manual describes Sail-Drive Models SD20, SD50,SD50-4T.For engine handling and operation, refer to the respective operation manuals for EngineModels 1GM10C, 2YM15, 3YM20, 3YM30, 3JH4E, 4JH4E and 4JH3-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 modelSail-drive model1GM10CSD202YM153YM20, 3YM303JH4ESD504JH4E4JH3-TCESD50-4TEN3
1. For Your Safety1. For Your Safety1.1 Safety Precautions For InspectionDANGERBatteryNever smoke or permit sparks near the battery, because it may emit explosive hydrogen gas. Place the battery in a well-ventilated place.DANGERFuelUse only diesel fuel. Never use other fuels, including gasoline, kerosene, etc., because they could cause a fire. The wrong fuel could alsocause the fuel injection pump and injector to fail due to lack of properlubrication. Be sure to check that you have selected the correct dieselfuel before filling the fuel tank.Do not use starting fluids or sprays. Their use may cause explosion, serious injury and engine damage.WARNINGFire PreventionBe sure to stop the engine and confirm that there are no open flames inthe 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 water.Never place oil or other flammable material in the engine room.Install a fire extinguisher near the engine room, and familiarize yourselfwith its use.WARNINGExhaust GasExhaust gas contains poisonous carbon monoxide and should not beinhaled.Be sure to install ventilation ports or ventilators in the engine room andensure good ventilation during engine operation.WARNINGMoving PartsDo not touch or let your clothing get caught in the moving parts of theengine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured.Never operate the engine without covers on the moving parts.EN4
1. For Your SafetyCAUTIONBurnsThe whole engine is hot during operation and immediately aftershut-down. The exhaust manifold, exhaust pipe and high pressure fuellines are very hot. Never touch these parts with your body or clothing.WARNINGAlcoholNever operate the engine while you are under the influence of alcohol.Never operate the engine when you are ill or not feeling well.DANGERBattery FluidBattery fluid is dilute sulphuric acid. It can blind you if it gets in youreyes, 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 water and call your doctor for treatment.WARNINGFire by Electric Short-CircuitsAlways turn off the battery switch before inspecting the electrical system.Failure to do so could cause short-circuiting and fires.WARNINGStop the engine before you service it.Turn the battery switch off. If you must inspect while the engine is in operation, never touch moving parts. Keep your body and clothing wellclear of all moving parts.CAUTIONScaldsWhen extracting oil from the engine while it is still hot, don't let the oilsplash on you.Wait until the temperature has dropped before extracting cooling waterfrom the engine. Don't let it splash on you.5EN
1. For Your SafetyEN6DANGERForbidden Modifications.Never release the limiting devices such as the engine speed limit, fuelinjection limit, etc.Modification will impair the safety and performance of the product andshorten product life.Also note that any troubles arising from modification are not covered byour warranty.DANGERPrecautions for Treating Waste.Never dispose of waste oil or other fluid in a field, sewer, river, or thesea.Treat waste matters safely observing regulations or laws.Ask a waste recovery company to collect it.
2. Specifications2. SpecificationsModelSD20Reduction gear systemDirection ofrotationSD50Input shaftPropeller shaftSD50-4TConstant mesh gear withdog clutch useCone clutchCounter-clockwise viewed from sternCounter-clockwise viewedfrom sternCounter-clockwise or clockwise viewed fromsternReduction ratio Ahead2.642.32Astern2.642.32Propeller speed (min-1)1364Lubrication systemLubrication oilcapacity1638Oil bath typeStandard unit2.2 L2.2 LLong-reachunit2.5 L2.35 L (Extension 58), 2.45 L (Extension100)Dry weightRemote-control device129330 KgControl headCableApplicable engine model (Fuelstop power at crankshaft)39 kg41 kgSingle control lever"MORSE" 33C (equivalent)4JH3-TCE3JH4E1GM10C (6.7kW/3600(29.4 kW/3000 min-1) (55.2kW/3800min-1)min-1)4JH4E2YM15 (10.3kW/3600 min-1)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.7EN
3. Selecting Lubricating Oil3. Selecting Lubricating Oil3.1 Choice of lube oilThe choice of lube oil is very important toa Sail-Drive. If an unsuitable oil is used, oroil change is neglected, it may result indamage, and a shorter Sail-Drive life.When selecting the lube oil, it must be oneof the following:3.2 Kind of lube oilEngine seriesGM, YMEngine model1GM10C2YM15Sail-drive model3YM203YM30SD20Lubrication oil forthe sail-driveENJH3, JH4API CC orgreater andSAE 10W30API GL4 or GL5 and SAE80W90 or 90Use only oil of quality “GL-4" or "GL-5" inthe API service, and SAE No. 90 or80W90.3JH4E4JH4E4JH3-TCESD50SD50SD50-4TAPI GL4 or GL5 and SAE80W90 or 90 or Quicksilver High Performance GearLubeQuicksilverHigh Performance GearLubeUse only oil of quality "cc" or greater in theAPI service, and SAE no. 10W30.(Applicable model: SD20 x 1GM10C)(Except model SD20 x 1GM10C andSD50/-4T)For SD20 (except if coupled with the 1GM10C) and SD50/-4TSupplierBrand NameAPI ServiceSAE No.SHELLShell Spilax oil EP 90GL-490SHELLShell Spilax oil HD 90GL-590CALTEXMultipurpose thuban EPGL-4/GL-5990MOBILMobilub HD 80W-90GL-580W-90ESSOEsso gear oil GP 90GL-490ESSOEsso gear oil GX 90GL-590Use "Quicksilver High Performance GearLube" for the SD50/-4T.8This lube oil is available through all MerCruiser, Mercury, Mariner and Force outlets in their Quicksilver accessoriesprogram.
3. Selecting Lubricating OilThis High Performance Gear Lube is available in the following sizes:VolumePart number Package300 ml92-802851Q1case of 24 tubes1L92-802854Q1case of 12 plasticbottles10 L92-802856Q1case of 2 cans60.5 L92-802857Q1single drum208 L92-802858Q1single drum3.3 Lube oil viscosityThe viscosity of the lube oil greatly influences Sail-Drive performanceEN9
4. Starting the New Sail-Drive for the First Time4. Starting the New Sail-Drive for the First Time4.1 Filling with lubricating oil4.1.1 SD20 and SD50/-4T(1) Remove the dipstick (yellow cap)and supply approved lube oil.Sail-Drive Model:SD20 & SD50/-4T(2) Check the amount of lube oil by inserting the dipstick as far as possible. Do not screw the dipstick in.(see the illustration below). The oillevel should reach the upper markon the dipstick.Lube oil capacity:Sail-drivemodelSD20SD50/-4TStandard unit2.2 L2.2 LLong-reachunit2.5 L2.35 L (Extension 58)2.45 L (Extension 100)CAUTIONENSince it takes about 10 minutes to fill upthe Sail-Drive with lube oil, owing to itsconstruction, check the supplied oilquantity again by using the dipstick 15minutes after completion of supply ofthe specified quantity of oil.ABCAUTIONThe lube oil capacity of the standardunit is different from that of thelong-reach unit. Confirm the capacityby means of the oil capacity nameplate.ACBDCDEEFFSD20SD50/SD50-4T003443-00EA DipstickB Upper limitC Lower limit10D Oil levelE Oil supply portF Oil capacity nameplate
4. Starting the New Sail-Drive for the First Time4.2 Check of instrument panel alarm system:Turn on the battery switch. Then the key in the "ON" position and check the lamps on thepanel (with the engine off).(A-type)(B-Type)234821431OFF71 Rubber seal (Sail-Drive)2 CW temp3 Charge6564 LO press5 Key switch6 Warning Buzzer(1) Lube oil warning lamp should be lit.(2) Cooling water temperature warninglamp should be out. (For small typepanel: A-type only)For the large type panel (B-type), raisethe CHECK switch "ON" to see if thecooling water temperature warninglamp lights.(3) Charging warning lamp should belit.(4) Rubber seal lamp should be out.79 57 Push button8 Tachometer9 Check switchon the instrument panel. If this happens, stop the engine and, under sail,quickly return to the nearest port for repairs.CAUTIONAll the above alarm signs will continueuntil you push the starting button orturn the key off.ABCDEFA(5) The warning buzzer should sound.WARNINGThe rubber seal alarm lamp warns ofseawater entering the boat. The watertight structure of the Sail-Drive is thedual type. Even if the rubber diaphragm(A) is damaged and seawater enters,the rubber diaphragm (B) prevents itfrom entering the inboard. The rubberseal switch between the rubber diaphragms (A) and (B) works the warningbuzzer and lights the rubber seal lampONON (Rubber seal lamp)BuzzerRubber seal switchDiaphragm (B)Diaphragm (A)SeawaterBCDEF003446-00E11EN
4. Starting the New Sail-Drive for the First Time4.3 Remote-Control Device Check4.3.0.1 SD20While cranking the engine slowly, shift thecontrol handle of the remote-control head(single lever control) rapidly through Neutral - Ahead - Neutral - Astern. If a shift operation is done slowly, the tip of the clutchdog is worn away by being hammered,BAand, consequently, the clutch fails to engage. Confirm that the operation lever ofthe Sail-Drive moves smoothly to Ahead,Astern and Stopper. Because theSail-Drive SD20 uses a dog clutch, theclutch is not engaged unless the operationlever is moved to the stopper position.MCNLODREENPQSFTUOld type :Serial No. 0001-2128 for SD10DGHIJKNew type :Serial No. 2129 and after for SD20003447-00ENew type: Serial No. 2129 and after for SD20A Control handleB AsternC NeutralD AheadE Operation leverF Cable clampG Remote control cableH PivotI AsternJ NeutralK Ahead12Old type: Serial No. 0001-2128 for SD10L Ahead stopperM Neutral positionN Astern stopperO Cable clampP Remote control cableQ Spring jointR Operation leverS AsternT NeutralU Ahead
4. Starting the New Sail-Drive for the First Time4.3.0.2 SD50 & SD50-4TAfter starting the engine, check the shiftaction by using the control head to shift theAhead and Astern positions. The Ahead/Astern clutch is a mechanical clutch calleda cone clutch. Although a grinding noise ismade when this type of clutch is engaged,it has no effect on the operation of the engine.ABCCAUTIONBecause of the rubbing produced at thefrictional face of the cone clutch, gripping action is lessened with use andperiodic inspection and maintenance isnecessary.DEFGH003448-00EA When attaching the cable mounting plate at a 90ºangle handleB Operation leverC Cable clampD Remote control cableE Propeller shaft clockwiseF PivotG NeutralH Propeller shaft counter-clockwise13EN
4. Starting the New Sail-Drive for the First Time4.4 Fitting for Fixed Propeller (2-blade)ABCDESpacerGreaseWasherPropellerNut Tightening torque 60-70 Nm (M16,SD20)80-100 Nm (M20, SD50/-4T)F Bolt M8x75mmTightening torque11-15 NmECABFD003449-00ELocking Procedure for Fixed Propeller Nut(Optional). When tightening the nut at60-70 Nm torque for the SD20, and 80-100Nm torque for the SD50/-4T, move theshift lever to ahead and hold the crankshaft V-pulley clamp nut with a wrench tostop the rotation.ENCAUTIONRubber bushing (Folding propeller)For the sail-drive, be sure to use thefolding propeller which is provided witha rubber bushing. If a propeller is usedwithout rubber bushing, the shaft, bearing, and gears of the sail-drive are surely damaged.4.5 Recommended Propeller Size (Max.)Engine modelSail-Drive ModelFolding type Dia. mm(inch)2-blade, fixed typeDia. mm (inch)SD20355 (14)380 (15)2YM15368 (14.5)380 (15)3YM20380 (15)405 (16)3YM30405 (16)420 (16.5)457 (18)457 (18)457 (18)457 (18)457 (18)457 autions on matching of the propeller(1) Be sure to confirm a matching ofthe propeller in a sea trial.14(2) Execute a propeller matching onthe basis of the propeller shaft rated output (continuous rating at propeller shaft). 95% of the enginerated output (continuous rating atcrankshaft) becomes the propellershaft rated output (continuous rating at propeller shaft).
4. Starting the New Sail-Drive for the First TimeNote: The propeller shaft output becomes95% of the engine rated output (continuousrating at crankshaft) in consideration of mechanical efficiency 95% of the sail-drive.(3) In the case of propeller calculation,further add 5%, at minimum, as thesea margin to the aforementionedmatching point. That is, 95% of thepropeller shaft rated output (Continuous rating at propeller shaft)becomes the best propeller matching. Note about sea margin: In actu-al navigation, there is an increasein resistance due to the waves,wind and fouling of the hull and,moreover, a drop in the efficiencydue to fouling of the propeller. Consequently, in the case of propellercalculation, it is necessary to allowthe engine output to have somemargin. For that reason, it is necessary to add the sea margin of 5%, atminimum.EN15
5. Method of Operation5. Method of Operation5.1 Engine Cooling WaterNote: For other items, refer to the engine operation manual.Opening or closing the cooling water system of the Sail-Drive Set Engine is done bythe cooling water cock fixed on the uppercase of the Sail-Drive. Be sure to open thecock and confirm that the C.W. has suctionby cranking the engine before starting theboat. The cooling water passes throughthe Sail-Drive case, cools the engine bythe cooling water pump, and is then discharged.Note: When sailing, set the remote control leverin neutral.Old type:Serial No.0001-2128 for Model SD20New type:Serial No.2129 and after for Model SD205.1.1 SD20ENEDFAGBHCDI003442-00EA AternB NeutralC Ahead16D NeutralE Cock, C.W.F C.W. hoseG To C.W. pumpH Hose clampI Seawater inlet
5. Method of Operation5.1.2 SD50/SD50-4TA40BD40EENFC003450-00EA OpenB To C.W. pumpC Cock C.W.D Propeller shaft ClockwiseE NeutralF Propeller shaft Counter-clockwise17
6. Periodic Inspections and Maintenance6. Periodic Inspections and MaintenanceEvery day50 hrs. or after1 monthEvery 100 hrs.Every 250hrs.FirstOSD20OSD50/-4TOEvery 1 yearEvery 2 yearsLubricating Oil(1)Check oil level: fill(2)Change lube oilBefore operationOCooling Water(1)Open/close cooling water cock(2)Clean cooling water suction hole(3)Drain cooling waterBefore/afteroperationOOAfter operationORemote Control SystemEN(1)Inspect remote controldevice(2)Inspect and replaceclutch shifterAnti-Corrosive Zinc(1)Inspect and replace anti-corrosive zincFirstOReplace ifthe thickness is lessthan 10 mm.OSerial No. 2129and after forSD20OReplace ifwear ismore than50%OLower Case(1)Repair case coatingOInspect andreplace, if thereis cracking, or atleast every 6yearsOBoat Bottom Water- tightness(1)Inspect and replace rubber diaphragm seal ring(2)Inspect seal sensorFlexible mount(1)Inspect and replacemounting height.OReplace ifclearance isless than 1mm.OA003451-00EA: Clearance18
6. Periodic Inspections and Maintenance6.1 Lubricating oil system6.1.1 SD20(1) Check the oil level before every operation.(2) Change the oil after the first 50hours of operation or after longstorage and every 100 hours of operation thereafter. Lube oil shouldbe changed while the engine is stillwarm.forcefully if the drain plug is removedfrom the drive unit immediately afteroperation.SD20ABChange oil in the following manner:(1) Put the boat hull on a block.Drain the oil by removing the lowergear case drain plug, and the uppergear case oil dipstick.ENWARNINGLet the drive unit cool at least 5 minutesafter operation before removing the oildrain plug. Hot oil could spurt outCD003440-00EABCDDipstickUpper gear caseLower gear caseLube oil drain plug19
6. Periodic Inspections and Maintenance6.1.2 SD50/-4T(1) Check the oil level before every operation.(2) Change the oil after the first 50hours of operation or after longstorage, and every 250 hours of operation thereafter. Lube oil shouldbe changed while the engine is stillwarm.SD50/SD50-4TAWARNINGBLet the drive unit cool at least 5 minutesafter operation before removing the oildrain plug. Hot oil could spurt outforcefully if the drain plug is removedfrom the drive unit immediately afteroperation.ENC003441-00EA Dipstick20B PlugC Drain plug
6. Periodic Inspections and Maintenance6.2 Procedure for filling and removing oil in the Sail-Drive; SD50/-4TWhen the boat is (6.2.1) in the water and (6.2.2) out of the waterUsed equipment:DescriptionPart codeQuantityRemarksBottle of Quicksilver High Performance Gear Lube fromMerCruiserMerCruiser Part code92-850743A12Each bottle contains 0.946 liter of oil.Mandatory for SD50/-4T. For othermodels see page 8.Market pump from MerCruiseron bottleMerCruiser Part code91-85729A11Adapter joint196311-929601 (2)O-ring for adapter24311-0001001 (2)Stiff rubber hosesCompressor setHand pump2-128210-0000801Thread std. M10 x 1.5 max. length 12mm.Inner diameter ø14-16 mm hoseclips (If Yanmar part is used, part codeis 196440-92970)ENOption parts21
6. Periodic Inspections and Maintenance6.2.1 When the boat is in the water6.2.1.1 Preparing the sail-drive:A6.2.1.2 Removing oil (total quantity2.2 liter)BCADEN003453-00E003452-00EABCDO-ringAdapter jointOil changing plugTread M10 x 1.5(1) Take out the oil changing plug located under the shift lever.(2) Screw in the adapter joint (19631192960) with the O-ring(24311-000100). When using ownadapter joint, max. length of threadis 12 mm.(3) Attach a stiff rubber hose with innerdiameter ø14 16 mm with hoseclips to the adapter joint at the oilchanging position. Hose must belong enough to drain to bucket orpump. (If Yanmar original rubberhose is used, part code is196440-92970)22A Plug6.2.1.3 Fastest way: Blowing out byusing Air pressureFirst follow steps (1), (2), (3) on page 22(1) Take out the plug from the uppercase cover.(2) Screw in a second adapter joint (P/N 196311-92960
Reduction gear system Constant mesh gear with dog clutch use Cone clutch Direction of rotation Input shaft Counter-clockwise viewed from stern Propeller shaft Counter-clockwise viewed from stern Counter-clockwise or cl ockwise viewed from stern Reduction ratio Ahead 2.64 2.32 Astern 2.64 2.32 Propeller speed (min-1) 1364 1293 1638
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does not sag. The tighter the shade sail the less movement and less movement means longer life of the shade sail (Fig. 12). D. For Temporary Installations using rope (Fig. 13). 4 TURNBUCKLE: Used to attach shade sail corner ring to a fixing point and provide tension on the shade sail PAD EYE: Used to attach shade sail corner ring to a wall or post
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Gravity-offload system . . The 20-m four-quadrant solar sail system test article was fixed at the central hub of the solar sail. The position coordinates for the sail membrane shape were measured by photogrammetry with 768 reflective targets placed on the sail membrane. The reflective targets used in the photogrammetry can be seen in Fig. 4 .
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sail to bring the leech to between 2"-8" / 50-205mm from the tip of the lower spreader and the sail should be between 3"-8" / 75-205mm outside the shroud base. The sail will be inside the upper spreader as shown in the photo at right. First Reef Mark: With the genoa furled to the first reefing mark and the mark facing aft, the
