Transcription
Sail-DriveOPERATION MANUALSD20SD50SD50-4TP/N: 0ASDM-G00101SAILDRIVE
Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar andareregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.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 storageand retrieval systems - without the written permission of Yanmar Marine International. 2009 Yanmar Marine International0309iiSD Operation Manual 2009 Yanmar Marine International
TABLE OFCONTENTSPageIntroduction.1Safety.3Safety Precautions.3General Information . 4Before You Operate . 4During Operation and Maintenance . 5Product Overview.9Overview.9Owner / Operator Responsibilities . 9New Sail-Drive Break-In: . 9Dealer / Distributor Responsibilities . 9Component Identification.10Galvanic Corrosion.11Corrosion Control.11Shore Power.12Underwater Drive Coating.13Before You Operate.15Propeller Selection.16Recommended Propeller Size (Maximum) . 16Fitting a Fixed Propeller (2-Blade) . 17Lubricating Oil.18Filling With Lubricating Oil - SD20, SD50 and SD50-4T.19Checking the Instrument Panel Alarm System.20Daily Checks.23Visual Checks. 23Sail-Drive Operation.25Remote Control Device Check.26SD20 . 26SD50 / SD50-4T. 28Engine Cooling Water.29SD20 . 29SD Operation Manualiii 2009 Yanmar Marine International
TABLE OF CONTENTSSD50 / SD50-4T. 30Periodic Maintenance.31Tightening Fasteners.33Torque Charts.34Standard Torque Values . 34Standard Torque Chart . 34Periodic Maintenance. 35Periodic Maintenance Table.36When The Vessel Is Out Of The Water, Perform TheFollowing:.38Removing Deposits From The Lower Gear Case . 38Repairing Damaged Coating . 38Inspecting the Anode. 38Inspecting The Folding Propeller. 38Draining Water. 38Periodic Maintenance Procedures.39After Initial 50 Hours of Operation. 39Every 100 Hours of Operation . 48Every 250 Hours of Operation . 49Every 500 Hours of Operation . 49Every Year . 50Every 2000 Hours of Operation. 51Every 5 Years . 51Specifications.53System Diagrams.55Maintenance Log.80ivSD Operation Manual 2009 Yanmar Marine International
INTRODUCTIONThis Operation Manual describes Sail-Drive Models SD20, SD50, SD50-4T. For enginehandling and operation, refer to the respective operation manuals for Engine Models1GM10C, 2YM15, 3YM20, 3YM30, 3JH4CE, 3JH5CE, 4JH4ACE, 4JH5CE and 4JH4-TCE.However, instructions for the marine gear box are not necessary as they are included.Engines and Sail-Drive combinations are available as follows:Engine modelSail-Drive Model1GM10CSD202YM153YM20, D Operation Manual1 2009 Yanmar Marine International
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SAFETYYanmar considers safety of greatimportance and recommends that anyonethat comes into close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual.!This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.SAFETY PRECAUTIONSDANGERIndicates a hazardous situation which, ifnot avoided, will result in death orserious injury.WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.NOTICEIndicates a situation which can causedamage to the Sail-Drive, personal propertyand / or the environment or cause theequipment to operate improperly.SD Operation Manual3 2009 Yanmar Marine International
SAFETYGeneral InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.Before You OperateDANGERThe safety messages that follow haveDANGER level hazards. These safetymessages describe a hazardoussituation which, if not avoided, willresult in death or serious injury.NEVER permit anyone toinstall or operate the SailDrive without proper training. Read and understand this OperationManual before you operate or service theSail-Drive to ensure that you follow safeoperating practices and maintenanceprocedures. Safety signs and labels are additionalreminders for safe operating andmaintenance techniques. See your authorized Yanmar marinedealer or distributor for additional training.Crush HazardNEVER stand under a hoistedSail-Drive.If the hoist mechanism fails,the Sail-Drive will fall on you.When you need to transport aSail-Drive for repair, have a helper assistyou to attach it to a hoist and load it onto atruck.NEVER support Sail-Drive with equipmentnot designed to support the weight of theSail-Drive such as wood blocks or by onlyusing a jack.NEVER use the Sail-Drive lifting eye to liftthe engine and Sail-Drive as an assembly.Use the engine lifting eyes to lift the engineand Sail-Drive. Only use the Sail-Drive liftingeye to lift the Sail-Drive as a separatecomponent.4SD Operation Manual 2009 Yanmar Marine International
SAFETYDuring Operation andMaintenanceWARNINGThe safety messages that follow haveWARNING level hazards.DANGERThe safety messages that follow haveDANGER level hazards.Explosion HazardWhile the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area aroundthe battery well-ventilated and keep sparks,open flame and any other form of ignition outof the area.Fire HazardEnsure that appropriate firedetection and extinguishingequipment are installed andchecked periodically forproper operation.These safety messages describe ahazardous situation which, if notavoided, could result in death or seriousinjury.Fire HazardUndersized wiring systemscan cause an electrical fire.Sever HazardNEVER service the Sail-Drivewhile under tow or if theengine is running at idlespeed. The propeller mayrotate under thesecircumstances.Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or whenfeeling ill.SD Operation Manual5 2009 Yanmar Marine International
SAFETYCAUTIONWARNINGExposure HazardALWAYS wear personalprotective equipmentincluding appropriateclothing, gloves, workshoes, eye and hearingprotection as required bythe task at hand.Entanglement HazardNEVER leave the key in thekey switch when you areservicing the Sail-Drive.Someone may accidentallystart the engine and notrealize you are servicing it.NEVER operate the engine while wearing aheadset to listen to music or radio becauseit will be difficult to hear the warning signals.Burn HazardSome of the engine and SailDrive surfaces become veryhot during operation andshortly after shut-down. Keephands and other body partsaway from hot surfaces.The safety messages that follow haveCAUTION level hazards.These safety messages describe ahazardous situation which, if notavoided, could result in minor tomoderate injury.Poor Lighting HazardEnsure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.Tool HazardALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening machine parts.Exposure HazardALWAYS wear eye protectionwhen servicing the Sail-Driveor when using compressed airor high-pressure water. Dust,flying debris, compressed air,pressurized water or steam may injure youreyes.Sudden Movement HazardALWAYS stop the engine before beginningservice.Exhaust HazardNEVER block windows,vents, or other means ofventilation if the engine isoperating in an enclosed area.All internal combustionengines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.6SD Operation Manual 2009 Yanmar Marine International
SAFETYNOTICEThese notices describe a situationwhich, if not avoided, can cause damageto the Sail-Drive, personal property and /or the environment or cause equipmentto operate improperly.It is important to perform daily checks aslisted in this Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor Sail-Drive performance and canhelp extend the life of the Sail-Drive andengine.ALWAYS be environmentallyresponsible.The anode of the Sail-Drive is onlycalculated for the Sail-Drive. Changing thematerial of the propeller may requireadditional anodes to be installed on the saildrive.Failure to use the correct anode materialmay result in inadequate protection andexcessive corrosion of underwater drivesystem components. Use only zinc oraluminum anodes in brackish and saltwaterapplications. In freshwater applications, usealuminum or magnesium anodes for bestresults. NEVER use magnesium anodes inbrackish or salt water, as they willdeteriorate rapidly, which will lead to severedamage to the drive system.Follow the guidelines of theEPA or other governmentalagencies for the properdisposal of hazardous materials such aslubrication oil, diesel fuel and enginecoolant. Consult the local authorities orreclamation facility.NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.NEVER attempt to modify the Sail-Drive’sdesign or safety features. NEVER release or modify the limitingdevices such as the engine speed limit,fuel injection limit, etc. Modification will impair the safety andperformance of the product and shortenproduct life. Modifications to the design, safety orlimiting features will void the warranty.If the Sail-Drive oil temperature is too high,stop engine immediately and check the SailDrive oil level and check the oil cooler forproper coolant and water flow.SD Operation Manual7 2009 Yanmar Marine International
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PRODUCT OVERVIEWOVERVIEWNew Sail-Drive Break-In:Owner / OperatorResponsibilitiesThe operator must, and assumes allresponsibility to: Read and understand the operationmanual prior to operating the sail-drive; Perform all safety checks as necessary toensure safe operation; Comply with and follow all lubrication andmaintenance instructions andrecommendations; and Have an authorized Yanmar dealer /distributor perform periodic checkups.Conducting normal maintenance serviceand replacing consumable parts asnecessary is the responsibility of the owner /operator and necessary to provide the bestdurability, performance and dependability ofthe Sail-Drive while keeping your overalloperating expenses to a minimum.Individual operating habits and usage mayincrease the frequency of performingmaintenance service condition. Monitorconditions frequently to determine if themaintenance intervals suggested in themanual are frequent enough for your SailDrive. On the initial engine start-up, allow theengine to idle for approximately 15minutes while you check for proper SailDrive function and Sail-Drive oil leaks. During the break-in period, carefullyobserve Sail-Drive seal indicators forproper Sail-Drive function. During the break-in period, check the SailDrive oil levels frequently.Dealer / DistributorResponsibilitiesIn general, a dealer's responsibilities to thecustomer include predelivery inspectionand preparation such as: Ensure that the vessel is properlyequipped. Prior to delivery, make certain that theYanmar Sail-Drive and other equipmentare in proper operating condition. Make all necessary adjustments formaximum efficiency. Familiarize the customer with the on-boardequipment. Explain and demonstrate the operation ofthe Sail-Drive and vessel.SD Operation Manual9 2009 Yanmar Marine International
PRODUCT OVERVIEWCOMPONENT ��––DipstickUpper Gear CaseLower Gear CaseLubricating Oil Drain PlugFigure 15 – Propeller6 – Seawater Inlet7 – Flexible Mount10SD Operation Manual 2009 Yanmar Marine International
PRODUCT OVERVIEWGALVANIC CORROSIONCORROSION CONTROLGalvanic corrosion results whenever two ormore dissimilar metals (like those found onthe sail-drive) are submerged in aconductive solution, such as saltwater,polluted water or water with a high mineralcontent because a chemical reaction takesplace causing electrical current to flowbetween the metals. The electrical currentflow causes the metal that is mostchemically active, or anodic, to erode. If notcontrolled, galvanic corrosion may corrodeSail-Drive components.It is the boat designer’s responsibility and/orthe re-powering engineer’s responsibility todesign the proper systems and equipmentto control and reduce the possibility ofgalvanic corrosion.However, it is essential that the owner/operator frequently monitor the anodes forwear, inspect the sail-drive for corrosion andreplace the anodes often enough to providea sacrificial surface for the electrical currentto attack. Galvanic isolators and isolationtransformers are also available from theaftermarket (not supplied by Yanmar). TheGalvanic isolator is a device that is installedin series with the (AC) grounding (GREEN)conductor of the shore-power cable toeffectively block low-voltage DC galvaniccurrent flow but permit the passage ofalternating current (AC) *.The rate of corrosion depends on numerousfactors, such as: the number, size and location of sacrificialanodes on the sail-drive and vessel; the marina environment, such as straycurrent in the water, fresh or salt water anduse and isolation of shore power; improper application of marine paint orantifouling paint; failure to repaint damaged areas; and how the vessel is bonded.Please check with the boat builder, dealer orother professional to determine if yourvessel and/or Sail-Drive is adequatelyprotected from galvanic corrosion.NOTICE: The anode of the Sail-Drive is onlycalculated for the Sail-Drive. Changing thematerial of the propeller may requireadditional anodes to be installed on the SailDrive.*“The Boatowner's Guide to Corrosion”, by Everett Collier.SD Operation Manual11 2009 Yanmar Marine International
PRODUCT OVERVIEWNOTICE: Failure to use the correct anodematerial may result in inadequate protectionand excessive corrosion of underwater drivesystem components. Use only zinc oraluminum anodes in brackish and saltwaterapplications. In freshwater applications, usealuminum or magnesium anodes for bestresults. NEVER use magnesium anodes inbrackish or salt water, as they willdeteriorate rapidly, which will lead to severedamage to the drive system.SHORE POWERIf sacrificial anodes erode quickly or if signsof corrosion are evident, the owner shouldtake immediate corrective action. Yanmarrecommends consulting an engineerspecializing in marine electricity andcorrosion control to determine the best wayto correct the rapid erosion of the anodes.NOTICE: If the AC shore power ground isnot isolated from the boat ground, sacrificialanodes may be unable to neutralize theincreased galvanic potential. Corrosiondamage that results from the impropersystem design or application is not coveredby the Yanmar Limited Warranty.Vessels that are connected to shore powerrequire additional protection to preventdestructive low voltage galvanic currentsfrom passing through the shore powerground wire. Galvanic isolators are availablefrom the aftermarket (not supplied byYanmar) to block these currents while stillproviding a path to ground for dangerousshock currents.12SD Operation Manual 2009 Yanmar Marine International
PRODUCT OVERVIEWUNDERWATER DRIVECOATINGThe lower gear case coating may bedamaged when hit by objects in the water,or when having deposits removed from it.The underwater coating must be inspectedat least once per year and when it is believedthat an object was hit that may have causeddamage. Repair and repaint damagedareas immediately.Observe the following precautions whenapplying antifouling or marine paint to thebottom of the boat hull: ALWAYS follow the paint/coatingmanufacturer's directions for surfacepreparation and application. ALWAYS use a high quality primer andtopcoat paint specifically designed foraluminum outboards, Sail-Drives or SternDrives. NEVER paint the sacrificial anodesinstalled on the Sail-Drive. NEVER paint the Sail-Drive with a materialthat contains copper or tin. NEVER paint over drain holes, sacrificialanodes, or other items specified by thesacrificial anode Manufacturer.Contact
INTRODUCTION This Operation Manual describes Sail-Drive Models SD20, SD50, SD50-4T. For engine handling and operation, re
