Saildrive 20 Manual

SAIL-DRIVE

Sail-DriveOPERATION MANUAL

SD20SD50

SD50-4T

P/N: 0ASDM-G00101

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 and areregistered 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 International

0309

ii SD Operation Manual© 2009 Yanmar Marine International

TABLE OFCONTENTS

PageIntroduction......................................................................1Safety...............................................................................3

Safety Precautions.........................................................3General Information ................................................. 4Before You Operate ................................................. 4During Operation and Maintenance ............................. 5

Product Overview..............................................................9Overview......................................................................9

Owner / Operator Responsibilities ............................... 9New Sail-Drive Break-In: ........................................... 9Dealer / Distributor Responsibilities ............................. 9

Component Identification...............................................10Galvanic Corrosion.......................................................11Corrosion Control.........................................................11Shore Power...............................................................12Underwater Drive Coating..............................................13

Before You Operate..........................................................15Propeller Selection.......................................................16

Recommended Propeller Size (Maximum) .................. 16Fitting a Fixed Propeller (2-Blade) ............................. 17

Lubricating Oil.............................................................18Filling With Lubricating Oil - SD20, SD50 and SD50-4T.........19Checking the Instrument Panel Alarm System.....................20Daily Checks...............................................................23

Visual Checks....................................................... 23Sail-Drive Operation.........................................................25

Remote Control Device Check........................................26SD20 .................................................................. 26SD50 / SD50-4T.................................................... 28

Engine Cooling Water...................................................29SD20 .................................................................. 29

SD Operation Manual iii© 2009 Yanmar Marine International

SD50 / SD50-4T.................................................... 30Periodic Maintenance.......................................................31

Tightening Fasteners....................................................33Torque Charts.............................................................34

Standard Torque Values ......................................... 34Standard Torque Chart ........................................... 34Periodic Maintenance............................................. 35

Periodic Maintenance Table...........................................36When The Vessel Is Out Of The Water, Perform TheFollowing:...................................................................38

Removing Deposits From The Lower Gear Case .......... 38Repairing Damaged Coating .................................... 38Inspecting the Anode.............................................. 38Inspecting The Folding Propeller............................... 38Draining Water...................................................... 38

Periodic 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 ....................................................... 51

Specifications..................................................................53System Diagrams.............................................................55

Maintenance Log.........................................................80

TABLE OF CONTENTS

iv SD 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 model Sail-Drive Model1GM10C

SD202YM153YM20, 3YM303JH4CE

SD503JH5CE4JH4ACE4JH5CE4JH4-TCE SD50-4T

SD Operation Manual 1© 2009 Yanmar Marine International

This Page Intentionally Left Blank

INTRODUCTION

2 SD Operation Manual© 2009 Yanmar Marine International

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 PRECAUTIONS DANGER

Indicates 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.


General 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 Operate DANGER

The 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 Sail-Drive 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 a

Sail-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.

SAFETY


During Operation andMaintenance

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 around

the 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.

WARNINGThe safety messages that follow haveWARNING level hazards.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 these

circumstances.Alcohol and Drug Hazard

NEVER operate the enginewhile under the influence ofalcohol or drugs or whenfeeling ill.

SAFETY


WARNINGExposure Hazard

ALWAYS 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 not

realize 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 Sail-Drive surfaces become veryhot during operation andshortly after shut-down. Keephands and other body parts

away from hot surfaces.Sudden Movement Hazard

ALWAYS stop the engine before beginningservice.

Exhaust HazardNEVER block windows,vents, or other means ofventilation if the engine isoperating in an enclosed area.All internal combustion

engines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.

CAUTIONThe 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.

SAFETY


NOTICEThese 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.Follow the guidelines of theEPA or other governmentalagencies for the proper

disposal 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 limiting

devices 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 Sail-Drive oil level and check the oil cooler forproper coolant and water flow.

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 sail-drive.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.

SAFETY



SAFETY


PRODUCT OVERVIEWOVERVIEWOwner / OperatorResponsibilitiesThe operator must, and assumes allresponsibility to:• Read and understand the operation

manual prior to operating the sail-drive;• Perform all safety checks as necessary to

ensure safe operation;• Comply with and follow all lubrication and

maintenance instructions 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 Sail-Drive.

New Sail-Drive Break-In:• On the initial engine start-up, allow the

engine to idle for approximately 15minutes while you check for proper Sail-Drive 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 Sail-Drive oil levels frequently.

Dealer / DistributorResponsibilitiesIn general, a dealer's responsibilities to thecustomer include predelivery inspectionand preparation such as:• Ensure that the vessel is properly

equipped.• Prior to delivery, make certain that the

Yanmar 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.


COMPONENT IDENTIFICATION

(1)

(2)

(3)

(4)

0006440

(5)

(6)

(7)

Figure 11 – Dipstick2 – Upper Gear Case3 – Lower Gear Case4 – Lubricating Oil Drain Plug

5 – Propeller6 – Seawater Inlet7 – Flexible Mount

PRODUCT OVERVIEW


GALVANIC CORROSIONGalvanic 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.

CORROSION CONTROLIt 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 sacrificial

anodes on the sail-drive and vessel;• the marina environment, such as stray

current 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 Sail-Drive.

* “The Boatowner's Guide to Corrosion”, by Everett Collier.

PRODUCT OVERVIEW


NOTICE: 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.If 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.

SHORE POWERVessels 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.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.

PRODUCT OVERVIEW


UNDERWATER 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/coating

manufacturer's directions for surfacepreparation and application.

• ALWAYS use a high quality primer andtopcoat paint specifically designed foraluminum outboards, Sail-Drives or Stern-Drives.

• 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 your authorized Yanmar Marinedealer or distributor for assistance.NOTICE: Galvanic corrosion damage,normal maintenance and consumable partsare not covered by the Yanmar LimitedWarranty.

PRODUCT OVERVIEW



PRODUCT OVERVIEW


BEFORE YOU OPERATEThis section of the Operation Manualdescribes propeller selection, propellerfitting, lubricating oil specifications and howto replenish them. It also describes the dailyinstrument panel and remote-control devicechecks.Before you operate the Sail-Drive, reviewthe Safety section on page 3.


PROPELLER SELECTIONRecommended Propeller Size (Maximum)

Engine Model Sail-Drive Model Folding TypeDiameter

2-Blade Fixed TypeDiameter

1GM10C

SD20

14 in. 14 in.2YM15 14.5 in. 15 in.3YM20 15 in. 16 in.3YM30 16 in. 16.5 in.

3JH4CE

SD50 18 in. 18 in.3JH5CE4JH4ACE4JH5CE

4JH4–TCE SD50-4T 18 in. 18 in.

NOTICE: Make sure the propeller (fixed orfolding) has a rubber bushing. If a propelleris used without a rubber bushing, the shaft,bearing and gears of the Sail-Drive will bedamaged.

BEFORE YOU OPERATE


Fitting a Fixed Propeller (2-Blade)

(1)

(2) (3)

(4) (5)(6)

0005446

Figure 11 – Spacer2 – Grease3 – Propeller

4 – Washer5 – Nut *6 – Bolt **

Size Tightening Torque* M16 (SD20)

M20 (SD50, SD50-4T)60 to 70 N·m (44 to 52 lb-ft)80 to 100 N·m (59 to 74 lb-ft)

** M8 x 75 mm 11 to 15 N·m (8 to 11 lb-ft)

Locking Procedure for Fixed Propeller Nut (Optional)When tightening the nut to 60 to 70 N·m (44 to 52 lb-ft) torque for the SD20, and80 to 100 N·m (59 to 74 lb-ft) torque for the SD50 and SD50-4T, move the shift lever to aheadand hold the crankshaft V-pulley clamp nut with a wrench to stop the propeller rotating.

BEFORE YOU OPERATE


LUBRICATING OILThe choice of lubricating oil is very important. If an unsuitable oil is used, or an oil change isneglected, it may result in damage and reduce the life of the Sail-Drive. When selecting alubricating oil, use one of the following:Lubricating Oil Chart

Engineseries

GM, YM JH3, JH4, JH5

Enginemodel

1GM10C 2YM15, 3YM20, 3YM30 3JH4E, 3JH5E, 4JH4AE, 4JH5E 4JH4-TE

Sail-Drivemodel

SD20 SD20 SD50 SD50-4T

Lubricatingoil for theSail-Drive

API CC orgreater

and SAE10W30

API GL4 or GL5 and SAE80W90 or 90

QuickSilver® High Performance Gear Oil

Use only oil of quality GL-4 or GL-5 in the API service, and SAE No. 90 or 80W90. (Exceptmodel SD20 x 1GM10C & SD50 / SD50-4T).Use only oil of quality CC or greater in the API service, and SAE No. 10W30. (Applicablemodel: SD20 x 1GM10C).For SD20 (except if coupled with the 1GM10C)

Supplier Brand Name API Service SAE No.SHELL Shell Spilax oil EP 90 GL-4 90SHELL Shell Spilax oil HD 90 GL-5 90CALTEX Multipurpose thuban EP GL-4/GL-59 90MOBIL Mobilub HD 80W-90 GL-5 80W-90ESSO Esso gear oil GP 90 GL-4 90ESSO Esso gear oil GX 90 GL-5 90

Use QuickSilver® * High Performance Gear Oil for the SD50 / SD50-4T.

* QuickSilver® is a registered trademark of Brunswick Corporation.

BEFORE YOU OPERATE


FILLING WITHLUBRICATING OIL - SD20,SD50 AND SD50-4T

Sail-Drivemodel

SD20 SD50, SD50-4T

Standardunit

2.2 L(2.3 qt)

2.2 L (2.3 qt)

Long-reachunit

2.5 L(2.6 qt)

2.35 L (2.5 qt)Extension 582.45 L (2.6 qt)Extension 100

NOTICE: The lubricating oil capacity of thestandard unit is different from that of thelong-reach unit. Confirm the capacity bymeans of the oil capacity nameplate.1. Remove the dipstick (yellow cap). Fill

with approved lubricating oil.2. Check the amount of lubricating oil by

inserting the dipstick as far as possible.Do not screw the dipstick in(Figure 3, (1)). The oil level shouldreach the upper mark on the dipstick(Figure 3, (2)).

NOTICE: It takes about 10 minutes to fill upthe Sail-Drive with lubricating oil. Check theoil level 15 minutes after adding thespecified quantity of oil.

(1)

(2)

(3)

0005573

Figure 21 – Dipstick2 – Upper Limit3 – Lower Limit

SD20

0005441

(1)

(2)

Figure 31 – Oil Supply Port2 – Oil Capacity Nameplate

SD50/SD50-4T

(1)

(2)

0005574

Figure 41 – Oil Supply Port2 – Oil Capacity Nameplate

BEFORE YOU OPERATE


CHECKING THE INSTRUMENT PANEL ALARM SYSTEMNew B-Type

0000472SD

(1)(2)(3)(4)

(5) (6)(7) (8)

Figure 51 – Battery Low Charge Alarm2 – Sail-Drive Seal Warning Lamp3 – Engine Oil Low Pressure Lamp4 – Coolant High Temperature Alarm5 – Hour Meter6 – Tachometer7 – Key Switch8 – STOP Button

B (Keyless) - Type

0

10

20 30

40

50

(8) (7) (5)(6)

(1) (2) (3) (4)

026102-00X

Figure 61 – Coolant High Temperature

Indicator2 – Engine Oil Low Pressure

Indicator3 – Water in Sail Drive Seal Indicator4 – Battery Low Charge Indicator5 – ON/OFF/START Switch6 – GLOW/STOP Switch7 – Hourmeter8 – Tachometer

BEFORE YOU OPERATE


New C-Type

0000473SD

(1)(2)(3)(4)(5) (11)

(6) (12) (7) (8) (9) (10)

Figure 71 – Battery Low Charge Alarm2 – Sail-Drive Seal Warning Lamp3 – Fuel Filter Warning Lamp4 – Seawater Insufficient Flow Alarm5 – Coolant Temperature Gauge6 – Engine Oil Pressure Gauge7 – Hour Meter8 – Tachometer9 – Key Switch10–STOP Button11–Coolant High Temperature

Warning Lamp12–Engine Oil Low Pressure

Warning Lamp

C (Keyless) - Type

(10) (9)

(2)

(11) (8) (7)

(1)

(12)

(5) (6)(4)(3)

026103-00X

Figure 81 – Coolant High Temperature

Indicator2 – Coolant Temperature Gauge3 – Not Used On This Engine4 – Water in Fuel Filter Indicator5 – Water in Sail Drive Charge

Indicator6 – Battery Low Charge Indicator7 – ON/OFF/START Switch8 – GLOW/STOP Switch9 – Hourmeter10–Tachometer11–Engine Oil Pressure Gauge12–Engine Oil Low Pressure

Indicator

BEFORE YOU OPERATE


Turn the battery switch on. Turn the key tothe ON position and check the lamps on thepanel (Figure 5, Figure 7) with the engineoff:1. The lubricating oil warning lamp should

be illuminated (Figure 5, 3,Figure 7, 6) .

2. The cooling water temperature warninglamp should be out (Figure 5, 4,Figure 7, 5) .

3. The charge warning lamp should beilluminated (Figure 5, 1, Figure 7, 1) .

4. The rubber seal warning lamp should beout (Figure 5, 2, Figure 7, 2) .

5. The warning buzzer should sound.Note: All the above alarm signals willcontinue until you push the starting button orturn the key to the OFF position.

WARNING! The rubber seal alarm lampwarns of seawater entering the vessel.The watertight structure of the Sail-Drive is dual type. Even if the rubberdiaphragm A (Figure 9, (5)) is damagedand seawater enters, the rubberdiaphragm B (Figure 9, (4)) prevents itfrom entering the vessel. The rubberseal switch between the rubberdiaphragms (Figure 9, (5)) and(Figure 9, (4)) sounds the warningbuzzer and lights the rubber seal lampon the instrument panel. If this happens,stop the engine and under sail, quicklyreturn to the nearest port for repairs.

(2) (3)

(1)

(4)

(5)019410-01X

Figure 91 – ON (Rubber Seal Lamp)2 – Rubber Seal Switch3 – Diaphragm (B)4 – Diaphragm (A)5 – Seawater

BEFORE YOU OPERATE


DAILY CHECKSBefore starting the Sail-Drive, make sure itis in good operating condition. Make sureyou check the following items:Visual Checks1. Check for damaged or missing parts.2. Check for loose, missing or damaged

fasteners.3. Check oil level. See Filling With

Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

4. Open cooling water cock beforeoperation. Drain cooling water andclose cooling water cock afteroperation. See Engine Cooling Water on page 29

NOTICE: If any problem is noted during thevisual check, the necessary correctiveaction should be taken before you operatethe engine.

BEFORE YOU OPERATE



BEFORE YOU OPERATE


SAIL-DRIVE OPERATIONBefore you operate the Sail-Drive, read thefollowing safety information and review theSafety section on page 3.

WARNINGThe safety messages that follow haveWARNING level hazards.These safety messages describe ahazardous situation which, if not avoided,could result in death or serious injury.To prevent accidental equipmentmovement, NEVER start the engine in gear.Before starting the engine, ALWAYS makesure that all bystanders are clear of the area.Keep children and pets away while theengine is operating.Avoid unexpected equipment movement.Shift the Sail-Drive into the NEUTRALposition any time the engine is at idle.


REMOTE CONTROL DEVICECHECKSD20NOTICE: Before operating the engine,check Sail-Drive oil level. While cranking theengine slowly, shift the control handle of theremote-control head (single lever control)rapidly through NEUTRAL - AHEAD -NEUTRAL - ASTERN. If a shift operation isdone slowly, the tip of the clutch dog is wornaway by being hammered, and,consequently, the clutch fails to engage.Confirm that the operation lever of the Sail-Drive moves smoothly to AHEAD, ASTERNand NEUTRAL. Because the Sail-DriveSD20 uses a dog clutch, the clutch is notengaged unless the operation lever ismoved to the NEUTRAL position.

NOTICE: When sailing, set the remotecontrol lever in neutral. Not doing so WILLintroduce slippage and void your warranty(Figure 1, (2)).

(1)

(2)

(3)

(4)

019631-00X

Figure 11 – Astern2 – Neutral3 – Ahead4 – Control Handle

SAIL-DRIVE OPERATION


(1)(2)(3)

(4)

(5)

(6)

(7) (8)(9)

(10)

019719-00X

Figure 21 – Astern2 – Neutral3 – Ahead4 – Operation Handle5 – Cable Clamp6 – Remote Control Cable7 – Ahead Stop8 – Neutral Position9 – Astern Stop10–Spring Joint

D

D

(1)(2)

(3)

(4)

(6)

(5)

(7)

019720-00X

Figure 31 – Astern2 – Neutral3 – Ahead4 – Operation Lever5 – Cable Clamp6 – Remote Control Cable7 – Pivot



SD50 / SD50-4TAfter starting the engine, check the shiftaction by using the control head to shift theAHEAD and ASTERN positions. TheAHEAD / ASTERN clutch is a mechanicalclutch called a cone clutch. Although agrinding noise is made when this type ofclutch is engaged, it has no effect on theoperation of the engine.CAUTION! Because of the rubbingproduced at the frictional face of thecone clutch, friction is decreased withuse and periodic inspection andmaintenance is necessary.NOTICE: When sailing, set the remotecontrol lever in neutral. Not doing so WILLintroduce slippage and void your warranty.NOTICE: Running for long periods at lowrpm with the Sail-Drive engaged can causeslipping and premature wear of the coneclutch.

(2)

(3)

(4)

(5) (8)(7)

(6)

(1)

003448-01X

Figure 41 – Mounting Plate at 90° Angle2 – Operation Lever3 – Cable Clamp4 – Remote Control Cable5 – Propeller Shaft Clockwise6 – Pivot7 – Neutral8 – Propeller Shaft Counter-

Clockwise



ENGINE COOLING WATEROpening or closing the cooling water systemof the engine driving the Sail-Drive is doneby the cooling water cock fixed on the uppercase of the Sail-Drive. Be sure to open thecock (Figure 5, (1)) and confirm that thecooling water has suction by cranking theengine before starting the vessel. Thecooling water passes through the Sail-Drivecase, cools the engine by the cooling waterpump, and is then discharged.SD20

(1)(2)

(3)

(4)

(5)

0005447

Figure 51 – Cooling Water Cock2 – Cooling Water Hose3 – To Cooling Water Pump

4 – Hose Clamp5 – Seawater Inlet



SD50 / SD50-4T

0005448

(1)

(2)

(3)

Figure 61 – To Cooling Water Pump2 – Cooling Water Cock

3 – Open



PERIODIC MAINTENANCEBefore you perform maintenance on theSail-Drive, read the following safetyinformation and review the Safety section onpage 3.This section of the Operation Manualdescribes the procedures for proper careand maintenance of the Sail-Drive.

WARNINGThe safety messages that follow haveWARNING level hazards.These safety messages describe ahazardous situation which, if notavoided, could result in death or seriousinjury.

Sever HazardNEVER wear jewelry,unbuttoned cuffs, ties or loosefitting clothing and ALWAYStie long hair back whenworking near moving / rotating

parts. Keep hands, feet and tools away fromall moving parts.Always remove any tools or shop rags usedduring maintenance from the area beforeoperation.NEVER service the Sail-Drive while undertow or if the engine is running at idle speed.The propeller may rotate under thesecircumstances.ALWAYS stop the engine before you beginto service the Sail-Drive and secure thepropeller so it will not turn.


WARNINGElectrical Shock Hazard

ALWAYS turn off the batteryswitch (if equipped) ordisconnect the negativebattery cable before servicingthe Sail-Drive.

ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

CAUTIONThe safety messages that follow haveCAUTION level hazards.These safety messages describe ahazardous situation which, if notavoided, could result in minor ormoderate injury.

Slipping and Tripping HazardEnsure that adequate floorspace is set aside forservicing Sail-Drive. The floorspace must be clean, flat andfree of spilled liquids and

debris to prevent slipping or tripping.

PERIODIC MAINTENANCE


NOTICEThese notices describe a situation which, ifnot avoided, can cause damage to the Sail-Drive, personal property and / or theenvironment, or cause equipment tooperate improperly.Always tighten components to the specifiedtorque. Loose parts can cause equipmentdamage or cause it to operate improperly.Only use replacement parts specified. Otherreplacement parts may affect warrantycoverage.NEVER attempt to modify the Sail-Drive’sdesign or safety features. Failure to complymay impair the marine gear’s safety andperformance characteristics and shortenthe Sail-Drive’s life. Any alterations to thisSail-Drive may affect the warranty coverageof your Sail-Drive.

TIGHTENING FASTENERSUse the correct amount of torque whentightening fasteners. Applying excessivetorque may damage the fastener orcomponent and too little torque may causea leak or component failure.

The tightening torque in the StandardTorque Chart should be applied only to thebolts with a “7” head. (JIS strengthclassification: 7T).Apply 60% torque to bolts that are not listed.Apply 80% torque when tightened toaluminum alloy.



TORQUE CHARTSStandard Torque Values

M6 x 1.0 M8 x 1.25 M10 x 1.25or 1.5

M12 x 1.25or 1.5

M14 x 1.5 M16 x 1.5

Cast Ironor Steel

10.8 ± 1.0N·m8.0 ± 0.8lb-ft

25.5 ± 2.0N·m18.8 ± 1.5lb-ft

49.1 ± 4.9N·m36.2 ± 3.6lb-ft

88.3 ± 10.0N·m65.1 ± 7.4lb-ft

137.2 ± 4.9N·m101.2 ± 3.6lb-ft

225.4 ± 10.0N·m166.2 ± 7.4lb-ft

Aluminum 8.8 ± 1.0N·m6.5 ± 0.8lb-ft

20.6 ± 2.0N·m15.2 ± 1.5lb-ft

39.2 ± 2.0N·m28.9 ± 1.5lb-ft

70.6 ± 4.9N·m52.1 ± 3.6lb-ft

109.8 ± 4.9N·m81.0 ± 3.6lb-ft

180.3 ± 10.0N·m133.0 + 7.4lb-ft

Standard Torque ChartThread size × Pitch

mmM6×1.0 M8×1.25 M10×1.5 M12×1.75 M14×1.5 M16×1.5

TighteningTorque

lb-in. 96.0 ± 9.0 - - - - -lb-ft - 19.0 ± 2.0 36.0 ± 4.0 65.0 ± 7.0 101.0 ± 7.0 167.0 ± 7.0N·m 10.8 ± 1.0 25.5 ± 2.9 49.0 ± 4.9 88.3 ± 9.8 137.0 ± 9.8 226.0 ± 9.8

kgf-m 1.1 ± 0.1 2.6 ± 0.3 5.0 ± 0.5 9.0 ± 1.0 14.0 ± 1.5 23.0 ± 2.0



Periodic MaintenanceCAUTION! Establish a periodic maintenance plan according to the Sail-Driveapplication and make sure you perform the required periodic maintenance atintervals indicated. Failure to follow these guidelines will impair the Sail-Drive’ssafety and performance characteristics, shorten the Sail-Drive's life and may affectthe warranty coverage on your Sail-Drive.The Importance of Periodic MaintenanceSail-Drive deterioration and wear occur in proportion to the length of time the Sail-Drive hasbeen in service and the conditions it is subjected to during operation. Periodic maintenanceprevents unexpected downtime, reduces the number of accidents due to poor Sail-Driveperformance and helps extend the life of the Sail-Drive.The Importance of Daily ChecksThe Periodic Maintenance Table assumes that the daily checks are performed on a regularbasis. Make a habit of performing daily checks before the start of each operating day. SeeFilling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19, Checking the Instrument Panel Alarm System on page 20 and Engine Cooling Water on page 29, and refer to theOperation Manual for your engine.Keep a Log of Sail-Drive Hours and Daily ChecksKeep a log of the number of hours the Sail-Drive is run each day and a log of the daily checksperformed. Also note the date, type of repair (e.g., replaced bearings), and parts used forany service needed between the periodic maintenance intervals. Failure to perform periodicmaintenance will shorten the life of the Sail-Drive.Yanmar Replacement PartsYanmar recommends that you use genuine Yanmar parts when replacement parts areneeded. Genuine replacement parts help ensure long Sail-Drive life.Tools RequiredBefore you start any periodic maintenance procedure, make sure you have the tools youneed to perform all of the required tasks.Ask Your Authorized Yanmar Marine Dealer or Distributor For HelpOur professional service technicians have the expertise and skills to help you with anymaintenance or service related procedures.Daily and periodic maintenance is important to keep the Sail-Drive in good operatingcondition. The following is a summary of maintenance items by periodic maintenanceintervals. Periodic maintenance intervals vary depending on Sail-Drive application and arehard to establish definitively. The following should be treated only as a general guideline.Note: These procedures are considered normal maintenance and are performed at theowner’s expense.



PERIODIC MAINTENANCE TABLE◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

Daily(See Daily Checks on page 23.)

50Hours

OrAfter 1Month

Every100

HoursEvery250

HoursEvery500

hoursEveryYear

Every2000

HoursEvery

5Years

Lubricating Oil Check Oil

Level, Fill IfNecessary

Beforeoperation

◯

ChangeLubricating Oil First

◊SD20

◊SD50,SD50-

4T◊

Cooling Water Open/Close

Cooling WaterCock

Before / afteroperation

◯

Clean CoolingWater SuctionHole

◯

Drain CoolingWater

Afteroperation

◯

Remote Control System Inspect

RemoteControl Device

◯

Cone Clutch and Shifter Inspect /

replace or lap ● Replace the

cone-clutch ● Anode Inspect And

ReplaceAnode

◊

Lower Case Repair Case

Coating ● Boat Hull Water-Tightness Inspect

RubberDiaphragm

◯ ◊

Inspect SealSensor ◯



◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily

(See Daily Checks on page 23.)

50Hours

OrAfter 1Month

Every100

HoursEvery250

HoursEvery500

hoursEveryYear

Every2000

HoursEvery

5Years

Flexible Mount Inspect and/or

replace theflexible mount,mountingheight

●

Replace theflexible mount ●



WHEN THE VESSEL IS OUTOF THE WATER, PERFORMTHE FOLLOWING:Removing Deposits From TheLower Gear CaseRemove seaweed, seashells and othermarine growth from the lower gear case.Completely remove deposits around thecooling water intake (Figure 1, (2)) sincethe engine may overheat if the cooling waterintake amount is insufficient.Repairing Damaged CoatingThe lower gear case coating may bedamaged when hit by objects in the water,or when having deposits removed from it.NEVER use paint containing copper or tin.This will damage the drive and void thewarranty. Use a high quality primer andtopcoat paint specifically designed foraluminum outboards or stern-drives. Followthe manufacturer's directions for surfacepreparation and application. Contact yourauthorized Yanmar Marine dealer ordistributor for assistance.Inspecting the AnodeSee Inspecting and Replacing the Anode on page 48.Inspecting The Folding PropellerConfirm that the blade of the foldingpropeller opens smoothly. Inspect for wearon the blade-fixing pins, replacing themwhen wear is excessive. Apply seawater-proof grease to the pins in the blade gearand propeller shaft.

Draining WaterDrain the engine cooling water, togetherwith the water in the Sail-Drive case. If thiswater is not drained, freezing may cause theengine block and / or the Sail-Drive case tocrack.

0005464

(2)

(1)

Figure 11 – Lower Gear Case2 – Seawater Inlet



PERIODIC MAINTENANCEPROCEDURES

After Initial 50 Hours ofOperation

Perform the following procedures after thefirst 50 hours of operation.• Draining and Replacing Lubricating Oil• Inspecting and Replacing the Clutch

ShifterDraining and Replacing LubricatingOil - SD20When the vessel is out of the water, drain theoil by removing the lower gear case drainplug, and the upper gear case oil dipstick.CAUTION! Let the drive unit cool at least5 minutes after operation beforeremoving the oil drain plug. Hot oil couldspurt out forcefully if the drain plug isremoved from the drive unitimmediately after operation.

SD20(1)

(2)

(3)

(4)

0005450

Figure 21 – Dipstick2 – Upper Gear Case3 – Lower Gear Case4 – Lubricating Oil Drain Plug

Inspecting and Replacing the ClutchShifterSee your authorized Yanmar dealer ordistributor for procedure.



Draining and Replacing LubricatingOil - SD50 / SD50-4TLubricating oil should be changed while theengine is still warm. CAUTION! Let thedrive unit cool at least 5 minutes afteroperation before removing the oil drainplug. Hot oil could spurt out forcefully ifthe drain plug is removed from the driveunit immediately after operation.

SD50 / SD50–4T

0005451

(1)(2)

(3)

Figure 31 – Dipstick2 – Plug3 – Drain Plug



Equipment UsedDescription Part Code Quantity Remarks

Bottle of Quicksilver®High Performance GearLube from MerCruiser®

MerCruiser® Part code92-850743A1

2 Each bottle contains0.946 L (1 qt) of oil. Man-datory for SD50,SD50-4T. For other mod-els see p. 7.

Market pump fromMerCruiser® on bottle

MerCruiser® Part code91-85729A1

1-

Adapter joint 196311-92960 1* Thread std. M10 x 1.5maximum length 12 mm.

O-ring for adapter 24311-000100 1* -Stiff rubber hoses

-2 Inner diameter 14 to 16

mm (0.5 to 0.625 in.) plushose clamps (If Yanmarpart is used, part code is196440-92970).

Compressor set - 1 -Hand pump 28210-000080 1 Optional parts

* When vessel is out of the water, 2 are required.



When Vessel Is In The WaterPreparing the Sail-Drive

(1)

(2)

(3)

(4)

0005452

Figure 41 – O-Ring2 – Adapter Joint3 – Oil Changing Plug4 – Thread M10x1.5

1. Remove the oil changing plug locatedunder the shift lever.

2. Screw in an adapter joint with an O-ring.When using your own adapter joint, themaximum length of thread should be12 mm.

3. Attach a stiff rubber hose (innerdiameter 14 to 16 mm [0.5 to 0.625 in.])with hose clamps to the adapter joint atthe oil changing position(Figure 4, (2)). The hose must be longenough to reach the bucket or pump. Ifa Yanmar original rubber hose is to beused, the part number is 196440-92970.

Removing Oil

(1)

0005453

(2)

(3)

Figure 51 – Plug2 – Air Pressure Hose3 – Adapter Joint

Fastest Way: Blowing Out by using AirPressureNote: Use Compressed Air (0.5 to 1 Bar[7.25 to 14.5 psi]) from main system, 12 Vportable compressor or from portable handpump or foot pump.WARNING! ALWAYSwear safety glasses when usingcompressed air.1. Take out the plug from the upper case

cover.2. Screw in a second adapter joint with an

O-ring at the oil inlet position. Screw inthe oil plug at the dipstick position.

3. Connect the air pressure hose with hoseclamps.



Option 1: Using Compressed air frommain system or 12 V portablecompressor.1. Connect a hose to the top adapter joint

and to a compressed air source(Figure 5, (2)). Within 10 to 15 minutesalmost all oil will be blown out.

0005454

(1)

(2)

(3)

Figure 61 – One-Way (Non-Return) Valve2 – Adapter Joint Screwed Into

Cover3 – Foot Pump

Option 2: Using Compressed air withhelp from a portable hand pump or footpump1. Install a one-way (non-return) valve

(Figure 6, (1)) into the pressure line.This is done to maintain pressure duringuse of the pump.

2. Connect the hand pump or foot pumpwith pressure line to the adapter joint(Figure 6, (2)).

3. Pump out the oil until empty. The first 0.9L (1 qt) will take approximately3 minutes. The second part takes moretime as mostly air will be pumped out;this will take approximately 12 minutes.

Using Yanmar PumpRefer to Preparing the Sail-Drive on page 42 and Fastest Way: Blowing Out by using Air Pressure on page 42.

0005455

Figure 7Connect the hand pump with hoses asshown above (Figure 7), and startpumping. Be aware that oil has to flow downthrough restricted parts of the casing andthen back up again, so pressure will initiallybe high and pumping will be difficult.Pausing for a few minutes will help. Afterpumping out about 0.9 L (1 qt) of oil, mostlyyou will be pumping out air, but continuouspumping is necessary. Thoughapproximately 100 to 200 ml (0.1 to 0.2 qt)of old oil will remain in the drive unit, it willnot cause a problem when mixed with cleanoil.The hand pump and rubber hose areavailable from Yanmar, and are optionalparts for SD50 / SD50-4T. Any type of handpump or rubber hose (inner diameter 14 to16 mm [0.5 to 0.625 in.]) available from yourlocal supplier can be used.



Replacing OilRefer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.Fastest way: By using MerCruiser pumpor simple market pumpRefer to Preparing the Sail-Drive on page 42.

(1)

0005575

Figure 81 – Plug

1. Use a MerCruiser® pump like the oneshown (Figure 8) or use a similar pumpavailable locally.

2. Attach the pump to a new bottle ofQuicksilver® High Performance GearLube from MerCruiser®.

3. Connect the hose with a hose clip to theadapter joint below the shift lever.

4. Remove the plug from the upper casecover (Figure 8, (1)).

5. Operate the pump to fill the Sail-Drivewith oil. After bottle is empty, change thebottle while the pump and hose remainconnected to the adapter joint.

6. After filling, first screw in and tighten theplug at the top cover (Figure 8, (1)).Then remove the oil bottle, pump, hoseand adapter joint and screw in the oilplug with a gasket.

Using Yanmar Hand Pump

0005456

(1)

Figure 91 – Plug



1. Connect the hoses as shown above(Figure 9).

2. Remove the plug from the upper casecover (Figure 9, (1)).

3. Operate the pump to fill the Sail-Drivewith oil. Be aware that oil has to flowdown through restricted parts of thecasing and then back up again, sopressure will initially be high andpumping will be difficult. Pausing for afew minutes will help. The hand pumpand rubber hose are available fromYanmar, and are optional parts forSD50 / SD50-4T. Any type of handpump or rubber hose (inner diameter14 to 16 mm [0.5 to 0.625 in.]) availablelocally can be used.

4. After filling, first screw in and tighten theplug at the top cover. Then remove thehand pump, hose and adapter joint andscrew in the oil plug with a gasket.

Not Using PumpRefer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.

When The Vessel Is Out Of TheWaterPreparing The Sail-Drive

0005457

(1)

Figure 101 – Plug

1. Remove the bottom drain plug.2. Screw in the adapter joint with the

O-ring. When using own adapter joint,maximum length of thread is 12 mm.

3. Attach a stiff rubber hose with an innerdiameter of 14 to 16 mm(0.5 to 0.625 in.) with hose clamps to theadapter joint at the oil drain position. Thehose must be long enough to drain to thebucket.

4. Remove the dipstick and oil inlet plugfrom the upper case cover.



Removing Oil By DrainingRefer to Preparing The Sail-Drive on page 45.Oil draining is possible when the vessel isout of the water but will take a greateramount of time.1. After approximately 0.6 L (0.6 qt) has

been drained, remove the oil changingplug. If you remove the plug before this,oil may spill out because maximum oillevel is higher than the plug.

0005458

(2)

(1)

Figure 111 – Thread M10x1.52 – Oil Changing Plug

Fastest way: Blowing out by using AirpressureRefer to Preparing the Sail-Drive on page 42, then to Fastest Way: Blowing Out by using Air Pressure on page 42. Be awarethat oil is divided into two channelsconnected by the lower gear and lower drainport.

Replacing OilRefer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.Using MerCruiser® Pump or simplemarket pumpRefer to Preparing The Sail-Drive on page 45.

0005459

(2) (3)

(1)

Figure 121 – Plug2 – O-Ring3 – Adapter Joint

1. Use a MerCruiser® pump with like theone shown above (Figure 12), or use asimilar pump available locally.

2. Attach the pump to a new bottle ofQuicksilver® High Performance GearLube from MerCruiser®.

3. Remove the oil changing plug frombelow the shift lever.

4. Connect the hose with a hose clip to theadapter joint at the drain position.

5. Take out the plug from the upper casecover.



6. Pump the oil into the drive. After the firstbottle is empty, screw in the oil changingplug.

7. Change the bottle while the pump andhose remain connected to the adapterjoint.

8. After filling, first screw in and tighten theplug at the top cover. Then remove theoil bottle, pump, hose and adapter jointand screw in the oil drain plug.

Using Yanmar Hand PumpRefer to Preparing The Sail-Drive on page 45.

0005460

(1)

Figure 131 – Plug

1. Connect the hose from the bottom anda suction hose to the Yanmar pump withhose clip (Figure 13).

2. Take out the plug from the upper casecover (Figure 13, (1)).

3. Pump the oil into the drive. Be awarethat oil has to flow up through restrictedparts of the drive, so pumping will behard. Waiting a few minutes will help.After pumping in about 1 L (1.1 qt) of oil,screw in the oil changing plug. Be awarethat the drain hose can easily slip out ofthe bucket and cause oil spilling. Thehand pump and rubber hose areavailable from Yanmar, and are optionalparts for SD50 / SD50-4T. Any type ofhand pump or rubber hose of innerdiameter 14 to 16 mm (0.5 to 0.625 in.)available locally can be used.

0005461

Figure 144. After filling, first screw in and tighten the

plug at the top cover. Then remove thepump, hose and adapter joint and screwin the oil drain plug.

By not using pumpRefer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19.



Every 100 Hours of OperationPerform the following maintenance every100 hours of operation.• Changing the Lubricating Oil (SD20)• Inspecting and Replacing the AnodeChanging the Lubricating Oil (SD20)See Draining and Replacing Lubricating Oil - SD20 on page 39.Inspecting and Replacing the AnodeTo prevent corrosion of the Sail-Drive bodyby sea or lake water, replace the anodeevery 100 hours of operation, once every sixmonths or when it has reduced to half of theoriginal volume (size).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 sail-drive.

SD20

while the boat in the water

ANODE

196420-02441

(1)

(3)

(2)

(4)

(5)

019416-01X

Figure 151 – Safety Label2 – Anode3 – Anode4 – Upper Gear Case5 – Lower Gear Case

SD50/SD50–4T

(1)

(2)

0005463

Figure 161 – Lower Gear Case2 – Anode

An anode is provided on the lower gearcase. To inspect and replace the anode onthe lower gear case, the vessel must beremoved from the water.Note: An optional two-part anode isavailable from Yanmar for the lower gearcase. This option may allow the anode in thelower gear case to be changed withoutremoving the vessel from the water, or by anunderwater diver.Optional Two-Part Anode Information

Part Number Description Qty.196440-02660 anode 2196440-02690 mounting

plate2

196440-02700 flat head bolt 426453-080202 8 X 20 bolt 2



Every 250 Hours of OperationPerform the following maintenance every250 hours of operation.• Changing the Lubricating Oil (SD50,

SD50-4T)• Inspecting and Replacing the Clutch

ShifterChanging the Lubricating Oil (SD50,SD50-4T)See Draining and Replacing Lubricating Oil - SD50 / SD50-4T on page 40.Inspecting and Replacing the ClutchShifterSee your authorized Yanmar dealer ordistributor for procedure.

Every 500 Hours of Operation• Inspecting and / or Replacing the

Cone-ClutchInspecting and / or Replacing theCone-ClutchSee your authorized Yanmar dealer ordistributor for procedure.



Every YearPerform the following maintenance everyyear of operation.• Cleaning Cooling Water Suction Hole• Inspecting Remote Control Device• Repairing Case Coating• Inspecting and Replacing Rubber

Diaphragm Seal Ring• Inspecting Seal Sensor• Inspecting and / or Replacing the

Flexible MountCleaning Cooling Water SuctionHoleSee Removing Deposits From The Lower Gear Case on page 38.Inspecting Remote Control DeviceSee Remote Control Device Check on page 26.Repairing Case CoatingSee Repairing Damaged Coating on page 38.Inspecting and Replacing RubberDiaphragm Seal RingRubber diaphragms (A) and (B) (SD20 &SD50, SD50-4T)The rubber diaphragms (A) and (B) of theSail-Drive are important parts for the hull andcrew safety. Since rubber degeneratesduring use, be sure to inspect them everytwo years. The vessel must be lifted onto ablock for this procedure. To replace, consultyour Yanmar Marine dealer.Inspecting Seal SensorSee (Figure 9) on page 22. See yourauthorized Yanmar Marine dealer ordistributor for inspection procedure.

Inspecting and / or Replacing theFlexible MountReplace if clearance is less than 1 mm(Figure 17, (1)). See your authorizedYanmar Marine dealer or distributor forprocedure.

(1)

0005449

Figure 17



Every 2000 Hours of Operation• Replacing the Flexible Mount• Replacing the Cone-ClutchReplacing the Flexible MountSee your authorized Yanmar dealer ordistributor for procedure. Flexible Mountmust be replaced every 2000 hours.Replacing the Cone-ClutchSee your authorized Yanmar dealer ordistributor for procedure.

Every 5 Years• Replacing Rubber Diaphragm Seal

RingReplacing Rubber Diaphragm SealRingTo replace, consult your Yanmar Marinedealer.






SPECIFICATIONSModel SD20 SD50 SD50-4TReduction Gear System Constant mesh

gear with dogclutch

Cone clutch

Direction Of Rotation Input Shaft Counterclockwise viewed from sternPropeller Shaft Counter-clock-

wise viewed fromstern

Counter-clockwise or clockwiseviewed from stern

Reduction Ratio Ahead 2.64 2.32Astern 2.64 2.32

Propeller Speed (rpm) 1364 1293 1337Lubrication System Oil bath typeLubricating OilCapacity

Standard Unit 2.2 L (2.3 qt) 2.2 L (2.3 qt), SD40: 1.8L (1.9 qt)Long-Reach Unit 2.5 L (2.4 qt) 2.35 L (Extension 58) [2.5 qt], 2.45 L

(Extension 100) [2.6 qt]Dry Weight 30 kg (66 lb) 39 kg (86 lb) 41 kg (90 lb)Remote-ControlDevice

Control Head Single control leverCable MORSE 33C (equivalent)

Applicable Engine Model (Maximum Rated Out-put Power At Crankshaft)

1GM10C:6.7 kW (9.1 hp) /3600 rpm2YM15:10.3 kW (14 hp) /3600 rpm3YM20:16.2 kW (22 hp) /3600 rpm3YM30:22.1 kW (30 hp) /3600 rpm

3JH4CE:28.7 kW (39 hp) /3000 rpm4JH4ACE39.6 kW (53 hp) /3000 rpm3JH5CE:28.7 kW (39 hp) /3000 rpm4JH5CE:39.6 kW (53 hp) /3000 rpm

4JH4-TCE:55.2 kW (75 hp) /3200 rpm

Note: A propeller with rubber bushing mustbe used in all SD series Sail-Drives.Note: 1 hp metric = 0.7355 kW



SPECIFICATIONS


SYSTEM DIAGRAMSColor coding for wiring diagrams

R RedB BlackW WhiteY YellowL BlueO Orange

L/B Blue/BlackW/L White/BlueY/W Yellow/WhiteW/R White/RedL/R Blue/RedW/B White/BlackR/B Red/Black

Allowable length by cross sectional area ofbattery cable

Section of cablemm2 (in.2)

Allowable lengthL = 1 + 2 + 3 m (ft)

15 (0.023) < 0.86 (0.26)20 (0.031) < 1.3 (0.40)30 (0.046) < 2.3 (0.70)40 (0.062) < 2.8 (0.85)50 (0.077) < 3.5 (1.07)60 (0.093) < 4.1 (1.25)


A-Type Instrument Panel

B B

E

L/B W

/L

Y/W

W/R B

W/R

B

O L/R

R

R/B

L

B L R

BS

R WW L/

BW

/LY

/WW

/RB O L/

RW

/B

RW L/

BW

/LY

/WR

/BB O L/

RL

W/R

RW L/

BW

/LY

/WR

/B

W/R

R/B

W

R/B

R/B

R/B

R/B

R

30AC

(22)

(21)

(20)

(26)

0005

465

(18)

(13)

(14)

(16)

(15)

(12)

(11)

(10)

(9)

(8)

(3)(4

)

(7)

(17)

(6)

(1)

(5)

(2)

(23)

(24)

(25)

Figure 1

SYSTEM DIAGRAMS


A-Type Instrument PanelApplicable Engine Model:1GM10C

1 Cable, battery to switch2 Cable, switch to starter3 Cable, battery to starter4 Battery Recommended capacity GM,

12V-70AH 1GM,12V-100AH (Mini-mum)

5 Battery switch6 FUSE7 Starter motor8 Alternator9 Not used

10 Cooling Water temp. switch11 Engine Oil pressure switch12 Spare connector13 Extension cable 3 m [9.8 ft] (Standard)14 The total length extension cable must

be less than 6 m (19.7 ft)15 Rubber seal switch (Sail-Drive)16 Amplifier17 Ground18 Sail-Drive extension cable 0.3 m (1 ft)19 Not used (Except 1GMC)20 Key switch21 Push button switch22 Charge lamp23 Cooling Water temp. lamp24 Engine Oil pressure lamp25 Rubber seal lamp (Sail-Drive)26 Buzzer

Note: If the cross-sectional area of the wirebeing used is equal to or less than 20 mm2(approximately AWG 4), the combinedlengths of items 1, 2 and 3 must be less than2.5 m (8.2 ft).If the cross-sectional area of the wire beingused is equal to or less than 40 mm2(approximately AWG 1), the combinedlengths of items 1, 2 and 3 must be less than5 m (16.4 ft).Note: Battery, battery switch and cables arenot supplied by Yanmar.

SYSTEM DIAGRAMS


B-Type Instrument Panel

0038

77-0

0E

3 8

10 11

9

1

B B

E

L/B

W/L

Y/W

W/R

B

W/RB

OP P

L/R

R

R/B

L

B L R

BS

R WW L/

BW

/LY

/W

W/R

B O L/R

W/B

R BY/W

W/R

R/B

W/L

L/B

W

RB

L/BO

BR/B

W/RY/W

W/L

R/B

RW L/

BW

/LY

/W

R/B

B O L/R

L

PP

R

W/L

B

R/B

26

19

14

15

1728

16

18

13

7

4

23 24 25 26

12

30AC

2120

22

27

R/B

L/B

WW

R/B

W/L

R/B

W/R

R/B

Y/W

5

Figure 2

SYSTEM DIAGRAMS


B-Type Instrument PanelApplicable Engine Model:1GM10C

1 Cable, battery to switch2 Cable, switch to starter3 Cable, battery to starter4 Battery Recommended capacity GM,

12V-70AH 1GM, 12V-100AH (Mini.)5 Battery switch6 FUSE7 Starter motor8 Alternator9 Not used

10 Cooling Water temp. switch11 Engine Oil pressure switch12 Tachometer sender13 Extension cable 3 m. (Standard)14 The total length extension cable must

be less than 6 m.15 Rubber seal switch (Sail-Drive)16 Amplifier17 Ground18 Sail-Drive extension cable 0.3 m.19 Not used (Except 1GMC)20 Light switch21 Key switch22 Push button switch23 Charge lamp24 Cooling Water temp. lamp25 Engine Oil pressure lamp26 Rubber seal lamp (Sail-Drive)27 Buzzer28 Tachometer

Note: If the cross-sectional area of the wirebeing used is equal to or less than 20 mm2(approximately AWG 4), the combinedlengths of items 1, 2 and 3 must be less than2.5 m (8.2 ft).If the cross-sectional area of the wire beingused is equal to or less than 40 mm2(approximately AWG 1), the combinedlengths of items 1, 2 and 3 must be less than5 m (16.4 ft).Note: Battery, battery switch and cables arenot supplied by Yanmar.

SYSTEM DIAGRAMS


4JH4-TE with B x B Type Panel

-+

S

BL

E

LBRB

YW

WL

OY

G

R

3L

12V

1

3

2

L=1+

2+3(

m)

Allo

wab

le le

ngth

by

cros

s se

ctio

nal a

rea

of b

atte

ry c

able

10R10

B

B

2R WB

r

2B5R

BL

E

LB RB

RLB R

B

5R

B

Y

-+12

V

1

3

2

R

P-

+

3R

+-B L YG RB

sect

ion

of c

able

Allo

wab

le le

ngth

(mm

2 )15

(mm

2 )<

0.86

(m)

20(m

m2 )

< 1.

3(m

)<

2.3(

m)

30(m

m2 )

40(m

m2 )

< 2.

8(m

)<

3.5(

m)

50(m

m2 )

2W

2R

60(m

m2 )

< 4.

1(m

)

G1

+-

P

G2

30

LL

R

O

B

YW

WL

YG

LB

R

LL

R

O

B

YW

WL

YG

LB

G1

G2

30

17A

C

W 17A

C

W

P

3W

3L

3RY

W

RB

WL

LBOW

GB YG

WB

YB

GB

YR

GR

WR

GY

G2

17G

LOW

OFF

ON

STA

RT

Key

sw

itch

30A

CG

1

WB

r

WB

r

W/Y

3R

B

1

2 3 1011

1215 15

17

18

16

19

2020

21

22

2324

2526

2829

24

3030

31

32

33

27

16

13

45

67

89

2 3 1011

12

14

45

67

89

008433-00E

0004506

Figure 3

SYSTEM DIAGRAMS


4JH4-TE with B x B Type PanelColor Coding Engine Harness

R Red +B Black -W White IgnitionL Blue Air heater / glow (op-

tion)RB Red / Black Alternator exciterLB Blue / Black Alternator charge

alarmYW Yellow /

WhiteEngine oil pressurealarm

YB Yellow /Black

Engine oil pressure

YG Yellow /Green

Sail-drive seal

WL White / Blue Water temperaturealarm

WB White /Black

Water temperature

WG White /Green

Seawater flow alarm

GR Green / Red Fuel filter alarmO Orange Pulse for tachometer

WBr White /Brown

Electric stop

1 Option2 Alarm Lamps3 Buzzer4 Engine Oil Pressure5 Coolant Temperature6 Sail-Drive Seal7 Battery Low Charge Alarm8 Fuse (3A)9 Stop Switch

10 Diodes11 Key Switch12 Tachometer / Hour Meter13 Instrument panel (sub station) (Op-

tion)14 Instrument panel (main station) (Op-

tion)15 Wire Harness16 Relay17 Wire Harness for Sub Panel18 Amplifier (Sail-Drive Only)19 Procured by Customer20 Battery21 Battery Switch22 Engine Stop Solenoid with VE Pump23 Air Heater24 Option25 Stop Relay26 Starter Relay27 Starter28 Coolant Temperature Switch29 Engine Oil Pressure Switch30 Alternator31 Ground Bolt32 Sail-Drive Only33 Details of Coupler (View from A-A)

SYSTEM DIAGRAMS


4JH4-TE with C x B Type Panel

-+

S

BL

E

LBRB

YW

WL

OY

G

R

3L

12V

1

3

2

L=1+

2+3(

m)

Allo

wab

le le

ngth

by

cros

s se

ctio

nal a

rea

of b

atte

ry c

able

10R10

B

B

2R WB

r

2B5R

BL

E

LB RB

RLB R

B

5R

B

Y

-+12

V

1

3

2

R

P-

+

3R

+-B L YG RB

sect

ion

of c

able

Allo

wab

le le

ngth

(mm

2 )15

(mm

2 )<

0.86

(m)

20(m

m2 )

< 1.

3(m

)<

2.3(

m)

30(m

m2 )

40(m

m2 )

< 2.

8(m

)<

3.5(

m)

50(m

m2 )

2W

2R

60(m

m2 )

< 4.

1(m

)

LL

R

O

B

YW

WL

YG

LB

G1

G2

30

17A

C

W

P

3W

3L

3RY

W

RB

WL

LBOW

GB YG

WB

YB

GB

YR

GR

WR

GY

G2

17G

LOW

OFF

ON

STA

RT

Key

sw

itch

30A

CG

1

WB

r

W/Y

3R

B

+-

P

WB

rR

LL

R

O

WG

GY

GLB +

-+

-Y

BW

B

G1

G2

30

B

WL

YW

17A

C

W

WB

YB

GR

B

1

2 3 1011

1215 15

17

1838

16

19

2020

21

22

2324

2526

2829

24

3030

31

32

33

3940

27

16

13

45

67

89

2 3

1011

1237

36

14

3435

67

89

008434-00E

0004507

Figure 4

SYSTEM DIAGRAMS


4JH4-TE with C x B Type PanelColor Coding Engine Harness

R Red +B Black -W White IgnitionL Blue Air heater / glow (op-

tion)RB Red / Black Alternator exciterLB Blue / Black Alternator charge

alarmYW Yellow /

WhiteEngine oil pressurealarm

YB Yellow /Black

Engine oil pressure

YG Yellow /Green

Sail-drive seal

WL White / Blue Water temperaturealarm

WB White /Black

Water temperature

WG White /Green

Seawater flow alarm

GR Green / Red Fuel filter alarm

O Orange Pulse for tachometerWBr White /

BrownElectric stop

1 Option2 Alarm Lamps3 Buzzer4 Engine Oil Pressure5 Coolant Temperature6 Sail-Drive Seal7 Battery Low Charge Alarm8 Fuse (3A)9 Stop Switch

10 Diodes11 Key Switch12 Tachometer / Hour Meter13 Instrument Panel (sub station) (Op-

tion)14 Instrument panel (main station) (Op-

tion)15 Wire Harness16 Relay17 Wire Harness for Sub Panel18 Amplifier (Sail-Drive Only)19 Procured by Customer20 Battery21 Battery Switch22 Engine Stop Solenoid with VE Pump23 Air Heater24 Option25 Stop Relay26 Starter Relay27 Starter28 Coolant Temperature Switch29 Engine Oil Pressure Switch30 Alternator31 Ground Bolt32 Sail-Drive Only33 Details of Coupler (View from A-A)34 Seawater35 Fuel Filter36 Engine Oil Pressure Meter / Alarm37 Water Temperature Meter / Alarm38 Fuel Filter Switch39 Engine Oil Pressure Sender40 Coolant Temperature Sender

SYSTEM DIAGRAMS


B-Type Instrument Panel for 3YM30, 3YM20 and 2YM15

-+

S

BL

E

3R

0.85LB0.85RB

0.85

YW

0.85

WL

0.85

O0.

85Y

G

R

2L

12V

1

3

2

L=1+

2+3(

m)

10R10

B

0.85

B

2B

2R WB

r

2B 5R

+ -

W/Y

B3B

R

B

Y

+-B L YG

RB

Sec

tion

of c

able

Allo

wab

le L

engt

h(m

m2 )

15(m

m2 )

<0.

86(m

)20

(mm

2 )<

1.3(

m)

<2.

3(m

)30

(mm

2 )40

(mm

2 )<

2.8(

m)

<3.

5(m

)50

(mm

2 )

2W

60(m

m2 )

<4.

1(m

)

17

G1

+-

P

G2

30

WB

r

AC

R LL

R

W

O

B

YW

WL

YG

LB

2B2B

5R

2W

2B

1920

21

18

17

1516

2223

24

27

28

29

3014

11

10

9

7

8

23

45

6

1

1213

2526

0.85B

1289

90-7

7910

1192

47-7

7100

1202

70-7

7511

1197

17-7

7800

0.85WBr

2R

A A3R

3WYW

WL

WG

B

RBLB

OYG

Key

sw

itch

GLO

WO

FF

ON

STA

RT

30A

CG

1G

217

3L

0038

80-0

0E

Figure 5

SYSTEM DIAGRAMS


B-Type Instrument Panel for 3YM30,3YM30, 3YM20 and 2YM15

Color CodingR RedB BlackW WhiteL Blue

RB Red / BlackLB Blue / BlackYW Yellow / WhiteYG Yellow / GreenWL White / BlueWG White / GreenGR Green / RedO Orange

WBr White / Brown

1 Alarm Lamps2 Buzzer Oil Pressure3 Coolant Temperature4 Sail-Drive Seal5 Charge6 Fuse (3A)7 Stop Switch8 Diodes9 Key Switch

10 Instrument Panel11 Tachometer Hour Meter12 Wire Harness Option (L=3M)13 Wire Harness Option (L=6M)14 Amplifier (only for Sail-Drive)15 Relay16 Glow Plug17 Engine Stop Solenoid18 Battery Switch19 Allowable Length by Cross Sectional

Area of Battery Cable20 Procured by Customer21 Battery22 Stop Relay23 Starter Relay24 Starter25 Coolant Temperature Switch26 Engine Oil Pressure Switch27 Ground Bolt28 Alternator29 Sail-Drive Only30 Coupler (View from A-A)

SYSTEM DIAGRAMS


B-Type Instrument Panel for 3JH4E

YW

45

67

8

102

1 3

WL

YG

WB

r

9

3R

R W

R

LL

B

O P

17A

C

30

G1

G2

LB

1 2

3

1 2

3

YW

1415

1617

18

12

11 13

WL

YG

WB

rR

W

R

L

3R3W

YWW

LW

GB

RBLB

OYG

WB

YRY

WR

YBG

BG

GR

Key

sw

itch

GLO

W

OF

F

ON

STA

RT

30A

CG

1G

217

3L

AA 31

L

B

O P

40

39

3738

36

35

34

20

19

4445

46

47

48

49

41

43

17A

C

30

G1

G2

LB

B L YG

RB

12V

2R

2B

2B5R 3L

Opt

ion

WB

r

WL

YW

B W/Y

2R

2W S

B

3R

10B

10R Y O

B

BEBE

RLR

BLB

RB

LB

RB

YG

LB

RL

5R

12V 33

32

22

21 2627

2829

30

2324

25

0038

81-0

0E

Figure 6

SYSTEM DIAGRAMS


B-Type Instrument Panel for 3JH4EColor Coding

R RedB BlackW WhiteL Blue

RB Red / BlackLB Blue / BlackYW Yellow / WhiteYB Yellow / BlackYG Yellow / GreenWL White / BlueWB White / BlackWG White / GreenGR Green / RedO Orange

WBr White / Brown

1 Starter Switch2 Stop Switch3 Tachometer / Hour Meter4 Buzzer5 Lubricating Oil Low Pressure Alarm6 Coolant High Temperature Alarm7 Water in Sail-Drive Seal Alarm8 Battery Low Charge Alarm9 Relay (for 2 Station: Option)

10 Fuse (3A)11 Starter Switch12 Stop Switch13 Tachometer / Hour Meter14 Buzzer15 Engine Oil Low Pressure Alarm16 Coolant High Temperature Alarm17 Water in Sail-Drive Seal Alarm18 Battery Low Charge Alarm19 Option20 Alarm Lamps21 Air Heater (Option)22 Engine Stop Solenoid23 Stop Relay24 Starter Relay25 Starter26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch28 Alternator (Option)29 Alternator30 Water in Sail-Drive Seal Sensor (on

Sail-Drive)31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)32 Battery (Option)33 Battery34 Diodes35 Instrument Panel (Sub Station) (Op-

tion)36 Wire Harness37 Alarm Lamps38 Fuse (3A)39 Diodes40 Instrument Panel (Main Station) (Op-

tion)41 Wire Harness42 Wire Harness for Sub Panel43 Only for Sail-Drive44 Relay45 Option46 Procured by Customer47 Battery Switch48 Ground Bolt49 Only for Sail-Drive

SYSTEM DIAGRAMS


C-Type Instrument Panel for 3JH4E

YW

45

67

8

102

1 3

37

36

38

39

41 43

44

4546

47

42

40

WL

YG

WB

r

9

3R

R W

R

LL

B

O P

17A

C

30

G1

G2

LB

1 2

3

1 2

3

YG

1415

1617

18

12

11 13

GY

G

WB

rR W

R

L

3R3W

YWW

LW

GB

RBLB

OYG

WB

YRY

WR

YBG

BG

GR

Key

sw

itch

GLO

W

OF

F

ON

STA

RT

30A

CG

1G

217

3L

A A 31

L

B

O P

17A

C

30

G1

G2

LB

20

WB

WL

19

YB

YW

B L YG

RB

12V

2R

2B

2B5R 3L

WB

r

WL

YW

B W/Y

2R

2W S

B

3R

10B

10R Y O

B

BEBE

RLR

BLB

RB

LB

RB

YG

LB

RL

5R

12V 33

32

22

50 51

53

52

54

4849

21 2627

YB

WB

3435

2829

30

2324

25

0038

82-0

0E

Figure 7

SYSTEM DIAGRAMS


C-Type Instrument Panel for 3JH4EColor Coding



WBr White / Brown

1 Starter Switch2 Stop Switch3 Tachometer / Hour Meter4 Buzzer5 Lubricating Oil Low Pressure Alarm6 Coolant High Temperature Alarm7 Water in Sail-Drive Seal Alarm8 Battery Low Charge Alarm9 Relay (for 2 Station: Option)

10 Fuse (3A)11 Starter Switch12 Stop Switch13 Tachometer / Hour Meter14 Buzzer15 Lubricating Oil Low Pressure Alarm16 Coolant High Temperature Alarm17 Water in Sail-Drive Seal Alarm18 Battery Low Charge Alarm19 Engine Oil Pressure Meter20 Coolant Temperature Meter21 Air Heater (Option)22 Engine Stop Solenoid23 Stop Relay24 Starter Relay25 Starter26 Coolant High Temperature Switch

27 Engine Oil Low Pressure Switch28 Alternator (Option)29 Alternator30 Water in Sail-Drive Seal Sensor (on


plifier (Sail-Drive Only)32 Battery (Option)33 Battery34 Engine Oil Pressure Sensor (Option)35 Coolant Temperature Sensor (Option)36 Option37 Alarm Lamps38 Diodes39 Instrument Panel (Sub Station) (Op-

tion)40 Wire Harness41 Alarm Lamps42 Fuse (3A)43 Diodes44 Instrument Panel (Main Station) (Op-

tion)45 Wire Harness46 Wire Harness for Sub Panel47 Only for Sail-Drive48 Relay49 Option50 Procured by Customer51 Battery Switch52 Ground Bolt53 Option54 Only for Sail-Drive

SYSTEM DIAGRAMS


B-Type Instrument Panel for 4JH4AE

3W3L

3RYW RB

WL

LBOW

GB YG

WB YB

GBG

YRGRW

RY

G2

17G

LOW

OFF

ON

STA

RT

30A

CG

1

-

+

S

BL

E

3R

LBRB

YW

WL

OY

G

Ear

th b

olt

Wire

harn

ess

R

Wire

har

ness

fo

r sub

pan

el

Opt

ion

3L

12V

1

3

2

Bat

tery

sw

itch

Pro

cure

d by

cus

tom

er

Inst

rum

ent p

anel

(sub

sta

tion)

(Opt

ion)

10R10

B

B

2B

2R WB

r

2B5R

+ -

BL

E

LB RB

R

LB RB

Opt

ion

Rel

ayW

/Y

B5R

B

Y

-+12

V

1

3

2

RW

Br

P-

+W

ire h

arne

ss

3R

Ala

rm la

mps

Fu

se(3

A)

Ala

rm la

mps

+-B

AA

L YG RB

only

for s

ail d

rive

only

for s

ail d

rive

2W

2R

diod

es

Inst

rum

ent p

anel

(mai

n st

atio

n) (O

ptio

n)

G1

+-

P

G2

30

WB

r

diod

es

LL

R

O

B

YW

WL

YG

LB

R

LL

R

O

B

YW

WL

YG

LB

G1

G2

30

17A

C

W 17A

C

W

R

P

B

(4JH

4AE

onl

y)

45

67

810

2

1 3

9

1415

1617

18

12

11 13

31

3332

22

21 2627

2829

3036

2324

25

0004594

Figure 8

SYSTEM DIAGRAMS


B-Type Instrument Panel for 4JH4AEColor cod-ing

Description



WBr White / Brown

1 Starter Switch2 Stop Switch3 Tachometer / Hour Meter4 Buzzer5 Engine Oil Low Pressure Alarm6 Coolant High Temperature Alarm7 Water in Sail-Drive Seal Alarm8 Battery Low Charge Alarm9 Relay (for 2 station - Optional)

10 Fuse (3A)11 Starter Switch12 Stop Switch13 Tachometer / Hour Meter14 Buzzer15 Lubricating Oil Low Pressure Alarm16 Coolant High Temperature Alarm17 Water in Sail-Drive Seal Alarm18 Battery Low Charge Alarm19 -20 -21 Air Heater22 Engine Stop Solenoid23 Stop Relay24 Starter Relay25 Starter26 Coolant High Temperature Switch27 Engine Oil Low Pressure Switch28 Alternator (Optional)29 Alternator30 Water in Sail-Drive Seal Sensor Am-

plifier (on Sail-Drive)31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)32 Battery (Optional)33 Battery34 -35 -36 Fuel Feed Pump (4JH4AE Only)

SYSTEM DIAGRAMS


C-Type Instrument Panel for 4JH4AE

-+

S

BL

E

3R

LBRB

YW

WL

WB

OY

G

Ear

th b

olt

Wire

harn

ess

R

YB

Wire

har

ness

for s

ub p

anel

Opt

ion

3L

12V

1

3

2

Bat

tery

sw

itch

Pro

cure

d by

cus

tom

er

Inst

rum

ent p

anel

(sub

sta

tion)

(Opt

ion)

10R10

B

B

2B

2R WB

r

2B5R

+ -

BL

E

LB RB

R

LB RB

Rel

ayW

/Y

B5R

B

Y

-+12

V

1

3

2

RW

Br

30

G2

G1

17A

C

P-

+W

ireha

rnes

s

3R

Ala

rm la

mps

+-B

AA

L YG RB

only

for s

ail d

rive

only

for s

ail d

rive

2W

2R

diod

es

Inst

rum

ent p

anel

(mai

n st

atio

n) (O

ptio

n)

+-

P

WB

rFu

se(3

A)

Ala

rm la

mps

diod

es

LL

R

W

O

B

YW

WL

YG

LB

R

LL

R

O

WG

GY

GLB +

-+

-Y

BW

B

G1

G2

30

B

WL

YW

17A

C

W

(4JH

4AE

Onl

y)

P

BR

45

67

810

2

1 3

9

1415

1617

18

12

11 1320

19

31

3332

22

21 2627

2829

3036

3435

2324

25

3W3L

3RYW RB

WL

LBOW

GB YG

WB YB

GBG

YRGRW

RY

G2

17G

LOW

OFF

ON

STA

RT

30A

CG

1

0004595

Figure 9

SYSTEM DIAGRAMS


C-Type Instrument Panel for 4JH4AEColorcoding

Description



WBr White / Brown

1 Starter Switch2 Stop Switch3 Tachometer / Hour Meter4 Buzzer5 Engine Oil Low Pressure Alarm6 Coolant High Temperature Alarm7 Water in Sail-Drive Seal Alarm8 Battery Low Charge Alarm9 Relay (for 2 station - Optional)

10 Fuse (3A)11 Starter Switch12 Stop Switch13 Tachometer / Hour Meter14 Buzzer15 Seawater16 Fuel Filter17 Water in Sail-Drive Seal Alarm18 Battery Low Charge Alarm19 Engine Oil Pressure Meter / Alarm20 Coolant Temperature Meter / Alarm21 Air Heater22 Engine Stop Solenoid23 Stop Relay24 Starter Relay25 Starter26 Coolant High Temperature Switch27 Engine Oil Low Pressure Switch28 Alternator (Optional)29 Water in Sail-Drive Seal Sensor (on


plifier (on Sail-Drive)31 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)32 Battery (Optional)33 Battery34 Engine Oil Pressure Sensor (Optional)35 Coolant Temperature Sensor (Option-

al)36 Fuel Feed Pump (4JH4AE Only)

SYSTEM DIAGRAMS


2YM15, 3YM20, 3YM30 - B (Keyless) - Type Instrument Panel (optional)

026375-00X

(18)

(19)

(25)

(26)

(30)

(29) (3

1)

(32)

(20)

(28)

(27)

(24)

(17)

(13)

(14)

(15)

(16)

(7)

(8)

(6)

(5)

(4)

(3)

(2)

(1)

(9)

(10)

(11)

(12)

(12)

(22)

(21)

(23)

-+

S

B LE

3R

0.85LB0.85RB

0.85

YW

0.85

WL

0.85

O0.

85Y

G

R

2L

12V

1

3

2

10R10

B

0.85

B

2B

2R WB

r

2B 5R

+ -

W/Y

B3B

R

B

Y

+-B L YG RB

2W2B

2B

5R

2W

2B

0.85B

1197

17

1192

47-7

7100

1202

70-7

7511

1289

90-7

7910

-778

00

0.85WBr

2R

A A3R

3WYW

WL

WG

BRB

LBO

YG3L

+-

PO

0

0

47Ω

/3W

1N40

07

L

WB

r

W R L YW

R

B

YWWLYGLB

RB

RBRB

B

BR

B

II

II

I

I

Figure 10

SYSTEM DIAGRAMS


2YM15, 3YM20, 3YM30 - B (Keyless) -Type Instrument Panel (optional)

1 Optional2 Diodes3 Buzzer4 Engine Oil Low Pressure Alarm5 Coolant High Temperature Alarm6 Water in Sail-Drive Seal Alarm7 Battery Low Charge Alarm8 Fuse (3A)9 SWITCH GLOW (I) / OFF (0) / STOP

(II)10 SWITCH START (II) / ON (I) / OFF (0)11 Diode12 Switch13 Tachometer / Hourmeter14 Instrument Panel (Main Station) (Op-

tion)15 Wire Harness16 Wire Harness for Sub Panel17 Water in Sail-Drive Seal Sensor

Amplifier (Sail-Drive Only)18 Procured by Customer19 Battery20 Battery Switch21 Engine Stop Solenoid22 Relay23 Glow Plug24 Stop Relay25 Starter Relay26 Starter27 Coolant High Temperature Switch28 Engine Oil Pressure Switch29 Alternator30 Ground Bolt31 Sail-Drive Only for Sail-Drive32 Coupler (View from A-A)

SYSTEM DIAGRAMS


3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (optional)

026112-00X

-+

S

BL

E

3R

LBRB

YW

WL

OY

G

R

2L

12V

1

3

2

10R10

B

B

2B

2R WB

r

0.85

B5R

+ -

BL

E

LB RB

RLB R

B

W/Y

B5R

B

Y

-+12

V

1

3

2

3R

+-B L YG RB

2W

2R5R

2B

2B

+-

PO

0

0

47Ω

/3W

1N40

07

+-

PO

0

0

47Ω

/3W

1N40

07

WB

r

W

L

WB

r

WR L R L YWYW

R

B

YWWLYGLB

YWWLYGLB

RB

RB

RB

RB

RB

RB

L

BYGO

LBRBWBYB

WBr2L

WR

YWWL

RR

BB

B B

BR

B

R

P

B

3W3L

3RYW RB

WL

LBOW

GB YG

WB

YBG

BG

YRG

RW

RY

II I

III

II I

III

(21)

(22)

(16)

(16)

(3)

(1)

(2)

(4)

(5)

(6)

(7)

(9)

(10)

(11)

(12)

(12)

(8)

(3)

(2)

(4)

(5)

(6)

(7)

(9)

(10)

(11)

(12)

(12)

(8)

(24)

(25)

(23)

(26)

(27)

(31)

(32)

(31)

(29)

(30)

(28)

(21)

(13)

(14)

(13)

(15)

(34)

(35)

(33)

(19)

(17)

(17)

(18)

(20)

Figure 11

SYSTEM DIAGRAMS


3JH5E / 4JH5E with Keyless B and B x BType Instrument Panel (optional)

Colorcoding Description Engine Har-

nessR Red +B Black -W White IgnitionL Blue Air Heater / Glow

(option)RB Red / Black Alternator Excit-

erLB Blue / Black Alternator

Charge AlarmYW Yellow / White Engine Oil Pres-

sure AlarmYB Yellow / Black Engine Oil Pres-

sureYG Yellow / Green Sail-Drive SealWL White / Blue Water Tempera-

ture AlarmWB White / Black Water Tempera-

tureWG White / Green Seawater Flow

AlarmGR Green / Red Fuel Filter AlarmO Orange Pulse For Tach-

ometerWBr White / Brown Electric Stop

1 Option2 Diodes3 Buzzer4 Engine Oil Low Pressure Alarm5 Coolant High Temperature Alarm6 Water in Sail-Drive Seal Alarm7 Battery Low Charge Alarm8 Fuse (3A)9 SWITCH GLOW (I) / OFF (0) / STOP

(II)10 SWITCH START (II) / ON (I) / OFF (0)11 Diodes12 Switch13 Tachometer / Hourmeter14 Instrument Panel (Sub Station) (Op-

tion)15 Instrument Panel (Main Station) (Op-

tion)16 Relay17 Wire Harness18 Wire Harness for Sub Panel19 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)20 Procured by Customer21 Battery22 Battery Switch23 Engine Stop Solenoid24 Air Heater25 Stop Relay26 Starter Relay27 Starter28 Coolant High Temperature Switch29 Engine Oil Pressure Switch30 Option31 Alternator32 Ground Bolt33 Water in Sail-Drive Seal Sensor (Sail-

Drive Only)34 Fuel Feed Pump35 Details of Coupler (View from A-A)

SYSTEM DIAGRAMS


3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (optional)

026113-00X

-+

S

BL

E

3R

LBRB

YW

WL

OY

G

R

2L

12V

1

3

2

10R10

B

B

2B

2R WB

r

0.85

B5R

+ -

BL

E

LB RB

RLB R

B

W/Y

B5R

B

Y

-+12

V

1

3

2

3R

+-B L YG RB

2W

2R5R

2B

2B

+-

PO

0

47Ω

/3W

1N40

07

+-

PO

0

0

47Ω

/3W

1N40

07

WB

r

W

L

WB

r

WR L R L YWYW

R

WGGYGLB

YWWLYGLB

R

RBR

RB

RBRB

RB

L

BYGOLBRBWBYB

WBr

2L

W

RYWWL

R

WL

+-

+-

WB

YW

R

WLYW

B

B

B

R

B

B

B

WB

YB

RB

R

P

B

3W3L

3RYW RB

WL

LBOW

GB YG

WB

YBG

BG

YRG

RW

RY

II I

III

(21)

(21)

(23)

(25)

(26)

(27)

(32)

(31)

(31)

(19)

(13)

(14)

(15)

(16)

(16)

(20)

(17)

(17)

(18)

(3)

(9)

(10)

(11)

(12)

(12)

(8)

(1)

(2)

(4)

(5)

(6)

(7)

(13)

(3)

(9)

(10)

(11)

(12)

(12)

(8)

(2)

(36)

(37) (6)

(7)

(40)

(34)

(41) (35)

(28)

(24)

(33)

(29)

(30)

(22)

(38)

(39)

Figure 12

SYSTEM DIAGRAMS


3JH5E / 4JH5E with Keyless C x B TypeInstrument Panel (optional)

Colorcoding Description Engine Har-

nessR Red +B Black -W White IgnitionL Blue Air Heater / Glow

(option)RB Red / Black Alternator Excit-

erLB Blue / Black Alternator

Charge AlarmYW Yellow / White Engine Oil Pres-

sure AlarmYB Yellow / Black Engine Oil Pres-

sureYG Yellow / Green Sail-Drive SealWL White / Blue Water Tempera-

ture AlarmWB White / Black Water Tempera-

tureWG White / Green Seawater Flow

AlarmGR Green / Red Fuel Filter AlarmO Orange Pulse For Tach-

ometerWBr White / Brown Electric Stop

1 Option2 Diodes3 Buzzer4 Engine Oil Low Pressure Alarm5 Coolant High Temperature Alarm6 Water in Sail-Drive Seal Alarm7 Battery Low Charge Alarm8 Fuse (3A)9 SWITCH GLOW (I) / OFF (0) / STOP

(II)

10 SWITCH START (II) / ON (I) / OFF (0)11 Diodes12 Switch13 Tachometer / Hourmeter14 Instrument Panel (Sub Station) (Op-

tion)15 Instrument Panel (Main Station) (Op-

tion)16 Relay17 Wire Harness18 Wire Harness for Sub Panel19 Water in Sail-Drive Seal Sensor Am-

plifier (Sail-Drive Only)20 Procured by Customer21 Battery22 Battery Switch23 Engine Stop Solenoid24 Air Heater25 Stop Relay26 Starter Relay27 Starter Relay28 Coolant High Temperature Switch29 Engine Oil Pressure Switch30 Option31 Alternator32 Ground Bolt33 Water in Sail-Drive Seal Sensor (Sail-

Drive Only)34 Fuel Feed Pump35 Details of Coupler (View from A-A)36 Seawater Flow37 Fuel Filter38 Engine Oil Pressure Meter / Alarm39 Water Temperature Meter / Alarm40 Engine Oil Pressure Sender41 Coolant Temperature Sender

SYSTEM DIAGRAMS


MAINTENANCE LOGDate Operating

HoursMaintenance Performed Dealer Name Stamp or Signa-

ture

SYSTEM DIAGRAMS


Date OperatingHours

Maintenance Performed Dealer Name Stamp or Signa-ture

SYSTEM DIAGRAMS



SYSTEM DIAGRAMS


Documents

Saildrive 20 Manual