Sail-Drive OPERATION MANUAL SD20 SD50 SD50-4T P/N: 0ASDM-G00101 SAILDRIVE
Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement.
TABLE OF CONTENTS Page Introduction......................................................................1 Safety...............................................................................3 Safety Precautions.........................................................3 General Information ................................................. 4 Before You Operate ................................................. 4 During Operation and Maintenance ............................. 5 Product Overview.................
TABLE OF CONTENTS SD50 / SD50-4T.................................................... 30 Periodic Maintenance.......................................................31 Tightening Fasteners....................................................33 Torque Charts.............................................................34 Standard Torque Values ......................................... 34 Standard Torque Chart ........................................... 34 Periodic Maintenance.....................................
INTRODUCTION This Operation Manual describes Sail-Drive Models SD20, SD50, SD50-4T. For engine handling and operation, refer to the respective operation manuals for Engine Models 1GM10C, 2YM15, 3YM20, 3YM30, 3JH4CE, 3JH5CE, 4JH4ACE, 4JH5CE and 4JH4-TCE. However, instructions for the marine gear box are not necessary as they are included.
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SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual. ! This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.
SAFETY General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.
SAFETY During Operation and Maintenance WARNING The safety messages that follow have WARNING level hazards. DANGER The safety messages that follow have DANGER level hazards. Explosion Hazard While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area.
SAFETY CAUTION WARNING Exposure Hazard ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand. Entanglement Hazard NEVER leave the key in the key switch when you are servicing the Sail-Drive. Someone may accidentally start the engine and not realize you are servicing it. NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.
SAFETY NOTICE These notices describe a situation which, if not avoided, can cause damage to the Sail-Drive, personal property and / or the environment or cause equipment to operate improperly. It is important to perform daily checks as listed in this Operation Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor Sail-Drive performance and can help extend the life of the Sail-Drive and engine. ALWAYS be environmentally responsible.
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PRODUCT OVERVIEW OVERVIEW New Sail-Drive Break-In: Owner / Operator Responsibilities The operator must, and assumes all responsibility 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 and recommendations; and • Have an authorized Yanmar dealer / distributor perform periodic checkups.
PRODUCT OVERVIEW COMPONENT IDENTIFICATION (2) (1) (7) (3) (6) (4) (5) 0006440 1 2 3 4 – – – – Dipstick Upper Gear Case Lower Gear Case Lubricating Oil Drain Plug Figure 1 5 – Propeller 6 – Seawater Inlet 7 – Flexible Mount 10 SD Operation Manual © 2009 Yanmar Marine International
PRODUCT OVERVIEW GALVANIC CORROSION CORROSION CONTROL Galvanic corrosion results whenever two or more dissimilar metals (like those found on the sail-drive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content because a chemical reaction takes place causing electrical current to flow between the metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.
PRODUCT OVERVIEW NOTICE: Failure to use the correct anode material may result in inadequate protection and excessive corrosion of underwater drive system components. Use only zinc or aluminum anodes in brackish and saltwater applications. In freshwater applications, use aluminum or magnesium anodes for best results. NEVER use magnesium anodes in brackish or salt water, as they will deteriorate rapidly, which will lead to severe damage to the drive system.
PRODUCT OVERVIEW UNDERWATER DRIVE COATING The lower gear case coating may be damaged when hit by objects in the water, or when having deposits removed from it. The underwater coating must be inspected at least once per year and when it is believed that an object was hit that may have caused damage. Repair and repaint damaged areas immediately.
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BEFORE YOU OPERATE This section of the Operation Manual describes propeller selection, propeller fitting, lubricating oil specifications and how to replenish them. It also describes the daily instrument panel and remote-control device checks. Before you operate the Sail-Drive, review the Safety section on page 3.
BEFORE YOU OPERATE PROPELLER SELECTION Recommended Propeller Size (Maximum) Engine Model Sail-Drive Model 1GM10C 2YM15 3YM20 SD20 Folding Type Diameter 2-Blade Fixed Type Diameter 14 in. 14 in. 14.5 in. 15 in. 15 in. 16 in. 16 in. 16.5 in. SD50 18 in. 18 in. SD50-4T 18 in. 18 in. 3YM30 3JH4CE 3JH5CE 4JH4ACE 4JH5CE 4JH4–TCE NOTICE: Make sure the propeller (fixed or folding) has a rubber bushing.
BEFORE YOU OPERATE Fitting a Fixed Propeller (2-Blade) (1) (4) (5) (6) (3) (2) 0005446 Figure 1 1 – Spacer 2 – Grease 3 – Propeller 4 – Washer 5 – 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, and 80 to 100 N·m (59 to 74 lb-ft) to
BEFORE YOU OPERATE LUBRICATING OIL The choice of lubricating oil is very important. If an unsuitable oil is used, or an oil change is neglected, it may result in damage and reduce the life of the Sail-Drive.
BEFORE YOU OPERATE FILLING WITH LUBRICATING OIL - SD20, SD50 AND SD50-4T Sail-Drive model SD20 SD50, SD50-4T Standard unit 2.2 L (2.3 qt) 2.2 L (2.3 qt) Long-reach unit 2.5 L (2.6 qt) 2.35 L (2.5 qt) Extension 58 2.45 L (2.6 qt) Extension 100 SD20 (1) (2) Figure 3 1 – Oil Supply Port 2 – Oil Capacity Nameplate 0005441 SD50/SD50-4T NOTICE: The lubricating oil capacity of the standard unit is different from that of the long-reach unit.
BEFORE YOU OPERATE CHECKING THE INSTRUMENT PANEL ALARM SYSTEM B (Keyless) - Type New B-Type (1) (4) (3) (2) (1) 20 10 (8) (6) (7) (8) 0000472SD 1 2 3 4 5 6 7 8 – – – – – – – – Figure 5 Battery Low Charge Alarm Sail-Drive Seal Warning Lamp Engine Oil Low Pressure Lamp Coolant High Temperature Alarm Hour Meter Tachometer Key Switch STOP Button (3) (4) 30 40 0 (5) (2) 50 (7) (6) (5) 026102-00X Figure 6 1 – Coolant High Temperature Indicator 2 – Engine Oil Low Pressure Indicator 3 – Water i
BEFORE YOU OPERATE New C-Type (4) (3) (2) (1) (5) (11) (6) (12) (7) (8) (9) (10) 0000473SD Figure 7 1 – Battery Low Charge Alarm 2 – Sail-Drive Seal Warning Lamp 3 – Fuel Filter Warning Lamp 4 – Seawater Insufficient Flow Alarm 5 – Coolant Temperature Gauge 6 – Engine Oil Pressure Gauge 7 – Hour Meter 8 – Tachometer 9 – Key Switch 10–STOP Button 11–Coolant High Temperature Warning Lamp 12–Engine Oil Low Pressure Warning Lamp C (Keyless) - Type (1) (2) (12) (11) (10) (3) (9) (4) (5) (6) (8) (7
BEFORE YOU OPERATE Turn the battery switch on. Turn the key to the ON position and check the lamps on the panel (Figure 5, Figure 7) with the engine off: 1. The lubricating oil warning lamp should be illuminated (Figure 5, 3, Figure 7, 6) . 2. The cooling water temperature warning lamp should be out (Figure 5, 4, Figure 7, 5) . 3. The charge warning lamp should be illuminated (Figure 5, 1, Figure 7, 1) . 4. The rubber seal warning lamp should be out (Figure 5, 2, Figure 7, 2) . 5.
BEFORE YOU OPERATE DAILY CHECKS Before starting the Sail-Drive, make sure it is in good operating condition. Make sure you check the following items: Visual Checks 1. 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 before operation. Drain cooling water and close cooling water cock after operation.
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SAIL-DRIVE OPERATION Before you operate the Sail-Drive, read the following safety information and review the Safety section on page 3. WARNING The safety messages that follow have WARNING level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury. To prevent accidental equipment movement, NEVER start the engine in gear. Before starting the engine, ALWAYS make sure that all bystanders are clear of the area.
SAIL-DRIVE OPERATION REMOTE CONTROL DEVICE CHECK SD20 NOTICE: Before operating the engine, check Sail-Drive oil level. While cranking the engine slowly, shift the control handle of the remote-control head (single lever control) rapidly through NEUTRAL - AHEAD NEUTRAL - ASTERN. If a shift operation is done slowly, the tip of the clutch dog is worn away by being hammered, and, consequently, the clutch fails to engage.
SAIL-DRIVE OPERATION (8) (9) (7) (5) D (4) (6) (10) (4) (5) (6) (1) (2) (3) (1)(2)(3) (7) D 019720-00X 019719-00X Figure 2 1 – Astern 2 – Neutral 3 – Ahead 4 – Operation Handle 5 – Cable Clamp 6 – Remote Control Cable 7 – Ahead Stop 8 – Neutral Position 9 – Astern Stop 10–Spring Joint 1 2 3 4 5 6 7 – – – – – – – Figure 3 Astern Neutral Ahead Operation Lever Cable Clamp Remote Control Cable Pivot SD Operation Manual 27 © 2009 Yanmar Marine International
SAIL-DRIVE OPERATION SD50 / SD50-4T (1) After starting the engine, check the shift action by using the control head to shift the AHEAD and ASTERN positions. The AHEAD / ASTERN clutch is a mechanical clutch called a cone clutch. Although a grinding noise is made when this type of clutch is engaged, it has no effect on the operation of the engine.
SAIL-DRIVE OPERATION ENGINE COOLING WATER Opening or closing the cooling water system of the engine driving the Sail-Drive is done by the cooling water cock fixed on the upper case of the Sail-Drive. Be sure to open the cock (Figure 5, (1)) and confirm that the cooling water has suction by cranking the engine before starting the vessel. The cooling water passes through the Sail-Drive case, cools the engine by the cooling water pump, and is then discharged.
SAIL-DRIVE OPERATION SD50 / SD50-4T (3) (1) (2) 1 – To Cooling Water Pump 2 – Cooling Water Cock Figure 6 0005448 3 – Open 30 SD Operation Manual © 2009 Yanmar Marine International
PERIODIC MAINTENANCE Before you perform maintenance on the Sail-Drive, read the following safety information and review the Safety section on page 3. This section of the Operation Manual describes the procedures for proper care and maintenance of the Sail-Drive. WARNING The safety messages that follow have WARNING level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury.
PERIODIC MAINTENANCE WARNING CAUTION Electrical Shock Hazard ALWAYS turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the Sail-Drive. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. The safety messages that follow have CAUTION level hazards.
PERIODIC MAINTENANCE TIGHTENING FASTENERS NOTICE These notices describe a situation which, if not avoided, can cause damage to the SailDrive, personal property and / or the environment, or cause equipment to operate improperly. Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly. Only use replacement parts specified. Other replacement parts may affect warranty coverage.
PERIODIC MAINTENANCE TORQUE CHARTS Standard Torque Values M6 x 1.0 M8 x 1.25 M10 x 1.25 or 1.5 M12 x 1.25 or 1.5 M14 x 1.5 M16 x 1.5 Cast Iron or Steel 10.8 ± 1.0 N·m 8.0 ± 0.8 lb-ft 25.5 ± 2.0 N·m 18.8 ± 1.5 lb-ft 49.1 ± 4.9 N·m 36.2 ± 3.6 lb-ft 88.3 ± 10.0 N·m 65.1 ± 7.4 lb-ft 137.2 ± 4.9 N·m 101.2 ± 3.6 lb-ft 225.4 ± 10.0 N·m 166.2 ± 7.4 lb-ft Aluminum 8.8 ± 1.0 N·m 6.5 ± 0.8 lb-ft 20.6 ± 2.0 N·m 15.2 ± 1.5 lb-ft 39.2 ± 2.0 N·m 28.9 ± 1.5 lb-ft 70.6 ± 4.9 N·m 52.1 ± 3.6 lb-ft 109.
PERIODIC MAINTENANCE Periodic Maintenance CAUTION! Establish a periodic maintenance plan according to the Sail-Drive application and make sure you perform the required periodic maintenance at intervals indicated. Failure to follow these guidelines will impair the Sail-Drive’s safety and performance characteristics, shorten the Sail-Drive's life and may affect the warranty coverage on your Sail-Drive.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE TABLE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily (See Daily Checks on page 23.
PERIODIC MAINTENANCE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily (See Daily Checks on page 23.
PERIODIC MAINTENANCE WHEN THE VESSEL IS OUT OF THE WATER, PERFORM THE FOLLOWING: Removing Deposits From The Lower Gear Case Draining Water Drain the engine cooling water, together with the water in the Sail-Drive case. If this water is not drained, freezing may cause the engine block and / or the Sail-Drive case to crack. Remove seaweed, seashells and other marine growth from the lower gear case.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES SD20 (1) (2) After Initial 50 Hours of Operation Perform the following procedures after the first 50 hours of operation. • Draining and Replacing Lubricating Oil • Inspecting and Replacing the Clutch Shifter (3) Draining and Replacing Lubricating Oil - SD20 When the vessel is out of the water, drain the oil by removing the lower gear case drain plug, and the upper gear case oil dipstick.
PERIODIC MAINTENANCE Draining and Replacing Lubricating Oil - SD50 / SD50-4T SD50 / SD50–4T Lubricating oil should be changed while the engine is still warm. CAUTION! Let the drive unit cool at least 5 minutes after operation before removing the oil drain plug. Hot oil could spurt out forcefully if the drain plug is removed from the drive unit immediately after operation.
PERIODIC MAINTENANCE Equipment Used Quantity Remarks Bottle of Quicksilver® High Performance Gear Lube from MerCruiser® Description MerCruiser® Part code 92-850743A1 Part Code 2 Each bottle contains 0.946 L (1 qt) of oil. Mandatory for SD50, SD50-4T. For other models see p. 7. Market pump from MerCruiser® on bottle MerCruiser® Part code 91-85729A1 1 Adapter joint 196311-92960 1* O-ring for adapter 24311-000100 1* - 2 Inner diameter 14 to 16 mm (0.5 to 0.625 in.
PERIODIC MAINTENANCE When Vessel Is In The Water Removing Oil Preparing the Sail-Drive (1) (2) (1) (2) (3) (3) (4) 0005452 1 2 3 4 – – – – Figure 4 O-Ring Adapter Joint Oil Changing Plug Thread M10x1.5 0005453 1. Remove the oil changing plug located under the shift lever. 2. Screw in an adapter joint with an O-ring. When using your own adapter joint, the maximum length of thread should be 12 mm. 3. Attach a stiff rubber hose (inner diameter 14 to 16 mm [0.5 to 0.625 in.
PERIODIC MAINTENANCE Option 1: Using Compressed air from main system or 12 V portable compressor. 1. Connect a hose to the top adapter joint and to a compressed air source (Figure 5, (2)). Within 10 to 15 minutes almost all oil will be blown out. (1) Using Yanmar Pump Refer to Preparing the Sail-Drive on page 42 and Fastest Way: Blowing Out by using Air Pressure on page 42.
PERIODIC MAINTENANCE Replacing Oil Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19. Using Yanmar Hand Pump (1) Fastest way: By using MerCruiser pump or simple market pump Refer to Preparing the Sail-Drive on page 42. (1) 1 – Plug Figure 8 0005575 1. Use a MerCruiser® pump like the one shown (Figure 8) or use a similar pump available locally. 2. Attach the pump to a new bottle of Quicksilver® High Performance Gear Lube from MerCruiser®. 3.
PERIODIC MAINTENANCE 1. Connect the hoses as shown above (Figure 9). 2. Remove the plug from the upper case cover (Figure 9, (1)). 3. Operate the pump to fill the Sail-Drive with oil. Be aware that oil has to flow down through restricted parts of the casing and then back up again, so pressure will initially be high and pumping will be difficult. Pausing for a few minutes will help. The hand pump and rubber hose are available from Yanmar, and are optional parts for SD50 / SD50-4T.
PERIODIC MAINTENANCE Removing Oil By Draining Refer to Preparing The Sail-Drive on page 45. Replacing Oil Refer to Filling With Lubricating Oil - SD20, SD50 and SD50-4T on page 19. Oil draining is possible when the vessel is out of the water but will take a greater amount of time. Using MerCruiser® Pump or simple market pump Refer to Preparing The Sail-Drive on page 45. 1. After approximately 0.6 L (0.6 qt) has been drained, remove the oil changing plug.
PERIODIC MAINTENANCE 6. Pump the oil into the drive. After the first bottle is empty, screw in the oil changing plug. 7. Change the bottle while the pump and hose remain connected to the adapter joint. 8. After filling, first screw in and tighten the plug at the top cover. Then remove the oil bottle, pump, hose and adapter joint and screw in the oil drain plug. Using Yanmar Hand Pump Refer to Preparing The Sail-Drive on page 45. 3. Pump the oil into the drive.
PERIODIC MAINTENANCE SD50/SD50–4T Every 100 Hours of Operation Perform the following maintenance every 100 hours of operation. • Changing the Lubricating Oil (SD20) • Inspecting and Replacing the Anode Changing the Lubricating Oil (SD20) See Draining and Replacing Lubricating Oil - SD20 on page 39.
PERIODIC MAINTENANCE Every 250 Hours of Operation Perform the following maintenance every 250 hours of operation. • Changing the Lubricating Oil (SD50, SD50-4T) • Inspecting and Replacing the Clutch Shifter Every 500 Hours of Operation • Inspecting and / or Replacing the Cone-Clutch Inspecting and / or Replacing the Cone-Clutch See your authorized Yanmar dealer or distributor for procedure.
PERIODIC MAINTENANCE Inspecting and / or Replacing the Flexible Mount Every Year Perform the following maintenance every year 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 Mount Replace if clearance is less than 1 mm (Figure 17, (1)). See your authorized Yanmar Marine dealer or distributor for procedure.
PERIODIC MAINTENANCE Every 2000 Hours of Operation • Replacing the Flexible Mount • Replacing the Cone-Clutch Replacing the Flexible Mount See your authorized Yanmar dealer or distributor for procedure. Flexible Mount must be replaced every 2000 hours. Every 5 Years • Replacing Rubber Diaphragm Seal Ring Replacing Rubber Diaphragm Seal Ring To replace, consult your Yanmar Marine dealer. Replacing the Cone-Clutch See your authorized Yanmar dealer or distributor for procedure.
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SPECIFICATIONS SD20 Model Reduction Gear System Direction Of Rotation Reduction Ratio SD50 Constant mesh gear with dog clutch Cone clutch Input Shaft Counterclockwise viewed from stern Propeller Shaft Counter-clockwise viewed from stern Counter-clockwise or clockwise viewed from stern Ahead 2.64 2.32 Astern 2.64 2.32 Propeller Speed (rpm) 1364 1293 Lubrication System Oil bath type Lubricating Oil Capacity 1337 Standard Unit 2.2 L (2.3 qt) 2.2 L (2.3 qt), SD40: 1.8L (1.
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SYSTEM DIAGRAMS Color coding for wiring diagrams R Red B Black W White Y Yellow L Blue O Orange L/B Blue/Black W/L White/Blue Y/W Yellow/White W/R White/Red L/R Blue/Red W/B White/Black R/B Red/Black Allowable length by cross sectional area of battery cable Section of cable mm2 (in.2) Allowable length L = 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.
56 © 2009 Yanmar Marine International (11) (10) (9) (8) (3) E B L R (12) B B (7) B S R R W Figure 1 SD Operation Manual L/R O Y/W W/L L/B R/B L (2) (6) B (5) B W/R R W L/B W/L Y/W W/R B O L/R W/B (14) (13) (15) (17) (16) R W L/B W/L Y/W R/B B O L/R L (18) W/R (1) R W L/B W/L Y/W R/B W/R AC (26) 30 (20) R/B (4) W (21) R/B R/B R/B R/B 0005465 (25) (24) (23) (22) SYSTEM DIAGRAMS A-Type Instrument Panel W/R
SYSTEM DIAGRAMS A-Type Instrument Panel Applicable Engine Model: 1GM10C 1 Cable, battery to switch 2 Cable, switch to starter 3 Cable, battery to starter 4 Battery Recommended capacity GM, 12V-70AH 1GM,12V-100AH (Minimum) 5 Battery switch 6 FUSE 7 Starter motor 8 Alternator 9 Not used 10 Cooling Water temp. switch 11 Engine Oil pressure switch 12 Spare connector 13 Extension cable 3 m [9.8 ft] (Standard) 14 The total length extension cable must be less than 6 m (19.
58 © 2009 Yanmar Marine International 12 11 10 9 8 B B 7 P P E B L R B S L/B R/B L O L/R Y/W W/L R R W 2 6 W/R B R W L/B W/L Y/W B O L/R W/R W/B 14 13 19 15 17 16 R W L/B W/L Y/W B O L/R R/B L 18 R W L/B W/L Y/W B P 28 P L/B O R B 5 21 W/L R/B W/R B B R/B 20 R/B 30 27 AC R/B 1 W/R Y/W W/L 3 4 W W L/B 25 26 W/R R/B 24 23 Y/W R/B W/L R/B R/B 003877-00E 22 SYSTEM DIAGRAMS B-Type Instrument Panel Figure 2 SD Operation Manual B W/R
SYSTEM DIAGRAMS B-Type Instrument Panel Applicable Engine Model: 1GM10C 1 Cable, battery to switch 2 Cable, switch to starter 3 Cable, battery to starter 4 Battery Recommended capacity GM, 12V-70AH 1GM, 12V-100AH (Mini.) 5 Battery switch 6 FUSE 7 Starter motor 8 Alternator Note: If the cross-sectional area of the wire being used is equal to or less than 20 mm2 (approximately AWG 4), the combined lengths of items 1, 2 and 3 must be less than 2.5 m (8.2 ft).
60 © 2009 Yanmar Marine International 10 3 2 10 3 YW 4 YW 4 WL 5 WL 5 YG 6 YG 6 LB 7 LB 7 14 8 13 8 W L + B 12 11 O - P L O 30 AC R 12 - P G2 G1 17 W + B L 11 G1 L 30 AC G2 17 R R 9 R 9 WBr WBr 15 15 17 16 3R 2B 5R Figure 3 SD Operation Manual 18 B L YG RB 3L + - 16 24 5R 28 WL 23 3R 33 22 3L 3W 25 19 + 0004506 RB LB O YG - L R E B LB RB 21 YB GB G GR WB YR Y WR 30 3 20 12V 24 YW WL WG B 29 YW WBr 2R s
SYSTEM DIAGRAMS 4JH4-TE with B x B Type Panel Color Coding 1 Option Engine Harness 2 Alarm Lamps R Red + 3 Buzzer B Black - 4 Engine Oil Pressure W White Ignition 5 Coolant Temperature L Blue Air heater / glow (option) 6 Sail-Drive Seal 7 Battery Low Charge Alarm 8 Fuse (3A) RB Red / Black Alternator exciter LB Blue / Black Alternator charge alarm 9 Stop Switch Diodes YW Yellow / White Engine oil pressure alarm 10 11 Key Switch YB Yellow / Black Engine oil pressu
62 © 2009 Yanmar Marine International YW 3 2 10 WL 5 + 36 B 10 WG - YB G 34 35 YW 4 WL YG 6 YG 6 + LB 7 LB 7 Figure 4 SD Operation Manual - 37 14 WB 8 13 8 W W + L - P 12 11 L O O 30 AC 12 - P G2 G1 17 R + B L 11 G1 L 30 AC G2 17 R R 9 R WBr WBr 15 15 17 16 3R 2B 5R 18 B L YG RB 3L + - 16 38 28 WL 23 GR 24 5R 22 B 3R 33 3L 25 39 YB 3W 29 YW WBr 2R 19 WB 30 - 0004507 RB LB O YG YW WL WG B 24 3 20
SYSTEM DIAGRAMS 4JH4-TE with C x B Type Panel Color Coding 1 Option Engine Harness 2 Alarm Lamps R Red + 3 Buzzer B Black - 4 Engine Oil Pressure W White Ignition 5 Coolant Temperature L Blue Air heater / glow (option) 6 Sail-Drive Seal 7 Battery Low Charge Alarm 8 Fuse (3A) RB Red / Black Alternator exciter LB Blue / Black Alternator charge alarm 9 Stop Switch Diodes YW Yellow / White Engine oil pressure alarm 10 11 Key Switch YB Yellow / Black Engine oil pressu
8 3 YW WL 2 5 YG LB 4 1 10 6 64 © 2009 Yanmar Marine International + B L O -P 9 11 L G2 G1 30 17 AC R W R 7 WBr 12 13 15 A A 14 B L YG RB + - 3BR 128990-77910 2L 5R 2B 0.85WBr 2B 2B 16 22 26 3L 3R 3W 119247-77100 WBr 2R 0.85YW 119717 -77800 25 0.85WL 2B 17 + - 0.85B 18 + 2W 21 12V 30 RB LB O YG YW WL WG B 20 1 2 19 - 3 GLOW OFF ON START 29 0.85B 27 003880-00E 30 AC G1 G2 17 Key switch 0.85 O 0.
SYSTEM DIAGRAMS B-Type Instrument Panel for 3YM30, 3YM30, 3YM20 and 2YM15 Color Coding R Red B Black W White L Blue RB Red / Black LB Blue / Black YW Yellow / White YG Yellow / Green WL White / Blue WG White / Green GR Green / Red O WBr Orange White / Brown 1 Alarm Lamps 2 Buzzer Oil Pressure 3 Coolant Temperature 4 Sail-Drive Seal 5 Charge 6 Fuse (3A) 7 Stop Switch 8 Diodes 9 Key Switch 10 Instrument Panel 11 Tachometer Hour Meter 12 Wire Harness Option (L=3M)
34 37 YW WL 5 6 7 8 YG LB 66 © 2009 Yanmar Marine International 39 YW WL YG LB 14 15 16 17 18 4 38 35 10 13 12 30 L B O P L G2 G1 40 11 R O P L 17 AC W 3 B 1 L G2 G1 30 17 AC W R R WBr WBr 41 36 3R 31 A A 2B 5R 43 B L YG RB 3L 44 5R 26 WL 3L 27 23 RB LB O YG YW WL WG B WBr YW 2B 3R 3W 21 45 22 2R LB RB YB GB G GR WB YR Y WR L R E B 47 Option 28 32 3 46 3R O Y 10R GLOW OFF ON START 2W S L R YG 49 B 48 003881-00E 30 AC G
SYSTEM DIAGRAMS B-Type Instrument Panel for 3JH4E Color Coding 27 Engine Oil Low Pressure Switch 28 Alternator (Option) R Red 29 Alternator B Black 30 W White Water in Sail-Drive Seal Sensor (on Sail-Drive) L Blue 31 Water in Sail-Drive Seal Sensor Amplifier (Sail-Drive Only) 32 Battery (Option) 33 Battery 34 Diodes 35 Instrument Panel (Sub Station) (Option) RB Red / Black LB Blue / Black YW Yellow / White YB Yellow / Black YG Yellow / Green WL White / Blue 36 Wire Ha
38 41 YW WL 5 6 7 8 YG LB 68 © 2009 Yanmar Marine International 20 19 YG LB WL YB G YW B 43 YG 14 15 16 17 18 4 42 B 12 30 O P L G2 G1 L O P L 17 AC W R L G2 G1 30 17 AC R W 11 3 1 13 44 WB 39 10 2 R R WBr WBr 45 40 46 3R 31 A A 2B 5R 47 B L YG RB 3L 48 WL 49 3L 3R 3W 21 26 5R 22 WBr 34 YB 23 RB LB O YG YW WL WG B 27 YW 2B 2R 32 35 WB 3 E B YB GB G GR WB YR Y WR 28 L R 53 51 50 LB RB 1 O GLOW OFF ON START E B L R
SYSTEM DIAGRAMS C-Type Instrument Panel for 3JH4E Color Coding 27 Engine Oil Low Pressure Switch 28 Alternator (Option) R Red 29 Alternator B Black 30 W White Water in Sail-Drive Seal Sensor (on Sail-Drive) L Blue 31 Water in Sail-Drive Seal Sensor Amplifier (Sail-Drive Only) 32 Battery (Option) 33 Battery 34 Engine Oil Pressure Sensor (Option) 35 Coolant Temperature Sensor (Option) 36 Option 37 Alarm Lamps 38 Diodes 39 Instrument Panel (Sub Station) (Option) RB Red / Bla
5 YW 6 YG 70 © 2009 Yanmar Marine International diodes YW LB WL YG W 0004594 Figure 8 SD Operation Manual + 3 B - P O + 13 B - P L 11 G1 L O 30 AC G2 17 W R R 12 Instrument panel (main station) (Option) LB Fuse(3A) WBr Wire harness Wire harness for sub panel 2B 5R Wire harness Relay 31 B L YG RB + - only for sail drive A A 3L 5R 21 26 WL 3L WBr 2R 32 12V + 1 2 RB LB O YG YW WL WG B 23 27 YW 2B 3R 3W 22 L L 1 + - R 3R G1 30 AC WB
SYSTEM DIAGRAMS B-Type Instrument Panel for 4JH4AE Color coding Description R Red B Black W White L Blue RB Red / Black LB Blue / Black YW Yellow / White YB Yellow / Black YG Yellow / Green WL White / Blue WB White / Black WG White / Green GR Green / Red O WBr Orange White / Brown 1 Starter Switch 2 Stop Switch 3 Tachometer / Hour Meter 4 Buzzer 5 Engine Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail-Drive Seal Alarm 8 Battery Low Charge
5 YW 6 YG 72 © 2009 Yanmar Marine International YW + - 19 B diodes WG LB YB G Figure 9 SD Operation Manual W + 3 B - P L 1 G1 L O 30 AC G2 17 R + - 20 LB WB Fuse(3A) W + 13 - P L 11 G1 L O 30 AC G2 17 R Instrument panel (main station) (Option) WL YG 10 2 R R 12 Instrument panel (sub station) (Option) 8 Alarm lamps WL 7 14 15 16 17 18 diodes 4 WBr WBr Wire harness Wire harness Wire harness for sub panel 9 3R 5R 31 B L YG RB 3L + -
SYSTEM DIAGRAMS C-Type Instrument Panel for 4JH4AE Color coding Description R Red B Black W White L Blue RB Red / Black LB Blue / Black YW Yellow / White YB Yellow / Black YG Yellow / Green WL White / Blue WB White / Black WG White / Green GR Green / Red O WBr Orange White / Brown 1 Starter Switch 2 Stop Switch 3 Tachometer / Hour Meter 4 Buzzer 5 Engine Oil Low Pressure Alarm 6 Coolant High Temperature Alarm 7 Water in Sail-Drive Seal Alarm 8 Battery Low Charge
LB YW WL YG RB (9) 74 © 2009 Yanmar Marine International Figure 10 SD Operation Manual (14) L B 1N4007 (10) (1) (11) O - P (13) + B R RB (12) II RB 47Ω/3W (7) (6) (5) (4) (2) (3) (8) 0 I (12) 0 II I RB B YW W R L WBr (15) (16) A A B L YG RB + - (22) 3BR (17) 2L 128990 -77910 5R 2B 0.85WBr 2B 2B WBr 2R 119247-77100 (24) (20) 3L 3R 3W (28) 0.85YW (23) 119717 -77800 (27) 0.85WL 2B (21) + - 0.
SYSTEM DIAGRAMS 2YM15, 3YM20, 3YM30 - B (Keyless) Type Instrument Panel (optional) 1 Optional 2 Diodes 3 Buzzer 4 Engine Oil Low Pressure Alarm 5 Coolant High Temperature Alarm 6 Water in Sail-Drive Seal Alarm 7 Battery Low Charge Alarm 8 Fuse (3A) 9 SWITCH GLOW (I) / OFF (0) / STOP (II) 10 SWITCH START (II) / ON (I) / OFF (0) 11 Diode 12 Switch 13 Tachometer / Hourmeter 14 Instrument Panel (Main Station) (Option) 15 Wire Harness 16 Wire Harness for Sub Panel 17 Water in Sai
(2) YW WL YG YW WL YG 47Ω/3W (7) (6) (5) (4) (3) 47Ω/3W (7) (6) RB RB (8) + Figure 11 SD Operation Manual + (15) (13) - P (12) (9) (14) (11) L B L B 1N4007 O O - P (13) B RB (12) B R RB R RB RB II 0 I II 0 I LB LB © 2009 Yanmar Marine International (8) 76 RB (5) (10) (12) (12) B YW W R L WBr YW L W R WBr (17) (17) (18) (16) 3R 0.
SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless B and B x B Type Instrument Panel (optional) Option 2 Diodes 3 Buzzer 4 Engine Oil Low Pressure Alarm 5 Coolant High Temperature Alarm 6 Water in Sail-Drive Seal Alarm 7 Battery Low Charge Alarm 8 Fuse (3A) Color coding Description R Red + B Black - W White Ignition L Blue Air Heater / Glow (option) RB Red / Black Alternator Exciter 9 SWITCH GLOW (I) / OFF (0) / STOP (II) LB Blue / Black Alternator Charge Alarm 10 SWITCH START
(2) YW YW WL YG Figure 12 SD Operation Manual YW R + WL WG G YG (38) - 47Ω/3W (7) (6) (37) (36) (3) 47Ω/3W (7) (6) LB LB B RB (8) RB WL R R + + (15) (39) WB (12) (9) (14) - O - P (13) R RB B (12) II 0 I 0 B (8) RB R RB © 2009 Yanmar Marine International L + R B 1N4007 (11) L B (13) - P O (12) (10) (12) 0 I II B 78 YW W R L WBr YW R L W WBr WB YB (5) (17) (17) (18) (16) 3R 0.
SYSTEM DIAGRAMS 3JH5E / 4JH5E with Keyless C x B Type Instrument Panel (optional) Color coding Description R Red + B Black - W White Ignition Blue Air Heater / Glow (option) Red / Black Alternator Exciter L RB Engine Harness 10 SWITCH START (II) / ON (I) / OFF (0) 11 Diodes 12 Switch 13 Tachometer / Hourmeter 14 Instrument Panel (Sub Station) (Option) 15 Instrument Panel (Main Station) (Option) 16 Relay 17 Wire Harness 18 Wire Harness for Sub Panel 19 Water in Sail-Drive
SYSTEM DIAGRAMS MAINTENANCE LOG Date Operating Hours Maintenance Performed 80 Dealer Name Stamp or Signature SD Operation Manual © 2009 Yanmar Marine International
SYSTEM DIAGRAMS Date Operating Hours Maintenance Performed SD Operation Manual Dealer Name Stamp or Signature 81 © 2009 Yanmar Marine International
SYSTEM DIAGRAMS This Page Intentionally Left Blank 82 SD Operation Manual © 2009 Yanmar Marine International
