"service manual"
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1. other hardware or other excessive electrical currents related to additional components or changes to the electrical AC and DC systems on board the vessel The ZF SD 10 will be mechanically connected to the powering engine The design of the electrical system of the engine will impact the selection of a proper galvanic protection system Isolated systems If the engine alternator and starting motor uses an isolated circuit having both a battery and connection terminal then the system can be treated as an isolated system Non Isolated systems If either the starter motor or the alternator uses a single battery and uses the body or case as a ground through the engine then the system of the SD 10 and the engine must be considered as grounded to the battery negative and not isolated 23 VI CORROSION PROTECTION Suggested actions For information on this topic review the published guidelines as contained in ABYC guidebook Section E 2 Upon final delivery of the vessel a review of the electrical bonding system should be conducted An expert in the field of electrical bonding should be called upon to review the completed vessel This review should determine if there is an appropriate amount or sizing of sacrificial anodes installed in order to protect the mechanical components engine and SD 10 from damage from galvanic corrosion Please keep in mind changes made to the vessels AC and DC systems may impact the2. towed or anchoring in a river because the propeller may rotate WARNING When the engine runs idle but the propeller shaft should not be driven such as when charging the battery with the generator the shifting lever see Fig 2 must be held in the neutral position N to prevent the boat from moving IV Operation 3 Gear shift operation CAUTION Make certain that control rod or cable is easily movable 3 1 Lever travel see Fig 3 Minimum travel of gear shift lever O A O B must be 35 mm 1 3 8 for outer pivot point and 30 mm 1 3 16 for inner pivot point 3 2 Lever position In neutral position perpendicular to control rod or cable Gear shift lever can be fixed in any position by means of clamping screw Minimum distance between gear shift lever and cover 0 5 mm 0 02 Opening or loosening of cover requires renewed adjustment by specialized personnel only 3 3 Regular checks are required to ensure the strict observance of item 3 1 and 3 2 IV Operation Minimum lever travel for control cable Do not open cover a p 209 55 h7 Do not unscrew the nut Oil suction plug Ma 10 2 Nm Fig 3 11 V MAINTENANCE Maintenance programs described below are valid for the SD 10 transmission unit not the engine For the intervals and procedures for maintenance of the engine refer to the operation manual and maintenance of the engine ROU
3. TINE MAINTENACE MAINTENANCE SCHEDULE MAINTENANCE TO BE PERFORMED At the beginning of the day and when you refuel Check the transmission oil fluid level Every two months of operation Check the battery connections and acid level Check the anitfouling condition and if necessary apply it to the foot Ensure that the clamps and the wiring connections are secure Clean the clamps every two operating months or every 50 hours according to the interval that occurs first In case of use in saltwater the interval is reduced to every 25 hours or 30 days of operation according to the interval that occurs first 12 1 Check the oil level by removing the dipstick Wipe the dipstick with a clean lint free cloth 2 Insert the dipstick so that it rests on top of the threads into the case Remove the dipstick and check the fluid level on the dipstick The fluid level must be between the marks of minimum and maximum on the dipstick Add oil as necessary 3 a Maximum b Minimum c Upper edge of threaded hole d Rod V MAINTENANCE SCHEDULED MAINTENANCE After the first 25 hours and not more than 30 hours Change the oil Every 250 hours of operation or once a year according to the interval Change the oil that occurs first Lubricate and check that the sea chest opens and closes freely Every 500 hours or once a year according to the interval that occurs Lubric
4. Ta SD 10 Description and 4 OWNERS Manual Owners Manual SD 10 Section Introduction Il Gear Identification Ill Brief description IV Operation V Maintenance VI Corrosion protection I Introduction Customer s Responsibility The Customer Operator is responsible to perform the necessary safety checks to ensure that lubrication cooling maintenance and recommended practices are strictly followed for safe enjoyable operation All Transmission units are covered by a limited warranty Therefore In respect to the handling of the transmission units the instructions stated in this manual are to be strictly followed Maintenance programs described below are valid for the SD 10 transmission unit not the engine For the intervals and procedures for maintenance of the engine refer to the operation manual and maintenance of the engine CAUTION The manufacturer is not liable for any damages or losses caused by faulty installation wrong handling of the equipment and or deficient maintenance The Customer has to make sure that any external forces as well as vibration caused by torsion and bending are avoided The interaction between engine shaft and propeller may lead to torsional vibration producing a hammering noise of gears and might damage the engine and or transmission The Supplier is not liable for such torsional vibration inherent to the installation I Introduction This manual includes among other things
5. anty claims A Service Manual is available from the manufacturer 1 General All SD 10 transmissions have been submitted to a test run before shipment During normal operation the transmission should only be shifted with the engine at idle speed In emergency cases it is also admissible to shift at higher soeeds Visual checks for leakage should be made from time to time WARNING Work on the transmission must only be performed with the engine and propeller at standstill CAUTION Before the first startup the transmission must be filled with transmission fluid Start the engine only when the transmission is in neutral position CAUTION Using the transmission with an insufficient oil level will damage the gears An excessive oil level may cause leakage at the shaft seals and the transmission breather and raise the operating temperature considerably 2 Sailing Boat sailing moving in tow or anchoring When the engine is off and the boat sails moves in tow or is anchored the propeller may turn with the water current CAUTION When the boat sails with engine switched off the shift position of the gearbox can be 1 in neutral position and in this case the propeller is free to rotate 2 in the opposite position of the travel direction to lock the propeller Note do not put the shifting lever of the gearbox in forward position otherwise the transmission could be damaged WARNING Do not work on the transmission when being
6. ate the propeller shaft splines and tighten the propeller first nuts Check that pipe fittings are properly tight Check that in the grounding circuit continuity are not loose or damaged connections Ensure that the electrical system fasteners are not loose da maged or corroded Make sure that there are not any loose damaged or corroded wires and connectors Check that the hose clamps on flexible pipes are properly tight Apply an antifouling Each year Check the the foot sealing menbrane not present cracks or wa ter seepage Replace every 7 years Replace the foot sealing membrane 14 V OIL CHANGE Un screw the oil dipstick Prepare a suitable container to collect the fluid Remove the lower plug and drain the oil Dispose of used oil properly 15 V OIL CHANGE Connect a hand oil pump onto the fitting of the oil drain hole in the SD 10 drive Be careful not to damage the thread of the drain hole Using low pressure pump add oil 3L SAE 15W 40 Replace the O rings on the oil cap Sail drive lubricate it and prepare to reassemble it V OIL CHANGE Screw in the oil dipstick Remove the oil pump fitting and quickly install the oil plug Torque 10Nm Add oil at the dipstick hole to reach the proper level as indicated on the dipstick 17 V REMOVING PROPELLER Place a block of wood between the propeller blade and the hull Using a 6mm Allen wren
7. ch loosen and remove the locking screw of the bullet Insert a suitable tool into the hole Loosen and remove the propeller spinner nut V REMOVING PROPELLER Remove the wooden block Remove the propeller If necessary use a plastic hammer and gently tap to remove Remove the propeller sleeve V INSTALLING PROPELLER Assemble the propeller shaft thrust bearing sleeve Install chamfered side away from propeller Put some anti corrosion grease on the grooves of the propeller shaft EMPLOYMENT Propeller shaft splines Propeller shaft splines Propeller shaft splines 20 V INSTALLING PROPELLER Align the splines and insert the propeller on the propeller shaft The propeller shaft must fit evenly on the splines Wipe off excess grease Install the propeller shaft nut 21 V INSTALLING PROPELLER Place a block of wood between one of the propeller blades and the hull Mount the special insert T2 on a suitable torque wrench and insert into the hole in the propeller nut and tighten to a torque of 125 Nm Install the locking screw in the center Tighten the locking screw to a torque of 23 Nm 22 VI CORROSION PROTECTION The SD 10 is equipped with a replaceable sacrificial anode on the lower leg of the drive This anode is designed to dissolve in response to electrical current generated while in sea water This anode is not designed to accommodate
8. protection of the installed anode system Damage to the SD 10 as a result of failure to maintain a good balanced galvanic protection system is not the responsibility of ZF Marine 24 VI ANODE REPLACEMENT To minimize galvanic corrosion the SD 10 system has a sacrificial anode placed on the foot of the sail drive However in particularly adverse conditions we recommend the use of additional anti corrosion anode kit to be installed separately The anodes provide protection against corrosion under normal use Remove propeller 25 VI ANODE REPLACEMENT Using a 6mm Allen key remove the screws of the anode Remove the anode of the foot If necessary remove using a plastic mallet 26 VI ANODE REPLACEMENT Remove the spacer sleeve and clean any scale Apply to the propeller shaft splines a thick layer of lubricant and or corrosion protection material Insert the propeller thrust sleeve onto the shaft Place a new anode on the foot 27 VI ANODE REPLACEMENT Tighten to a torque of 12 Nm with the cross method Install propeller 28
9. the following four main chapters lil Description This part briefly describes function operation and design of the SD 10 types IV Operation This part describes the procedures for operation and all necessary safety measures V Maintenance This part contains all maintenance and service tasks to be performed by the operator Important information related to technical reliability and operational safety are highlighted by the identifying words as follows WARNING Any procedure practice condition statement etc which is not strictly followed could result in injury or death of personnel VI Corrosion Protection This part contains information on corrosion protection II Gear Identification Name Plate The name plate is fixed onto the transmission MODEL SD 10 Transmission Type iA 2 16 Transmission ratio propeller rotation opposite engine rotation iB 2 16 Transmission ratio propeller rotation same to a engine rotation SER N XXXXXXXX Transmission serial number P N 3321 005 011 Transmission part number Ill Brief Description 2 The ZF SD 10 Sail Drive is a reliable and well designed piece of machinery They are of sturdy construction and utmost reliability Nevertheless the user should make a point of observing the following instructions for installation operation and maintenance Failure to do so or unauthorized changes in the transmission will preclude all and any warr
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