Yanmar ZT350 series Operation Manual
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Yanmar ZT350 series Operation Manual

Yanmar ZT350 series Operation Manual

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ZT350
series
OPERATION MANUAL
P/N: 0AZTD-G00100
STERN-DRIVE

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Summary of Contents for Yanmar ZT350 series

  • Page 1 ZT350 series OPERATION MANUAL P/N: 0AZTD-G00100 STERN-DRIVE...
  • Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

  • Page 3: Table Of Contents

    Trim Cylinder Anodes ........Propeller Shaft Anode ........Features and Controls ........... Remote Controls ..........Power Trim ........... Stern-Drive Trim Angle ........Trim and Tilt / Trailering Switch ......Electrical System ........... ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 4 ..... Performing Periodic Maintenance ...... The Importance of Daily Checks ......Yanmar Replacement Parts ......Tools Required ..........Ask Your Authorized Yanmar Marine Dealer or Distributor for Help ......... Tightening Fasteners ..........Torque Charts ............Standard Torque Values ........Torque Specifications ........

  • Page 5: Introduction

    INTRODUCTION Welcome to the world of Yanmar Marine! • Read and understand this Operation Yanmar Marine offers engines, stern-drive Manual before you operate your vessel to systems and accessories for all types of ensure that safe operating practices and vessels, from runabouts to sailboats, and maintenance procedures are followed.

  • Page 6: Record Of Ownership

    INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Stern-Drive Model: Stern-Drive Transom Assembly Serial No.: Stern-Drive Unit Serial No.: Stern-Drive Gear Ratio: Date Purchased: Engine Model:...

  • Page 7: Safety

    SAFETY SAFETY PRECAUTIONS Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its DANGER products, such as those who install, operate, maintain or service Yanmar Indicates a hazardous situation which, if products, exercise care, common sense...

  • Page 8: General Information

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar Marine dealer or distributor for additional training. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 9: During Operation And Maintenance

    NEVER support the stern-drive with equipment not designed to support the weight of the stern-drive such as wooden pieces, blocks or by only using a jack. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 10 Stop the engine before you begin to service the stern-drive and secure the propeller so it will not turn. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 11 Flying Object Hazard ALWAYS wear eye protection when servicing the stern-drive or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 12 Failure to comply may impair the stern- drive’s safety and performance characteristics and shorten the stern-drive’s life. Any alterations to this stern-drive may affect the warranty coverage of your stern- drive. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 13 Use the engine lifting eyes to lift the engine and stern-drive. Only use the stern-drive lifting eye to lift the stern-drive as a separate component. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 14 SAFETY This Page Intentionally Left Blank ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 15: Product Overview

    Responsibilities maintenance instructions and In general, a dealer's responsibilities to the recommendations; and customer include predelivery inspection • Have an authorized Yanmar Marine and preparation such as: dealer / distributor perform periodic checkups. • Ensure that the vessel is properly equipped.

  • Page 16: Component Identification

    Figure 1 1 – Steering System Location 5 – Trim Cylinder 2 – Transom Assembly 6 – Speedometer Pitot Hole 3 – Drive Unit 7 – Y-CaPS Electrode 4 – Antiventilation Plate ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 17: Location Of Serial Numbers

    PRODUCT OVERVIEW Location of Serial Numbers The serial numbers are the manufacturer's keys to numerous engineering details which apply to your Yanmar stern-drive. When contacting Yanmar about service, always specify model and serial numbers. 0006017 Figure 2 1 – Transom Assembly Serial Number 2 –...

  • Page 18: Corrosion Protection

    (not supplied by stern drive for corrosion and replace the Yanmar) to block these currents while still anodes often enough to provide a sacrificial providing a path to ground for dangerous surface for the electrical current to attack.

  • Page 19: Underwater Drive Coating

    NOTICE: Galvanic corrosion damage, 2 – Ventilation Plate Anode normal maintenance and consumable 3 – Y-CaPS Electrode parts are not covered by the Yanmar 4 – Trim Cylinder Anodes Limited Warranty. 5 – Propeller Shaft Anodes NOTICE: Replace anodes if eroded 50 percent or more.

  • Page 20: Gear Housing Anodic Plates

    0006036 0006038 Figure 5 Figure 7 1 – Ventilation Plate Anode 1 – Propeller Shaft Anode ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 21: Features And Controls

    Remote Controls vessel onto plane, reach the desired engine rpm or vessel speed, and improve the The Yanmar ZT350 can be controlled performance of the vessel when there is a mechanically with push-pull cables or change in water or boating conditions. The electronically.

  • Page 22: Stern-Drive Trim Angle

    CAUTION! Always raise and lower dual stern-drives evenly together. Damage to the tie bar connecting the two stern-drives together could result from twisting or binding if the stern-drives are raised or lowered separately. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 23: Electrical System

    Correct the cause of the electrical overload before operating the trim system. If the electrical overload problem still exists, contact your authorized Yanmar Marine dealer or distributor. 0006011 Figure 11 1 –...

  • Page 24: Yanmar Cathodic Protection System

    Yanmar Cathodic Protection System Test Y-CaPS to ensure adequate output. The test should be performed where the The Yanmar Cathodic Protection System vessel is moored, using a reference (Y-CaPS) has a 20A in-line fuse electrode and test meter. Contact your...

  • Page 25: Stern-Drive Operation

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar Marine dealer or distributor for additional training. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 26 Entanglement Hazard NEVER operate the engine while wearing a headset to listen to music or the radio because it will be difficult to hear the warning signals. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 27: Propeller Selection

    Problems associated with propellers include ventilation, cavitation and blow-out. These problems have similar symptoms and are best diagnosed by an expert. If a propeller related problem develops, see your Yanmar Marine dealer or distributor. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 28: Installing The Propellers

    2 – Rear Propeller 6 – Front Propeller Thrust Hub 3 – Rear Propeller Thrust Hub 7 – Propeller Shaft Anode 4 – Front Propeller Nut 8 – Propeller Shaft Anode Bolt and Washer ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 29: Removing The Propeller

    Check the propeller at least every 20 hours. Rear Propeller Nut Torque N·m lb-ft Install the propeller shaft anode bolt with a washer. Torque the bolt. Propeller Shaft Anode Bolt Torque N·m lb-ft ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 30: Daily Checks

    / drain plug and / or if oil appears discolored, contact your authorized Yanmar Marine dealer or distributor immediately. Both conditions may indicate a water leak somewhere in the stern-drive.

  • Page 31: Check The Power Trim Pump Fluid

    TRIM-IN position. of lubrication. Contact your authorized Observe the oil level in the reservoir. Yanmar Marine dealer or distributor. The oil level should be maintained within the MIN and MAX lines on the Remove the oil reservoir cap reservoir (Figure 4, (2)).

  • Page 32: Fill Power Trim Pump Fluid

    Fill the Power Trim Pump Fluid Note: The power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Yanmar Marine dealer or distributor if the power trim fluid needs to be changed. 0006014...

  • Page 33: Maintenance

    NEVER support the stern-drive with equipment not designed to support the weight of the stern-drive such as wooden pieces, blocks or by only using a jack. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 34 Entanglement Hazard NEVER leave the key in the key switch when servicing the engine or stern-drive. Someone may accidentally start the engine and not realize you are servicing it. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 35 Consult the local authorities or reclamation facility. NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 36: Periodic Maintenance

    Yanmar Replacement Parts Failure to follow these guidelines will Yanmar recommends using genuine impair the stern-drive’s safety and Yanmar parts when replacement parts are performance characteristics, shorten necessary. Genuine replacement parts help the stern-drive’s life and may affect the ensure long life.

  • Page 37: Torque Charts

    1 - 14 UNS 80 ± 5.0 N·m 59 ± 3.7 lb-ft Propeller Shaft Bolt for Rear of Outer 2-1/8 – 16 UNS 135 ± 5.0 N·m 100 ± 3.7 lb-ft Propeller Shaft ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 38: Periodic Maintenance Table

    MAINTENANCE PERIODIC MAINTENANCE TABLE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily See Daily Every 50 Every 100 Every 250 Every Checks Weekly Hours Hours Hours Year on page Check the Stern-Drive...
  • Page 39 MAINTENANCE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily See Daily Every 50 Every 100 Every 250 Every Checks Weekly Hours Hours Hours Year on page Test the Y-CaPS ◯ ◯ Output on ZT350...

  • Page 40: General Inspection

    Power trim fluid does not require changing help maintain top operating performance unless it becomes contaminated with water and correct potential problems before they or debris. Contact your authorized Yanmar occur. Marine dealer or distributor if the power trim fluid needs to be changed.

  • Page 41: Periodic Maintenance Procedures

    Check the stern-drive oil level within one week of the first use as follows: Remove the oil vent plug and gasket (Figure 1, (1)). 0006031 Figure 1 1 – Oil Vent Plug 2 – Gasket ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 42: After Initial 50 Hours Of Operation

    (Figure 2, (1)) to lubricate the engine coupler splines through the grease fittings, if equipped. Use a typical hand-operated grease gun to apply the grease. 0006033 Figure 2 1 – Engine Coupler Grease Fitting ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 43: Every 50 Hours Of Operation

    • Lubricating the Cable and the Linkages Lubricating the Propeller Shaft and Retorqueing the Nut If operating in only freshwater, this maintenance may be extended to every four months. See Installing the Propellers on page 24. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 44 See General Inspection on page 36. for damage and corrosion. Checking the Engine Alignment Testing the Y-CaPS Unit Output See your authorized Yanmar Marine dealer See Yanmar Cathodic Protection System on or distributor. page 20. Lubricating the Unit Bearing (Gimbal...
  • Page 45 Engine Rear Mount Bolt Torque Heavy-Duty Type Shaft Splines and Lithium Grease, O-Rings N·m lb-ft NLGI #2 Checking the Remote Control for Loose, Missing or Damaged Parts See Remote Controls on page 17. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 46 0006000 Figure 7 1 – Extended Steering Cable Description Where Used Urea Grease Water Resistant Type, Steering Cable NLGI #2 ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 47: Every 250 Hours Of Operation

    If using copper- or tin-based anti-fouling paint, avoid an electrical interconnection between the Yanmar Product, Anodic Blocks, or Y-CaPS and the paint by allowing a minimum of 40 mm (1-1/2 in.) of UNPAINTED area on the transom of the vessel and around these items.
  • Page 48 Install the oil reservoir (Figure 11, (3)) in the bracket. Place the stern-drive in full trim limit OUT position. Remove the oil fill / drain plug and gasket (Figure 12). ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 49 Oil Vent Plug Torque Yanmar Marine dealer or N·m lb-ft distributor. 12. Continue to pump gear oil into the oil reservoir circuit until the gear oil appears in the oil reservoir. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 50 Quickly install the gasket and oil fill / drain plug. Torque the oil fill / drain plug. Oil Fill / Drain Plug Torque N·m lb-ft 16. Check the oil level in the oil reservoir after first use. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 51: Every Year

    • Inspecting the Bellows and the Damaged Connections on page 40. Clamps Testing the Y-CaPS Unit Output • Checking the Engine Alignment See Yanmar Cathodic Protection System on • Lubricating the Unit Bearing (Gimbal page 20. Housing) • Lubricating the Engine Coupler...
  • Page 52 MAINTENANCE This Page Intentionally Left Blank ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 53: Troubleshooting

    If any are parts. loose or missing, see your authorized Yanmar Marine dealer or distributor immediately. Contaminated power See your authorized — steering fluid. Yanmar Marine dealer or distributor. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 54 Trim pump oil level is Fill pump with oil. Operate (Electric low. Motor Operates but Stern-drive binding in Check for obstruction. — Stern-drive Does Not gimbal ring. See your authorized Move) Yanmar Marine dealer or distributor. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 55: Long-Term Storage

    STORAGE NOTICE: Yanmar strongly recommends that this service be performed by an authorized Yanmar Marine dealer or distributor. Damage caused by freezing IS NOT covered by the Yanmar Warranty. 0006361 Figure 1 1 – Under Side of Gear Housing 2 – First Anode Cavity Drain Passage 3 –...

  • Page 56: Stern-Drive Recommissioning

    Place the stern- drive in the full DOWN / TRIM-IN position. Stern-Drive Recommissioning Carefully inspect the stern-drive for leaks. Check the steering system, shift and throttle control for proper operation. ZT350 Operation Manual © 2008 Yanmar Marine International...

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