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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 informa- tion storage and retrieval systems - without the written permission of YANMAR CO., LTD. Date of issue: Jun. 2011...
General Information............... 4 Before You Operate............... 4 During Operation and Maintenance..........4 Location of Safety Decals..............9 Product Overview.................. 11 Yanmar 8LV Features and Applications..........11 New Engine Break-In..............12 Component Identification..............13 Service Side ................13 Non-Service Side................. 13 Location of Nameplate ..............
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Keep a Log of Engine Hours and Daily Checks ......36 Yanmar Replacement Parts ............36 Tools Required ................36 Ask Your Authorized Yanmar Marine Dealer or Distributor for Help ..............36 Tightening Fasteners..............37 EPA Maintenance Requirements ............39 EPA Requirements for USA and Other Applicable Countries ..
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System Diagrams .................. 69 Wiring Diagram.................. 69 8LV Wiring Diagram ..............70 EPA Warranty USA Only............... 73 YANMAR CO., LTD. Limited Emission Control System Warranty - USA Only................... 73 Your Warranty Rights and Obligations ........74 Warranty Period................74 Warranty Coverage ..............74 Exclusions ...................
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TABLE OF CONTENTS This Page Intentionally Left Blank 8LV Series Operation Manual...
If you have any marine leisure boating, the worldwide reputation of questions about these differences, please contact Yanmar Marine is second to none. We design our your authorized Yanmar Marine dealer or engines to respect nature. This means quieter distributor.
INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: _______________________________________________________________________ Engine Serial No.: ____________________________________________________________________ Date Purchased: _____________________________________________________________________ Dealer: _____________________________________________________________________________ Dealer Phone: _______________________________________________________________________ 8LV Series Operation Manual...
8LV Series Operation Manual SAFETY Yanmar considers safety of great importance and DANGER recommends that anyone that comes into close contact with its products, such as those who install, DANGER indicates a hazardous situation operate, maintain or service Yanmar products,...
• Contact your authorized Yanmar Marine any other form of ignition out of dealer or distributor for additional training. the area. 8LV Series Operation Manual...
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SAFETY WARNING WARNING FIRE AND EXPLOSION HAZARD SEVER HAZARD • Diesel fuel is flammable and • Rotating parts can cause severe explosive under certain injury or death. Never wear conditions. jewelry, unbuttoned cuffs, ties or loose fitting clothing and Always tie long hair back when working near moving/rotating parts such •...
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• Always ensure that all connections are Always use a piece of wood or cardboard. tightened to specifications after repair is Contact your authorized Yanmar Marine made to the exhaust system. All internal dealer or distributor repair the damage. combustion engines create carbon monoxide...
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NOTICE when you handle Long Life engine coolant. If If a Yanmar Marine Engine is installed at an angle contact with the eyes that exceeds the specifications stated in the or skin should occur, Yanmar Marine Installation manuals, engine oil may...
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Operating the engine in NEUTRAL engine’s life. Any alterations to this engine may void must be avoided. During the first 50 hours, avoid its warranty. Be sure to use Yanmar genuine operation below 2000 min (rpm). During the replacement parts.
SAFETY LOCATION OF SAFETY DECALS Figure 1 and Figure 2 show the location of safety decals on Yanmar 8LV series marine engines. CAUTION : Overcranking engine with water lift muffler can cause damage. 128171-07150 DO NOT STEP ON COVERS. POSSIBILITY OF A FALL.
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SAFETY 037427-00X00 Figure 2 Part Number 120324-07240 128296-07300 8LV Series Operation Manual...
This engine is designed for pleasure craft use. knowledge and engineering skills. See Yanmar’s local subsidiary in your region or your authorized It is recommended that new vessels be propped so Yanmar Marine dealer or distributor.
Once past the initial 10 hours until 50 hours, the A new Yanmar diesel engine must be operated at engine should be used over its full operating range, suitable speeds and power settings during the...
PRODUCT OVERVIEW COMPONENT IDENTIFICATION Service Side Figure 1 and Figure 2 illustrate a typical version of a 8LV series engine. Your engine may have different equipment from that illustrated. Lubricating oil feeding port Silencer Fuel priming pump Turbo-charger Fuel filter Lubricating oil filter Mixing elbow Alternator...
PRODUCT OVERVIEW LOCATION OF NAMEPLATE The nameplate of Yanmar 8LV series engines are shown in Figure 3. Check the engine’s model, output, rpm and serial number on the nameplate. Please replace if damaged or lost. The engine nameplate is attached to the top surface of the engine air cooler (Figure 4).
PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Removes dirt and water from the fuel. Drain the filter periodically. The filter element should Fuel Filter be replaced periodically. The fuel/water separator (if equipped) should be drained periodically. See Draining the Fuel/Water Separator on page 44. Fuel Supply Pump Pumps fuel from the tank to the fuel injection system.
If this system is not utilized in specific accordance with the instructions in this manual or the system is modified in any way, Yanmar will not be responsible for any warranty failures in the operation of the system or the vessel utilizing the system.
If the system does not function normally, contact your authorized Yanmar Marine dealer or distributor and ask for diagnostics. 8LV Series Operation Manual...
PRODUCT OVERVIEW ■ Switch Panel (to start and stop the engine) The switch panel has the following functions. Eng. START/STOP switch Check Eng. indicator Emergency stop switch Power switch 037627-00E04 Figure 9 To start and stop the engine: Press the START/STOP switch. ■...
8LV Series Operation Manual BEFORE YOU OPERATE This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to replenish them. It also describes the daily engine checks. Before performing any operations within this section, review the Safety section on page 3.
• Biodiesel may have adverse effects on some ■ Bio-Diesel Fuels elastomers (seal materials) and may result in fuel Yanmar approves the use of biodiesel fuels that do leakage and dilution of the engine lubricating oil. not exceed a blend of 5 % non-mineral oil based •...
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BEFORE YOU OPERATE ■ Additional Technical Fuel Requirements ■ Handling of Diesel Fuel • The fuel cetane number should be 45 or higher. 1. Water and dust in the fuel may cause engine failure. When fuel is stored, be sure that the •...
BEFORE YOU OPERATE Filling the Fuel Tank Bleeding the Fuel System Bleeding must be done if any fuel system DANGER maintenance has been performed (replacement of Never refuel with the engine running. See fuel filter, etc.) or if the engine does not start after Safety on page 3.
• Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter. • Yanmar does not recommend the use of engine oil “additives”. ■ Handling Engine Oil 1. When handling and storing engine oil, be careful not to allow dust and water to contaminate the oil.
BEFORE YOU OPERATE Checking the Engine Oil Adding Engine Oil 1. Remove the yellow oil filler port cap from filler port (1, Figure 5) and fill with engine oil. NOTICE Prevent dirt and debris from contaminating the engine oil. Carefully clean the dipstick and the surrounding area before you remove the cap.
BEFORE YOU OPERATE ENGINE COOLANT Checking and Adding Coolant Engine Coolant Specifications NOTICE • Texaco Long Life Coolant (LLC), both standard The 8LV series engine has filter port on the coolant and premixed, product code 7997 and 7998 tank. • Havoline Extended Life Antifreeze/Coolant, 1.
• The level of the coolant tank often decrease. • The level of the reservoir tank does not change. In these cases, there may be water or air leaks in the cooling system. Contact your authorized Yanmar Marine dealer or distributor. 8LV Series Operation Manual...
8LV Series Operation Manual ENGINE OPERATION This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to replenish them. It also describes the daily engine checkout. Before performing any operations within this section, review the Safety section on page 3.
ENGINE OPERATION STARTING THE ENGINE (START UP) 1. Open the seacock. 2. Open the fuel tank cock. 3. Turn the battery switch on for engine and VCS. 4. Press the Power switch on the switch panel of the selected station (1, Figure 1). •...
ENGINE OPERATION If the Engine Fails to Start NOTICE Before pressing the Start switch again, confirm that The engine will seize if it is operated when the engine has stopped completely. If the starter seawater discharge is too small or if load is motor is operated before the engine has completely applied without any warming up operation.
ENGINE OPERATION THROTTLE AND SHIFT Neutral Reverse Idle Forward Idle CONTROL WARNING Panel SUDDEN MOVEMENT HAZARD Full speed Full speed The boat will start to move when the marine reverse forward gear is engaged: Adjusting screw • Ensure the boat is clear of all obstacles 037634-00E00 forward and aft.
ENGINE OPERATION CAUTIONS DURING 4. Alarm buzzer sounds during operation. OPERATION NOTICE If any alarm indicator with audible alarm sound NOTICE appears on the display during engine operation, • Engine trouble can arise if the engine is operated stop the engine immediately. Determine the for a long time under overloaded conditions with cause and repair the problem before you the control lever in the full throttle position...
1000 min (rpm)) for about 5 minutes. NOTICE 037639-00E00 For maximum engine life, Yanmar recommends Figure 7 that when shutting the engine down, you allow the engine to idle, without load, for 5 minutes. This will allow the engine components that...
ENGINE OPERATION Emergency Stop CONTROL THE BACKUP PANEL ■ Electric Emergency Stop WARNING Do not use unless there is an emergency. NOTICE Never use the Emergency Stop switch for a normal 1. Check that the Power switch on the switch engine shutdown.
ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION • Check that battery switch is turned to OFF. • Fill the fuel tank. See Filling the Fuel Tank on page 22. • Close seacock(s). • If there is a risk of freezing, check that the cooling system contains enough coolant.
8LV Series Operation Manual PERIODIC MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. Before performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 3.
Yanmar Replacement Parts Accumulation of this gas within an enclosure Yanmar recommends that you use genuine Yanmar could cause illness or even death. Make sure parts when replacement parts are needed. that all connections are tightened to...
PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. ■ Main Bolt and Nut Tightening Torque Thread Tightening Torque Tightening Parts...
PERIODIC MAINTENANCE EPA MAINTENANCE Pay particular attention to these important points: REQUIREMENTS • Replacing the engine oil To maintain optimum engine performance and • Replacing the engine oil filter compliance with the Environmental Protection • Replacing the fuel filter Agency (EPA) Regulations for Engines, it is essential that you follow the Periodic Maintenance •...
Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty coverage on your engine. Contact your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a ●.
Interval Check turbo-charger adjustment 3000 hours Check electronic engine control unit and its associated sensors and actuators Note: The inspection and maintenance items shown above are to be performed at your Yanmar Marine dealer or distributor. 8LV Series Operation Manual...
Daily Checks NOTICE Before you head out for the day, make sure the If any problem is noted during the visual check, Yanmar engine is in good operating condition. the necessary corrective action should be taken before operating the engine. NOTICE It is important to perform the daily checks as listed ■...
PERIODIC MAINTENANCE ■ Changing the Engine Oil and Replacing After Initial 50 Hours of Operation the Engine Oil Filter Element The engine oil on a new engine becomes Perform the following maintenance after the initial contaminated from the initial break-in of internal 50 hours of operation.
This is considered normal maintenance and the separator and drain any water and dirt. adjustment requires specialized knowledge and • After draining the separator, reinstall the plug techniques. Consult your authorized Yanmar securely. Marine dealer or distributor. Check for any unusual noise and vibration in the engine/boat hull, while gradually increasing and decreasing the engine speed.
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PERIODIC MAINTENANCE • Always make sure to bleed the air after the 1. Turn the battery master switch to OFF or element has been replaced. disconnect the negative (-) battery cable. 2. Do not operate with insufficient battery electrolyte as the battery will be destroyed. 3.
PERIODIC MAINTENANCE ■ Replacing the Fuel Filter Element Every 250 Hours of Operation WARNING Perform the following maintenance every 250 hours • When removing any fuel system component or one year of operation, whichever comes first. to perform maintenance (such as replacing the fuel filter), put an approved container •...
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033658-00X from the water drain line below the seawater pump during operation, replace the mechanical Figure 7 seal. Contact your authorized Yanmar Marine dealer or distributor. 5. Remove the alarm switch ((3, Figure 6) and (Figure 7)) with a wrench.
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PERIODIC MAINTENANCE There are two types of special service tools for 3. Turn the jack screw (B, Figure 9) clockwise to removing the impeller: remove the impeller from the pump body. NOTICE The seawater pump turns counterclockwise as viewed from the side cover, so the impeller must be installed as shown in Figure 8.
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PERIODIC MAINTENANCE ■ Replacing the Zinc Anode ■ Changing the Coolant The timing for replacing zinc anode varies CAUTION depending on the characteristics of the seawater and operational conditions. Inspect the zinc Wear eye protection and rubber gloves when periodically and remove the corroded area on the you handle engine coolant.
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If a significant drop in engine output is noted (10 % or more), clean the turbo-charger. This should be done only by a trained and qualified 037430-00X00 technician. Contact your authorized Yanmar Marine dealer or distributor. Figure 17 ■ Damage of Belt...
Replace the rubber hoses every 500 hours or 2 years, whichever comes first. 2. Check that the belt fits properly in the ribbed Contact your authorized Yanmar Marine dealer or grooves. distributor. NOTICE ■ Replacing the Exhaust/Water Mixing...
This can cause declining cooling performance. The following items need to be inspected: • Heat Exchanger • Pressure Cap Contact your authorized Yanmar Marine dealer or distributor. ■ Adjusting the Propeller Shaft Alignment Contact your authorized Yanmar Marine dealer or distributor.
The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized Yanmar Marine dealer or distributor. Before performing any storage procedures within this section, review the Safety section on page 3.
LONG-TERM STORAGE PREPARING THE ENGINE FOR Draining the Seawater Cooling System LONG-TERM STORAGE ■ Location of Seawater Drain Plug NOTICE (Colored Gray) Do not drain closed cooling system for long-term Fuel Oil Cooler storage. Antifreeze must be used to avoid freezing and damaging of components.
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LONG-TERM STORAGE Do not drain the freshwater/coolant in the cold season or before long-term storage. If LLC (Long Life Coolant) has not been added to the cooling freshwater, be sure to add LLC or drain off the freshwater from the cooling system daily after use. NOTICE If the freshwater without LLC is not removed, it may freeze and damage parts of the cooling water...
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LONG-TERM STORAGE This Page Intentionally Left Blank 8LV Series Operation Manual...
8LV Series Operation Manual TROUBLESHOOTING Before performing any troubleshooting procedures within this section, review the Safety section on page 3. If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem. 8LV Series Operation Manual...
TROUBLESHOOTING TROUBLESHOOTING AFTER Is there water, oil or fuel leakage? Are there any loose bolts or connections? STARTING Check the engine room daily for any leaks or loose Just after the engine has started, check the connections. following items at a low engine speed: Is there sufficient fuel in the fuel tank? Is sufficient water being discharged from the seawater outlet pipe?
If the engine does not operate properly, refer to the Troubleshooting Chart on page 60 or contact your authorized Yanmar Marine dealer or distributor. Supply the authorized Yanmar Marine dealer or distributor with the following information: • Model name and serial number of your engine •...
TROUBLESHOOTING TROUBLESHOOTING CHART Symptom Probable Cause Measure Indicators light on the Shift to low speed operation immediately, and check which indicator has come on. Stop the instrument panel and engine and inspect. If no abnormality is identified and there is no problem with operation, alarm sounds during return to port at lowest speed and request repairs.
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TROUBLESHOOTING Symptom Probable Cause Measure Engine is not running smoothly Operation failure of Nozzle operation failure Replace injection valve Broken fuel valve spring Replace Uneven fuel injection Clogged fuel filter Replace quantities Faulty operation of regulator valve Replace Air trapped in fuel injection system Bleed air from system and prime system Faulty operation of fuel supply pump...
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TROUBLESHOOTING Symptom Probable Cause Measure Insufficient output Insufficient fuel Oil leak from fuel injection pipe joint Tighten injection Faulty operation of regulator valve Replace Clogged fuel filter Replace Clogged fuel pipe Clean Failure of fuel supply pump Repair Insufficient injection by Clogged injection hole Replace fuel injection nozzle...
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TROUBLESHOOTING Symptom Probable Cause Measure Breakdown of turbo-charger Drop in intake pressure Dirty air filter Clean Leak from intake piping Repair Leak of exhaust gas Repair High intake air temperature Complete thermal insulation of exhaust pipe Ensure intake air path is unrestricted from outside air Clean air filter Drop in air pressure in engine room...
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TROUBLESHOOTING Symptom Probable Cause Measure Pulsation of intake air Uneven cylinder combustion Adjust for uniform combustion pressure Rapid change in load Operate correctly Excessively dirty compressor side Clean Intake temperature too high Clean cooling fin Complete thermal insulation of exhaust pipe Ensure intake air path is unrestricted from outside air Other...
TROUBLESHOOTING FAILSAFE DIAGNOSIS FUNCTIONAL SPECIFICATION CHART Failsafe Action Level 1: Derate engine speed and limit it to 2000 min or less Level 2: Derate engine speed and limit it to 1000 min or less Failsafe Action DTC Description Warning Level 1 Level 2 Others Stop ×...
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TROUBLESHOOTING Failsafe Action Level 1: Derate engine speed and limit it to 2000 min or less Level 2: Derate engine speed and limit it to 1000 min or less Failsafe Action DTC Description Warning Level 1 Level 2 Others Stop ×...
8LV Series Operation Manual SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS 8LV Series Engine Specifications Engine Model 8LV320(Z) 8LV350(Z) 8LV370(Z) Pleasure use Type V, 4-Cycle, water-cooled diesel engine Crankshaft rotation (viewed from flywheel) Counterclockwise Combustion system Direct injection Aspiration Turbo-charger with air cooler...
SPECIFICATIONS Engine Model 8LV320(Z) 8LV350(Z) 8LV370(Z) Turbo-charger MHI TD04 Starter motor DC 12 V - 2.7 kW Alternator 12 V - 180 A Overall length 1133 mm (44.61 in.) Engine dimension Overall width 884 mm (34.80 in.) without marine gear Overall height 783.5 mm (30.85 in.)
8LV Series Operation Manual SYSTEM DIAGRAMS WIRING DIAGRAM 8LV series-Type Instrument Panel 8LV series Instrument Panel are available for 12 V standard. 8LV Series Operation Manual...
8LV Series Operation Manual EPA WARRANTY USA ONLY YANMAR CO., LTD. LIMITED Part Number Engine Model EMISSION CONTROL SYSTEM 119798-07600 8LV370 WARRANTY - USA ONLY 119798-07610 8LV350 The following EPA Warranty only applies to engines 119798-07620 8LV320 built on or after November 21, 2010 and labeled...
Where a warrantable emissions condition exists, of non-recommended fuels and lubricating oils, Yanmar will repair your engine at no charge to you accident-caused damage, and replacement of for diagnosis, parts, and labor. Warranty service or...
EPA WARRANTY USA ONLY Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar Marine dealer or distributor, you should contact Yanmar America Corporation for assistance. Yanmar America Corp. (YA)