Yanmar ZT350 series Operation Manual
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Yanmar ZT350 series Operation Manual

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ZT350
series
OPERATION MANUAL
P/N: 0AZTD-G00101
STERN-
DRIVE

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Summary of Contents for Yanmar ZT350 series

  • Page 1 ZT350 series OPERATION MANUAL P/N: 0AZTD-G00101 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

    Propeller Shaft Anode ..........16 Features and Controls...........17 Remote Controls ........... 17 Power Trim ............17 Stern-Drive Trim Angle ........... 18 Trim and Tilt / Trailering Switch ......... 18 Electrical System........... 19 ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 4 Performing Periodic Maintenance ......33 The Importance of Daily Checks ....... 34 Yanmar Replacement Parts ........34 Tools Required ............. 34 Ask Your Authorized Yanmar Marine Dealer or Distributor for Help..........34 Tightening Fasteners............34 Torque Charts.............35 Standard Torque Values ......... 35 Torque Specifications..........

  • Page 5: Introduction

    INTRODUCTION Welcome to the world of Yanmar Marine! • Constant efforts are made to improve the Yanmar Marine offers engines, stern-drive quality and performance of Yanmar systems and accessories for all types of products, so some details included in this...

  • 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 Keep operation. hands and other body parts away from hot surfaces. 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 This will keep the anodes in the water and will keep the exhaust pipe engaged with the exhaust port of the drive. 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 galvanic corrosion. Yanmar) to block these currents while still providing a path to ground for dangerous To help control the effects of galvanic shock currents. NOTICE: If the AC shore...

  • Page 19: Additional Protection

    This will keep the anodes in the NOTICE: Galvanic corrosion damage, water and will keep the exhaust pipe normal maintenance and consumable parts engaged with the exhaust port of the are not covered by the Yanmar Limited drive. Warranty. ( 4 ) 0005989 Figure 3 1 –...

  • 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 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 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 Propeller Shaft Anode Bolt Torque 4. Install and torque the front propeller nut. N·m lb-ft Check the propeller at least every 20 hours. Front Propeller Nut Torque N·m lb-ft ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 30: Removing The Propeller

    Check the Stern-Drive Oil Level Description Where Used GL-5 Hypoid Gear Oil Oil Reservoir Note: The oil level will rise and fall during operation. Check the oil level before starting, when the engine is cold. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 31 Damage to the stern-drive may with the specified oil. See Fill the Stern- occur because of lack of lubrication. Contact Drive with Oil on page 27. your authorized Yanmar Marine dealer or distributor. ( 1 ) 1. Remove the oil reservoir cap (Figure 3, (1)).

  • Page 32: Check 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. 1. Place the stern-drive in the full DOWN / TRIM-IN position.
  • Page 33 MIN and MAX lines on the reservoir (Figure 6, (2)). 0006014 Figure 6 1 – Fill Cap Assembly 2 – MIN and MAX Lines 3 – Reservoir 4. Install the fill cap assembly. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 34 STERN-DRIVE OPERATION This Page Intentionally Left Blank ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 35: 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 36 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 37: Periodic Maintenance

    Follow the guidelines of the stern-drive warranty coverage. See your EPA or other governmental authorized Yanmar Marine dealer or agencies for the proper distributor for assistance when disposal of hazardous materials such as checking items marked with a ●.

  • Page 38: The Importance Of Daily Checks

    Yanmar Replacement Parts Yanmar recommends using genuine Yanmar parts when replacement parts are necessary. Genuine replacement parts help ensure long life. Tools Required Before starting any periodic maintenance...

  • Page 39: Torque Charts

    1 - 14 UNS 80 ± 5.0 N·m 59 ± 3.7 lb-ft peller 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 40: 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 Weekly Checks on Hours Hours Hours Year page 26 Check the Stern-Drive...
  • Page 41 MAINTENANCE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Daily See Daily Every 50 Every 100 Every 250 Every Weekly Checks on Hours Hours Hours Year page 26 Check the Engine ● ●...

  • Page 42: 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 43: Periodic Maintenance Procedures

    1. Remove the oil vent plug and gasket (Figure 1, (1)). 0006031 Figure 1 1 – Oil Vent Plug 2 – Gasket 2. If necessary, add oil until an air-free stream of oil flows from the oil vent hole. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 44: 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 45: 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 46 See General Inspection on page 38. Check the electrical connections and leads Checking the Engine Alignment for damage and corrosion. See your authorized Yanmar Marine dealer Testing the Y-CaPS Unit Output or distributor. See Yanmar Cathodic Protection System Lubricating the Unit Bearing (Gimbal on page 20.
  • Page 47 Remove the drive unit and lubricate the universal-joint shaft splines (Figure 6, (1)) and the O-rings (Figure 6, (2)). 0006004 Figure 6 1 – Universal-Joint Shaft Splines 2 – Universal-Joint O-Rings Description Where Used Multi-Purpose Universal-Joint Heavy-Duty Type Shaft Splines and Lithium Grease, O-Rings NLGI #2 ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 48 Checking the Remote Control for Loose, Missing or Damaged Parts See Remote Controls on page 17. 0006000 Figure 8 1 – Extended Steering Cable Description Where Used Urea Grease Water Resistant Type, Steering Cable NLGI #2 ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 49 Resistant Type, Clevis Pin NLGI #2 5. Before starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway. ZT350 Operation Manual © 2008 Yanmar Marine International...

  • Page 50: Every 250 Hours Of Operation

    See Torqueing the Rear Engine Mount Bolts the vessel and around these items. on page 44. Changing the Stern-Drive Oil Note: The Stern-Drive oil must be changed every 250 hours or every year, whichever comes first. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 51 3. Install the oil reservoir (Figure 12, (3)) be checked immediately by your in the bracket. authorized Yanmar Marine dealer or 4. Place the stern-drive in full trim limit distributor. OUT position. 5. Remove the oil fill / drain plug and gasket (Figure 13).
  • Page 52 16. Check the oil level in the oil reservoir N·m lb-ft after first use. 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 53: Every Year

    See Checking the Engine Alignment on page 42. Lubricating the Unit Bearing (Gimbal Housing) See Lubricating the Unit Bearing (Gimbal Housing) on page 42. Lubricating the Engine Coupler See Lubricating the Engine Coupler on page 40. ZT350 Operation Manual © 2008 Yanmar Marine International...
  • Page 54 Damaged Connections See Checking the Circuit for Loose or Damaged Connections on page 42. Testing the Y-CaPS Unit Output See Yanmar Cathodic Protection System on page 20. Checking the Steering System for Loose, Missing or Damaged Parts See Checking the Steering System for...

  • Page 55: Troubleshooting

    If any are parts. loose or missing, see your authorized Yan- mar 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 56 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 57: Long-Term 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 58: Stern-Drive Recommissioning

    Place the stern-drive in the full DOWN / TRIM-IN position. Stern-Drive Recommissioning 1. Carefully inspect the stern-drive for leaks. 2. Check the steering system, shift and throttle control for proper operation. ZT350 Operation Manual © 2008 Yanmar Marine International...

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