Yanmar ZT350 series, Operation Manual

Page 1: ...STERN DRIVE ZT350 series OPERATION MANUAL P N 0AZTD G00101 ...

Page 2: ...a product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and are registered trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved 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 informati...

Page 3: ...11 Component Identification 12 Location of Serial Numbers 13 Corrosion Protection 14 Galvanic Corrosion 14 Corrosion Control 14 Shore Power 14 Underwater Drive Coating 14 Additional Protection 15 Gear Housing Anodic Plates 16 Ventilation Plate Anode 16 Trim Cylinder Anodes 16 Propeller Shaft Anode 16 Features and Controls 17 Remote Controls 17 Power Trim 17 Stern Drive Trim Angle 18 Trim and Tilt ...

Page 4: ...ne Dealer or Distributor for Help 34 Tightening Fasteners 34 Torque Charts 35 Standard Torque Values 35 Torque Specifications 35 Periodic Maintenance Table 36 General Inspection 38 Power Trim Pump Fluid 38 Periodic Maintenance Procedures 39 Weekly 39 After Initial 50 Hours of Operation 40 Every 50 Hours of Operation 41 Every 100 Hours of Operation 41 Every 250 Hours of Operation 46 Every Year 49 T...

Page 5: ...fore you operate your vessel to ensure that safe operating practices and maintenance procedures are followed Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar Marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part o...

Page 6: ...Model Stern Drive Transom Assembly Serial No Stern Drive Unit Serial No Stern Drive Gear Ratio Date Purchased Engine Model Engine Horsepower Propeller Number Propeller Pitch Propeller Diameter Hull Identification Number HIN Boat Manufacturer Boat Model Dealer Dealer Phone INTRODUCTION 2 ZT350 Operation Manual 2008 Yanmar Marine International ...

Page 7: ...ime 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 PRECAUTIONS DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or s...

Page 8: ...rate DANGER The safety messages that follow have DANGER level hazards These safety messages describe a hazardous situation which if not avoided will result in death or serious injury NEVER permit anyone to install or operate the engine or stern drive without proper training Read and understand this Operation Manual before you operate or service the engine or stern drive to ensure that you follow s...

Page 9: ...using serious injury or death 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 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 Explosion Hazard While the engine is ...

Page 10: ... engine is operating Always remove any tools or shop rags used during maintenance from the area before operation Stop the engine before you begin to service the stern drive and secure the propeller so it will not turn Alcohol and Drug Hazard NEVER operate the engine while under the influence of alcohol or drugs or when feeling ill Exposure Hazard ALWAYS wear personal protective equipment including...

Page 11: ...t in minor or moderate injury NEVER permit anyone to install or operate the stern drive or engine without proper training Safety signs and labels are additional remindersforsafeserviceand maintenance techniques Read and understand this Operation Manual before you operate or service the stern drive to ensure that you follow safe servicing practices and maintenance procedures Poor Lighting Hazard En...

Page 12: ...l and engine coolant 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 Before operating the engine check stern drive oil level If the stern drive oil temperature is too high stop engine immediately and check the stern drive oil level and check the oil cooler for proper coolant and ...

Page 13: ...f the stern drive is only calculated for the stern drive Changing the material of the propeller may require additional anodes to be installed on the stern drive Anytime the boat is left in the water and the engine is not running the drive must be left in the fully down position This will keep the anodes in the water and will keep the exhaust pipe engaged with the exhaust port of the drive SAFETY Z...

Page 14: ...This Page Intentionally Left Blank SAFETY 10 ZT350 Operation Manual 2008 Yanmar Marine International ...

Page 15: ...frequent enough for stern drive NOTICE The anode of the stern drive is only calculated for the stern drive Changing the material of the propeller may require additional anodes to be installed on the stern drive New Stern Drive Break In On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper stern drive function and stern drive oil leaks Durin...

Page 16: ... 6 5 4 7 1 Figure 1 1 Steering System Location 2 Transom Assembly 3 Drive Unit 4 Antiventilation Plate 5 Trim Cylinder 6 Speedometer Pitot Hole 7 Y CaPS Electrode PRODUCT OVERVIEW 12 ZT350 Operation Manual 2008 Yanmar Marine International ...

Page 17: ...gineering details which apply to your Yanmar stern drive When contacting Yanmar about service always specify model and serial numbers 0006017 2 1 Figure 2 1 Transom Assembly Serial Number 2 Drive Unit Serial Number PRODUCT OVERVIEW ZT350 Operation Manual 13 2008 Yanmar Marine International ...

Page 18: ...s the number size and location of anodes on the stern drive and vessel the marina environment such as stray current in the water fresh or salt water and use and isolation of shore power improper application of marine paint or antifouling paint failure to repaint damaged areas and how the vessel is bonded Please check with the boat builder dealer or other professional to determine if your vessel an...

Page 19: ...anty Additional Protection In addition to the corrosion protection devices take these steps to inhibit corrosion 1 Paint the stern drive See Touching Up the Stern Drive Paint and Spray with Corrosion Guard on page 46 2 Spray stern drive components on the inside of the vessel annually with Corrosion Guard to protect the finish from dulling and corrosion External stern drive components may also be s...

Page 20: ...e front of the drive shaft housing on top of the ventilation plate 0006036 1 Figure 5 1 Ventilation Plate Anode Trim Cylinder Anodes The trim cylinder anodes are installed on each trim cylinder 0006037 1 Figure 6 1 Trim Cylinder Anodes Propeller Shaft Anode The propeller shaft anode is located behind the aft propeller 0006038 1 Figure 7 1 Propeller Shaft Anode PRODUCT OVERVIEW 16 ZT350 Operation M...

Page 21: ... onto plane reach the desired engine rpm or vessel speed and improve the performance of the vessel when there is a change in water or boating conditions The performance of the vessel depends on load weight and distribution Distribute the weight evenly from bow to stern and from port to starboard Trimming will not improve the vessel s performance due to an imbalanced load 0006019 Figure 8 0006020 F...

Page 22: ...ailering Switch Raising and lowering of the stern drive is controlled by the combination trim and tilt trailering switch The trim portion of the switch operates the trim system in either the bow up or bow down directions The tilt portion or trailering portion of the switch operates the tilt system for trailering beaching launching and shallow water operation low speed below 1200 rpm CAUTION Never ...

Page 23: ...lectrical overload the fuse will blow out or the circuit breaker will shut off 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 1 2 Figure 11 1 1A Fuse Holder 2 Auto Reset Circuit Breaker PRODUCT OVERVIEW ZT350 Operation Manual 19 2008 Yanmar Marine Inter...

Page 24: ...te resulting in a loss of corrosion protection Test Y CaPS to ensure adequate output The test should be performed where the vessel is moored using a reference electrode and test meter Contact your authorized Yanmar Marine dealer or distributor for assistance if necessary 0006335 1 2 3 Figure 12 1 Y CaPS Controller 2 20A In Line Fuse Holder 3 Electrode PRODUCT OVERVIEW 20 ZT350 Operation Manual 200...

Page 25: ...not avoided will result in death or serious injury NEVER permit anyone to install or operate the engine or stern drive without proper training Read and understand this Operation Manual before you operate or service the engine or stern drive to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenan...

Page 26: ...l and Drug Hazard NEVER operate the engine while under the influence of alcohol or drugs or when feeling ill 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 CAUTION The safety messages that follow have CAUTION level hazards These safety messages describe a hazardous situation which if not ...

Page 27: ...avy loads Keep these guidelines in mind when selecting a propeller NOTICE NEVER attempt to change propellers until after determining the average load and individual requirements Your Yanmar Marine dealer or distributor is most qualified to help you select a propeller Engine rpm must be within the recommended operating range Refer to the Engine Operator s Manual WARNING To prevent accidental start ...

Page 28: ...opeller Nut 2 Rear Propeller 3 Rear Propeller Thrust Hub 4 Front Propeller Nut 5 Front Propeller 6 Front Propeller Thrust Hub 7 Propeller Shaft Anode 8 Propeller Shaft Anode Bolt and Washer STERN DRIVE OPERATION 24 ZT350 Operation Manual 2008 Yanmar Marine International ...

Page 29: ... torque the front propeller nut Check the propeller at least every 20 hours Front Propeller Nut Torque N m lb ft 135 99 5 Slidetheaftthrusthubontothepropeller shaft with the tapered side toward the propeller hub toward end of shaft 6 Align the splines and place the propeller on the propeller shaft 7 Install and torque the rear propeller nut Check the propeller at least every 20 hours Rear Propelle...

Page 30: ...from time to time Before operating the stern drive make sure it is in good operating condition Make sure you check the following items and have any repairs completed before you operate the stern drive NOTICE Anytime the boat is left in the water and the engine is not running the drive must be left in the fully down position This will keep the anodes in the water and will keep the exhaust pipe enga...

Page 31: ...rive Fill the Stern Drive with Oil See Changing the Stern Drive Oil on page 46 when filling the entire stern drive NOTICE If more than 60 ml 2 fl oz of gear oil is required to fill the reservoir a seal may be leaking Damage to the stern drive may occur because of lack of lubrication Contact your authorized Yanmar Marine dealer or distributor 1 Remove the oil reservoir cap Figure 3 1 2 Fill the oil...

Page 32: ...h the specified fluid See Fill the Power Trim Pump Fluid on page 28 0006013 1 Figure 5 1 MIN Line 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 1 Place the stern drive in the full DOWN TRIM IN position 2 Uns...

Page 33: ...hin the MIN and MAX lines on the reservoir Figure 6 2 0006014 2 3 1 Figure 6 1 Fill Cap Assembly 2 MIN and MAX Lines 3 Reservoir 4 Install the fill cap assembly STERN DRIVE OPERATION ZT350 Operation Manual 29 2008 Yanmar Marine International ...

Page 34: ...This Page Intentionally Left Blank STERN DRIVE OPERATION 30 ZT350 Operation Manual 2008 Yanmar Marine International ...

Page 35: ...e a hazardous situation which if not avoided will result in death or serious injury Crush Hazard ALWAYS use lifting equipment with sufficient capacity to lift the stern drive NEVER stand under a hoisted stern drive If the hoist mechanism fails the stern drive will fall on you causing serious injury or death NEVER support the stern drive with equipment not designed to support the weight of the ster...

Page 36: ...rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all moving parts Always remove any tools or shop rags used during maintenance from the area before operation Stop the engine before you begin to service the stern drive and secure the propeller so it will not turn Entanglement Hazard NEVER leave the key in the key switch when servicing the engine or stern drive So...

Page 37: ...e stern drive s safety and performance characteristics shorten the stern drive s life and may affect the stern drive warranty coverage See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a The Importance of Periodic Maintenance Stern drive deterioration and wear occur in proportion to the length of time the stern drive has been in service and the ...

Page 38: ...rting any periodic maintenance procedure make sure to have the tools needed to perform all of the required tasks on hand Ask Your Authorized Yanmar Marine Dealer or Distributor for Help Our professional service technicians have the expertise and skills to help with any maintenance or service related procedures TIGHTENING FASTENERS Use the correct amount of torque when tightening fasteners Applying...

Page 39: ...lt of Gimbal Ring M10 x 1 5 50 5 N m 37 4 lb ft Bolt for Anode of Cylin der Part 10 32 UNF 3 5 0 5 N m 2 6 0 4 lb ft Bolt for Rear Cover M8 x 1 25 6 0 1 0 N m 4 4 0 7 lb ft Plug M10 x 1 5 15 2 0 N m 11 1 5 lb ft Bolt for Valve Assembly M12 x 1 25 6 0 1 0 N m 4 4 0 7 lb ft Bolt for Rear of Inner Pro peller Shaft 1 14 UNS 80 5 0 N m 59 3 7 lb ft Bolt for Rear of Outer Propeller Shaft 2 1 8 16 UNS 13...

Page 40: ...g Fluid Fill if Necessary Before Op eration ChecktheWaterInlets for Debris or Marine Growth Clean if Nec essary Check the Seawater Inlet Hole Clean if Necessary Inspect the Anodes and Replace if 50 per cent eroded Replenish The Oil In Stern Drive First Time Only Lubricate the Propel ler Shaft and Retorque the Nut Touch Up the Stern Drive Paint and Spray with Corrosion Guard Change the Stern Drive ...

Page 41: ...ions Test the Y CaPS Out put on ZT350 Check the Steering System for Loose Missing or Damaged Parts Check the Remote Control for Loose Missing or Damaged Parts Lubricate the Cables and the Linkages Retorque the Rear En gine Mounts If operating in only freshwater this maintenance may be extended to every four months Every 250 hours or every year whichever comes first Lubricate engine coupler every 5...

Page 42: ...utor Repair nicks and corrosion damage on stern drive exterior finish NEVER use paint containing copper or tin This will damage the stern drive and void the warranty Use a high quality primer and topcoat paint specifically designed for aluminum outboards or stern drives Follow the manufacturer s directions for surface preparation and application POWER TRIM PUMP FLUID Power trim fluid does not requ...

Page 43: ...necessary Inspecting the Anodes Inspect the anodes and replace if 50 corroded See Corrosion Protection on page 14 Checking the Oil Level Check the stern drive oil level within one week of the first use as follows 1 Remove the oil vent plug and gasket Figure 1 1 0006031 2 1 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 3 Instal...

Page 44: ... drive Apply approximately 8 to 10 pumps of grease to the engine coupler grease fitting 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 1 Figure 2 1 Engine Coupler Grease Fitting Description Where Used Multi Purpose Heavy Duty Type Lithium Grease NLGI 2 Coupler Note Lubricate the coupler o...

Page 45: ...e Clamps Checking the Engine Alignment Lubricating the Unit Bearing Gimbal Housing Lubricating the Engine Coupler Checking the Circuit for Loose or Damaged Connections Testing the Y CaPS Output Checking the Steering System for Loose Missing or Damaged Parts Lubricating the Drive Unit and Universal Joint Shaft Spines and O Rings Torqueing the Rear Engine Mount Bolts Checking the Remote Control for ...

Page 46: ...bearing gimbal housing Use a typical hand operated grease gun to apply the grease 0006032 1 Figure 4 1 Unit Bearing Gimbal Housing Grease Fitting Description Where Used Urea Grease Water Resistant Type NLGI 2 Unit Bearing Gim bal Housing Lubricating the Engine Coupler See Lubricating the Engine Coupler on page 40 Checking the Circuit for Loose or Damaged Connections Check the electrical connection...

Page 47: ...from the reservoir tank 0006509 Figure 5 Remove the drive unit and lubricate the universal joint shaft splines Figure 6 1 and the O rings Figure 6 2 0006004 2 1 Figure 6 1 Universal Joint Shaft Splines 2 Universal Joint O Rings Description Where Used Multi Purpose Heavy Duty Type Lithium Grease NLGI 2 Universal Joint Shaft Splines and O Rings MAINTENANCE ZT350 Operation Manual 43 2008 Yanmar Marin...

Page 48: ...ause loss of steering control Grease the steering cable grease fitting 1 Turn the steering wheel until the steering cable is fully retracted into the cable housing Apply approximately three pumps of grease from a typical hand operated grease gun Note If the steering cable does not have a grease fitting the inner wire of the cable cannot be greased Description Where Used Lithium Grease With PTFE St...

Page 49: ...eering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway Lubricating the Shift Cable Typical Lubricate the shift cable pivot points Figure 10 1 and the guide contact surfaces Figure 10 2 0006010 1 1 1 2 Figure 10 1 Shift Cable Pivot Points 2 Guide Contact Surfaces Description Where Used SAE 30W Engine Oil Shift Cable Pivot P...

Page 50: ...r 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 2 1 0006341 Figure 11 1 Painted Vessel Transom 2 Minimum 40 mm 1 1 2 in of unpainted area around transom assembly NOTICE The drive unit and transom assembly c...

Page 51: ...hold the drained gear oil 3 Install the oil reservoir Figure 12 3 in the bracket 4 Place the stern drive in full trim limit OUT position 5 Remove the oil fill drain plug and gasket Figure 13 6 Drain the oil 0006030 2 1 Figure 13 1 Oil Fill Drain Plug 2 Gasket 7 Remove the oil vent plug and gasket Figure 14 1 Allow the oil to drain completely 0006031 2 1 Figure 14 1 Oil Vent Plug 2 Gasket NOTICE If...

Page 52: ...all the oil vent plug and gasket Torque the oil vent plug Oil Vent Plug Torque N m lb ft 15 11 12 Continue to pump gear oil into the oil reservoir circuit until the gear oil appears in the oil reservoir 13 Fill the oil reservoir so that the oil level is within the operating range NOTICE NEVER overfill Model Capacity Fluid Type ZT350 2500 mL 85 oz GL 5 Hypoid Gear Oil 0006337 2 1 Figure 16 1 Oil Re...

Page 53: ...icating the Engine Coupler Checking the Circuit for Loose or Damaged Connections Testing the Y CaPS Unit Output Checking the Steering System for Loose Missing or Damaged Parts Checking the Remote Control for Loose Missing or Damaged Parts Lubricating the Cable and the Linkages Touching Up the Stern Drive Paint and Spray with Corrosion Guard Changing the Stern Drive Oil Retorqueing the Rear Engine ...

Page 54: ...cking the Remote Control for Loose Missing or Damaged Parts See Remote Controls on page 17 Lubricating the Cable and the Linkages See Lubricating the Shift Cable Typical on page 45 Touching Up the Stern Drive Paint and Spray with Corrosion Guard See Touching Up the Stern Drive Paint and Spray with Corrosion Guard on page 46 Changing the Stern Drive Oil See Changing the Stern Drive Oil on page 46 R...

Page 55: ...have your authorized Yanmar Marine dealer or distributor replace the cable if damaged beyond repair 44 2 Steering Wheel Turns Hard or Jerky Low power steering pump fluid level Check for leaks Refill the system with fluid Stern drive belt is loose or in poor condition Replace and or adjust Insufficient lubrication on the steering components Lubricate Insufficient lubrication on the transom gimbal h...

Page 56: ...amaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring 19 4 Power Trim Does Not Operate Electric Motor Operates but Stern drive Does Not Move Trim pump oil level is low Fill pump with oil 28 Stern drive binding in gimbal ring Check for obstruction See your authorized Yanmar Marine dealer or distribu...

Page 57: ...rn Drive Lay Up 1 Use a piece of wire to check the water drain passages in the drive unit to ensure that they are open 0006361 1 4 3 2 Figure 1 1 Under Side of Gear Housing 2 First Anode Cavity Drain Passage 3 Second Anode Cavity Drain Passage 4 Speedometer Pitot Hole 2 Change the stern drive oil See Changing the Stern Drive Oil on page 46 3 Perform all other checks inspections lubrication and flu...

Page 58: ...aised position and may fail when the stern drive is returned to service 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 LONG TERM STORAGE 54 ZT350 Operation Manual 2008 Yanmar Marine International ...