OPERATION MANUAL STERN-DRIVE ZT370 en English
Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice.
ZT370_OM.book i ページ ２０１３年９月２７日 金曜日 午前１０時１６分 TABLE OF CONTENTS ZT370 Operation Manual Page Introduction..................................................................... 1 Record of Ownership ................................................. 2 Safety............................................................................... 3 Safety Precautions ..................................................... General Information ............................................. Before You Operate...............
ZT370_OM.book ii ページ ２０１３年９月２７日 金曜日 午前１０時１６分 TABLE OF CONTENTS Stern-Drive Operation................................................... 21 Propeller Selection ................................................... 22 Installing the Propellers ............................................ 23 Removing the Propeller ............................................ 25 Daily Checks............................................................. Visual Checks ....................................................
ZT370_OM.book 1 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 ZT370 Operation Manual INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, stern-drive systems and accessories for all types of vessels, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. Yanmar stern-drives are designed for a wide range of applications and are designed to reduce vibration and make your cruising more pleasurable.
ZT370_OM.book 2 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 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.
ZT370_OM.book 3 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 ZT370 Operation Manual SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the engine and stern-drive’s safety labels. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged.
ZT370_OM.book 4 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SAFETY SAFETY PRECAUTIONS General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures.
ZT370_OM.book 5 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SAFETY 12/05 WARNING Explosion Hazard While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area. Fire Hazard Undersized wiring systems can cause an electrical fire. Sever Hazard • Never service the stern-drive while under tow or if the engine is running at idle speed.
ZT370_OM.book 6 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SAFETY WARNING Exposure Hazard Always wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand. 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.
ZT370_OM.book 7 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SAFETY 12/05 CAUTION Poor Lighting Hazard Ensure that the work area is adequately illuminated. Always install wire cages on portable safety lamps. Tool Hazard Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. Flying Object Hazard Always wear eye protection when servicing the stern-drive or when using compressed air or high-pressure water.
ZT370_OM.book 8 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SAFETY NOTICE Only use replacement parts specified. Other replacement parts may affect warranty coverage. Never attempt to modify the stern-drive’s design or safety features. 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.
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ZT370_OM.book 10 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW Dealer/Distributor Responsibilities In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as: • Ensure that the vessel is properly equipped. • Prior to delivery, make certain that the Yanmar stern-drive and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. • Familiarize the customer with the on-board equipment.
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ZT370_OM.book 12 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 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.
ZT370_OM.book 13 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW 12/05 CORROSION PROTECTION Galvanic Corrosion Galvanic corrosion results whenever two or more dissimilar metals (like those found on the stern-drive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content because a chemical reaction takes place causing electrical current to flow between the metals.
ZT370_OM.book 14 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW Underwater Drive Coating Additional Protection The lower gear case coating may be damaged when hit by objects in the water, or when having deposits removed from it. The underwater coating must be inspected at least once per year and when it is believed that an object was hit that may have caused damage. Repair and repaint damaged areas immediately.
ZT370_OM.book 15 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW 12/05 Gear Housing Anodic Plates Trim Cylinder Anodes The gear housing anodic plates (1, Figure 4) are installed on the underside of the antiventilation plate. The trim cylinder anodes (1, Figure 6) are installed on each trim cylinder.
ZT370_OM.book 16 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW FEATURES AND CONTROLS Remote Controls The Yanmar ZT370 can be controlled mechanically with push-pull cables or electronically. Please refer to the Yanmar Engine Operation Manual or the Electronic Control System Operation Manual (if so equipped).
ZT370_OM.book 17 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW 12/05 Stern-Drive Trim Angle Trim and Tilt/Trailering Switch Trim angle is the angular relationship between the stern-drive and the transom of the vessel. Vessel trim while underway greatly affects vessel performance and efficiency. For best results, the vessel should be on plane and trimmed to reduce the wet surface. With less vessel in the water, both speed and fuel economy increase.
ZT370_OM.book 18 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW Electrical System The power trim pump’s electrical system is protected by either a 1A in-line fuse (1, Figure 11) or an auto-reset circuit breaker (2, Figure 11) located within the trim motor. In the event of an electrical 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.
ZT370_OM.book 19 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 PRODUCT OVERVIEW 12/05 Yanmar Cathodic Protection System The Yanmar Cathodic Protection System (Y-CaPS) has a 20 A in-line fuse (Figure 12) in the wire which connects to the positive (+) terminal on the controller. If the fuse blows, the system will not operate 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.
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ZT370_OM.book 21 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION ZT370 Operation Manual This section of the Operation Manual describes the procedures for proper operation of the stern-drive. Before you operate the ZT370, read the following safety information and review Safety on page 3.
ZT370_OM.book 22 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION PROPELLER SELECTION The propeller converts the engine’s power into the thrust needed to propel the vessel. Careful selection of your propeller is very important to proper vessel operation. Propellers are identified by two numbers, such as 15.75 20 left-hand and stainless steel propeller. In the number sequence, the first number is the diameter of the propeller and the second is the pitch.
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ZT370_OM.book 24 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION 1. Apply a liberal coat of lubricant to the propeller shaft. Recommended lubricants are shown in the table below. Description Urea grease water resistant type, NLGI #2 Lithium grease with PTFE Where used Propeller shaft 2. Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub (toward end of propeller shaft). 3. Align the splines and place the propeller on the propeller shaft. 4.
ZT370_OM.book 25 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION 12/05 REMOVING THE PROPELLER WARNING The remote control must be in NEUTRAL and the starter key removed from the switch before removing and/or installing the propeller. 1. Place a wood block between the propeller blades and the antiventilation plate to prevent rotation.
ZT370_OM.book 26 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION Check the Stern-Drive Oil Level Description BY3 series Quick Silver®*1 High Performance Gear Lube or GL-5 (SAE 80W90) 6LPA series Oil reservoir Quick Silver®*1 High Performance Gear Lube 8LV series *1: Where used Quick Silver is a registered trademark of Brunswick Corporation. Note: The oil level will rise and fall during operation. Check the oil level before starting, when the engine is cold. 1.
ZT370_OM.book 27 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION 12/05 2. Observe the oil level in the reservoir. The oil level should be maintained within the MIN and MAX lines (2, Figure 4) on the reservoir (1, Figure 4).
ZT370_OM.book 28 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 STERN-DRIVE OPERATION 3. Add oil to bring the oil level to within the MIN and MAX lines on the reservoir (2, Figure 6). 1 1 039053-00X00 Figure 5 ■ Fill the power trim pump fluid 3 Note: The power trim fluid does not require changing unless it becomes contaminated with water or debris. Consult 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.
ZT370_OM.book 29 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 ZT370 Operation Manual MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the stern-drive. Before you operate the ZT370, read the following safety information and review Safety on page 3 .
ZT370_OM.book 30 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE PERIODIC MAINTENANCE CAUTION Establish a periodic maintenance plan according to the stern-drive application and make sure to perform the required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the stern-drive’s safety and performance characteristics, shorten the stern-drive’s life and may affect the stern-drive warranty coverage.
ZT370_OM.book 31 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 TIGHTENING FASTENERS Use the correct amount of torque when tightening fasteners. Applying excessive torque may damage the fastener or component and too little torque may cause a leak or component failure. TORQUE CHARTS Standard Torque Values Nominal designation of screw thread Standard tightening torque M5 3.5 ± 0.5 N·m 2.6 ± 0.4 lb-ft M6 6.0 ± 1.0 N·m 4.4 ± 0.6 lb-ft M8 15 ± 2.0 N·m 11 ± 1.5 lb-ft M10 30 ± 2.0 N·m 22 ± 1.
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Maintenance.
ZT370_OM.book 34 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE GENERAL INSPECTION POWER TRIM PUMP FLUID Inspect the stern-drive at regular intervals to help maintain top operating performance and correct potential problems before they occur. Power trim fluid does not require changing unless it becomes contaminated with water or debris. Consult your authorized Yanmar Marine dealer or distributor if the power trim fluid needs to be changed. Check for loose, damaged or missing parts, hoses and clamps.
ZT370_OM.book 35 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 PERIODIC MAINTENANCE PROCEDURES Weekly Perform the following procedures on a weekly basis. 2 1 • Checking the water inlets • Checking the seawater inlet hole 039055-00X00 Figure 1 • Inspecting the anodes ■ Checking the water inlets 2. If necessary, add oil until an air-free stream of oil flows from the oil vent hole. Check the water inlets for debris or marine growth. Clean if necessary. 3. Install the oil vent plug and gasket.
ZT370_OM.book 36 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE After Initial 50 Hours of Operation Perform the following procedures after the first 50 hours of operation. • Lubricating the engine coupler • Changing the stern-drive oil ■ Lubricating the engine coupler 1 Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time. Note: The stern-drive may be equipped with a sealed engine coupler.
ZT370_OM.book 37 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 Every 50 Hours of Operation Every 100 Hours of Operation Perform the following maintenance every 50 hours of operation. Perform the following maintenance every 100 hours of operation. • Lubricate the engine coupler • Lubricating the propeller shaft and retorqueing the nut ■ Lubricate the engine coupler Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time.
ZT370_OM.book 38 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE ■ Retorqueing the gimbal ring to steering shaft connection 1 Torque the gimbal ring locknuts (1, Figure 3) for the steering shaft connection.
ZT370_OM.book 39 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 ■ Lubricating the engine coupler See Lubricating the engine coupler on page 36. 2. Turn the steering wheel until the steering cable (1, Figure 6) is fully extended. Lightly lubricate the exposed part of the cable. ■ Checking the circuit for loose or damaged connections Check the electrical connections and leads for damage and corrosion. ■ Testing the Y-CaPS unit output See Yanmar Cathodic Protection System on page 19.
ZT370_OM.book 40 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE Description Where used Urea grease water resistant type, NLGI #2 Clevis pin 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. Lubricating the shift cable (typical) Lubricate the shift cable pivot points (1, Figure 8) and the guide contact surfaces (2, Figure 8).
Maintenance.fm 41 ページ ２０１３年９月２７日 金曜日 午後１時１６分 MAINTENANCE 12/05 Every 250 Hours of Operation Perform the following maintenance every 250 hours of operation.
ZT370_OM.book 42 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 6. Drain the oil. NOTICE Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as lubrication oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. 1. Remove the oil reservoir from the bracket (1, Figure 10). 2 1 039082-00X00 Figure 11 7. Remove the oil vent plug (1, Figure 12) and gasket (2, Figure 12).
ZT370_OM.book 43 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 8. Remove the case plate cover (4, Figure 13), filter cover (3, Figure 13), magnet (2, Figure 13) and filter (1, Figure 13). Clean or replace the filter and magnet. 13.Fill the oil reservoir so that the oil level is within the operating range (Figure 14). NOTICE Never overfill.
ZT370_OM.book 44 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 15.Remove the pump from the oil fill/drain hole. Quickly install the gasket and oil fill/drain plug. Torque the oil fill/drain plug. Oil fill/drain plug torque N·m lb-ft 15 11 16.Check the oil level in the oil reservoir after first use. 17.Check the stern-drive oil level within one week of the first use as follows: 1- Remove the oil vent plug (1, Figure 15) and gasket (2, Figure 15).
ZT370_OM.book 45 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 ■ Lubricating the drive unit and universal-joint shaft splines and O-rings When you remove the stern-drive unit from the transom assembly, your should first remove the quick connect fitting. This will prevent oil leaks from the reservoir tank. 039065-00X00 Figure 16 Remove the drive unit and lubricate the universal-joint shaft splines (1, Figure 17) and the O-rings (2, Figure 17).
ZT370_OM.book 46 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE ■ Torqueing the rear engine mount bolts Every 1000 Hours of Operation Note: Refer to the Engine Installation Manual and/or Operation Manual for front engine mount information. Perform the following maintenance every 1000 hours of operation. • Replace of friction disc (Light duty commercial applications only) Torque the rear engine mount bolts (1, Figure 18).
ZT370_OM.book 47 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE 12/05 ■ Inspecting the bellows and the clamps Every Year Perform the following maintenance every year of operation.
ZT370_OM.book 48 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 MAINTENANCE ■ Lubricating the cable and the linkages See Lubricating the shift cable (typical) on page 40. Every 2 Years Perform the following maintenance every 2 years of operation. ■ Touching-up the stern-drive paint and spray with corrosion guard • Replace U-joint bellows See Touching-up the stern-drive paint and spray with corrosion guard on page 41.
ZT370_OM.book 49 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 ZT370 Operation Manual TROUBLESHOOTING Problem Possible cause 1 Remote control operates hard, binds, has excessive free play or makes unusual sounds Insufficient lubrication on the shift and throttle (if applied) linkage fasteners. Lubricate. Obstruction in the shift or throttle (if applied) linkages. Remove the obstruction. Loose or missing shift and throttle linkages. Check all throttle linkages.
ZT370_OM.book 50 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 TROUBLESHOOTING No. Problem 3 Power trim does not operate (Electric motor does not operate) Possible cause Action Blown fuse. Replace the fuse. 18 Circuit breaker is tripped. Wait until the breaker cools down and the breaker is restored. 18 Check all associated electrical connections and wires (especially battery cables). Clean and tighten faulty connection. Repair or replace wiring. 18 Trim pump oil level is low. Fill pump with oil.
ZT370_OM.book 51 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 LONG-TERM STORAGE ZT370 Operation Manual COLD WEATHER (FREEZING TEMPERATURE), SEASONAL AND EXTENDED 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. Stern-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.
ZT370_OM.book 52 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 LONG-TERM STORAGE 4. Place the stern-drive in the full DOWN/TRIM-IN position. CAUTION The stern-drive should be stored in the FULL DOWN/TRIM-IN position. The universal joint bellows may develop a set if the unit is stored in the raised position and may fail when the stern-drive is returned to service. Stern-Drive Recommissioning 1. Carefully inspect the stern-drive for leaks. 2. Check the steering system, shift and throttle control for proper operation.
ZT370_OM.book 53 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 ZT370 Operation Manual SPECIFICATIONS Stern-drive model Yanmar Applicable engine Reduction ratio ZT370 BY3 series 6LPA series 8LV series 1.65 1.78 1.97 2.18 1.65 1.78 1.65 1.
ZT370_OM.book 54 ページ ２０１３年９月２７日 金曜日 午前１０時１６分 SPECIFICATIONS Stern-drive model Tilt/trim system ZT370 Electric motor drive hydraulic power operation Anti-corrosion system Y-CaPS Mass (weight) Dry condition Electronic control cathodic protection 100 kg (220.5 lb) *1: Quick Silver is a registered trademark of Brunswick Corporation.
ڦMarine Operations Division Quality Assurance Dept. 5-3-1, Tsukaguchi-honmachi, Amagasaki Hyogo, 661-0001, Japan Phone: +81-6-6428-3251 Fax: +81-6-6421-5549 Overseas Office ڦYanmar Europe B.V. (YEU) Brugplein 11, 1332 BS Almere-de Vaart, Netherlands Phone: +31-36-5493200 Fax: +31-36-5493209 ڦYanmar Asia (Singapore) Corporation Pte Ltd.
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