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ZT370 Operation Manual

29

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 29 ページ２０１３年９月２７日　金曜日　午前１０時１６分

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Summary of Contents for ZT370

Page 1: ...en English STERN DRIVE OPERATION MANUAL ZT370 ...

Page 2: ...icy 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 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 a...

Page 3: ...sibilities 10 Component Identification 11 Location of Serial Numbers 12 Corrosion Protection 13 Galvanic Corrosion 13 Corrosion Control 13 Shore Power 13 Underwater Drive Coating 14 Additional Protection 14 Gear Housing Anodic Plates 15 Ventilation Plate Anode 15 Trim Cylinder Anodes 15 Propeller Shaft Anode 15 Features and Controls 16 Remote Controls 16 Power Trim 16 Stern Drive Trim Angle 17 Tri...

Page 4: ... Distributor for Help 30 Tightening Fasteners 31 Torque Charts 31 Standard Torque Values 31 Torque Specifications 31 Periodic Maintenance Table 32 General Inspection 34 Power Trim Pump Fluid 34 Periodic Maintenance Procedures 35 Weekly 35 After Initial 50 Hours of Operation 36 Every 50 Hours of Operation 37 Every 100 Hours of Operation 37 Every 150 Hours of Operation 40 Every 250 Hours of Operatio...

Page 5: ...rstand this Operation Manual before 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 b...

Page 6: ..._______________________________________________________ Engine Horsepower _____________________________________________________ Propeller Number _______________________________________________________ Propeller Pitch _________________________________________________________ Propeller Diameter ______________________________________________________ Hull Identification Number HIN ____________________...

Page 7: ...new part and label at the same time DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE indicates a situation whi...

Page 8: ...u 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 maintenance techniques Consult your authorized Yanmar Marine dealer or distributor for additional training During Operation and Maintenance DANGER Fire Hazard Ensure that appropriate fire detection and e...

Page 9: ...tate if any of the other engines are running WARNING Continued Rotating parts can cause severe injury or death Never wear jewelry unbuttoned cuffs ties or loose fitting clothing and always tie long hair back when working near moving rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all moving parts To prevent accidental equipment movement never start the engine i...

Page 10: ...he engine and stern drive surfaces become very hot during operation and shortly after shutdown Keep hands and other body parts away from hot surfaces WARNING Exhaust Hazard Never block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid ca...

Page 11: ... the daily checks as listed in this Operation Manual Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine or stern drive performance and can help extend the life of the engine and stern drive Always be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as lub...

Page 12: ... to lift the engine and stern drive as an assembly 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 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 Anytime the boat is left in t...

Page 13: ...ve while keeping your overall operating expenses to a minimum Individual operating habits and usage may increase the frequency of performing maintenance service condition Monitor conditions frequently to determine if the maintenance intervals suggested in the manual are frequent enough for stern drive NOTICE The anode of the stern drive is only calculated for the stern drive Changing the material ...

Page 14: ...uch 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 Explain and demonstrate the operation of the stern drive and vessel ZT370_OM book 10 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 15: ... ZT370 Operation Manual 11 COMPONENT IDENTIFICATION Figure 1 039031 00E01 Steering system location Transom assembly Drive unit Antiventilation plate Trim cylinder Y CaPS electrode ZT370_OM book 11 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 16: ...nufacturer s keys to numerous engineering details which apply to your Yanmar stern drive When contacting Yanmar about service always specify model and serial numbers Figure 2 039032 00E00 Transom assembly serial number Drive unit serial number 039033 00E00 ZT370_OM book 12 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 17: ...so available from the aftermarket not supplied by Yanmar to block stray current while still providing a path to ground for dangerous shock currents The rate of corrosion depends on numerous factors such as 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 a...

Page 18: ...ode manufacturer Consult your authorized Yanmar Marine dealer or distributor for assistance NOTICE Galvanic corrosion damage normal maintenance and consumable parts are not covered by the Yanmar limited warranty 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 cor...

Page 19: ... plate anode 1 Figure 5 is installed on the front of the drive shaft housing on top of the ventilation plate Figure 5 Trim Cylinder Anodes The trim cylinder anodes 1 Figure 6 are installed on each trim cylinder Figure 6 Propeller Shaft Anode The propeller shaft anode 1 Figure 7 is located behind the aft propeller Figure 7 039037 00X00 1 039034 00X00 1 039035 00X00 1 039036 00X00 1 ZT370_OM book 15...

Page 20: ... used to accelerate the vessel 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 l...

Page 21: ...ne and may bounce Trim and Tilt Trailering 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 s...

Page 22: ...ure 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 If the electrical overload problem still exists consult your authorized Yanmar Marine dealer or distributor Figure 11 039038 00X00 2 1 ZT370_OM book 18 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 23: ...f 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 Consult your authorized Yanmar Marine dealer or distributor for assistance if necessary Figure 12 039039 00E00 Electrode Y CaPS controller 20 A in line fuse holder ZT370_OM b...

Page 24: ...PRODUCT OVERVIEW 20 ZT370 Operation Manual This Page Intentionally Left Blank ZT370_OM book 20 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 25: ...DRIVE OPERATION 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 21 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 26: ... be selected for water skiing or for heavy loads Keep these guidelines in mind when selecting a propeller Your Yanmar Marine dealer or distributor is most qualified to help you select a propeller NOTICE Never attempt to change propellers until after determining the average load and individual requirements Engine rpm must be within the recommended operating range Refer to the Engine Operator s Manu...

Page 27: ...1 Rear propeller 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 Figure 1 1 2 3 4 5 6 7 8 039040 00X00 ZT370_OM book 23 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 28: ... 20 hours 5 Slide the aft thrust hub onto the propeller 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 8 Install the propeller shaft anode bolt with a washer Torque the bolt Description Where used Urea grease water resi...

Page 29: ...b off the propeller shaft DAILY CHECKS All stern drives have been submitted to a test run before shipment Visual checks for leakage should be made 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...

Page 30: ...or if oil appears discolored consult your authorized Yanmar Marine dealer or distributor immediately Both conditions may indicate a water leak somewhere in the stern drive Fill the stern drive with oil See Changing the stern drive oil on page 36 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 st...

Page 31: ... full DOWN TRIM IN position 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 Figure 4 3 The oil level is low if it is below the MIN line 1 Figure 5 on the reservoir Fill as necessary with the specified fluid See Fill the power trim pump fluid on page 28 Description Where used BY3 series Quick Silver 1 Hi...

Page 32: ... needs to be changed 1 Place the stern drive in the full DOWN TRIM IN position 2 Unscrew and remove the fill cap assembly 1 Figure 6 from the reservoir 3 Figure 6 with specified fluid 3 Add oil to bring the oil level to within the MIN and MAX lines on the reservoir 2 Figure 6 Figure 6 4 Install the fill cap assembly Description Where used Dextron III Automatic transmission fluid Power trim pump 03...

Page 33: ...ANCE 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 29 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 34: ...life of the stern drive Performing Periodic Maintenance WARNING Never block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death The Importance of Daily Checks The periodic maintenance schedule assumes that ...

Page 35: ...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 5 lb ft M12 45 2 0 N m 33 1 5 lb ft Item Size Torque Nut for U bolt of gimbal ring M10 1 5 50 5 N m 37 4 lb ft Bolt for anode of cylinder part 10 32 UNF 3 5 0 5 N m 2 6 0 4 lb ft Bolt for rear cover M8 1 25 6 0 1 0 N m 4 4 0 7 lb ft Plug M10 1 5 15 2 0 N m 11 1 5 lb ft Bolt for valve assembly M12 1 25 6 0 1 0 N m 4 4 0 7 l...

Page 36: ...th clean if necessary Check the seawater inlet hole clean if necessary Inspect the anodes and replace if 50 percent eroded Replenish the oil in stern drive First time only Lubricate the propeller shaft and retorque the nut 1 Touch up the stern drive paint and spray with corrosion guard Change the stern drive oil Recreational applications First time only 2 2 Light duty commercial applications 3 Fir...

Page 37: ...d connections Test the Y CaPS output on ZT370 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 engine mounts Lubricating the drive unit and universal joint shaft splines and O rings Replace U joint bellows Every 2 years 6 Replace control cable bellows Every 2 years 6 Repl...

Page 38: ... Yanmar Marine dealer or distributor 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 FLUI...

Page 39: ...the seawater inlet hole Clean if necessary Inspecting the anodes Inspect the anodes and replace if 50 corroded See Corrosion Protection on page 13 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 1 Figure 1 and gasket 2 Figure 1 Figure 1 2 If necessary add oil until an air free stream of oil flows from the oil vent hole 3...

Page 40: ... the stern drive Apply approximately 8 to 10 pumps of grease to the engine coupler grease fitting 1 Figure 2 to lubricate the engine coupler splines through the grease fittings if equipped Use a typical hand operated grease gun to apply the grease Figure 2 Note Lubricate the coupler on the ZT370 model every 50 hours if the vessel is operated at idle for prolonged periods of time Changing the stern...

Page 41: ...bellows and the clamps Checking the engine alignment Lubricating the steering shaft bushing 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 Checking the remote control for loose missing or damaged parts Lubricating the cable and ...

Page 42: ...se fitting 1 Figure 4 Use a typical hand operated grease gun to apply the grease Figure 4 Lubricating the unit bearing gimbal housing Apply approximately 8 to 10 pumps of grease to the unit bearing gimbal housing grease fitting 1 Figure 5 to lubricate the unit bearing gimbal housing Use a typical hand operated grease gun to apply the grease Figure 5 Gimbal ring locknut torque N m lb ft 50 37 03906...

Page 43: ...nd cause 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 2 Turn the steering wheel until the steering c...

Page 44: ...re 8 Perform the following maintenance every 150 hours of operation Changing the stern drive oil Light duty commercial applications only Changing the stern drive oil Light duty commercial applications only See Changing the stern drive oil on page 41 Description Where used Urea grease water resistant type NLGI 2 Clevis pin Description Where used SAE 30 engine oil Shift cable pivot points Lithium gr...

Page 45: ...the area where the vessel will be operated 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 Figure 9 NOTICE The drive unit and transom assembly can be painted with a good quality marine pain...

Page 46: ...d the drained gear oil 3 Install the oil reservoir 2 Figure 10 in the bracket 4 Place the stern drive in full trim limit OUT position 5 Remove the oil fill drain plug 1 Figure 11 and gasket 2 Figure 11 6 Drain the oil Figure 11 7 Remove the oil vent plug 1 Figure 12 and gasket 2 Figure 12 Allow the oil to drain completely Figure 12 NOTICE If any water drains from the oil fill drain hole or if it a...

Page 47: ...ir free stream of oil flows from the oil vent hole 11 Install the oil vent plug and gasket Torque the oil vent plug 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 Figure 14 NOTICE Never overfill 1 Quick Silver is a registered trademark of Brunswick Corporation ...

Page 48: ... follows 1 Remove the oil vent plug 1 Figure 15 and gasket 2 Figure 15 Figure 15 2 If necessary add oil until an air free stream of oil flows from the oil vent hole 3 Install the oil vent plug and gasket Torque the oil vent plug NOTICE Oil level in the oil reservoir will rise and fall during stern drive operation always check the level when the stern drive is cool and the engine is shut down Oil f...

Page 49: ...s will prevent oil leaks from the reservoir tank Figure 16 Remove the drive unit and lubricate the universal joint shaft splines 1 Figure 17 and the O rings 2 Figure 17 Figure 17 NOTICE Use new O ring seals each time the drive unit is installed Description Where used Multi purpose heavy duty type lithium grease NLGI 2 Universal joint shaft splines and O rings 039065 00X00 039066 00X00 1 2 ZT370_OM...

Page 50: ...ts 1 Figure 18 Figure 18 Perform the following maintenance every 1000 hours of operation Replace of friction disc Light duty commercial applications only Replace of friction disc Light duty commercial applications only Consult your authorized Yanmar Marine dealer or distributor Engine rear mount bolt torque N m lb ft 45 33 039078 00X00 1 Every 1000 Hours of Operation ZT370_OM book 46 ページ２０１３年９月２７...

Page 51: ...to steering shaft connection See Retorqueing the gimbal ring to steering shaft connection on page 38 Inspecting the bellows and the clamps See General Inspection on page 34 Checking the engine alignment See Checking the engine alignment on page 38 Lubricating the steering shaft bushing See Lubricating the steering shaft bushing on page 38 Lubricating the unit bearing gimbal housing See Lubricating...

Page 52: ...ueing the rear engine mounts See Torqueing the rear engine mount bolts on page 46 Replace of friction disc Light duty commercial applications only Consult your authorized Yanmar Marine dealer or distributor Perform the following maintenance every 2 years of operation Replace U joint bellows Replace control cable bellows Replace U joint bellows Consult your authorized Yanmar Marine dealer or distri...

Page 53: ...ked Straighten the cable or have your authorized Yanmar Marine dealer or distributor replace the cable if damaged beyond repair 39 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 lubrica...

Page 54: ...heck all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring 18 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 Consult your authorized Yanmar Marine dealer or distributor No Prob...

Page 55: ...eezing 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 Figure 1 2 Change the stern drive oil See Changing the stern drive oil on page 41 3 Perform all other checks inspections lubrication and fluid changes 039086 00E01 First anode cavity drain passage Under side of gear housing Second an...

Page 56: ... 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 52 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 57: ...3 4 22 in 400 1 609 6 mm 15 3 4 24 in 400 1 660 4 mm 15 3 4 26 in 400 1 711 2 mm 15 3 4 28 in Rear propeller 362 0 mm 508 mm 14 1 4 20 in 362 0 mm 558 8 mm 14 1 4 22 in 362 0 mm 609 6 mm 14 1 4 24 in 362 0 mm 660 4 mm 14 1 4 26 in 362 0 mm 711 2 mm 14 1 4 28 in Allowable propeller diameter Max 406 4 mm 16 in Oil Stern drive unit Quick Silver 1 High Performance Gear Lube or GL 5 SAE 80W90 2 5 l 84 ...

Page 58: ...e piping diagrams and related information see the engine specific section of Installation Manual and or the Service Manual Tilt trim system Electric motor drive hydraulic power operation Anti corrosion system Y CaPS Electronic control cathodic protection Mass weight Dry condition 100 kg 220 5 lb Stern drive model ZT370 ZT370_OM book 54 ページ２０１３年９月２７日金曜日午前１０時１６分 ...

Page 59: ... 6428 3251 Fax 81 6 6421 5549 ڦ Yanmar Engine Shanghai Co Ltd 10F E Block POLY PLAZA No 18 Dongfang Road Pudong Shanghai CHINA P R C 200120 Phone 86 21 6880 5090 Fax 86 21 6880 8090 ڦ Yanmar America Corporation YA 101 International Parkway Adairsville GA 30103 U S A Phone 1 770 877 9894 Fax 1 770 877 9009 1st edition March 2011 1st edition 2nd rev September 2011 1st edition 3rd rev February 2012 2...

Page 60: ...0AZTD EN0022 STERN DRIVE http yanmar com ...

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