Yanmar ZT370 User manual

en
English
STERN-DRIVE
OPERATION MANUAL
ZT370

MODEL
OPERATION MANUAL CODE
All Rights Reserved, Copyright
ZT370
0AZTD-EN0022
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.
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
information storage and retrieval systems - without the written permission of
YANMAR CO., LTD.

ZT370 Operation Manual i
ZT370 Operation ManualTABLE OF
CONTENTS
Page
Introduction..................................................................... 1
Record of Ownership ................................................. 2
Safety............................................................................... 3
Safety Precautions ..................................................... 4
General Information ............................................. 4
Before You Operate............................................. 4
During Operation and Maintenance..................... 4
Product Overview ........................................................... 9
Overview .................................................................... 9
Owner/Operator Responsibilities ......................... 9
New Stern-Drive Break-In:................................... 9
Dealer/Distributor Responsibilities..................... 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
Trim and Tilt/Trailering Switch ........................... 17
Electrical System ............................................... 18
Yanmar Cathodic Protection System................. 19
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TABLE OF CONTENTS
ii ZT370 Operation Manual
Stern-Drive Operation................................................... 21
Propeller Selection ................................................... 22
Installing the Propellers ............................................ 23
Removing the Propeller ............................................ 25
Daily Checks............................................................. 25
Visual Checks .................................................... 25
Check the Stern-Drive Oil Level......................... 26
Check the Power Trim Pump Fluid .................... 27
Maintenance .................................................................. 29
Periodic Maintenance ............................................... 30
The Importance of Periodic Maintenance .......... 30
Performing Periodic Maintenance ...................... 30
The Importance of Daily Checks ........................ 30
Yanmar Replacement Parts ............................... 30
Tools Required................................................... 30
Ask Your Authorized Yanmar Marine Dealer
or 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 Operation............................ 41
Every 1000 Hours of Operation.......................... 46
Every Year ......................................................... 47
Every 2 Years..................................................... 48
Troubleshooting............................................................ 49
Long-Term Storage....................................................... 51
Cold Weather (Freezing Temperature),
Seasonal and Extended Storage.............................. 51
Stern-Drive Lay Up............................................. 51
Stern-Drive Recommissioning............................ 52
Specifications................................................................ 53
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ZT370 Operation Manual 1
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.
To help you enjoy your Yanmar Marine
products for many years to come, please
follow these recommendations:
• Read and understand 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
be considered a permanent part of the
vessel and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your stern-drive. If you have any
questions about these differences,
please consult your authorized Yanmar
Marine dealer or distributor.
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INTRODUCTION
2ZT370 Operation Manual
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: __________________________________________________________
Engine Horsepower: _____________________________________________________
Propeller Number: _______________________________________________________
Propeller Pitch: _________________________________________________________
Propeller Diameter: ______________________________________________________
Hull Identification Number (HIN): ___________________________________________
Boat Manufacturer: ______________________________________________________
Boat Model: ____________________________________________________________
Dealer:_________________________________________________________________
Dealer Phone:___________________________________________________________
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ZT370 Operation Manual 3
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. Also, if
you need to replace a part that has a label
attached to it, make sure you order the
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 which can
cause damage to the machine, personal
property and/or the environment or cause
the equipment to operate improperly.
A
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.
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SAFETY
4ZT370 Operation Manual
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. Read and
understand all of the safety precautions
before operation or performing repairs or
maintenance.
Before You Operate
WARNING
• 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
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
extinguishing equipment
are installed and checked
periodically for proper
operation.
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 stern-drive such as
wooden pieces, blocks or by only
using a jack.
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SAFETY
12/05
ZT370 Operation Manual 5
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.
The propeller may rotate
under these
circumstances.
• If the vessel has more than one
engine, never service a stern-drive if
either of the engines are running. In
multi-engine configurations, the
propeller for an engine that is shut
down may rotate 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 in
gear.
• Before starting the engine, always
make sure that all bystanders are
clear of the area. Keep children and
pets away while the 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.
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SAFETY
6ZT370 Operation Manual
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.
• Never operate or service the engine
while wearing a headset to listen to
music or the radio because it will be
difficult to hear the warning signals.
Burn Hazard
Some of the 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 carbon monoxide
poisoning.
Electrical Shock Hazard
• Always turn off the
battery switch (if
equipped) or disconnect
the negative battery
cable before servicing
the equipment.
• Always keep the electrical connectors
and terminals clean. Check the
electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors.
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