Imv3 Rev4 Master Book 29dec08

Marine INSTALLATION MANUAL Volume 3 Marine Manual - Volume BY, Installation BY2, LH, LP, LY, 3CX,

SY Series and ZT350 P/N 0FMPE-U00304

MARINE INSTALLATION MANUAL

6BY2 Marine Installation Manual - Volume 3

Page Engine Specifications .......................... ....................................... .......................... .......................... .................2 ....2 Engine Room Space for Service ........... ........................ ......................... ......................... ................3 ...3 Marine Gear / Stern Drive Specifications ............ ......................... .......................... ..............4 .4 Flywheel Housing Dimensions (Borg Warner Flange)....................7 Flange)....................7 Flywheel Housing Dimensions (Stern Drive) ............ ........................ ......................8 ..........8 Fuel System Specifications ........... ........................ ......................... ......................... ........................9 ...........9 Piping Diagram .......................... ...................................... ......................... ......................... ......................... ..............10 .10 Cooling System Specifications ........... ....................... ......................... ........................ .................11 ......11 Air Intake and Exhaust Specifications ............ ........................ ........................ ..................13 ......13 Mixing Elbow ............ ......................... .......................... .......................... ......................... ......................... .................14 ....14 Alarm System Specifications ........... ........................ ......................... ......................... ....................15 .......15 Remote Control System ......................... ....................................... ........................... ........................15 ...........15 Electrical System ............ ......................... ......................... ......................... .......................... ........................16 ...........16 Standard Alternator Data................................. Data............................................. ......................... .................17 ....17 Performance Curves...................... Curves................................... ......................... ......................... ......................20 .........20 Engine Mount ............ ......................... ........................... .......................... ......................... .......................... ...............22 ..22 Installation Specifications ........... ...................... ........................ ......................... ........................ ..............23 ..23 Cold Starting Aids................................. Aids............................................. ........................ ......................... ................23 ...23 Water Heater Tank Connection ............ ........................ ......................... .......................... ...............24 ..24 Heat Insulation Requirements .......................... ..................................... ........................ .................24 ....24 Optional Accessories............................ Accessories........................................ ........................ ......................... ................24 ...24

Marine Installation Manual - Volume 3

SEPT 2008 (Rev. 4)

6BY2 - 1

6BY2

6BY2

6BY2

Parameter

Please refer to the Safety section at the beginning of this manual.

Engine Specifications Parameter

Data 6BY2-220

Configuration

6BY2-260

4-cycle Diesel, 15° Inclined, Dual Overhead Camshaft

Crankshaft Rotation (Viewed from Flywheel)

Counterclockwise

Combustion System

Direct Injection

Aspiration Number of Cylinders

Turbocharger with Charge Air Cooler

84 mm x 90 mm (3.307 in. x 3.543 in.)

Displacement

2.993 L (182.6 cu in.)

Continuous Rating Output at Crankshaft (at 3600 rpm)

124 kW (166 hp)

153 kW (208 hp)

Maximum Output at Crankshaft (at 4000 rpm)

162 kW (220 hp)

191 kW (260 hp)

10.8 m/sec (35.4 ft/sec)

11 m/sec (36.1 ft/sec)

Piston Speed (Maximum Output) Brake Mean Effective Pressure (Maximum Output) Maximum Torque High Idling Speed

6BY2 - 2

6BY2-220 Low Idling Speed (at 88°C [190°F])

6BY2-260

670 rpm*

Firing Order

1 - 5 - 3 - 6 - 2 - 4 - 1**

Engine Lubrication System

Enclosed, Forced

Engine Oil Capacity (0° incline)

11.0 L2 (11.62 qt)***

(Dry Weight without Gear/Drive or Mixing Elbow)

For Stern Drive: 338 kg For Marine Gear: 319 kg

Total Air Flow Requirements

3 2750 m /h 3 (97115 ft /h)

* 1080 rpm at startup for alternator alternator excitati excitation. on.

In-line 6

Bore x Stroke

Piston Speed (Continuous Rating Output)

Data

** No. 1 cylinder cylinder is at the the coolant coolant pump en end d of the engine. *** The engine oil capacity includes oil in the oil pan, channels, coolers, and filter.

Note: Rating condition, ISO 8665 Fuel temperature: 40°C (104°F) 1 hp metric = 0.7355 kW

12.0 m/sec (39.4 ft/sec)

1.62 MPa (234.96 psi)

1.92 MPa (260 hp)

500 N·m (369 ft-lb)

550 N·m (407 ft-lb)

4600 rpm

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Engine Room Space for Service 537 mm (21.15 in.)

391 mm (15.4 in.)

70 mm (2.8 in.)

) . n m i m 5 0 6 . 5 1 5 2 (

m ) . m n i 8 . 3 . 9 6 5 ( 1

267 mm (14.5 in.)

) m . n i m 8 . 5 . 9 4 3 9 2 (

0006581

Figure - 1 The installer is responsible for ensuring that there is sufficient engine room space to access the engine for service and repair. Superstructures and connected components should be installed so that the engine can be removed, fitted and serviced without time being lost to any obstructions. The following components must be easy to access: • Fuel filter(s)

• Coolant pump

• Fuel system components for bleeding the fuel system

• Heat exchanger

• Air filter

• Complete seawater pump assembly (to access impeller and filter)

• Engine oil filter(s)

• Zinc anodes

• Oil fill port and dipstick

• Batteries

• Engine oil drain plug

• Starter motor

• Marine Gear or Sail-Drive oil fill port / dipstick

• Alternator

• Coolant tank fill port

• Turbocharger

• Coolant drain cock(s)


SEPT 2008 (Rev. 4)

6BY2 - 3

6BY2

6BY2

Marine Gear / Stern Drive Specifications Use the KMH50 marine gear or ZT350 or Mercruiser Bravo 1, 2 or 3 stern drive with the 6BY2 series engine. Note: See the marine gear / stern drive manufacturers literature for additional information.

6BY2 - 4

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Borg Warner

S

1 0 6 4 ( 4 1 . 8 9 )

1 0 0 1 ( 3 9 . 4 1 ) 1 4 5 ( 5 . 7 1 )

2 2 7 8 9 7 ( ( 1 1 0 1 . . 9 3 8 ) )

716 (28.19)

847.45 (33.36) 709 (27.91) 700 (27.56) 460 (18.11)

240 (9.45)

A

A 7 1 6 . 4 8

3 3 2 ( 1 3 . 0 7 )

( 2 8 . 2 1 ) 2 0 3 ( 7 . 9 9 )

( A C V n E s 1 I 6 W c i ) h t S

5 4 8 . 5 ( 2 1 . 5 9 )

( S G S 6 E c h ) C n T t i I t O N A A - A - A

( 1 4 . 8 6 1 ) 1 5 . 5 ( . 6 1 )

S A E 2 0 / 4 0 - 2 6

0006541

Unit: mm (in.) Figure - 2


SEPT 2008 (Rev. 4)

6BY2 - 5

6BY2

6BY2

Stern Drive

6 1 4 . 5

1 0 0 1

( 2 4 . 1 9 )

( 3 9 . 4 1 ) 1 4 5 ( 5 . 7 1 )

2 2 8 7 7 9 ( ( 1 1 0 1 . . 3 9 ) 8 )

716 (28.19)

240 (9.45)

709 (27.91) 700 (27.56) 460 (18.11)

3 7 3

( 1 4 . 6 9 )

8 0 2

7 6 1

( 3 1 . 5 2 7 0 ) 3 . 9 9

( 2 9 . 9 6 )

( 8 . 0 3 )

4 2 9 ( 1 6 . 8 9 )

8 9 4 ( 3 5 . 2 )

( 1 5 4 . 8 9 7 . 1 )

( 9 3 4 . 7 . 2 1 1 )

( 7 2 1 . 8 . 1 )

0006495

Unit: mm (in.) Figure - 3

6BY2 - 6

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Flywheel Housing Dimensions (Borg Warner Flange) 119 (4.69)

235 (9.25)

0006489

Figure - 4 Unit: mm (in.)


SEPT 2008 (Rev. 4)

6BY2 - 7

6BY2

6BY2

Flywheel Housing Dimensions (Stern Drive) 220 (8.66)

241.3 (9.5) ) 6 0 4 . ( 3 . 0 1

0006490

Figure - 5 Unit: mm (in.)

6BY2 - 8

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Fuel System Specifications Parameter

Data 6BY2-220

6BY2-260

Maximum Fuel Feed Pump Suction Head

1.0 m (39.37 in.)

Maximum Fuel Feed Pump Discharge Volume

200.0 L/hr minimum (52.8 gal/hr minimum)

Maximum Fuel Feed Pump Discharge Pressure

5 bar (72.5 psi)

Fuel Inlet Pipe Connector Thread

3/8 NPT

Maximum Fuel Inlet Temperature Fuel Consumption at Rated Output

Fuel Line (minimum size)

70°C (158°F) 44.5 L/hr (11.7 gal/hr)

53 L/hr (14 gal/hr)

Hose acc. DIN ISO 7840 A1 (fire resistance hose) is requested. Max length of hose between prefilter and engine depends on suction height of complete suction line.

Inner diameter for inlet

8 mm (0.32 in.)

Inner diameter for outlet

12 mm (0.47 in.)

Note: Yanmar supplies a water separating prefilter for mounting by the installer. The engine is also equipped with an onengine fine filter.


SEPT 2008 (Rev. 4)

6BY2 - 9

6BY2

6BY2

Piping Diagram Fuel Flow (9)

(8) (15)

(10)

(7)

(11)

(2) (3)

(14) (6)

(12) (1) (13) (4) (16) 0006510

(5)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Fuel Inlet from Tank Fuel Filter (10 micron) Fuel Feed Pump Inlet Fuel Temperature Sensor High-Pressure Fuel Pump High-Pressure Fuel Supply Line High-Pressure Fuel Common Rail Fuel Injection Line Fuel Injector

10. Fuel Injector Return Hose 11. Common Rail Return Line 12. Return Fuel Tee with Back Pressure Valve 13. Return Fuel to Fuel Tank with Over Pressure Valve 14. Fuel Pressure Sensor 15. Fuel Pressure Regulator (ECU-Controlled) 16. Fuel Measuring Unit (ECU-Controlled)

Figure - 6

6BY2 - 10

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Cooling System Specifications Parameter

Data 6BY2-220

Cooling System

6BY2-260

Closed Cooling with Heat Exchanger

Coolant Capacity (Approximately)

13.0 L (13.7 qt)

Coolant Capacity (Recovery Tank)

1.0 L (1.0 qt)

Maximum Seawater Pump Flow Rate at Maximum Rating

165 L/min. (174 qt/min)

Maximum Seawater Pump Suction Head

0.5 m (19.69 in.)

Seawater Inlet Pipe Connector Outer Diameter

38.1 mm (1.5 in.)

Thermostat Operating Temperature (Full Open)

96°C (205°F)

Thermostat Operating Temperature (Opening)

88°C (190.4°F)

Maximum Overflow Pipe Length (Coolant Recovery Tank to Filler Cap)

1.0 m (39.37 in.)

Overflow Pipe Inner Diameter (Coolant Recovery Tank to Filler Cap) Water Heater Tank / Cabin Heater Pipe Inside Diameter

6 mm (0.250 in.)

10 mm (0.394 in.)*

* Must have a minimum pressure rating of 1.5 bar (22 psi).


SEPT 2008 (Rev. 4)

6BY2 - 11

6BY2

6BY2

Cooling Flow (2)

(3)

(1) (6) (4) (7)

(5)

(12) (9) (13)

(8)

(11) (10)

0006511

Note: Typicak 4BY2 engine shown. 6BY2 is similar. 1. 2. 3. 4. 5. 6. 7.

Seawater Supply Seawater Pump Hydraulic Oil Cooler Charge Oil Cooler Engine Heat Exchanger Exhaust / Seawater Mixing Elbow Exhaust / Seawater Exit

8. Engine Coolant Pump 9. Thermostat 10. Engine Oil Cooler 11. Engine Coolant Passages 12. Coolant Recovery Tank 13. Water Cooled Exhaust Manifold

Figure - 7

6BY2 - 12

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Air Intake and Exhaust Specifications Check for leaks at initial start. Parameter

Data 6BY2-220

Exhaust Pipe Outer Diameter Connection Air Volume Necessary for Combustion at WOT

6BY2-260

102 mm (4.0 in.)

3 950 m /h 3 (33549 ft /h)

Maximum Air Inlet Depression

4.0 kPa 408 mmAq (16.06 in.Aq)

Maximum Back Pressure

45 kPa 4589 mmAq (180.67 in.Aq)

EPA Exhaust Test Port Sizes

Maximum Output Exhaust Temperature Before Turbocharger Maximum Turbocharger Boost Pressure (min/max) Maximum Engine Room Ambient Temperature

Location: Mixing Elbow G 1/4 - 19 BSPP or G 3/8 - 19 BSPP4* 600°C (1112°F) at rated speed

650°C (1202°F) at rated speed

700°C (1292°F) at full load 2000 rpm

700°C (1292°F) at full load 2000 rpm

1950 / 2150 mbar (28.3 / 31.2 psi)

2000 / 2200 mbar (29.0 / 31.9 psi)

60°C (140°F)

* NOTE: Back pressure measured from EPA test port located on the mixing elbow. CAUTION! Test ports are British Standard Pipe Parallel (BSPP) not National Pipe Thread (NPT). BSPP and NPT threads are not compatible due to the thread pitch. Mixing can cause thread damage.


SEPT 2008 (Rev. 4)

6BY2 - 13

6BY2

6BY2

Mixing Elbow 410.5 (16.16) 351 (13.82)

) 3 7 4 . ( 0 2 1

404.5 (15.93) 336 (13.23)

) 1 3 . 8 5 . 7 0 2 1 (

ø ( ø 1 4 0 . 0 2 2 )

) 7 1 . 7 1 (

ø ( 1 ø 0 4 . 0 2 2 )

1 . 6 3 4

700.4 (27.57)

615.5 (24.23)

464.5 (18.29) 223.3 (8.79) ( ø ø 4 1 0 . 0 2 2 )

328 (12.91)

) 1 6 . 2 2 ( 2 . 4 7 5

( ø ø 4 1 0 . 0 2 2 )

) 2 9 , 9 1 (

) 2 0 . 2 2 (

) 7 1 . 9 1 (

4 . 9 5 5

9 . 6 8 4

775.3 (30.52)

9 . 6 0 5

732.8 (28.85)

0006602

Unit = mm (in.)

6BY2 - 14

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Alarm System Specifications Parameter

Data 6BY2-220

Coolant Overheat Alarm Operating Temperature

108°C (226°F)

Lube Oil Low Pressure Alarm (Alarm not available on Classic controls) Overspeed Protection (fuel cutoff)

6BY2-260

Below 1500 rpm: < 0.5 bar (7.25 psi) for more than one second Above 1500 rpm: < 2.0 bar (29 psi) for more than one second

Remote Control System Panel The 6BY2 series utilizes Yanmar Marine Electronic control technology, incorporating an LCD multi-function display panel. Refer to the appropriate Yanmar Electronic Control System Installation Manual for detailed component specifications and options. Yanmar Digital Display (1)

(2)

4600 rpm

2 1

0

3

100

84

PSi

(3)

4 0

X1000

2615 RPM

100 11 4

250 Fah

0003327

1. Tachometer 2. Engine Oil Pressure Meter 3. Multi-function Meter (Coolant Temperature, Lube Oil Temperature, Fuel Temperature, Boost Pressure, Voltage, Load Factor, Throttle Valve, Fuel Consumption Rate and Gear Shift Position) Figure - 8


SEPT 2008 (Rev. 4)

6BY2 - 15

6BY2

6BY2

Electrical System

Starter Specifications

Check all electrical connections per the wiring diagrams and ensure the bolts are tightened to the correct torque specifications.

Battery Specifications Parameter

Data 6BY2-220

Battery Size (Minimum)* Nominal Output Earth Polarity

6BY2-260

12 V, 85 Ah, 680 CCA (cold cranking amps) 12 V / 150 A Negative Ground

* Note: No other device can be connected to the starting battery.

Battery Cable Requirements Battery Cable Length

Battery Cable Area

AWG

1.0-2.5 m (3.3-8.2 ft)

50 mm2 (0.08 in.2)

1

2.0-4.0 m (6.6-13.1 ft)

70 mm2 (0.11 in.2)

2/0

2.5-5.0 m (8.2-16.4 ft)

95 mm2 (0.15 in.2)

3/0

3.25-6.5 m (10.7-21.3 ft)

120 mm2 (0.19 in.2)2

4/0

6BY2 - 16

SEPT 2008 (Rev. 4)

Parameter

Data 6BY2-220

6BY2-260

Yanmar Code

165000-70110

Starter Model

DENSO

Voltage

12 V

Output

2.0 kW (2.7 hp)

Direction of Rotation (Viewed from Pinion Side) Weight

Clockwise 3.5 kg (7.7 lb)

Number of Pinion Teeth

11

No-load Terminal Voltage

12 V

No-load Current

50 A or less


6BY2

6BY2 12/05

Starter Performance Curve SPEED (rpm)

OUTPUT (kW)

TORQUE (N•m)

VOLTS (V)

kW

V

N•m

rpm

CURRENT (A)

0004044

Figure - 9

Standard Alternator Data Parameter

Data 6BY2-220

Yanmar Code

6BY2-260

120640-00030

Alternator Model

Valeo

Alternator

12 V, 150 A

IC Regulator Model

7 788 823.1

Battery Voltage

12 V

Nominal Output

12 V / 150 A

Earth Polarity

Negative Ground

Rotation (Viewed from Pulley End)

Clockwise

Weight

6.9 kg (15.2 lb)


SEPT 2008 (Rev. 4)

6BY2 - 17

6BY2

6BY2

Wiring Diagram (8) (9)

(3) (4) (5) (7) (6)

F2 F1 F6

F4

F3

F5

X1/C

KL50

(49)

KL15

(211, 224)

201 203 205

207

182

X1/B

X1/R

(44)

(47)

(1)

p

(43)

(12)

(11)

K1

132

ϑ

X1/G

(46)

234

157

ϑ

(48)

KL87

232

154

(42)

(13) K2

X1/D

107 220

106 180

(45)

K3

139

(16)

(15)

(14)

187

(2) (41)

(16)

115

(53)

162

(40)

X1/H

245

X1/F

243

X1/L X1/W

124 114

(37)

X1/V

X1/N

252 X1/O

(36) p

(39) (38) ϑ

256

X1/K

239

X1/P

229

BOSCH EDC16 DDE 5

(19)

172

DRV

(20)

171

X1/M

230

ZME

(35) p

183 130

(21)

149

(34) (50)

156

173

(22)

151 111

175

178

F7

KL87

(18)

(23)

103

211

127

(24)

150

(33)

F8

(51)

251

174

(32)

(25)

102 238

126

X1/J

(26)

101 250

(30)

125 X1/E

(31)

208 202 204 206

233

246

KL31 X1/Q

X1/A

X1/U

(52)

(53) (28)

(27) X1/S X1/T

0003303

(29)

Figure - 10

6BY2 - 18

SEPT 2008 (Rev. 4)


+ (10)

6BY2

6BY2 12/05

1. Engine Control Unit (ECU) 2. Internal ECU Sensors (operating voltage and ambient air pressure) 3. Fuse (F2) 10 A1 - Ignition 4. Fuse (F1) 3 A - CAN Switched Power 5. Fuse (F6) 10 A - Auxiliary Power 6. Start Signal from Key Switch 7. Fuse (F4) 30 A - ECU Switched Power 8. Fuse (F3) 15 A - Fuel Supply Pump 9. Fuse (F5) 20 A - Fuel Pressure Regulator, Water-in-Fuel, Camshaft Sensor, and Fuel Volume Regulator 10. Circuit Breaker (Boatbuilder Installed) 11. Power to Starter Solenoid Primary Terminal 12. Starter Relay K1 13. Main Power Relay K2 14. Fuel Supply Pump Relay K3 15. Power to Fuel Supply Pump 16. B+ to Water-in-Fuel Sensor 17. Not Used 18. Check Engine Indicator Output 19. Fuel Rail Pressure Control Valve 20. Fuel Volume Control (high-pressure pump) 21. Fuel Injector No. 4 (4BY2) or No. 6 (6BY2) 22. Fuel Injector No. 2 (4BY2) or No. 2 (6BY2) 23. Fuel Injector No. 3 (4BY2) or No. 5 (6BY2) 24. Fuel Injector No. 1 (4BY2) or No. 3 (6BY2) 25. Fuel Injector No. 1 (6BY2) 26. Fuel Injector No. 4 (6BY2) 27. CAN Signal - Low

28. CAN Signal - High 29. Panel, ECU, and CAN Ground 30. K-Line 31. Neutral Start Switch (NC in neutral) 32. Jumper Fuse (F8) 3 A - CAN / Analog Throttle Selection, default is analog (fuse out). Insert 3 A fuse to configure for CAN. 33. Jumper Fuse (F7) 3 A - Single / Port Selection, default is single / port (fuse in). Remove fuse for starboard configuration. 34. Fuel Rail Pressure Sensor 35. Fuel Temperature Sensor 36. Subthrottle Sensor 2 37. Subthrottle Sensor 1 38. Oil Pressure Sensor 39. Water-in-Fuel Sensor 40. Camshaft Speed Sensor 41. Crankshaft Speed Sensor 42. Charge Air Pressure Sensor 43. Charge Air Temperature Sensor 44. Engine Coolant Temperature Sensor 45. Ignition Power Input from Key Switch (terminal X1-D) 46. Auxiliary Power Output (terminal X1-G) 47. NMEA + Power Supply (X7-R) 48. Battery Power to Key Switch (terminal X1-B) 49. CAN Signal Blocking Diode 50. High Bench 1 51. High Bench 2 52. Oil Pressure Switch (X1-Q) 53. NMEA Ground Supply 54. Power Resistor for the Generator

1

NEVER connect any additional devices to F2. F6 may be used however, it is not switched.


SEPT 2008 (Rev. 4)

6BY2 - 19

6BY2

6BY2

Performance Curves 6BY2-220 600

200

525

175

450

150

375

125

] m N [ e 300 u q r o t

torque

] W k [ 100 r e w o p

power

225

75

150

50

75

25

0

0 0

1000

2000

3000

4000

engine speed [rpm] 0006528

Figure - 11 6BY2-260 600

200

525

175

450

150

torque 375

125

] m N [ e 300 u q r o t

] W k [ 100 r e w o p

power

225

75

150

50

75

25

0

0 0

1000

2000

3000

4000

engine speed [rpm]

0006527

Figure - 12

6BY2 - 20

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Fuel Consumption 6BY2-220 specific fuel consumption

270 265 260 255

] h W250 k / g [ 245 n o i t 240 p m u s 235 n o c l 230 e u f c 225 i f i c e 220 p s 215 210 205 200 500

1000

1500

2000

2500

3000

3500

4000

4500


Figure - 13 6BY2-260 specific fuel consumption

270 265 260 255

] h W250 k / g [ 245 n o i t 240 p m u s 235 n o c l 230 e u f c 225 i f i c e 220 p s 215 210 205 200 500

1000

1500

2000

2500

3000

3500

4000

4500


Figure - 14 Marine Installation Manual - Volume 3

SEPT 2008 (Rev. 4)

6BY2 - 21

6BY2

6BY2

Engine Mount 10 (.39) TIGHTEN TO 110 Nm (81Lb-Ft) ON ASSEMBLY

TIGHTEN TO 50 Nm (37Lb-Ft) ON ASSEMBLY

49 (1.93)

15 7 (6.18)

4 (.16)

140 (5.51)

183 (7.20) 20 (.79)

75 (2.95)

30 (1.18)

13 (.51)

13 (.51)

0006604

Unit: mm (in.)

6BY2 - 22

SEPT 2008 (Rev. 4)


6BY2

6BY2 12/05

Type of Mount: Part Numer

Flexible 120650-08400

Mount ID

Trelleborg Movex Number 10-03964-01 Compound 16 x 45

Quantity

4

Installation Specifications Inclination Angle Specifications

Optional Rear Engine Mounts Type of Mount: Part Numer

Flexible 120650-08401

Mount ID

Trelleborg Movex Number 10-04418-01 Compound 16 x 55

Quantity

4 0000303B

Figure - 15 Inclination Angle Static

Running

Peak

Unit = degree

β

0-8 max

20

25

λ

0

-5

-10

α

0

20

30

Cold Starting Aids The 6BY2 series engine is equipped with a glow plug cold starting aid.


SEPT 2008 (Rev. 4)

6BY2 - 23

6BY2

6BY2

Water Heater Tank Connection The 6BY2 series engine supports water heating tank connections for onboard head and galley operation.

2

1

0004144

1. Water from Tank 2. Water to Tank Figure - 16

Heat Insulation Requirements Temperature proof from -30 to +90°C. Must fulfill the requirements of ISO 4589 for noise and temperature.

Optional Accessories The following is a list of the 6BY2 series optional accessories. • Yanmar digital display • Yanmar rocker switch panel (1st station) • Yanmar interface module, HARNESS • Yanmar control head • Yanmar NMEA, terminal and T-connector, CABLE

6BY2 - 24

SEPT 2008 (Rev. 4)


ZT350 Marine Installation Manual - Volume 3

Page Safety .......................... ...................................... ......................... .......................... ......................... ......................... ...................... ......... 4 Notice to Vessel OEM & Equipment Installer ........... ....................... ......................... ............... .. 9 Sales and Technical Assistance ............ ....................... ........................ .......................... ................ ... 9 Lubricants / Sealants / Adhesives ............ ........................ ........................ ....................... ........... 10 Special Tools ............ ......................... ......................... ........................ ........................ ........................ .................. ...... 11 Trim-In Limiter ............ ......................... ......................... ......................... ......................... ......................... ............... .. 11 Steering Tie Bar Considerations ......................... ...................................... ......................... ................. ..... 12 Internal Tie Bar Only........................ Only..................................... ......................... ......................... ................... ...... 12 Internal and External Tie Bar.................................. Bar............................................... ..................... ........ 12 External Power Steering with an External Tie Bar....................... Bar....................... 12 Corrosion Control .......................... ....................................... ......................... ........................ ......................... ............... .. 12 Shore Power................................. Power.............................................. .......................... .......................... ..................... ........ 12 Antifouling Paint........................ Paint..................................... ......................... ......................... .......................... ............. 13 Painting the Transom and Stern-Drive ......................... ..................................... ............... ... 13 Vessel Design Considerations ............ ........................ ......................... ......................... ..................... ......... 14 Transom Thickness ............ ......................... .......................... .......................... ......................... .................. ...... 14 Laying Out the Transom Cutout ............ ........................ ......................... ......................... .............. 14 Vessel Engine Mount Position ........... ........................ .......................... ......................... ................ .... 14 Selecting an Engine Exhaust System....................... System.................................... ................... ...... 15 Positioning the Drive Unit ............ ......................... .......................... ......................... ........................ ................ .... 16 Locating the Crankshaft Vertical Centerline Single Engine Installation ............ ........................ ......................... .......................... ....................... .......... 16 Locating the Crankshaft Vertical Centerline Dual Engine Installation................... Installation................................ .......................... ......................... .................. ...... 16 Finding the Crankshaft Horizontal Centerline (X-Dimension)...... (X-Dimension) ...... 17 Cutting the Vessel Transom ............ ......................... .......................... ......................... .................. ...... 19 Checking the Transom Thickness ............ ......................... .......................... ...................... ......... 20


JUNE 2008 (Rev. 4)

ZT350 - 1

ZT350

INSTALLATION INFORMATION Installing the Transom Assembly ............ ........................ ........................ ......................... .................. ..... 21 Connecting the Speedometer Pickup............ Pickup ......................... .......................... ................. .... 23 Drive Unit Seawater Pickup........................... Pickup........................................ .......................... ................. .... 23 Alternate Seawater Pickup ............ ......................... ......................... ........................ ..................... ......... 2 24 4 Connecting the Inlet Water Hose ............ ........................ ......................... ........................ ........... 25 Connecting the Oil Reservoir Hose ........... ........................ ......................... ..................... ......... 26 Installing the Oil Reservoir ............ ......................... ......................... ........................ ..................... ......... 27 Installing the Shift Plate ........... ........................ ......................... ......................... ......................... .............. .. 28 Installing the Steering System ........... ........................ .......................... .......................... ................ ... 28 Connecting the Steering Cables............. Cables .......................... .......................... ........................ ........... 30 Installing the Power Trim Pump ............ ......................... ......................... ......................... ............. 32 Exhaust Options .......................... ...................................... ........................ ......................... .......................... ................. .... 33 Through-the-Propeller Exhaust ............ ......................... .......................... .......................... ............. 33 Alternate Exhaust System ........... ........................ .......................... ......................... ...................... .......... 33 Installing the Engine ......................... ...................................... ......................... ......................... ........................ ........... 34 Aligning the Engine ............ ......................... ......................... ......................... .......................... ................... ...... 35 Electrical Connections.................. Connections............................... .......................... .......................... .......................... ............... 37 Engine Bonding Wire Connection ............ .......................... .......................... ..................... ......... 37 Trim Position Sender Connection............ Connection ......................... .......................... ....................... .......... 37 Y-CaPS Controller Connection............................. Connection.......................................... ....................... .......... 37 Hydraulic Connections ........... ........................ .......................... ......................... ......................... ..................... ........ 39 Oil Reservoir.......................... Reservoir...................................... ........................ ......................... .......................... ................. .... 39 Power Steering Hoses........................... Hoses........................................ .......................... ......................... ............ 40 Installing the Drive Unit ........... ........................ ......................... ........................ ......................... ..................... ........ 40 Speedometer Connection............................ Connection........................................ ......................... .................... ....... 48 Power Trim System / Steering Helm and Cable................................ Cable................................ 49 Control System........... System ....................... ......................... .......................... ........................... ........................... ............. 49 Pump Location ......................... ...................................... .......................... .......................... ......................... ............ 49 Steering Helm and Cable ........... ........................ .......................... .......................... ....................... .......... 49 Steering Cable Specifications ............ .......................... ........................... ........................... .............. 50 Installation of Steering Cable ............ ........................ ......................... .......................... ................. .... 51 Throttle and Shift Cables................................ Cables............................................. ......................... ...................... .......... 52 Shift and Throttle Cable Travel.............................. Travel.......................................... ...................... .......... 52 Verify Propeller Rotation with Mechanical Shift System.............. 52 Shift Cable Installation and Adjustment...................... Adjustment................................... ....................... .......... 53 Setting the Cable Length:........................ Length:..................................... .......................... ....................... .......... 54 Install the Drive Unit Shift Cable.................................... Cable................................................ .............. .. 54 Troubleshooting Shift Problems ............ ......................... ......................... ........................ .............. 57 Pre-Delivery Preparation ......................... ...................................... ......................... ......................... ................. .... 58 Power Steering S teering Fluid ............ ......................... ......................... ......................... ........................... ................. ... 58 Battery Connections .......................... ...................................... .......................... ........................... ................ ... 58 Check the Power Trim Pump Fluid............................. Fluid.......................................... ................. .... 59 Fill the Power Trim Pump Fluid ........... ........................ ......................... ......................... ............... .. 60 Check the Stern-Drive Oil Level .......................... ...................................... ........................ ............ 60 Fill the Stern-Drive with Oil............. Oil ......................... ........................ ......................... ..................... ........ 61 Propeller Selection .......................... ...................................... ......................... .......................... ................... ...... 62 General Propeller Installations ........... ........................ .......................... .......................... ............... .. 63 63

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JUNE 2008 (Rev. 4)


ZT350

INSTALLATION INFORMATION

12/05

Installing the Propellers ......................... ...................................... .......................... ......................... ............ 64 Removing the Propeller ......................... ..................................... ......................... ......................... .............. 65 Test Preparations ............ ........................ ......................... ......................... ......................... ....................... .......... 66 Engine Operation Tests.............................. Tests.......................................... ......................... ..................... ........ 66 Out-of-Water Testing............ Testing ......................... .......................... .......................... ......................... ................ .... 66 In-Water Testing ............ ........................ ........................ ......................... .......................... ......................... ............ 67 Drive Unit Operational Tests .......................... ....................................... ........................ ................ ..... 67 Cold Weather (Freezing Temperature), Seasonal and Extended Storage.................................. Storage.............................................. ......................... .......................... ............. 69


JUNE 2008 (Rev. 4)

ZT350 - 3

ZT350


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.

A

ZT350 - 4

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.

DEC 2007 (Rev. 3)

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the engine and stern-drive, personal property and / or the environment or cause the equipment to operate improperly.


ZT350


12/05

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.

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 the Operation Manual information before you install, 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. • See your authorized Yanmar marine dealer or distributor for additional training.

Crush Hazard ALWAYS use lifting equipment with sufficient capacity to lift the stern-drive.

NEVER stand under 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.


DEC 2007 (Rev. 3)

ZT350 - 5

ZT350


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 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. 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, propeller 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. Exposure Hazard ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand.

ZT350 - 6

DEC 2007 (Rev. 3)


ZT350


12/05

Entanglement Hazard NEVER leave the key in the key switch when servicing the engine or sterndrive. 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 shut-down. Keep hands and other body parts away from hot surfaces. 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.

The safety messages that follow have CAUTION level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in minor or moderate injury.

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. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Slipping and Tripping Hazard Ensure that adequate floor space is set aside for servicing stern-drive. The floor space must be flat and free of holes. Keep floor free of dust, mud, spilled liquids and parts to help prevent slipping and tripping.

ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.


DEC 2007 (Rev. 3)

ZT350 - 7

ZT350


The safety messages that follow have NOTICE level hazards. It is important to perform the daily checks as listed in this Operation Manual . Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine or sterndrive performance and can help extend the life of the engine and stern-drive.

NEVER use the stern-drive lifting eye 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 sterndrive as a separate component. The anode of the ZT350 is only calculated for the ZT350. Changing the material of the propeller may require additional anodes to be installed.

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. 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 water flow. Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly. 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.

ZT350 - 8

NOV 2008 (Rev. 4)


ZT350


12/05

NOTICE TO VESSEL OEM & EQUIPMENT INSTALLER This Installation Manual contains safety information designed to: • Make you aware of the hazards associated with the installation of the ZT350 stern-drive. • Inform you of the risk of injury associated with those hazards. • Tell you how to avoid or reduce the risk of injury. • Prior to work, read and understand the section(s) of this manual that pertain to the job. • Read and follow all safety warnings. NOTICE: Indicates critical information or instructions that are necessary for proper installation and / or operation. Note: See the appropriate Yanmar Technical Manual for application recommendations. This Installation Manual has been written and published by Yanmar Marine International to assist boat manufacturer's and service personnel when installing the products described herein. It is assumed that these personnel are familiar with the installation procedures for these products, or like or similar products, manufactured by Yanmar Marine International. It is also assumed that they have been trained in the recommended installation procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required.


We could not possibly know of and advise the marine trade of all conceivable procedures or methods by which a service might be performed, or of every possible hazard and / or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the installation or servicing procedure selected. All information, illustrations and specifications contained in this manual are based on the latest production information available at the time of publication. However, Yanmar Marine International reserves the right to change, alter or otherwise improve the product at any time without obligation or prior notice.

Sales and Technical Assistance The Yanmar dealer / distributor network is trained to assist with any sales or technical issues. This includes application engineering and service information. If you have an issue with the application of our product that cannot be resolved, contact your Yanmar Distributor Service Engineer. All requests for assistance should be directed to your local Yanmar distributor. The distributor for your area can be found by using the service locator on the Yanmar website (www.yanmarmarine.com) or by contacting Yanmar Marine International.

DEC 2007 (Rev. 3)

ZT350 - 9

ZT350


Tightening Torques for Standard Bolts and Nuts Note: Securely tighten all of the fasteners not listed below. Description

N·m

lb-in.

lb-ft

45

—

33

Connector Bolt (Seawater)

6

53

—

Plate Bolt (Seawater Inlet)

6

53

—

Exhaust Block-Off Plate Bolt

30

—

22

Steering System Upper and Lower Pivot Bolt

35

—

26

Steering Cable Coupler Nut

45

—

33

Rear Engine Mount Bolt

45

—

33

Stern Drive Unit Fastener

60

—

44

Front

135

—

99

Rear

80

—

59

30

—

22

Transom Plate Bolt

Propeller Locknut Propeller Shaft Anode Screw

Lubricants / Sealants / Adhesives Description

Where Used

Part Number

Power Steering Bushings Upper and Lower Pivot Bolts UREA Grease Water Resistant Type NLGI #2 Ex) Rykon Premium Grease EP

Clevis Pin Steering Cable End Propeller Shaft Splines Steering Cable and Clevis

Liquid Type Neoprene or Silicon Sealant

Electrical Connections

Multipurpose Heavy-Duty Type Lithium Grease NLGI #2 Ex) Valvoline Multipurpose Grease / GM

Drive Unit Pilot

SAE 30W Engine Oil

Shift Cable Pivot Points

GL5 Hypoid Gear Oil

Oil Reservoir

Y-CaPS Connections Universal Joint Shaft O-Rings Drive Shaft Splines Coupler Splines

Obtain Locally

Bell Housing Studs Lithium Grease with PTFE Ex) Cortec Co. Lithium EP Grease with PTFE

O-Ring Seals Anchor Pin Threads Shift Cable

UREA Grease Water Resistant Type NLGI #2 Ex) Rykon Premium Grease EP Dexron III Automatic Transmission Fluid

ZT350 - 10

Unit Bearing (Gimbal Housing)

Power Steering Pump Power Trim Pump

DEC 2007 (Rev. 3)


ZT350


12/05

Special Tools

Transom Cutout and Drill Fixture (196350-92020)

Use to determine where to cut and drill the boat’s transom for the stern-drive installation.

0006039

Hose Insert Tool

Remove and install the hose insert into the water inlet hose. 0006498

Alignment Shaft (196350-92010)

Aligns the engine and the drive unit during installation. 0006040

Trim-In Limiter WARNING! Only qualified personnel should install and evaluate the effectiveness of the Trim-In limiter. The vessel is required to be tested at trim-in range and several different speed settings. If an undesirable handling characteristic occurs when the drive unit is trimmed in at higher speeds, the trim-in range should be adjusted by using a Trim-in limiter. Wider trim-in ranges and higher speeds may cause handling problems on some vessels that could result in personal injury. The stern-lift will cause certain vessels (predominantly heavy, deep-V hulls) to list towards the port or starboard side during full power speeds with the stern-drive set to full Trim-In. The vessel will not roll over completely, but the list can often be significant enough to unseat the operator and / or passengers. This creates an unsafe situation.


This condition is primarily a result of vessel design and can only be reduced with thorough performance testing by the manufacturer (OEM) of the vessel. However, shifting hull weight to the stern may be helpful in controlling this tendency. To help reduce the effect of stern-lift, a Trim-In limiter is available for the Yanmar ZT350 sterndrive, as a service part. The Trim-In limiter reduces stern-lift by preventing the stern-drive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The use of a Trim-In limiter, and the evaluation of its effectiveness, can only be determined by trial and error adjustments and is ultimately the responsibility of the boat manufacturer.

JUNE 2008 (Rev. 4)

ZT350 - 11

ZT350


STEERING TIE BAR CONSIDERATIONS

CORROSION CONTROL

NOTICE: The use of multiple stern-drives requires a careful consideration of the type of steering system that should be used. CAUTION! Failure to observe the recommended tie bar arrangements could result in serious damage to the steering and / or power trim system components. This damage could adversely affect boat control.

Internal Tie Bar Only This system is recommended for vessels that operate at speeds up to 50 knots (58 mph). It is a direct connection between the slave sterndrive and the stern-drive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from Yanmar. Contact your Yanmar dealer or distributor.

Internal and External Tie Bar This system is recommended for vessels that operate at speeds from 50 to 60 knots (60 to 70 mph) or for the benefit of reduced steering backlash. Usually, external tie bars are attached at the aft power trim cylinder bosses, but if one drive is trimmed differently than the other, undue stress on the system is introduced. For this reason, dual trim control equipment should be installed to limit the tilt differential between the two drives to 20°. NOTICE: When using an internal power steering system, Yanmar does not recommend the use of an external tie bar by itself. This can cause excessive loads on the steering components and may result in an increase of the play in boat steering.

It is the boat designer's responsibility and/or the repowering engineer's responsibility to design the proper systems and equipment to control and reduce the possibility of galvanic corrosion. To help control the effects of galvanic corrosion, Yanmar Marine ZT350 stern-drives come with several anodes and an electronic anticorrosion system (Y-CaPS) that protect the stern-drive in moderate corrosive conditions. However, it is essential that the owner/operator frequently monitor the anodes for wear, inspect the stern drive for corrosion and replace the anodes often enough to provide a sacrificial surface for the electrical current to attack. Galvanic isolators are also available from the aftermarket (not supplied by Yanmar) to block stray current while still providing a path to ground for dangerous shock currents. NOTICE: The anode of the ZT350 is only calculated for the ZT350. Changing the material of the propeller may require additional anodes to be installed.

Shore Power Vessels that are connected to shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. A galvanic isolator is available to block these currents while still providing a path to ground for dangerous shock currents. NOTICE: If AC shore power is not isolated from the boat ground, the Y-CaPS and anodes may be unable to neutralize the increased galvanic potential.

External Power Steering with an External Tie Bar This system is recommended for vessels that operate at speeds of 70 knots (80 mph) or greater or for the ultimate in reduced steering backlash. This system does not use an internal tie bar, but requires dual trim control equipment. See Internal and External Tie Bar on page ZT350-12 .

ZT350 - 12

NOV 2008 (Rev. 4)


ZT350


12/05

Antifouling Paint NOTICE: Corrosion damage that results from the improper application of marine paint or antifouling paint is not covered by the Yanmar limited warranty. Observe the following precautions when applying antifouling or marine paint to the transom of the boat hull.

(1) (2)

• NEVER paint the anodes of installed on the sterndrive. • NEVER paint the Y-CaPS reference electrode and / or anode. • NEVER wash the stern-drive with a high pressure washer. This could damage the coating on the reference wire. • NEVER paint the stern-drive with a material that contains copper or tin. • NEVER paint over drain holes, anodes, Y-CaPS or other items specified by the anode manufacturer.

Painting the Transom and SternDrive Corrosion damage that results from improper application of anti-fouling paint will not be covered by the warranty.

0006341

Figure - 1 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 can be painted with a good quality marine paint or an anti-fouling paint that does not contain copper or any other material that could conduct electrical current. NEVER paint drain holes, anodes, Y-CaPS or items specified by the vessel manufacturer. NOTICE: NEVER wash the stern-drive with a power washer because it can damage the coating on the reference wire and increase corrosion.

Anti-fouling paint may be applied to the vessel hull and the vessel transom. NOTICE: NEVER paint the anodes or Y-CaPS electrode. Painting these components will render them ineffective as galvanic corrosion inhibitors. NOTICE: Use copper-based paint as anti-fouling protection for the vessel hull or vessel transom, as long as it is not prohibited by law in 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.


DEC 2007 (Rev. 3)

ZT350 - 13

ZT350


VESSEL DESIGN CONSIDERATIONS

(3) (3) (1) (2)

ALWAYS adhere to all applicable marine regulations such as the United States Coast Guard (USCG), European Union-Recreational Craft Directive (EU-RCD), and so on and the standards they reference such as the American Boat and Yacht Council (ABYC), Society of Automotive Engineers (SAE), International Standards Organization (ISO), and so on, when designing and constructing the boat and the boat components, such as the engine compartment, fuel delivery system and exhaust system.

(4) (5)

0006042

Figure - 2 1 – Transom Thickness 2 – Transom Angle 3 – Transom plate coverage 203 mm (8.0 in.) from the center. 4 – Inner Surface 5 – Outer Surface

When choosing a vessel that will potentially be modified for the installation of the ZT350 sterndrive, ensure that the vessel transom meets the following criteria:

Transom Thickness

• Transom thickness should be between 51 and 57 mm (2 - 2.25 in.).

Laying Out the Transom Cutout

See Checking the Transom Thickness on page ZT350-20 .

See Positioning the Drive Unit on page ZT350-16 .

• The inner and outer surface of the transom should be parallel to within 3 mm (0.125 in.).

Vessel Engine Mount Position

• The inner surface of the transom is flat to within 3 mm (0.125 in.).

The engine mount position should allow for a minimum of 6 mm (0.25 in.) of vertical adjustment on the front mounts of the engine.

• The outer surface of the transom is flat to within 2 mm (0.075 in.). • The transom angle is between 10 and 16° (13° is ideal). • Ensure that there is enough flat surface area on the transom to apply the transom plate. This would be 203 mm (8 in.) on either side of the center line of the transom.

Note: The mounting hardware that is incorporated with the engine usually allows for some adjustment. However, it is good practice to ensure that the engine mount points that hold the engine in the vessel are all in parallel planes. • Tie a string from the front right mount position and the left rear mount position. • Tie a string from the left front mount position and the right rear mount position. • The strings should touch at the point of intersection.

ZT350 - 14

DEC 2007 (Rev. 3)


ZT350


12/05

Selecting an Engine Exhaust System It is important to know what type of engine exhaust system will be used with the ZT350 Stern-Drive. The following chart describes the parts required for each system. Engine Exhaust System

Transom Exhaust

Through-the-Transom Exhaust Exhaust Cover Plate Through-the-Hull Exhaust

Transom Exhaust Bellows or Tube

Exhaust Tube

Through-the-Propeller Engine Exhaust Exhaust Pipe

See Exhaust Options on page ZT350-33 .


DEC 2007 (Rev. 3)

ZT350 - 15

ZT350


POSITIONING THE DRIVE UNIT Locating the Crankshaft Vertical Centerline - Single Engine Installation

Locating the Crankshaft Vertical Centerline - Dual Engine Installation Locate and mark the transom vertical centerline (See Locating the Crankshaft Vertical Centerline Single Engine Installation on page ZT350-16).

If the crankshaft vertical centerline is not already marked by the vessel manufacturer, locate and mark the vertical centerline on the transom in accordance with the following steps and methods:

NOTICE: The minimum distance between the crankshaft vertical centerlines for dual side-by-side applications is 838 mm (33 in.).

Use a large compass to locate the vertical centerline.

1. Make a set of marks equal to 1/2 the minimum distance 419 mm (16.5 in.) on both sides of the transom vertical centerline.

1. Mark identical locations on each side of the boat 305 mm (12 in.) from the bottom of the hull.

2. Draw the two crankshaft vertical centerlines through the intersection of the marks. (1)

2. Position the fixed end of a compass at the marks and draw arcs on the transom.

(1)

3. Draw the crankshaft vertical centerline through the intersection points of the two arcs. (5) (1) (2)

(2) (4)

(2)

(1)

(3)

(1)

(5)

(3) 0006043

Figure - 3 1 2 3 4 5

– 305 mm (12 in.) – Identical Side Marks – Compass Arc – Arc Intersection Points – Crankshaft Vertical Centerline

ZT350 - 16

DEC 2007 (Rev. 3)

0006044

Figure - 4 1 – 1/2 minimum distance between the crankshaft centerlines. 2 – Transom Vertical Centerline 3 – Dual Engine Crankshaft Vertical Centerlines


ZT350


12/05

Finding the Crankshaft Horizontal Centerline (X-Dimension) There are two general methods available for locating the horizontal centerline of the engine crankshaft. They are the “90° Tool Method” and the “Tape Measure Method”. Regardless of the method used, several vessel design considerations need to be examined before an optimum determination can be made. The following suggestions are offered as a general guideline. The actual “X-Dimension” should be the result of thorough design testing by the hull manufacturer. Vessel Characteristics

The 90° Tool Method Construct the 90° tool as shown in Figure - 5. (1)

90˚

(2)

Figure - 5 1 – 345 mm (13-9/16 in.) 2 – 1.2 m (4 ft)

NOTICE: The 345 mm (13-9/16 in.) dimension should only be raised or lowered after proper testing (See Finding the Crankshaft Horizontal Centerline (X-Dimension) on page ZT350-17) .

Speeds Below 22 Knots (25 mph)

Subtract 13 mm (0.5 in.) from X-Dimension

Heavy Duty Applications

Subtract 25 mm (1.0 in.) from X-Dimension

Speeds Between 22 Knots (25 mph) and 43 Knots (50 mph)

Use the X-Dimension given in the 90° Tool Method

• To lower the drive unit - subtract from the 345 mm (13 9/16 in.) dimension (Figure - 5, (1)).

Speeds Above 43 Knots (50 mph)

Increase the X-Dimension to improve performance.

• To raise the drive unit - add to 345 mm (13 9/16 in.) dimension (Figure - 5, (1)).

NOTICE: When the X-dimension is increased, the pulling power for skiing is decreased. During testing, increase the X-dimension in 13 mm (1/2 in.) increments until preferred performance is achieved. Never increase the X-dimension by more than: Maximum Increase in X-Dimension ZT350

25 mm (1 in.)

Use the 90° tool as follows: 1. Place the 90° tool along the boat bottom at the vertical centerline. 2. Locate the point at which the top of the 90° tool contacts the transom on the vertical centerline. 3. This is the crankshaft horizontal centerline or Xdimension.

Observe the following details during the testing process: • Ensure that the water supply does not become aerated when the drive unit is raised. • Use a clear water inlet hose to monitor incoming water while watching the engine temperature gauge to prevent the engine from overheating. NOTICE: Damage to Yanmar products caused by a crankshaft horizontal centerline that is too high, will not be covered by Yanmar warranty.


DEC 2007 (Rev. 3)

ZT350 - 17

ZT350

INSTALLATION INFORMATION 4. Draw a line perpendicular to the vertical centerline at the intersection of the crankshaft horizontal centerline.

Transom Angle

(2)

(3) (1)

0006046A

X-Dimension (measuring up from the keel)

16°

364 mm (14-5/16 in.)

15°

362 mm (14-1/4 in.)

14°

360 mm (14-3/16 in.)

13°

359 mm (14-1/8 in.)

12°

357 mm (14-1/16 in.)

11°

356 mm (14 in.)

10°

354 mm (13-15/16 in.)

1. On the vertical crankshaft centerline, measure up from the bottom of the vessel transom to the X-dimension selected from the chart. 2. This point is the crankshaft horizontal centerline at the X-dimension.

Figure - 6

3. Draw a line perpendicular to the vertical centerline at the crankshaft horizontal centerline.

(2)

(1)

(3) (1)

0006046B

Figure - 7 1 – 90° tool along the boat bottom at the vertical centerline. 2 – Contact Point 3 – Crankshaft Horizontal Centerline

(2)

(3)

0006047A

Figure - 8 (1)

The Tape Measure Method NOTICE: These dimensions should only be raised or lowered after proper testing (See Finding the Crankshaft Horizontal Centerline (X-Dimension) on page ZT350-17) . Use the following chart to determine the Xdimension.

(3)

(2) 0006047B

Figure - 9 1 – Vertical Centerline 2 – X-Dimension that corresponds to the transom angle selected from the chart. 3 – Crankshaft Horizontal Centerline

ZT350 - 18

DEC 2007 (Rev. 3)


ZT350


12/05

Cutting the Vessel Transom

Transom Cutout and Drill Fixture

Use the template or the Transom Cutout and Drill Fixture to drill and cut the vessel transom. These items are available separately from Yanmar Marine International. 1. Follow the instructions that are indicated on the template or provided with the drilling fixture. 2. Ensure that the centerlines of the template or the drilling fixture align with the marks determined previously. See Positioning the Drive Unit on page ZT350-16 .

Template

0006039

Figure - 11 1. Drill two 6 mm (1/4 in.) pilot holes at a 60° angle for the hole saw guides. 2. Use a hole saw to cut the two 51 mm (2 in.) holes for the steering lever cutout. NOTICE: If the hole saw cutout is made incorrectly, stern-drive steering lever may come in contact with the transom causing limited steering travel. (1) (2) 0006048

Figure - 10

(2)

0006049

Figure - 12 1 – 51 mm (2 in.) Steering Lever Cutout 2 – 60° from the surface of the transom


DEC 2007 (Rev. 3)

ZT350 - 19

ZT350

INSTALLATION INFORMATION 1. Cut the the trans transom om on the the cut line line at a 90° 90° angle angle.. Use caution when making the transom cutout. An incorrect cut could cause the gimbal housing or exhaust system to come in contact with the boat transom, making it difficult to mount the drive unit. 2. Seal the the insid inside e edge edge of the the transo transom m cutout cutout opening with a sealant to prevent water absorption and deterioration of the transom.

(3) 0006052

Figu Figure re - 15 (1)

1 – Mea Measur suring ing Trans Transom om Flatnes Flatness s 2 – Measur Measuring ing Trans Transom om Thickne Thickness ss 3 – Suitable Suitable tool tool to check check for uniform uniform transom transom thickness.

(2) (4)

Transom Specifications

(3)

Figu Figure re - 13 1 2 3 4

Thickness

Between 51-57 mm (2-2-1/4 in.).

Parallelism1

Inner and outer surfaces must be parallel within 3 mm (1/8 in.).

Surface Plane1

Transom surfaces in an area where transom assembly will be mounted (Includes vertical as well as horizontal dimensions): Inner Surface - flat within 3 mm (1/8 in.) Outer Surface - flat within 2 mm (1/16 in.)

Angle

10°-16° (13° Ideal)

0006050

– 90° from from the the surface surface of the transom. transom. – Cut Line Line – Exha Exhaus ustt Pipe Pipe Are Area a – Mounting Mounting holes holes perpendicu perpendicular lar (90°) (90°) to the transom surface (8 ea.).

Checking the Transom Thickness Ensure that the transom thickness and surface dimensions conform to specifications listed previously and to the chart below. See Vessel Design Design Considerations Considerations on page ZT350-14 ZT350-14 . 1

Measured in transom assembly mounting area.

(2) (1)

0006051

Figu Figure re - 14

ZT350 - 20

DEC 2007 (Rev. 3)


ZT350


12/05

INSTALLING THE TRANSOM ASSEMBLY

3. Secure Secure the the transom transom assem assembly bly with with hardwa hardware re as shown in Figure Figure - 1 16 6. 4. Torque Torque the transo transom m plat plate e bolt bolt..

1. Insert Insert wires, wires, hoses and shift shift cable through through the the corresponding openings in the inner transom plate. 2. Positi Position on the the gimbal gimbal hou housin sing g on the tran transom som and and hold it in place. NOTICE: Tighten the transom assembly fasteners using an X-pattern torque sequence. Tighten in small increments and go around the pattern several times until the proper torque is achieved.


Transom Plate Bolt Torque N·m

lb-ft

45

33

5. Atta Attach ch the the bon bondi ding ng wir wires es.. NOTICE: The steering lever bonding wire must be positioned as shown in Fi in Figu gure re - 16 to avoid stressing the wire when the steering lever moves.

DEC 2007 (Rev. 3)

ZT350 - 21

ZT350


(1)

(4)

(2)

(3)

(1)

(1)

5

7

(5) 3

2

1

4

8

6

0006053

Figu Figure re - 16 1 – Locknuts Locknuts and and Flat Flat Washers Washers (8 ea.) ea.) 2 – Steer Steering ing Leve Leverr Bondin Bonding g Wire 3 – Bo Bolt

ZT350 - 22

DEC 2007 (Rev. 3)

4 – Transom Transom Plat Plate e Bondin Bonding g Wire Wire 5 – Torq Torque ue Sequ Sequen ence ce


ZT350


12/05

Connecting the Speedometer Pickup

Drive Unit Seawater Pickup

CAUTION! Excess water in the bilge can damage the engine or cause the boat to sink. NEVER remove the plug from the speedometer pickup tube fitting unless the connection is to be used.

Seawater for engine cooling may be supplied through the drive unit or through an alternative method. When using the drive unit for engine cooling seawater, a quick connect seawater hose fitting is included in the engine loose parts.

1. Remove the protective cap from the male quick connect.

(2)

2. Connect a 4 mm (5/32 in.) hose (not provided) from the speedometer to the barb fitting. 3. Secure the hose to the fitting with a cable tie. (1) (1) (2)

(3)

0006055

Figure - 18 1 – Seawater Hose Fitting 2 – Connector (Seawater)

1. Install the fitting gasket (connector). (3) (4)

2. Install the connector (seawater). (5)

3. Install J-clip if oil reservoir hose assembly will be routed to the port side. 4. Install the lock washers and connector (seawater) bolts.

(2) 0006054

5. Torque the bolts.

Figure - 17 1 2 3 4 5

Seawater Inlet Fitting Bolt Torque

– Male Quick Connect – Female Quick Connect – Barbed Fitting – Tie Strap – Hose


lb-in.

6

53

(2)

4. Secure the hose to the transom with the hose clip and screw. 5. Ensure that the hose NEVER contacts the steering system components, the engine coupler or the drive shaft. CAUTION! Avoid water leaking into the boat. The speedometer hose is filled with water, especially during boat operation. Hose contact with moving or rotating engine parts could cause damage to the hose resulting in water leaking into boat. NEVER let the speedometer hose come in contact with the steering system components, the engine coupler or the drive shaft.

N·m

(1) (3)

(4)

0006056

Figure - 19 1 2 3 4

– Connector (Seawater) – J-Clip – Gasket (Connector) – Bolt and Lock Washer

DEC 2007 (Rev. 3)

ZT350 - 23

ZT350


Alternate Seawater Pickup Seawater for engine cooling can be supplied through an alternate (separate) seawater pickup, not through the drive unit. When using a separate seawater pickup, it is necessary to cover the drive unit seawater passage and to cut the water line in order to circulate seawater through the drive unit for cooling.

2. Install the plate (seawater inlet) with a new gasket. 3. Install the lock washers and plate bolts. 4. Torque the bolts. Plate (Seawater Inlet) Bolt Torque N·m

lb-in.

6

53

NOTICE: Installation of a water inlet cover plate will make it necessary to provide an alternate seawater pickup and related hardware. Depending upon application and boat configuration a through-the- hull or through-the-transom seawater pickup must be used. CAUTION! Avoid overheating the drive unit. The drive unit water inlet holes must be allowed to flow water without being obstructed, or overheating damage to drive unit may result. NEVER dead-end the water hose from the bell housing. The hose must be cut as recommended. (1)

1. Use the hose insert tool to remove the insert in the gimbal housing.

(2)

(3)

(2) (3)

(4) 0006058

Figure - 21 1 2 3 4

(3) (2)

–Bolts – Lock Washer – Plate (Seawater Inlet) – Gasket

(1)

0006499

Figure - 20 1 – Hose Insert Tool 2 – Insert 3 – Gimbal Housing

ZT350 - 24

JUNE 2008 (Rev. 4)


ZT350


12/05

Connecting the Inlet Water Hose (1) (2)

(2) (3)

(4)

(4)

(3) 0006059

Figure - 22 1 2 3 4

– Gimbal Housing – Speedometer Hose – Water Hose – Trim Sender Limit Switch Wires

WARNING! Avoid water leaking into the boat. Damage to U-joint bellows could result from water entering the boat. Do not damage the U- joint bellows when removing the section of the water hose attached between the gimbal housing and bell housing. Note: Move the trim sender limit switch wires and speedometer hose to avoid damaging them when cutting the inlet drive shaft water hose. The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut.

(1)

(5) 0006060

Figure - 23 1 2 3 4 5

– Water Hose – Speedometer Hose – Clip – Trim Sender Limit Switch Wires – Measurement: 127 mm (5 in.)

1. Cut completely through the inlet water hose 127 mm (5 in.) in front of the aft end of the hose where it is fitted into the bell housing. Do not damage the U-joint bellows. 2. Discard the loose hose piece. 3. Secure the trim sender limit switch wires and speedometer hose to the remaining section of water hose using the existing tie strap and clip.


DEC 2007 (Rev. 3)

ZT350 - 25

ZT350


Connecting the Oil Reservoir Hose

(3)

1. Connect the quick connector 90° of the gimbal housing hose assembly to the gimbal housing fitting.

(1) (2)

(1)

(4) (5)

(2)

(3)

0006062

Figure - 25 (3)

0006061

Figure - 24 1 – Gimbal Housing Hose Assembly 2 – Quick Connector 90° 3 – Gimbal Housing Fitting

CAUTION! Avoid drive unit damage. The quick release button on oil reservoir 90° hose fitting may not lock on gimbal housing if touching or depressed by connector (seawater), or plate (seawater inlet) if equipped. Ensure that the quick release button NEVER contacts the plate, or connector if equipped. Failure to do so may result in a loose 90° fitting, a loss of gear lube and / or damage to the drive unit.

1 2 3 4 5

– Plate (Seawater Inlet) – ACCEPTABLE Positions – Quick Release Button – NOT ACCEPTABLE Position – Quick Connector 90°

NOTICE: NEVER let the hose come in contact with the steering system components, the engine coupler or the drive shaft. 3. The oil reservoir hose assembly can be routed toward the port side of the engine. 4. Secure the hose assembly at the top side of the connector (seawater), or plate (seawater inlet), using the hose J-clip. (1)

2. Position the quick release button on the 90° hose fitting away from the connector (seawater), or plate (seawater inlet) if equipped. The release button must not contact the connector (seawater), or plate (seawater inlet), if equipped.

(2) 0006063

Figure - 26 1 – Oil Reservoir Hose 2 – Hose J-Clip

ZT350 - 26

DEC 2007 (Rev. 3)


ZT350


12/05

5. Secure the oil reservoir gimbal housing hose assembly with J-clips on the transom plate.

(1)

(2)

(3) (4) (1) 0006064

Figure - 27 0006065

1 – J-Clips

6. Temporarily position the hose out of the way until connection is completed after engine installation.

Installing the Oil Reservoir

Figure - 28 1 2 3 4

– Bracket (Oil Reservoir) – Oil Reservoir and Cap – Strap (Oil Reservoir) – Lag Screw and Flat Washer (obtain locally)

NOTICE: A bracket is included to allow oil reservoir to be located on the transom. The mounting location specified must be above the steering lever on the transom assembly. The hose must be positioned away from moving parts such as the steering system and engine coupler. 1. Install the oil reservoir bracket in the specified location and secure with lag screws and flat washers. 2. Install the oil reservoir in the bracket. Secure the reservoir with the retaining strap.


JUNE 2008 (Rev. 4)

ZT350 - 27

ZT350


Installing the Shift Plate

(1)

NOTICE: The shift plate and bracket are only for the mechanical shift type. They are not necessary for the electric shift type. NOTICE: The shift plate and bracket assembly must be installed within the reach of the drive unit shift cable. Install the shift plate to the inside of the transom. • Never mount the assembly near moving components. • Avoid causing sharp bends and kinks in the control cable. • Use fasteners that are appropriate for the mounting surface to install the mounting bracket.

0006067

Figure - 30 1 – Power Steering Bushings UREA Grease Water Resistant Type NLGI #2

(1)

Where Used

Part Number

Power Steering Bushings

Obtain Locally

3. Remove the upper and lower pivot bolts and lubricate the threads liberally.

(2) 0006066

(1)

(2)

Figure - 29 1 – Mounting Bolt Location 2 – Shift Plate

Installing the Steering System Note: For dual installations the power steering unit can be mounted on the port or starboard transom assembly. Measure the exact distance between stern-drive centerlines. Use a proper tie bar (See Internal and External Tie Bar on page ZT350-12) .

0006068

Figure - 31 1 – Lock Tab Washers 2 – Upper and Lower Pivot Bolt UREA Grease Water Resistant Type NLGI #2 Where Used

Part Number

Upper and Lower Pivot Bolts

Obtain Locally

1. Inspect the bushings for debris. 2. Lubricate the power steering bushings.

ZT350 - 28

JUNE 2008 (Rev. 4)

4. Position the steering assembly so that the pivot bolts will fit in the bushings in the power steering cylinder.


ZT350


12/05

5. Install the upper and lower pivot bolts along with the lock tab washers. Ensure that the lock tab washer tangs straddle the ridge on the inner transom plate.

(1)

(2)

Upper Pivot Bolt and Tab Washer Shown (Lower Similar).

(2)

(1)

(1)

0006070

Figure - 33 (2)

0006069

1 – Bent Tab 2 – Pivot Bolt

9. Wear eye protection while moving the spool barrel cable guide tube in the directions shown in Figure - 34. It will be less difficult to pull it out or push it in during the following installation steps. CAUTION! Moving the spool barrel cable guide tube with the hoses disconnected will leak fluid from the ports. Wear eye protection to avoid injury.

Figure - 32

(1)

(2)

1 – Locking Washer Tang 2 –Ridge

6. Turn the pivot bolts all the way in by hand. Ensure that the steering assembly pivots freely. 7. Torque the pivot bolts. Upper and Lower Pivot Bolt Torque N·m

lb-ft

35

26

(1)

(2)

8. Bend the locking washer tabs against the corresponding flats on the bolt heads. Note: It may be necessary to tighten the pivot bolts a little more to align the flats on bolt head with the tabs on the washer.

0006071

Figure - 34 1 – Port 2 – Spool Barrel Cable Guide Tube


JUNE 2008 (Rev. 4)

ZT350 - 29

ZT350

INSTALLATION INFORMATION 10. Connect the clevis to the steering lever.

Connecting the Steering Cables

11. Lubricate the clevis pin. Spread both ends of the clevis pin.

1. Coat the steering cable end with a liberal amount of lubricant.

Note: Insert the clevis pin from the top and rotate the pin to ensure that the cotter pin hole is as shown in Figure - 35.

2. Install the steering cable and secure with hardware as shown in Figure - 35.

(2)

NOTICE: The flat surfaces of the spool barrel cable guide tube must be positioned horizontally to prevent feedback in the steering system. 3. Use a wrench to hold the flat surfaces of the spool barrel cable guide tube horizontally.

(1)

4. Torque the coupler nut. Ensure that the flat surfaces are still aligned horizontally after torque is applied to the coupler nut. UREA Grease Water Resistant Type NLGI #2 Where Used Steering Cable End

(3) Cable Coupler Nut Torque

(4)

0006072

Figure - 35 1 2 3 4

N·m

lb-ft

45

33

– Clevis – Steering Lever – Cotter Pin – Clevis Pin UREA Grease Water Resistant Type NLGI #2 Where Used Clevis Pin

CAUTION! The steering cable and outer casing must move freely for the steering system to function properly. Never fasten any items to the steering cable and / or the outer casing. (1)

0006073

Figure - 36 1 – Steering Cable and Outer Casing

ZT350 - 30

JUNE 2008 (Rev. 4)


ZT350


12/05

(1) (2)

(7)

(6)

(5)

(4)

(3)

(2)

0006074

Figure - 37 1 2 3 4

– Clevis Pin – Spool Barrel Cable Guide Tube – Cable Coupler Nut – Steering Cable


5 – Cotter Pin 6 – Clevis 7 – Steering Cable End

DEC 2007 (Rev. 3)

ZT350 - 31

ZT350


Installing the Power Trim Pump • Within length limits of the hydraulic hoses coming from gimbal housing assembly.

Note: An adapter harness may be needed to connect the remote control trim pump harness to the pump. Acquire an adapter harness that has a “PACKARD METRIPACK 150” series 3-pin connector.

• Close to the battery so that the trim pump battery leads can be connected.

2. Connect the power trim pump control harness to the trim pump connector.

The mounting location for the trim pump should be:

(1)

• Easily accessible to trim pump oil fill and vent locations. • In an area where the pump will not be exposed to water. • Prevent the power assist steering cylinder from coming in contact with the trim pump when the steering wheel is turned to the limit in either direction.

(2)

Mount the pump in the selected position. Note: Make hydraulic connections as quickly as possible to prevent oil from leaking out of the system. 1. Connect the hydraulic hoses to the trim pump. Ensure that the quick connect fittings completely seat when connecting the hoses.

0006076

Figure - 39

(2)

1 – Power Trim Pump Control Harness 2 – Trim Pump Connector

3. Connect the trim limit switch wires and secure with a wire retainer and tie strap. (1)

(1)

(2)

Figure - 40

(3) 0006075

Figure - 38

1 – Trim Limit Switch Wires 2 – Wire Retainer and Tie Strap (obtain locally)

1 – Hydraulic Hose (UP hose) 2 – Quick Connect Fittings 3 – Hydraulic Hose (DOWN hose)

ZT350 - 32

0006077

DEC 2007 (Rev. 3)


ZT350


12/05

EXHAUST OPTIONS

Alternate Exhaust System

Through-the-Propeller Exhaust

1. Install the exhaust block-off plate as shown in Figure - 43, using the four bolts and lock washers.

NOTICE: To prevent water and / or exhaust from entering the boat, the exhaust tube and the gimbal housing mating surfaces must be clean, free of nicks and scratches, and the O-ring must be properly seated in the groove.

2. Torque the cover plate bolts. (1) (2)

(1) (2)

0006080

Figure - 43 0006078

Figure - 41 1 – Gimbal Housing Exhaust Tube Mating Surface 2 – O-Ring

1 – Bolts and Lock Washers 2 – Exhaust Block-Off Plate Exhaust Block-Off Plate Bolt Torque N·m

lb-ft

30

22

Install the engine exhaust tube as shown in Figure - 42.

(1)

0006079

Figure - 42 1 – Engine Exhaust Tube

Please refer to the relevant manual for the correct tightening torque.


JUNE 2008 (Rev. 4)

ZT350 - 33

ZT350


INSTALLING THE ENGINE CAUTION! Avoid product damage caused by improper engine alignment. Improper engine alignment can be caused by mismatched flywheel housing mounts and inner transom plate mounting hardware. Ensure that the flywheel housing mounts and the inner transom plate mounting hardware, port and starboard, are the correct parts and match before installing the engine.

(6)

NOTICE: Use hard rubber washers on the inner transom plate engine mounts.

(4)

(1) (7) (2)

(5)

(3)

1. Attach a sling to the lifting eyes on the engine and adjust so that the engine is level when suspended. 2. Lift the engine into position in the boat using an overhead hoist. WARNING! Only use a hoist with adequate lifting capacity of the engine. CAUTION! When lowering the engine into position, NEVER set the engine on the shift cable. The shift cable outer casing can be crushed causing difficult or improper shifting. 3. Align the rear engine mounts with the inner transom plate mounts. 4. Set the engine on the front engine mounts and inner transom plate mounts. Do not relieve the hoist tension at this time. NOTICE: Engine attaching hardware must be installed in the sequence illustrated. Install and torque rear engine mounting bolts with hardware as illustrated. (1)

(2)

(3)

0006086

Figure - 45 1 2 3 4 5 6 7

– Bolt – Spacer – Steel Washer (obtain locally) – Inner Transom Plate Mount – Hard Rubber Washer – Rear Engine Mount – Washer

5. Adjust the front engine mounts until they rest on the boat stringers. 6. Set the engine on the stringers. 7. Relieve the hoist tension. 8. Disconnect the sling from the engine lifting eyes. NOTICE: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer. This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer (structure) height to obtain the 6 mm (1/4 in.) dimension.

0006085

Figure - 44 1 – Steel Washer (obtain locally) 2 – Corrected Engine Mount 3 – Hard Rubber Washer

ZT350 - 34

DEC 2007 (Rev. 3)


ZT350


12/05

Aligning the Engine CAUTION! Avoid drive unit damage. Use the Yanmar Alignment Tool ONLY. Alignment tools other than the Yanmar Alignment Tool may cause damage to the gimbal bearing, the engine coupler, or both.

(1)

(2)

1. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines. If necessary, hit the sides of the Alignment Tool with a soft mallet at 90° increments to help align the gimbal bearings to the coupler. (3)

(2)

(3)

(4) 0006083

Figure - 47 1 – Insert this end of the alignment tool through the gimbal housing assembly. 2 – Alignment Shaft 3 – 90° Increments Alignment Shaft (196350-92010)

(2)

(1)

Aligns the engine and the sterndrive during installation.

2. If the Alignment Tool does not fit, remove it and carefully adjust engine mounts as necessary. NOTICE: Turn both front engine mount adjustment nuts an equal amount in the direction required to align the engine. To Adjust the Engine Up or Down: (a) Loosen locknuts on mounts. (b) Turn adjusting nuts as necessary. (c) Temporarily tighten locknuts. To Move the Engine to the Left or Right:

0006082

Figure - 46 1 – The end of the alignment shaft is inserted through the gimbal housing assembly. 2 – Alignment Shaft 3 – Unit Bearing (Gimbal Housing) 4 – Engine Coupler


(a) The locknuts on mounts should be loose. (b) Move the engine in the slotted mount holes as necessary, if equipped. 3. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines again.

DEC 2007 (Rev. 3)

ZT350 - 35

ZT350

INSTALLATION INFORMATION 4. On models where the front engine mounts cannot be lowered enough to allow for proper engine alignment: (a) Attach a sling and lifting arm to the engine lifting eyes and adjust so that the engine is level when suspended. (b) Remove the rear engine mounting bolts and hardware. (c) Use an overhead hoist to lift the engine enough to install the stainless steel washer inside the inner diameter of both fiber washers. Note: This will position the washer between the new engine mount and the transom mounting support, which should raise the engine slightly, resulting in additional front mount adjustment. 5. Install both rear engine mounting bolts with hardware as illustrated. (a) Set the engine on the stringers. (b) Relieve the hoist tension. (c) Disconnect the sling from the engine lifting eyes. (d) Insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines. 6. Repeat this process until the Alignment Tool installs easily (slides freely with two fingers) all the way into and out of engine coupler splines. Never twist the alignment tool into position.

ZT350 - 36

DEC 2007 (Rev. 3)

7. Torque the rear engine mount bolts. Rear Engine Mount Bolts N·m

lb-ft

45

33

8. Fasten the front mount assemblies to the boat stringers using appropriate hardware (as per manufacturer's design specifications). (a) Torque both front mount locking nuts. (b) Recheck alignment with the Alignment Tool. NOTICE: The Alignment Tool must enter the coupler splines freely. If not, remove the Alignment Tool and readjust the alignment. (c) Remove the Alignment Tool when alignment is complete. 9. If operating in a saltwater environment, apply sealant to the threads and nuts of the engine mounting hardware to help protect against corrosion. This will allow for easier loosening in the future. Note: Yanmar recommends that the shipping hardware remain on the transom assembly during shipment if the boat will be shipped without the drive unit installed. On boats that will be shipped with the drive unit installed, fold the bell housing dust cover flap back into place and tape shut. 10. Ensure that all hardware is properly installed.


ZT350


12/05

ELECTRICAL CONNECTIONS

Y-CaPS Controller Connection (Cathodic Protection System)

Engine Bonding Wire Connection NOTICE: When routing all wire harnesses and hoses, ensure that they are routed and secured away from hot spots on the engine and away from any moving parts. 1. Connect the engine bonding wire, supplied with engine package, from the engine to the transom assembly.

1. Connect the wires to the Y-CaPS controller assembly. NOTICE: The opposite end of the RED wire and BLACK wire must be connected directly to the battery terminals. NEVER connect them to a switched circuit. The Y-CaPS system must function continuously to provide proper corrosion protection.

2. Tighten the inner transom plate screw securely. NOTICE: NEVER attach any accessory ground (-) wires to the transom plate ground point. Accessory ground wires can only be attached to the ground stud on the engine.

(2)

(1)

(1)

(2)

(3)

(4) 0006089

(3)

Figure - 50 0006087

Figure - 48 1 – Engine Ground Stud 2 – Inner Transom Plate Grounding Screw 3 – Engine Bonding Wire

Trim Position Sender Connection Connect the trim position sender leads from the gimbal housing to the leads from the engine harness. Signal to Gauge

(1) GND

RED

(2)

BLK 0006088

1 – BROWN Wire - From the electrode on the transom assembly. 2 – BLACK Wire - From the engine harness, if equipped, or to the negative (-) battery terminal. 3 – RED Wire - Connect (other end) to the positive (+) battery terminal. 4 – YELLOW Wire - From the anode on the transom assembly.

2. Connect wires the to Y-CaPS electrode. 3. Apply a thin coat of sealant to all wire connections. Liquid Type Neoprene or Silicon Sealant Where Used

Part Number

Electrical Connections

Obtain Locally

Figure - 49 1 – From the engine harness. (Refer to the appropriate Engine and Control System Installation Manual.) 2 – From the gimbal housing.


DEC 2007 (Rev. 3)

ZT350 - 37

ZT350

INSTALLATION INFORMATION (1)

(2)

(3)

(5)

(4)

0006090

Figure - 51 1 – BLACK Wire - From the engine harness, if equipped, or to the negative (-) battery terminal. 2 – RED Wire - To the positive (+) battery terminal.

ZT350 - 38

DEC 2007 (Rev. 3)

3 – YELLOW Lead - From the anode on the transom assembly. 4 – Y-CaPS Electrode Connector 5 – BROWN Wire - From the electrode on the transom assembly.


ZT350


12/05

HYDRAULIC CONNECTIONS

(5) (4) (3)

Oil Reservoir

(2)

CAUTION! If the oil reservoir hose is kinked, the reservoir will not function properly and damage to the drive unit will occur. Ensure the oil reservoir hose is not kinked when connected.

(1)

NOTICE: Avoid using excessive hose when routing to the oil reservoir. The hose should be routed directly, in as straight of a line as possible, to avoid low spots (traps) in the system. 1. Locate the white oil reservoir quick connect at the rear of the engine. 2. Ensure the oil reservoir hose is mounted in the J-clip on the transom plate. (3) (2)

0006092

Figure - 53 1 2 3 4 5

– Quick Connect (if equipped) – Oil Reservoir Hose –Clamp – Fitting – Oil Reservoir

4. Route the oil reservoir hose, assemblies if equipped with quick connect, to the oil reservoir.

(1)

0006091

Figure - 52 1 – Oil Reservoir hose assembly 2 – Quick connect fitting (Male and female quick connect fittings have check valve) 3 – Gimbal housing hose assembly

3. Fasten the quick connect fitting between gimbal housing hose assembly and the oil reservoir hose assembly.


5. If necessary, cut the oil reservoir hose to the correct length at the oil reservoir. 6. Connect and securely clamp the oil reservoir hose to the oil reservoir fitting. NOTICE: NEVER let the oil reservoir hose come in contact with the steering system components, the engine coupler or the drive shaft. 7. Secure the oil reservoir hose with cable ties.

DEC 2007 (Rev. 3)

ZT350 - 39

ZT350


Power Steering Hoses

INSTALLING THE DRIVE UNIT

CAUTION! To avoid injury or property damage route the hydraulic hoses to avoid extreme heat, stress on the hose fittings and / or hose kinks or a loss of steering control may occur.

1. Apply lubricant to the threads of the bell housing studs.

Route the hoses away from extreme heat, without any kinks in the hoses and without stress on the hose fittings. 1. Attach both hydraulic hose fittings to the steering control valve. 2. Ensure that the quick connect fittings are securely engaged. 3. Position the hoses as illustrated.

(1)

(2) (1)

0006094

Figure - 55 1 – Studs (6 ea.) Lithium Grease with PTFE Where Used Bell Housing Studs

Part Number Obtain Locally

NOTICE: Yanmar recommends applying multipurpose, heavy-duty type grease to the drive unit pilot to help prevent corrosion. 0006093

Figure - 54 1 – Return Hose 2 – Pressure Hose

NOTICE: NEVER let the hose come in contact with the steering system components, the engine coupler, the U-joint shaft or the drive shaft. Secure the hoses to avoid contact with hot or moving components.

ZT350 - 40

JUNE 2008 (Rev. 4)


ZT350


12/05

2. Lubricate the drive unit pilot, U-joint shaft Orings, and drive shaft splines.

Lithium Grease with PTFE Where Used O-Ring Seals

(1)


4. Lift the drive unit by using the eye-bolt mounted on the top cover. (1)

(2)

(2) (3)

0006095

Figure - 56 1 – Drive Unit Pilot 2 – O-Rings 3 – Splines Multipurpose Heavy-Duty Type Grease NLGI #2 Where Used

Part Number

0006097

Drive Unit Pilot

Figure - 58

U-Joint Shaft O-Rings

Obtain Locally

1 – Eye-Bolt M10 (Obtain Locally) 2 – Plug-Bolt and Gasket (Remove)

Drive Shaft Splines

3. Ensure that the drive shaft U-joint bellows are clean and free of debris. Apply lubricant to O-ring seals.

NOTICE: As the drive unit is inserted into the bell housing, the shift cable must be connected to the jaws of the shift linkage assembly in the drive unit.

(1) (2)

(2) 0006096

Figure - 57 1 – U-Joint Bellows (Clean) 2 – O-Ring Seals (Lubricate)


JUNE 2008 (Rev. 4)

ZT350 - 41

ZT350

INSTALLATION INFORMATION 5. Mechanical Shift Type Pull the shift cable out as far as it moves by hand.

6. Mechanical Shift Type Pull the slider (shift linkage) out as far as it goes with a piece of wire.

(1)

(2)

(1)

0006099

Figure - 61

0006098

1 – Slider (Shift Linkage) 2 – Wire (obtain locally)

Electric Shift Type Don’t pull the connector wire from the driveshaft housing end by 20 mm or more.

Figure - 59 1 – Shift Cable

Electric Shift Type Don’t pull the shift cable, it doesn’t expand and contract.

(1)

0006501

Figure - 62

(1) 1 – 20 mm Max

0006500

Figure - 60 1 – Shift Cable

ZT350 - 42

JUNE 2008 (Rev. 4)


ZT350


12/05

7. Mechanical Shift Type Follow steps 1, 2 and 3 in Figure - 63 to connect the cable to the slider (shift linkage).

(2) (1)

(3)

0006100

Figure - 63 Electric Shift Type Connect the wires that are the same color. (3)

(4)

(5)

(3)

(4)

(5) (2)

(1)

0006502

Figure - 64 1. Drive Unit Side 2. Transom Assembly Side 3. Black Wire


4. White Wire 5. Orange Wire

JUNE 2008 (Rev. 4)

ZT350 - 43

ZT350

INSTALLATION INFORMATION 8. Mechanical Shift Type After the cable is connected, push it into the inside of the housing.

CAUTION! Make sure the cable is not caught in the transom assembly and the drive unit.

(2)

(1)

(3) 0006504 0006101

Figure - 65 Electric Shift Type After the cable is connected, push it into the housing.

Figure - 67 1 – Drive Unit 2 – Transom Assembly 3 – Wire

Figure - 68 shows where to store the connectors (Figure - 68, (1)) after the drive unit has been installed.

0006503

(1)

Figure - 66

0006505

Figure - 68

ZT350 - 44

JUNE 2008 (Rev. 4)


ZT350


12/05

9. Place the drive unit in position on the bell housing and install as follows: (a) Position the trim cylinders so that they point straight back.

(d) Slide the drive unit all-the-way into the bell housing. (e) Secure the drive unit to the bell housing with 5 flat washers and 6 locknuts.

(b) Position the drive unit so that the U-joint shaft aligns with the bell housing bore. (c) Guide the U-joint shaft through the bearing in the gimbal housing and into the engine coupler. Make sure that the slider engages the bell housing shift cable assembly.

(1) (2)

(1)

CAUTION! DO NOT allow the edge of the bell housing (Figure - 69, (1)) and the edge of the drive shaft housing (Figure - 69, (2)) on the stern-drive to contact when installing the stern- drive.

(1)

0006102

Figure - 70 1 – Locknut and Flat Washer 2 – Locknut Only

(f) Torque the drive unit locknuts. Drive Unit Locknut Torque N·m

lb-ft

60

44

10. Remove the eye-bolt from the top cover and replace the plug and washer to prevent corrosion. 11. Apply lubricant to all of the components (except plastic caps) during installation.

(1)

12. Install the trim cylinders on the aft end of the drive unit with the hardware as illustrated.

(2)

13. Tighten the locknuts until the washer and nut contact the shoulder on the anchor pin.

0006506

Figure - 69


JUNE 2008 (Rev. 4)

ZT350 - 45

ZT350

INSTALLATION INFORMATION 14. Install the plastic caps and hand-tighten. (1)

(1)

(2)

(3)

15. Open the oil valve screw in the drive shaft housing before the engine is operated the first time.

(1)

0006103A

Figure - 71 1 – Rubber Bushing (4 ea.) 2 – Large Inner Diameter Flat Washer (2 ea.) 3 – Aft Anchor Pin

(2)

(3)

0006363A

Figure - 73 1 – Oil Valve Screw (1)

(2)

(4)

(1)

0006103B

Figure - 72 1 2 3 4

– Rubber Bushing (4 ea.) – Small Inner Diameter Flat Washer (2 ea.) – Locknut (2 ea.) – Plastic Cap (2 ea.) Lithium Grease with PTFE Where Used Anchor Pin Threads

ZT350 - 46


JUNE 2008 (Rev. 4)

0006363B

Figure - 74 1 – 9 mm Wrench (hold the nut) 2 – Screwdriver (turn left one rotation)

16. Hold the nut with the wrench and turn the valve screw one turn counterclockwise.


ZT350


12/05

17. Remove the oil reservoir cap and fill the reservoir with lubricant (GL5 Hypoid Gear Oil).

18. Fill the reservoir to the “OPERATING RANGE” (Full) line. 19. Install the oil reservoir cap. Ensure that the rubber gasket is inside the reservoir cap. Do not over-tighten the cap.

(1)

20. Recheck the oil level after the first use.

0006364

Figure - 75 1 – Oil Reservoir Cap GL5 Hypoid Gear Oil Where Used Oil Reservoir



JUNE 2008 (Rev. 4)

ZT350 - 47

ZT350


Speedometer Connection Figure - 76 shows the speedometer hose piping.

(7)

(1)

(2)

(8)

(4)

(3)

(5)

(3)

(6)

0006507

Figure - 76 1 2 3 4

– Speedometer Hose – Trim Sender Wire – Engine Cooling Hose – Bell Housing

5 6 7 8

– Cable Band A* – Cable Band B** – Straight Area – Exhaust Opening

*This cable band attaches the Speedometer Hose (1) and the Trim Sender Wire (2) to the Engine Cooling Hose (3). The fixed place is the Straight Area (7) of the Engine Cooling Hose (3). The Speedometer Hose (1) passes the port side of the Engine Cooling Hose (3), and it passes the port side of the Exhaust Opening (8). **This cable band attaches the Speedometer Hose (1) to the Bell Housing (4).

ZT350 - 48

JUNE 2008 (Rev. 4)


ZT350


12/05

1. Raise the drive unit to gain access to the area between the gimbal housing and the drive unit, immediately on top of the transom end of the antiventilation plate. 2. Insert the speedometer tube fitting into the opening on the topside of the ventilation plate in position as illustrated.

POWER TRIM SYSTEM / STEERING HELM AND CABLE Control System Use the appropriate control panel or in-handle trim control arrangement (for instance Teleflex controls) with the power trim system. Install the trim control according to the instructions included with the power trim system.

Pump Location

(1)

Select a mounting location for the trim pump that meets the following requirements: • Within a comfortable reach of the hydraulic hoses (coming from the gimbal housing assembly). • Close enough to the battery so trim pump battery leads can be connected.

(2) 0006365

Figure - 77 1 – Speedometer Tube Fitting 2 – Opening

• Allows easy access to the trim pump oil fill and vent locations. • In an area where the pump will not be exposed to water.

3. With the fitting fully seated, turn the handle to the left to a tightly seated position.

• Mount the trim pump so that when the steering wheel is turned either to the right or left the power assist steering cylinder does not come in contact with trim pump.

Steering Helm and Cable The stern drive is shipped with the steering cable guide preset for cables with end dimensions that comply with ABYC standards, as outlined in the NMMA certification handbook. Yanmar recommends using the steering cable with a coupler nut. There must also be a means of locking it to the guide tube as specified in the ABYC requirements.

(1) 0006366

Figure - 78

WARNING! Failure to use a steering cable locking device could cause a loss of steering. Yanmar recommends using the steering cable with a self-locking coupler nut.

1 – Handle

Use an external locking device if using a steering cable that does not have a self-locking coupler nut.


JUNE 2008 (Rev. 4)

ZT350 - 49

ZT350


Steering Cable Specifications

Ensure that the steering cable is the correct length, particularly when installed in larger boats.

WARNING! Power steering units only - If the steering cable is installed with improper dimensions, it may cause severe damage to the transom assembly and / or steering system. NEVER attempt to adjust the cable guide tube on the power steering unit, as the guide tube and locknut have been torqued (with Loctite®) at the factory, and an attempt to loosen nut or tube may result in damage to tube.

Route the cable so it does not go around any sharp bends. Remove and avoid any kinks or loops when mounting the cable. Use the following illustration to determine the cable end dimension when the power steering cable is fully-extended. NOTICE: Power steering pump lugging (squealing) in a hard right turn (against the lock) may mean that the steering cable has been installed using incorrect dimensions. (3)

(2)

(4)

(1) (5) (6)

(11)

(10)

(12)

(7)

(8) (9) 0006388

Figure - 79 1 2 3 4 5 6 7

– Coupler / Nut - 7/8 UNF - 28 Thread – 298 mm (11-3/4 in.) Minimum – Interface Point – 12.7 mm (1/2 in.) Maximum – 10.7 mm (27/64 in.) Minimum Flat – 3.1 mm (7/64 in.) Minimum Radius – 15.9 mm (5/8 in.) Maximum Diameter End Fitting 8 – 9.5 mm (3/8 in.) 9 – 9.8 mm (3/8 in.) Diameter Through Hole (chamfered each side)

ZT350 - 50

JUNE 2008 (Rev. 4)

10 – 1-3/8 in. (34.9 mm) Maximum 11 – 15.9 mm (5/8 in.) Diameter Tube 12 – Cable Travel: Mid-Travel Position - 429 mm (16-7/8 in.) Total travel to be 203 mm (8 in.) minimum to 228 mm (9 in.) maximum. Travel each side of mid-travel position - 102 mm (4 in.) minimum, 114 mm (4-1/2 in.) maximum.


ZT350


12/05

Installation of Steering Cable When installing the steering cable (Figure - 80, (6)) between the rotary or rack helm (Figure - 80, (1)) and the steering lever of the stern-drive (Figure - 80, (5)), follow the following specifications: • NEVER exceed a 20 cm (8 in.) radius bend in the cable (Figure - 80, (2)) • Keep plus or minus 25 mm (1 in.) free motion of cable and power steering valve (Figure - 80, (3)) and be sure to prevent any interferences with other objects. • NEVER tie down or clamp the steering cable within 90 cm (3 ft) of the power steering cylinder (Figure - 80, (4)).

(5) (1) (7)

(4) (2)

(6)

(3)

0006437

Figure - 80 1 – Rotary or rack helm 2 – Minimum 20 cm (8 in.) bend radius 3 – Plus or minus 25 mm (1 in.) free motion of cable housing and power steering valve 4 – NEVER tie down or clamp within 90 cm (3 ft) of the power steering cylinder.

5 – Steering lever 6 – Steering Cable 7 – Power Steering Cylinder

CAUTION! Be sure the steering cable is correctly installed. Verify that all cable bends, free motion of cable housing and restraints of the cable are within specifications. Incorrect installation of the steering cable could result in erratic or loss of steering.


JUNE 2008 (Rev. 4)

ZT350 - 51

ZT350


THROTTLE AND SHIFT CABLES Shift and Throttle Cable Travel Yanmar recommends using a Teleflex remote control and cables to ensure proper shift and throttle operation. If a control other than Yanmar Teleflex is used, a shift control cable must be (at the shift plate end) 70 mm (2-3/4 in.) to 77 mm (3-1/32 in.) with a 50 to 70 N (11 to 16 lb.) load applied to the cable end.

Verify Propeller Rotation with Mechanical Shift System NOTICE: Use this method to verify the correct propeller rotation (RH or LH) for this drive unit. The front propeller on the drive unit is always LH Rotation and the rear propeller is always RH Rotation. The shift cable end guide must move in direction 1 shown in Figure - 81, when the control lever is placed in the FORWARD gear position.

0006367

Figure - 81 NOTICE: Route the cable away from sharp bends and moving parts. NEVER fasten items to the shift cables.

ZT350 - 52

JUNE 2008 (Rev. 4)


ZT350


12/05

SHIFT CABLE INSTALLATION AND ADJUSTMENT Shift Cable Installation for Electric Shift Type 1. Connect the shift cable to the control system and the engine. Please refer to the manual of the control system and the engine. (5)

(3)

(6) (1)

(2) (7) (4)

(3)

(3)

(3)

(5)

(4)

(5)

(4)

(3)

(3)

(6)

(7)

(5)

(4) (3)

0006508

Figure - 82 1 2 3 4 5 6 7

– FORWARD connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P – REVERSE connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P – Black: for earth signal (negative) – White: for REVERSE signal – Orange: for FORWARD signal – Name tag: FORWARD – Name tag: REVERSE


JUNE 2008 (Rev. 4)

ZT350 - 53

ZT350


Shift Cable Installation for Mechanical Shift Type

Install the Drive Unit Shift Cable.

1. Install the shift cable into the remote control. Refer to the appropriate instructions that come with the system you are using.

1. Insert the cotter pins from the top. Spread the ends of the cotter pins fully.

2. Loosen the stud and move it to the dimension as shown in the illustration below. Tighten the stud.

(2)

(1)

(2) (1) 0006368

Figure - 83 1 – Stud 2 – 76 mm (3 in.) - Center of the pivot bolt to the center of the stud.

Setting the Cable Length: Find the NEUTRAL position at the shift cable for the drive unit. Measure the distance between the control cable barrel center and the center of the attachment hole of the cable end. Adjust it at the screw of the attachment if necessary, and then lock the nut. This distance should be 180.6 mm (7-7/64 in). (1)

(3) (4) 0006370

Figure - 85 1 2 3 4

– Short Cotter Pin – Washers (2 ea.) – Long Cotter Pin – Drive Unit Shift Cable

(2) 0006369

Figure - 84 1 – Lock Nut 2 – 180.6 mm (7-7/64 in) - The control cable barrel center and the center of the attachment hole.

ZT350 - 54

JUNE 2008 (Rev. 4)


ZT350


12/05

2. Locate the center of the remote control and control cable play (backlash): (a) Shift the remote control to NEUTRAL. (b) Push in on the control cable end with enough pressure to remove play, and mark position 2 on tube. (c) Pull out on the control cable end with enough pressure to remove play and mark position 3 on tube. (d) Measure the distance between marks 2 and 3 and mark position 1 half-way between marks 2 and 3.

(1)

(2)

(3)

(4)

(5)

0006372

Figure - 87

(1) 1 2 3 4 5

– Stud – Control Cable Barrel – Backlash Center – Control Cable End Guide – Clevis Pin

4. Install the shift control cable. (2)

5. Install the washer and cotter pin to secure the barrel. Spread the ends of the cotter pin.

(3) 0006371

Figure - 86

6. Install the clevis pin. 7. Install the cotter pin into the clevis pin. Spread the ends of the cotter pin.

NOTICE: Keep center mark 1 aligned with sleeve end face when making the following adjustment.

(2)

(3)

(4)

Adjust the Shift Control Cable 1. Temporarily install the shift control cable end guide into the shift lever and insert the clevis pin. 2. Adjust the shift control cable barrel so that the hole in the barrel centers with the vertical centerline of the stud. Ensure that the backlash center mark is aligned with the edge of the control cable end guide. CAUTION! NEVER attempt to install or remove the shift control cable barrel from the stud without first removing the end guide clevis pin from the shift lever and removing the cable. Attempting to bend the shift control cable to install or remove the barrel will put undue stress on the cable end guide and shift lever. Damage to both could occur. 3. Remove the shift control cable end guide from the shift lever by removing the clevis pin.


(1) 0006373

Figure - 88 1 2 3 4

– Washers - (on both sides of barrel) – Cotter Pin – Cotter Pin (partially shown) – Clevis Pin

8. Shift the remote control lever into the FORWARD position. 9. Measure the distance between the shift control cable barrel center and the shift lever stud center. This distance should be 155.6 ± 1.5 mm (6-1/8 ± 1/16 in).

JUNE 2008 (Rev. 4)

ZT350 - 55

ZT350

INSTALLATION INFORMATION 10. If the distance does not satisfy the dimension, loosen the shift lever stud and slide the stud up or down until the distance is within the stated the dimension. When the adjustment is correct, tighten the stud.

(2)

(2)

(1) (3)

0006375

Figure - 90 (1) (3) 0006374

Figure - 89 1 – Barrel Retainer Cotter Pin 2 – 155.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control cable barrel center and the shift lever stud center. 3 – Shift Lever Stud

11. Shift the remote control into REVERSE. 12. Measure the distance between the control cable barrel center and the shift lever stud center. This distance should be 205.6 ± 1.5 mm (8-3/32 ± 1/16 in).

1 – Barrel Retainer Cotter Pin 2 – 205.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control cable barrel center and the shift lever stud center. 3 – Shift Lever Stud

15. Ensure that all of the cotter pins are secure and that the ends of the cotter pins are spread completely. 16. Lubricate the shift cable pivot points. SAE 30W Engine Oil Where Used Shift Cable Pivot Points

13. If the distance does not satisfy the dimension, loosen the shift lever stud and slide the stud up or down, until the distance is within the stated dimension. 14. When the adjustment is correct, tighten the stud.

ZT350 - 56

JUNE 2008 (Rev. 4)



ZT350


12/05

Troubleshooting Shift Problems Note: Use the following information to troubleshoot hard shifting or chucking / roughing when shifting into forward gear. 1. When installing the control box into the side panel of the boat, ensure that the cables have enough clearance to operate (Figure - 91). This is necessary because the cables move up and down when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with. This will cause very hard shifting.

4. Never strap or clamp the control cables to any other cables or rigid structure within 1000 mm (3 ft) of the control box. Make sure there are no kinks in the cable. 5. Ensure that there is enough clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. 6. Ensure that the engine was not set down on the intermediate shift cable during installation; this will crush the inner cable tubing and cause improper and / or stiff shifting. 7. NEVER fasten the shift cable with straps or clamps to any other cable within 1500 mm (5 ft.) of the shift plate. 8. Avoid over-tightening the shift cable to the transom with any type of plastic clips or fasteners within 1500 mm (5 ft.) of the shift plate.

0006376

Figure - 91 2. Route the shift cable from the control box through the side gunnel of the hull without inducing any extremely sharp bends (Figure - 91) to prevent stiff shifting. 3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and coat it with lubricant (Figure - 92, (1)). Move it back and forth to allow even distribution of the lubricant. (1)

9. Do not over-tighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud. Note: Lubricate attaching points with engine oil. SAE 30W Engine Oil Where Used Shift Cable Pivot Points


10. The drive unit shift cable must be routed to allow sufficient length for connection to shift plate. Note: Make a final check of the adjustments with the boat in the water and with the engine running. If this cannot be done, or is not done at the manufacturing facility, make arrangements with the dealer to do this as part of the pre-delivery inspection.

(1)

0006377

Figure - 92 1 – Lubrication Point Lithium Grease with PTFE Where Used Shift Cable End



JUNE 2008 (Rev. 4)

ZT350 - 57

ZT350


PRE-DELIVERY PREPARATION NOTICE: Before starting pre-delivery read the General Information and Installation Requirements completely. When the drive unit installation is complete, complete these final steps to prepare the package for delivery to the customer. It is the boat manufacturer's responsibility to perform these steps, or to make arrangement with the dealer to have these procedures completed.

(1) (2)

Power Steering Fluid NOTICE: Use only Dexron III automatic transmission fluid (ATF), in a power steering system. CAUTION! NEVER operate the engine and power steering without fluid or the pump will be damaged.

0006378

Figure - 93 Dexron III Automatic Transmission Fluid Where Used Power Steering Pump


Battery Connections NOTICE: The engine electrical system is negative (-) ground.

1 – Positive Battery Lead (RED) 2 – Negative Battery Lead (BLACK)

6. Ensure that all battery terminal connections are tight. 7. Spray the battery terminal connections with a sealant to help retard corrosion.

1. Position the battery as close to the engine as possible. 2. Connect the engine positive (+) battery cable (usually RED) to the positive (+) battery terminal. 3. Connect the engine negative (-) battery cable (usually Black) to the negative (-) battery terminal. 4. Connect the Power Trim pump RED (+) battery cable to the positive (+) battery terminal. 5. Connect the Power Trim pump BLACK (-) battery cable to the negative (-) battery terminal.

ZT350 - 58

JUNE 2008 (Rev. 4)


ZT350


12/05

Check the Power Trim Pump Fluid NOTICE: ALWAYS check the oil level with stern- drive in the full DOWN / TRIM-IN position.

3. The oil level is low if it is below the MIN line (Figure - 95, (1)) on the reservoir. Fill as necessary with the specified fluid. See Fill the Power Trim Pump Fluid on page ZT350-60 .

1. Place the stern-drive in 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 on the reservoir (Figure - 94, (2)). (1)

0006013

Figure - 95 1 – MIN Line

(1)

(2)

0006012

Figure - 94 1 – Reservoir 2 – MIN and MAX Lines


JUNE 2008 (Rev. 4)

ZT350 - 59

ZT350


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 / TRIMIN position. 2. Unscrew and remove the fill cap (Figure - 96, (1)) assembly from the reservoir (Figure - 96, (3)) with specified fluid. Dexron 3 Automatic Transmission Fluid Where Used Power Trim Pump

3. Add lubricant to bring the oil level to within the MIN and MAX lines on the reservoir (Figure - 96, (2)).

Check the Stern-Drive Oil Level GL-5 Hypoid Gear Oil Where Used Oil Reservoir

Note: The oil level will rise and fall during operation. Check the oil level before starting, when the engine is cold. 1. Check the stern-drive lube oil level (Figure - 97). Keep the oil level at or near the OPERATING RANGE (full) line on the oil reservoir. 2. The oil level is low if it is below the ADD line on the oil reservoir. Fill as needed with the specified oil. See Fill the Stern-Drive with Oil on page ZT350-61. (1)

(3) (2)

(2) (1) 0006336

Figure - 97

(3)

1 – Oil Reservoir 2 – ADD Line 3 – OPERATING RANGE Line

000

Figure - 96 1 – Fill Cap Assembly 2 – MIN and MAX Lines 3 – Reservoir

NOTICE: If any water is visible at the bottom of the oil reservoir or appears at the oil fill / drain plug and / or if oil appears discolored, contact your authorized Yanmar Marine dealer or distributor immediately. Both conditions may indicate a water leak somewhere in the stern-drive.

4. Install the fill cap assembly.

ZT350 - 60

JUNE 2008 (Rev. 4)


ZT350


12/05

Fill the Stern-Drive with Oil 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 - 98, (1)).

GL-5 Hypoid Gear Oil Where Used Oil Reservoir

3. When replacing the cap, ensure that the rubber gasket is inside the oil reservoir cap and install the cap. Do not over-tighten.

2. Fill the oil reservoir to the OPERATING RANGE (Figure - 98, (2)) (full) line with specified fluid. NOTICE: Do not overfill .

(1)

(2)

0006337

Figure - 98 1 – Oil Reservoir Cap 2 – OPERATING RANGE Line


JUNE 2008 (Rev. 4)

ZT350 - 61

ZT350


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 x 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. Left-hand is counterclockwise rotation for front propeller. Righthand is clockwise rotation for rear propeller. Pitch is the angle of the blades expressed in the theoretical distance a propeller travels in each revolution. If for example the pitch is 20, each revolution of the propeller pushes the vessel 20 in. through the water. A 28 pitch is considered “higher” pitched and a 20 pitch propeller is considered “lower” pitched. A smaller pitch propeller should be selected for water skiing or for heavy 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 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-up, complete the following before installing or removing the propeller: ◆

◆

Put the remote control to the NEUTRAL position. Put the main switch to OFF position and remove the key.

WARNING! NEVER use your hand to hold the propeller when loosening the nut. Put a wood block between the antiventilation plate and the propeller blade to prevent the propeller from turning. 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 - 62

JUNE 2008 (Rev. 4)


ZT350


12/05

General Propeller Installations WARNING! A rotating propeller, especially when driven by an operating engine, can cause severe injury. Prior to installing or removing the propeller, ensure that the remote control is in the NEUTRAL position, the lanyard switch, if equipped, is in the OFF position, and the ignition switch is in the OFF position with the key removed from the switch. WARNING! A rotating propeller can cause severe injury. Place a block of wood between the anti-ventilation plate and the propeller to protect hands from the propeller blades and to prevent the propeller from turning when removing and tightening the propeller nut. NOTICE: Installation is correct when at least 2 threads of the propeller shaft are exposed through the propeller locknut after applying torque to the locknut. Place a block of wood between the antiventilation plate and the propeller when tightening the propeller nut.

0006382

Figure - 99 To aid in the future removal of the propeller, liberally apply lubricant on the propeller shaft splines. UREA Grease Water Resistant Type NLGI #2 Where Used Propeller Shaft Splines


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Installing the Propellers

(2) (3)

(8)

(7)

(6)

(5) (4)

(1)

0006015

Figure - 100 1 2 3 4

– Rear Propeller Nut – Rear Propeller – Rear Propeller Thrust Hub – Front Propeller Nut

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– Front Propeller – Front Propeller Thrust Hub – Propeller Shaft Anode – Propeller Shaft Anode Bolt and Washer


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1. Apply a liberal coat of lubricant to the propeller shaft. Recommended lubricants are shown in the table below. Description

Where Used

Urea Grease Water Resistant Type, NLGI #2 Lithium Grease With PTFE

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. Install and torque the front propeller nut. Check the propeller at least every 20 hours. Front Propeller Nut Torque N·m

lb-ft

135

99

5. Slide the aft thrust hub onto the propeller shaft, with the tapered side toward the propeller hub (toward end of shaft).

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. WARNING! Place a block of wood between the antiventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut. 2. Turn the rear propeller nut (36 mm [1-7/16 in.]) counterclockwise to remove the nut. 3. Slide the propeller and the thrust hub off the propeller shaft. 4. Turn the front propeller nut (70 mm [2-3/4 in.]) counterclockwise to remove the nut. 5. Slide the propeller and the thrust hub off the propeller 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 Propeller Nut Torque N·m

lb-ft

80

59

8. Install the propeller shaft anode bolt with a washer. Torque the bolt. Propeller Shaft Anode Bolt Torque N·m

lb-ft

30

22


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Test Preparations

Engine Operation Tests

WARNING! NEVER leave the helm unattended when performing tests with the boat in the water.

WARNING! If engine is to be tested with the boat out of the water, the propeller must be removed to avoid injury.

NOTICE: During operation ensure that the engine seawater pump suction does not collapse the hose to the water source, causing the engine water supply to stop.

CAUTION! Overheating from insufficient coolant will cause engine and drive unit damage. Ensure that there is sufficient water available at the water inlet holes during operation.

1. Ensure that there is a sufficient supply of coolant to the drive unit seawater inlet holes and / or the through-hull-seawater inlet holes. 2. Use the correct flushing attachment for the seawater pickup found on the drive unit. CAUTION! If using a flush test device (attachment), install over the seawater intake holes and connect a water hose. NEVER use full water tap pressure. Also, avoid operating the engine above 1500 rpm, because the suction created could cause the water hose to collapse causing the water supply to be cut off. 3. Check all engine-related items as specified by the engine manufacturer. See the engine manufacturer's instructions. Note: See the Operation Manual provided with your engine / vessel for operating specifications and fluid capacities. 4. NOTICE: The drive unit oil level in the oil reservoir will rise and fall during the drive unit operation. Always check the oil level in the reservoir when the drive unit is cool and when the engine is shut down. 5. Check the drive unit oil level in the oil reservoir.

1. Ensure that the coolant system drain plugs and petcocks are installed and tight. 2. Ensure that the coolant system hoses are installed and clamped securely.

Out-of-Water Testing The following information is for engine operation tests with the boat out of the water: NOTICE: On vessels with the drive unit seawater inlet blocked off at the gimbal housing and using a through-the-hull seawater inlet, a constant supply of coolant must be available for both the drive unit and the engine during operation. 1. Install a flushing attachment over the drive unit and / or the alternate seawater inlet pickup holes. 2. Connect a hose between the flushing attachments and a water source. NOTICE: If using a flushing attachment (sometimes referred to as a flush test device) over the seawater inlet holes and a water hose as shown, NEVER use full water source pressure. Open the water source about 1/2 maximum. NEVER use full water pressure.

6. Test the audio warning system, if equipped. (1) (2)

0006384

Figure - 101 1 – Typical Flushing Attachment (Obtain Locally) 2 – Water Hose

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3. See Test Preparations on page ZT350-66 for other checks.

In-Water Testing The following information is for engine operation tests with the boat in the water. WARNING! NEVER leave the helm unattended when testing the vessel in the water. NOTICE: The water level must be above the seawater inlet holes on the drive unit or the through-the-hull pickup.

Drive Unit Operational Tests WARNING! NEVER leave the helm unattended when performing tests with the boat in the water. CAUTION! Instruments can warn of engine problems. Watch the temperature gauge on the dash to ensure that the engine does not overheat to avoid engine damage. 1. Refer to the Engine Operation Manual and start the engine.

1. On engines with a drive unit seawater inlet: The water level must be above the seawater inlet holes on the drive unit.

(1) (2) 0006385

Figure - 102 1 – Minimum Water Level 2 – Water Inlet Holes

2. On engines with a through-the-hull seawater inlet: Ensure that the water level is above the seawater inlet holes on the through-the-hull seawater inlet.

Wide Open Throttle Test NOTICE: Follow the Engine Operation Manual to operate the engine at full throttle before the break- in period is complete. 1. To test if the correct propeller has been installed, operate the boat with a full load onboard at wide open throttle (WOT) and check the rpm with an accurate tachometer. Engine rpm should be near top of the specified range so that engine speed will not fall below specifications under a heavy load. If the engine speed is too high, replace the propeller with a higher pitch propeller. 2. See Test Preparations on page ZT350-66 for other checks.


2. Operate the engine at IDLE rpm until it reaches normal operating temperature. 3. Turn the steering wheel to starboard, then to port, and ensure that the drive unit turns the correct way. 4. Check the power steering system for a lugging condition (engine rpm drops and / or the power steering pump tone changes). 5. Turn the steering wheel to the LEFT (Port) until it stops and then continue to apply pressure. If the pump lugs, check the following: (a) Check for an obstruction between the gimbal ring and the gimbal housing, and all moving steering components. (b) Ensure that the steering lever is not contacting the cutout in the transom. Modify the cutout if there is contact between the transom and the cutout. 6. Turn the steering wheel to the RIGHT (starboard) until it stops and then continue to apply pressure. If the pump lugs, check the following: (a) Check for an obstruction between gimbal ring and gimbal housing, and all moving steering components. (b) Ensure that the steering lever is not contacting the cutout in the transom. Modify the cutout if there is contact between the transom and the cutout. 7. Check steering cable end dimension with the cable FULLY EXTENDED. See Steering Helm and Cable on page ZT350-49 for proper steering cable dimensions. 8. Turn the engine off.

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INSTALLATION INFORMATION 9. Lubricate the steering cable and clevis. NOTICE: Ensure that the cable end that enters the clevis is heavily lubricated.

11. Ensure that there is nothing attached to steering cable casing. The cable must be free to move when actuated. 12. Check the power steering pump fluid level. 13. Position the drive unit so it is straight back.

(1)

14. Turn the engine off. 15. Check the power steering fluid level and add as necessary.

(2)

(4)

(3)

0006386

Figure - 103 1 2 3 4

– Clevis – Steering Lever – Clevis Pins and Cotter Pins – Steering Cable End UREA Grease Water Resistant Type NLGI #2 Where Used

Steering Cable End


10. Restart the engine and observe the drive unit.If drive unit creeps, an external tension may exist on steering cable.

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CAUTION! If the power package will not be used for an extended period of time, or will be exposed to freezing temperatures, drain the water from the drive unit. ALWAYS drain water to prevent corrosion and freeze damage to the engine and / or the drive unit. If the power package will not be used for an extended period of time, or will be exposed to freezing temperatures, drain the water from the drive unit. See Cold Weather (Freezing Temperature), Seasonal and Extended Storage on page ZT350-69 . CAUTION! The drive unit should be stored in the FULL DOWN / IN position. The U-joint bellows may develop a set if the drive unit is stored in the raised position and may fail when the drive unit is returned to service.


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Cold Weather (Freezing Temperature), Seasonal and Extended Storage NOTICE: Yanmar strongly recommends that this service should be performed by an authorized Yanmar dealer / distributor. Damage caused by freezing is not covered by the Yanmar Warranty.

CAUTION! The drive unit should be stored in the FULL DOWN / IN position. The U-joint bellows may develop a set if the unit is stored in the raised position and may fail when the unit is returned to service. Store the drive unit in the full DOWN (IN) position.

Use a piece of wire to check the water drain passages in the drive unit to ensure that they are open.

(1) (2) (3)

(4) 0006387

Figure - 104 1 2 3 4

– Underside of Anticavitation Plate – First Anode Cavity Drain Passage – Second Anode Cavity Drain Passage – Speedometer Pitot Hole


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