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Yanmar Marine Stern Drive Zt370 Service Installation manual – PDF Download
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Yanmar Marine Stern Drive Zt370 Service Installation manual
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Description
Yanmar Marine Stern Drive Zt370 Service Installation manual
FILE DETAILS:
Yanmar Marine Stern Drive Zt370 Service Installation manual
LANGUAGE:ENGLISH
PAGES:140
DOWNLOADABLE:YES
FILE TYPE:PDF
YANMAR MARINE STERN DRIVE ZT370 SERVICE INSTALLATION MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Yanmar Marine Stern Drive Zt370 Service Installation manual
This manual provides boat designers. naval architects, installers and builders with the instructions necessary to safely Install YANMAR marine propulsion Systems. Optimum boat and engine performance are achieved when the appropriate diesel marine engine, marine gear, propeller and accessories are selected for an application.Accurate information Is required during the engine selection and space planning processes for each lfeboat/rescue boat application. Numerous :alculations are needed in determining vessel mdormance characteristics. Boat designers, naval architects, installers and builders use the data and brmuias to provide systems that satisfactorily answer the operator’s exacting requirements.
TABLE OF CONTENTS:
Yanmar Marine Stern Drive Zt370 Service Installation manual
Cover............................................................................................................................ 1 Table of Contents................................................................................................................ 3 Introduction..................................................................................................................... 5 Welcome to the world of YANMAR Marine!....................................................................................... 5 About This Manual............................................................................................................ 5 Safety........................................................................................................................... 7 Safety Precautions........................................................................................................... 8 General Information.............................................................................................................. 13 Notice to Vessel OEM and Equipment Installer................................................................................. 15 Sales and Technical Assistance........................................................................................... 15 General Specifications....................................................................................................... 16 Tightening Torques........................................................................................................... 17 Tightening Fasteners..................................................................................................... 17 Tightening Torques for Standard Bolts and Nuts........................................................................... 17 Special Tightening Torques............................................................................................... 17 Propeller nut - outer................................................................................................ 18 Hose Clamps.............................................................................................................. 20 Lubricants/Sealants/Adhesives................................................................................................ 21 Special Tools................................................................................................................ 22 Identification............................................................................................................... 23 Transom Assembly......................................................................................................... 23 Stern-Drive Assembly..................................................................................................... 24 Gear ratio identification............................................................................................ 24 Vessel Design.................................................................................................................... 25 Vessel Design Considerations................................................................................................. 27 Checking Transom Thickness............................................................................................... 27 New installation (transom thickness)................................................................................. 27 Re-power installation (transom thickness)............................................................................ 28 Vessel Engine Mount Position............................................................................................. 28 Selecting an Engine Exhaust System....................................................................................... 29 Installing Engine and Drive Unit................................................................................................. 31 Positioning the Drive Unit................................................................................................... 33 Preparation before Actual Installation................................................................................... 33 Locating the Crankshaft Vertical Centerline - Single Engine Installation................................................. 33 Locating the Crankshaft Vertical Centerline - Dual Engine Installation................................................... 34 Finding the Crankshaft Horizontal Centerline (X-Dimension)............................................................... 34 Cutting the Vessel Transom............................................................................................... 36 Required tools....................................................................................................... 36 Marking and drilling procedure....................................................................................... 37 Installing the Transom Assembly.............................................................................................. 39 Transom Assembly and Engine Connection Installation Information.............................................................. 41 ZT370 Stern-Drive Applicable Engines..................................................................................... 41 Specifications........................................................................................................... 41 Coupling Installation Procedures......................................................................................... 43 4BY3-180Z damper coupling installation............................................................................... 43 Engine Cooling Seawater Hose Installation................................................................................ 48 6LPA-STZP2 and 6LPA-STZP3 cooling seawater hose installation......................................................... 48 Cooling Seawater Intake (Drive Only) Installation........................................................................ 49 4BY3-180Z, 6BY3-220Z and 6BY3-260Z cooling seawater intake installation.............................................. 49 Flywheel Housing Replacement or Modification............................................................................. 54 6LPA-STZP2 and 6LPA-STZP3 flywheel housing replacement or modification............................................... 54 Cooling Seawater Mixing (Drive Exhaust) Installation..................................................................... 55 4BY3-180Z cooling seawater mixing for drive exhaust installation..................................................... 55 Exhaust Pipe to Drive Exhaust Installation............................................................................... 60 4BY3-180Z, 6BY3-220Z and 6BY3-260Z exhaust pipe from stern-drive exhaust port installation........................... 60 Water Bypass for Drive Exhaust Installation.............................................................................. 63 4BY3-180Z, 6BY3-220Z and 6BY3-260Z water bypass from stern-drive drain port installation............................. 63 Power Steering Hydraulic Oil Pipes Connection............................................................................ 67 6LPA-STZP2 power steering hydraulic oil pipe installation............................................................ 67 Shift Bracket Replacement................................................................................................ 68 6LPA-STZP2 and 6LPA-STZP3 shift bracket replacement.................................................................. 68 Flywheel Housing to Stern-Drive Transom Plate Spacer Installation........................................................ 69 6LPA-STZP2 and 6LPA-STZP3 spacer installation between engine flywheel housing and ZT370 stern-drive transom plate.... 69 Neutral Safety Switch Installation....................................................................................... 70 4BY3-180Z, 6BY3-220Z and 6BY3-260Z neutral safety switch installation................................................ 70 Shift Cable Installation................................................................................................. 72 BY3 series, 6LPA and 8LV series trim harness installation............................................................ 73 Trim Position Sender Installation........................................................................................ 76 BY3 series, 6LPA and 8LV series trim position sender installation.................................................... 76 Engine Bonding Wire Connection............................................................................................... 77 Installing the Oil Reservoir................................................................................................. 77 Installing the Air Separator Tank........................................................................................ 77 Connecting the Oil Reservoir Hose........................................................................................ 78 Seawater Pickup Installation................................................................................................. 80 Drive Unit Seawater Pickup............................................................................................... 80 Alternate Seawater Pickup................................................................................................ 80 Modifying the Inlet Water Hose........................................................................................... 82 Installing the Bypass Return Seawater Plug............................................................................... 83 Y-CaPS Controller Connection................................................................................................. 83 Installing the Steering System............................................................................................... 85 Power Steering Hoses..................................................................................................... 87 Steering Helm and Cable.................................................................................................. 87 Steering Cable Specifications............................................................................................ 88 Installation of Steering Cable........................................................................................... 89 Connecting the Steering Cables........................................................................................... 90 Steering Tie Bar Considerations.......................................................................................... 92 Internal tie bar only................................................................................................ 92 Internal tie bar installation (optional)............................................................................. 92 Internal and external tie bar........................................................................................ 92 External power steering with an external tie bar..................................................................... 92 Exhaust Options.............................................................................................................. 93 Through-the-Propeller Exhaust............................................................................................ 93 Alternate Exhaust System................................................................................................. 93 Power Trim System............................................................................................................ 94 Control System........................................................................................................... 94 Trim Position Sender Connection.......................................................................................... 94 Installing the Power Trim Pump........................................................................................... 94 Installing the Engine........................................................................................................ 97 Aligning the Engine...................................................................................................... 98 Aligning gimbal bearing.............................................................................................. 98 Adjusting engine mounts.............................................................................................. 99 Speedometer Connection.......................................................................................................101 Connecting the Speedometer Pickup........................................................................................102 Shift Plate and Cable Installation and Adjustment (Mechanical Shift System)..................................................103 Installing the Shift Plate...............................................................................................103 Installing the Drive Unit Shift Cables...................................................................................103 Verify propeller rotation............................................................................................103 Verify shift cable travel............................................................................................103 Setting drive unit shift cable length................................................................................104 Drive Unit Shift Cables Installation.................................................................................104 Shift Cable Installation (Electric Shift System).............................................................................109 Troubleshooting Shift Problems...............................................................................................110 Installing the Drive Unit....................................................................................................111 Trim and Tilt Limiters.......................................................................................................117 Trim-In Limiter..........................................................................................................117 Corrosion Protection.........................................................................................................120 Galvanic Corrosion.......................................................................................................120 Corrosion Control........................................................................................................120 Shore Power..............................................................................................................120 Antifouling Paint........................................................................................................121 Painting the Transom and Stern- Drive....................................................................................121 Pre-Delivery.....................................................................................................................123 Pre-Delivery Preparation.....................................................................................................125 Power Steering Fluid.....................................................................................................125 Battery Connections......................................................................................................125 Check the Power Trim Pump Fluid..........................................................................................126 Fill the Power Trim Pump Fluid...........................................................................................126 Check the Stern-Drive Reservoir Oil Level................................................................................127 Fill the Stern-Drive Reservoir with Oil..................................................................................128 Check the Stern-Drive Oil Level..........................................................................................129 Propeller Selection......................................................................................................130 Installing the Propellers................................................................................................130 Propeller installation precautions...................................................................................130 Removing the Propeller...................................................................................................133 Test Preparations........................................................................................................133 Engine Operation Tests...................................................................................................134 Out-of-Water Testing.....................................................................................................134 In-Water Testing.........................................................................................................135 Wide-Open Throttle Test..............................................................................................135 Drive Unit Operational Tests.............................................................................................135 Y-CaPS Functionality Tests...............................................................................................137 Cold Weather (Freezing Temperature), Seasonal and Extended Storage.......................................................137 Removal of Stern-Drive...................................................................................................137
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