Yanmar 8LV320, 8LV350, 8LV370, 8LV320Z, 8LV350Z Operation Manual

8LV320

8LV350

8LV370

8LV320Z

8LV350Z

8LV370Z

0A8LV-G00100
PRINTED IN JAPAN

California

Proposition 65 Warning

Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth
defects, and other reproductive harm.

California

Proposition 65 Warning

Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer and
reproductive harm.
Wash hands after handling.

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and/or specifications
to explain and/or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. Yanmar and are
registered trademarks of YANMAR CO., LTD. in Japan, the United States and/or other
countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means ­graphic, electronic, or mechanical, including photocopying, recording, taping, or informa­tion storage and retrieval systems - without the written permission of YANMAR CO., LTD.

Overseas Office

■Yanmar (Head office)

1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311

■Yanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: [phone] Fax: [phone]

■Yanmar Asia (Singapore) Corporation Pte Ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: [phone] Fax: [phone]

Marine Operations Division

Production Dept.
Tsukaguchi Plant
Quality Assurance Dept.

3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,
Hyogo, Japan 661-0001
Phone: [phone] Fax: [phone]

■

■Yanmar Engine (Shanghai). Co., Ltd.

18F, North Tower, Shanghai Stock Exchange Building
528 South Pudong Road, Pu Dong Shanghai, China 200120
Phone: [phone] Fax: [phone]

■Yanmar America Corporation (YA)

101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: [phone] Fax: [phone]

Date of issue: Jun. 2011

OPERATION MANUAL

All Rights Reserved, Copyright

8LV SeriesModel

0A8LV-G00100Code

OPERATION MANUAL

8LV Series

1st Edition : Jun. 2011

Issued by : YANMAR CO.,LTD. Marine Operations Division

Edited by : YANMAR TECHNICAL SERVICE CO.,LTD.

TABLE OF

CONTENTS

8LV Series Operation Manual

Introduction ............................................................................................. 1

Record of Ownership........................................................................... 2

Safety........................................................................................................ 3

Safety Precautions .............................................................................. 4

General Information....................................................................... 4

Before You Operate....................................................................... 4

During Operation and Maintenance............................................... 4

Location of Safety Decals.................................................................... 9

Product Overview.................................................................................. 11

Yanmar 8LV Features and Applications............................................ 11

New Engine Break-In................................................................... 12

Component Identification................................................................... 13

Service Side ................................................................................ 13

Non-Service Side......................................................................... 13

Page

Location of Nameplate ...................................................................... 14

Function of Major Components ......................................................... 15

Vessel Control System (VCS) ........................................................... 16

Display......................................................................................... 17

Before You Operate............................................................................... 19

Diesel Fuel ........................................................................................ 20

Diesel Fuel Specifications ........................................................... 20

Filling the Fuel Tank .................................................................... 22

Bleeding the Fuel System............................................................ 22

Engine Oil.......................................................................................... 23

Engine Oil Specifications ............................................................ 23

Engine Oil Viscosity..................................................................... 23

Checking the Engine Oil.............................................................. 24

Adding Engine Oil........................................................................ 24

8LV Series Operation Manual

i

TABLE OF CONTENTS

Engine Coolant.................................................................................. 25

Engine Coolant Specifications..................................................... 25

Coolant (Closed Cooling System) ............................................... 25

Checking and Adding Coolant..................................................... 25

Checking the Engine Oil and Engine Coolant ................................... 26

Engine Operation .................................................................................. 27

Starting the Engine(Start Up) ............................................................ 28

If the Engine Fails to Start ........................................................... 29

After the Engine has Started ....................................................... 29

Warm Up Mode (Shift Disconnect).................................................... 29

Throttle and Shift Control .................................................................. 30

Neutral......................................................................................... 30

Forward ....................................................................................... 30

Reverse ....................................................................................... 30

Forward (Reverse) to Reverse (Forward) ................................... 30

Cautions During Operation................................................................ 31

Shut-Down the Engine (Stopping)..................................................... 32

Normal Stopping.......................................................................... 32

Emergency Stop.......................................................................... 33

Control the Backup Panel ................................................................. 33

Checking the Engine After Operation................................................ 34

Periodic Maintenance ........................................................................... 35

Precautions ....................................................................................... 36

The Importance of Periodic Maintenance.................................... 36

Performing Periodic Maintenance ............................................... 36

The Importance of Daily Checks ................................................. 36

Keep a Log of Engine Hours and Daily Checks .......................... 36

Yanmar Replacement Parts ........................................................ 36

Tools Required ............................................................................ 36

Ask Your Authorized Yanmar Marine Dealer or

Distributor for Help ...................................................................... 36

Tightening Fasteners................................................................... 37

EPA Maintenance Requirements ...................................................... 39

EPA Requirements for USA and Other Applicable Countries ..... 39

EPA Requirements...................................................................... 39

Conditions to Ensure Compliance with EPA Emission Standards

.... 39

Inspection and Maintenance ....................................................... 39

Periodic Maintenance Schedule........................................................ 40

Inspection and Maintenance of EPA Emission-Related Parts..... 41

Periodic Maintenance Procedures .................................................... 42

Daily Checks ............................................................................... 42

After Initial 50 Hours of Operation ............................................... 43

Every 50 Hours of Operation....................................................... 44

Every 250 Hours of Operation..................................................... 46

Every 500 Hours of Operation..................................................... 51

Every 1000 Hours of Operation................................................... 52

Long-Term Storage ............................................................................... 53

Preparing the Engine for Long-Term Storage ................................... 54

Draining the Seawater Cooling System....................................... 54

ii

8LV Series Operation Manual

TABLE OF CONTENTS

Troubleshooting.................................................................................... 57

Troubleshooting After Starting........................................................... 58

Troubleshooting Information.............................................................. 59

Troubleshooting Chart....................................................................... 60

Failsafe Diagnosis Functional Specification Chart ............................ 65

Specifications........................................................................................ 67

Principal Engine Specifications ......................................................... 67

8LV Series Engine Specifications................................................ 67

8LV Series Marine Gear Specifications....................................... 68

System Diagrams .................................................................................. 69

Wiring Diagram.................................................................................. 69

8LV Wiring Diagram .................................................................... 70

EPA Warranty USA Only....................................................................... 73

YANMAR CO., LTD. Limited Emission Control System Warranty -

USA Only........................................................................................... 73

Your Warranty Rights and Obligations ........................................ 74

Warranty Period........................................................................... 74

Warranty Coverage ..................................................................... 74

Exclusions ................................................................................... 74

Owner’s Responsibility ................................................................ 74

Customer Assistance................................................................... 75

Maintenance Log......................................................................... 76

8LV Series Operation Manual

iii

TABLE OF CONTENTS

This Page Intentionally Left Blank

iv

8LV Series Operation Manual

8LV Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine! Yanmar
Marine offers engines, drive systems and
accessories for all types of boats, from runabouts to
sailboats, and from cruisers to mega yachts. In
marine leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We design our
engines to respect nature. This means quieter
engines, with minimal vibrations, cleaner than ever.
All of our engines meet applicable regulations,
including emissions, at the time of manufacture.

To help you enjoy your Yanmar 8LV series engine
for many years to come, please follow these
recommendations:

• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.

• Keep this Operation Manual in a convenient place
for easy access.

• If this Operation Manual is lost or damaged, order
a new one from your authorized Yanmar Marine
dealer or distributor.

• Constant efforts are made to improve the quality
and performance of Yanmar products, so some
details included in this Operation Manual may
differ slightly from your engine. If you have any
questions about these differences, please contact
your authorized Yanmar Marine dealer or
distributor.

• The specifications and components (instrument
panel, fuel tank, etc.) described in this manual
may differ from ones installed on your vessel.
Please refer to the manual provided by the
manufacturer of these components.

• Refer to the Yanmar Limited Warranty Handbook
for a complete warranty description.

• Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.

8LV Series Operation Manual

1

INTRODUCTION

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for service, parts or
literature.

Engine Model: _______________________________________________________________________

Engine Serial No.: ____________________________________________________________________

Date Purchased: _____________________________________________________________________

Dealer: _____________________________________________________________________________

Dealer Phone: _______________________________________________________________________

2

8LV Series Operation Manual

8LV Series Operation Manual

DANGER

WARNING

CAUTION

NOTICE

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
machine’s safety decals. 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.

This safety alert symbol appears
with most safety statements. It
means attention, become alert, your

A

safety is involved! Please read and
abide by the message that follows
the safety alert symbol.

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

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

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

NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.

8LV Series Operation Manual

3

SAFETY

WARNING

DANGER

WARNING

SAFETY PRECAUTIONS

General Information

There is no substitute for common sense and
careful practices. Improper practices or
carelessness can cause burns, cuts, mutilation,
asphyxiation, other bodily injury or death. This
information contains general safety precautions
and guidelines that must be followed to reduce risk
to personal safety. Special safety precautions are
listed in specific procedures. Read and understand
all of the safety precautions before operation or
performing repairs or maintenance.

Before You Operate

• Never permit anyone to install or
operate the engine without proper
training.

During Operation and Maintenance

CRUSH HAZARD

• Never stand under hoisted
engine. If the hoist mechanism
fails, the engine will fall on you.

• If the engine needs to be transported for
repair, have a helper assist you attach it to a
hoist and load it on a truck.

• The engine lifting eyes are engineered to lift
the weight of the marine engine only. Always
use the engine lifting eyes when lifting the
engine.

• Additional equipment is necessary to lift the
marine engine and marine gear together.
Always use lifting equipment with sufficient
capacity to lift the marine engine.

• Read and understand this Operation Manual
before you operate or service the engine to
ensure that you follow safe operating
practices and maintenance procedures.

• Safety signs and labels are additional
reminders for safe operating and maintenance
techniques.

• Contact your authorized Yanmar Marine
dealer or distributor for additional training.

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 flames and
any other form of ignition out of
the area.

4

8LV Series Operation Manual

SAFETY

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

FIRE AND EXPLOSION HAZARD

• Diesel fuel is flammable and
explosive under certain
conditions.

• Never use a shop rag to catch the fuel.

• Wipe up all spills immediately.

• Never refuel with the engine running.

• Never use diesel fuel as a cleaning agent.

• Store any containers containing fuel or other
flammable products in a well-ventilated area,
away from any combustibles or sources of
ignition.

• Never jump-start the engine. Sparks caused
by shorting the battery to the starter terminals
may cause a fire or explosion. Only use the
key switch to start the engine.

SEVER HAZARD

• Rotating parts can cause severe
injury or death. Never wear
jewelry, unbuttoned cuffs, ties or
loose fitting clothing and Always
tie long hair back when working
near moving/rotating parts such
as the flywheel or PTO shaft. Keep
hands, feet and tools away from
all moving parts. Never operate
the engine without the guards in
place.

• Before you start the engine make sure that all
bystanders are clear of the area. Keep
children and pets away while the engine is
operating.

• Check the engine that any tools or shop rags
used during maintenance have been removed
from the area.

FIRE HAZARD

• Undersized wiring systems can
cause an electrical fire.

• Store any equipment in a designated area
away from moving parts.

• Never use the engine compartment for
storage.

ALCOHOL AND DRUG HAZARD

• Never operate the engine while
under the influence of alcohol or
drugs or 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.

ENTANGLEMENT HAZARD

• Never leave the key in the key
switch when you are servicing the
engine. Someone may
accidentally start the engine and
not realize you are servicing it.

8LV Series Operation Manual

• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the warning signals.

5

SAFETY

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

PIERCING HAZARD

• Avoid skin contact with
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious
injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.

• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Contact your authorized Yanmar Marine
dealer or distributor repair the damage.

BURN HAZARD

• Some of the engine surfaces
become very hot during operation
and shortly after shut-down. Keep
hands and other body parts away
from hot engine 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.

• Always ensure that all connections are
tightened to specifications after repair is
made to the exhaust system. All internal
combustion engines create carbon monoxide
gas during operation and special precautions
are required to avoid carbon monoxide
poisoning.

WELDING HAZARD

• Always turn off the battery switch (if
equipped) or disconnect the negative battery
cable and the leads to the alternator when
welding on the equipment.

SUDDEN MOVEMENT HAZARD

• Always stop the engine before beginning
service.

• Be sure the boat is in open water away from
other boats, docks or other obstructions
before increasing rpm. Avoid unexpected
equipment movement. Shift the marine gear
into the NEUTRAL position any time the
engine is at idle.

• To prevent accidental equipment movement,
Never start the engine in gear.

• Remove the engine control unit multi-pin
connector. Connect the weld clamp to the
component to be welded and as close as
possible to the welding point.

• Never connect the weld clamp to the engine
or in a manner which would allow current to
pass through a mounting bracket.

• When welding is completed, reconnect the
alternator and engine control unit prior to
reconnecting the batteries.

SHOCK HAZARD

• Always turn off the battery switch
(if equipped) or disconnect the
negative battery cable before
servicing the equipment.

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

• Never use undersized wiring for the electrical
system.

6

8LV Series Operation Manual

SAFETY

WARNING

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

NOTICE

NOTICE

NOTICENOTICE

NOTICE

NOTICE

Never remove the coolant filler cap if the engine
is hot. Steam and hot engine coolant will spray
out and seriously burn you. Allow the engine to
cool down before you attempt to remove the
cap.

POOR LIGHTING HAZARD

• Ensure that the work area is adequately
illuminated. Always install wire cages on
portable safety lamps.

TO O L H A Z A RD

• 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 engine or when using compressed air or
high-pressure water. Dust, flying debris,
compressed air, pressurized water or steam
may injure your eyes.

It is important to perform daily checks as listed in
the Operation Manual. Periodic maintenance
prevents unexpected downtime, reduces the
number of accidents due to poor engine
performance and helps extend the life of the
engine.

Contact your authorized Yanmar Marine dealer or
distributor if you need to operate the engine at high
altitudes. At high altitudes the engine will lose
power, run rough and produce exhaust gases that
exceed the design specifications.

Always be environmentally
responsible.

Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel fuel
and engine coolant. Consult the local authorities or
reclamation facility.

COOLANT HAZARD

• Wear eye protection
and rubber gloves
when you handle Long
Life engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.

• DO NOT drain the coolant system. A full
coolant system will prevent corrosion and
frost damage.

• If seawater is left inside of the engine, it may
freeze and damage parts of the cooling
system when the ambient temperature is
below 0 °C (32 °F).

Never dispose of hazardous materials by dumping
them into a sewer, on the ground or into ground
water or waterways.

If a Yanmar Marine Engine is installed at an angle
that exceeds the specifications stated in the
Yanmar Marine Installation manuals, engine oil may
enter the combustion chamber causing excessive
engine speed, white exhaust smoke and serious
engine damage. This applies to engines that run
continuously or those that run for short periods of
time.

8LV Series Operation Manual

7

SAFETY

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

If you have an installation with two or three engines,
and only one engine is operating, please note that if
the propeller shaft thru-hull (stuffing box) is
lubricated by engine water pressure and the
engines are interconnected, care must be taken
that water from the running engine does not enter
the exhaust of the non-running engine(s). This
water could cause seizure of the non-running
engine(s). Contact your authorized Yanmar Marine
dealer or distributor for a complete explanation of
this condition.

If you have an installation with two or three engines,
and only one engine is operating, the water pickup
(thru-hull) of the non-running engine(s) should be
closed. This will prevent water from being forced
past the seawater pump and eventually finding its
way into the engine. The result of water entering
the engine could cause seizure or other serious
problems.

If you have an installation with two or three engines,
and only one engine is operating, it is important to
limit the amount of throttle applied to the running
engine. If you observe black smoke or movement of
the throttle does not increase engine rpm, you are
overloading the engine that is running. Immediately
throttle back to approximately 2/3 throttle or to a
setting where the engine performs normally. Failure
to do so may cause the running engine to overheat
or cause excess carbon buildup which may shorten
the engine's life.

If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine. Contact your authorized
Yanmar Marine dealer or distributor for service
before operating the engine.

Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:

• Avoid operating in extremely dusty conditions.

• Avoid operating in the presence of chemical
gases or fumes.

• Never run the engine if the ambient temperature
is above +40 °C (+104 °F) or below -16 °C
(+3 °F).

• If the ambient temperature exceeds +40 °C
(+104 °F), the engine may overheat and cause
the engine oil to break down.

• If the ambient temperature is below -16 °C
(+3 °F), rubber components such as gaskets and
seals will harden causing premature engine wear
and damage.

• Contact your authorized Yanmar Marine engine
dealer or distributor if the engine will be operated
outside of this standard temperature range.

Never engage the starter motor while the engine is
running. Damage to the starter motor pinion and/or
ring gear will result.

New Engine Break In: On the initial engine start-up,
check for proper engine oil pressure, diesel fuel
leaks, engine oil leaks, coolant leaks, and for
proper operation of the indicators and/or gauges.
During the first 50 hours of operation operate your
new engine under a substantial load at all times.
For best break-in results operate the engine at
various speeds. Operating the engine in NEUTRAL
must be avoided. During the first 50 hours, avoid
operation below 2000 min
break-in period, carefully observe the engine oil
pressure and engine temperature. During the
break-in period, check the engine oil and coolant
levels frequently.

8

-1

(rpm). During the

Any part which is found defective as a result of
inspection, or any part whose measured value does
not satisfy the standard or limit, must be replaced.

Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may void
its warranty. Be sure to use Yanmar genuine
replacement parts.

8LV Series Operation Manual

LOCATION OF SAFETY DECALS

Figure 1 and Figure 2 show the location of safety decals on Yanmar 8LV series marine engines.

SAFETY

1

CAUTION : Overcranking
engine with water lift
muffl e r can cause damage.

128171-07150

32

DO NOT STEP
ON COVERS.
POSSIBILITY
OF A FALL.

No. Part Number

1 128296-07260

2 128171-07150

3 128296-07300

4 128296-07350

5 196630-12980

6 119578-07890

456

119578-07890

037426-00X00

Figure 1

8LV Series Operation Manual

9

SAFETY

1

2

No. Part Number

1 120324-07240

2 128296-07300

037427-00X00

Figure 2

10

8LV Series Operation Manual

8LV Series Operation Manual

PRODUCT

OVERVIEW

YANMAR 8LV FEATURES AND APPLICATIONS

The 8LV series are four-stroke direct injection
diesel engines equipped with liquid coolant
systems.

The 8LV series is V-8-cylinder and turbocharged
with an air cooler and equipped a common rail fuel
injection system.

This engine is designed for pleasure craft use.

It is recommended that new vessels be propped so
the engines can operate at 95 % load at 3800 min
(rpm).

Failure to do so can lead to reduced vessel
performance, lead to increased smoke levels and
cause permanent damage to your engine.

The engine must be installed correctly with coolant
lines, exhaust gas lines and electrical wiring. Any
auxiliary equipment attached to the engine should
be easy to use and accessible for service. To
handle the drive equipment, propulsion systems
(including the propeller) and other onboard
equipment, always observe the instructions and
cautions given in the operation manuals supplied
by the shipyard and equipment manufacturers.

-1

The 8LV series engines are designed to be
operated at maximum throttle (3600 to 3800 min
(rpm)) for less than 5 % of total engine time (30
minutes out of every 10 hours) and cruising speed
(3600 min
total engine time (9 hours out of every 10 hours).

The laws of some countries may require hull and
engine inspections, depending on the use, size and
cruising area of the boat. The installation, fitting
and surveying of this engine all require specialized
knowledge and engineering skills. See Yanmar’s
local subsidiary in your region or your authorized
Yanmar Marine dealer or distributor.

-1

(rpm) or less) for less than 90 % of

-1

8LV Series Operation Manual

11

PRODUCT OVERVIEW

NOTICE

New Engine Break-In

As with all reciprocating engines, the way your
engine is operated during its first 50 hours of
operation plays a very significant role in
determining how long it will last and how well the
engine will perform over its lifetime.

A new Yanmar diesel engine must be operated at
suitable speeds and power settings during the
break-in period to make the sliding parts, such as
piston rings, break-in properly and to stabilize
engine combustion.

During the break-in period, the engine coolant
temperature gauge should be monitored,
temperature should be lower than 80 °C (176 °F).

During the first 10 hours of operation, the engine

-1

should be run at maximum min
to 500 min

-1

(rpm) (approximately 60 to 70 % of
load) most of the time. This will ensure the sliding
parts break in properly. During this period, avoid
operating at maximum engine speed and load to
avoid damaging or scoring sliding parts.

Do not operate at WOT (wide open throttle) for
more than a minute at a time during the first
10 hours of operation.

(rpm) minus 400

Perform this procedure in seawaters:

• With the position of marine gear in NEUTRAL,
accelerate from the low speed position to the high
speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50 hours, the
engine should be used over its full operating range,
with special emphasis on running at relatively high
power settings. This is not the time for an extended
cruise at idle or low speed. The boat should be run

-1

at maximum speed minus 400 min

(rpm) most of
the time (approximately 70 % load), with a 10
minute run at maximum minus 300 min

-1

(rpm)
(approximately 80 % load) every 30 minutes and a
4 - 5 minute period of operation at WOT (wide open
throttle) once each 30 minutes. During this period,
be sure not to operate your engine at low speed
and light load for more than 30 minutes. If operating
engine at low speed and light load by necessity, just
after the low idle operation, be sure to rev up the
engine.

To complete engine break-in, perform After Initial

50 Hours of Operation maintenance procedures on
page 43.

Do not operate the engine at low idle or at low
speed and light load for more than 30 minutes at a
time. Since unburned fuel and engine oil will adhere
to the piston rings when operating at low speeds for
long periods, this will interfere with proper
movement of the rings and the lube oil consumption
may increase. Low idle speed does not allow
break-in of sliding parts.

If operating engine at low speed and light load, you
must rev up the engine (i.e. increase the engine
speed for a short time) to clean the carbon from the
cylinders and fuel injection valve.

12

8LV Series Operation Manual

PRODUCT OVERVIEW

COMPONENT IDENTIFICATION

Service Side

Figure 1 and Figure 2 illustrate a typical version of a 8LV series engine. Your engine may have different

equipment from that illustrated.

Lubricating oil
feeding port

Silencer

Turbo-charger

Mixing elbow

Turbo-charger

Silencer

Non-Service Side

Fuel priming pump

Fuel filter

Lubricating oil filter

Alternator

Fuel oil cooler

Dipstick

037423-00E00

Figure 1

Air cooler

Heat exchanger

ECUbox

Engine lubricating oil cooler

Figure 2

Seawater pump

037424-00E00

8LV Series Operation Manual

13

PRODUCT OVERVIEW

/

/

Gear Model

ENG.No.

MFG. DATE

/

Model

min

-1

min

-1

min

-1

Continuous power kW

Speed of prop. shaft

Fuel stop power kW

129670-07200

LOCATION OF NAMEPLATE

The nameplate of Yanmar 8LV series engines are
shown in Figure 3. Check the engine’s model,
output, rpm and serial number on the nameplate.
Please replace if damaged or lost.

The engine nameplate is attached to the top
surface of the engine air cooler (Figure 4).

Figure 3

Model

Gear Model

Continuous power kW

Speed of prop. shaft

Fuel stop power kW

ENG.No.

MFG. DATE

Figure 4

/

-1

min

/

/

-1

min

-1

min

037425-00X00

14

8LV Series Operation Manual

PRODUCT OVERVIEW

FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Removes dirt and water from the fuel. Drain the filter periodically. The filter element should

Fuel Filter

Fuel Supply Pump Pumps fuel from the tank to the fuel injection system.

Fuel Priming Pump

Fuel Cooler Cool the fuel with seawater to reduce the high temperature of the fuel circuit.

Engine Oil Filler Port Filler port for engine oil.

Engine Oil Filter

Cooling System

Closed Cooling
Circulation Pump

Seawater Pump

Coolant Filler Cap

Coolant Reservoir Tank

Oil Cooler - Engine A heat exchanger that cools high temperature engine oil using coolant.

Turbo-charger

Charge Air Cooler

Intake Silencer (Air
Cleaner)

Nameplates

Starter Starter motor for the engine. Powered by the battery.

Alternator Driven by belt and generates electricity and charges the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level.

be replaced periodically. The fuel/water separator (if equipped) should be drained
periodically. See Draining the Fuel/Water Separator on page 44.

This is a manual fuel pump. Pushing the knob on the top of the fuel filter feeds the fuel.
The pump is also used to bleed air from the fuel system.

Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is
distributed to the engine’s moving parts. The filter is a cartridge type and the element
should be replaced periodically. See Changing the Engine Oil and Replacing the Engine
Oil Filter Element on page 47.

There are two cooling systems: closed cooling with coolant (freshwater) and seawater.
The engine is cooled by the closed cooling circuit. The closed circuit is cooled by seawater
using a heat exchanger. The seawater also cools the marine gear oil and intake air
through the air cooler(s) in an open circuit.

The centrifugal water pump circulates coolant inside the engine. The circulating pump is
driven by a belt.

Pumps seawater from outside vessel to the engine. The seawater pump is belt-driven and
has a replaceable rubber impeller. Never operate it without seawater, as this will damage
the impeller.

When the coolant temperature rises, the pressure inside the coolant tank increases and
opens the pressure valve in the filler cap. When the pressure valve in the filler cap is
opened, hot water and steam pass through a rubber hose to the coolant reservoir tank.
When the engine cools and the pressure inside the coolant tank drops, the vacuum valve
in the filler cap opens and the coolant in the coolant reservoir tank returns to the coolant
tank through the pipe and filler cap. This minimizes coolant consumption.

The pressure valve in the filler cap releases vapor and hot water overflow to the coolant
reservoir tank. When the engine stops and the coolant cools, the pressure in the coolant
tank drops. The filler cap vacuum valve then opens to send water back from the coolant
reservoir tank. This minimizes coolant consumptions. The closed cooling system coolant
level can easily be checked and refilled in this tank.

The turbo-charger pressurizes the air coming into the engine. It is driven by a turbine that
is energized by exhaust gases.

This heat exchanger cools the pressurized charging air from the turbo-charger with
seawater to increase the charging air quantity.

The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates are provided on the engine and the marine gear and have the model, serial
number and other data.

8LV Series Operation Manual

15

PRODUCT OVERVIEW

VESSEL CONTROL SYSTEM (VCS)

8LV series engine is a fully electric engine, which is controlled by Yanmar’s original “Vessel Control System
(VCS)”.

The control equipment consists of the Switch Panel, the Display, the Drive & Helm ECU, the Control Head
and the Backup Panel, which are connected by the cable harness to the engine and marine gear or stern
drive for remote control operation.

Note: The Yanmar Vessel Control System (VCS) was designed to operate the 8LV engine and drive

system. There are many control functions and diagnostic functions that are integrated together to
insure safe operation. If this system is not utilized in specific accordance with the instructions in this
manual or the system is modified in any way, Yanmar will not be responsible for any warranty failures
in the operation of the system or the vessel utilizing the system.
Yanmar has designed the Vessel Control System (VCS) in conjunction with the 8LV engine. The
system has many functions that must be configured and calibrations must be made before the
vessel can be operated. Please arrange to have a Yanmar trained technician inspect the vessel prior
to the vessels operation.

1

NTRL

SEL

NEUTRAL

TROL

23 4 5

8

6

No. Description

1 Shift and Throttle Control Head

2 Switch Panel (to start and stop the engine)

3 VCS Digital Display

4Helm ECU

5Drive ECU

6 Backup Panel

7 Cable Harness Set

8 Adapter, Terminal

M/G or Stern drive

To engine

7

To engine

037618-00E00

Figure 5

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8LV Series Operation Manual

PRODUCT OVERVIEW

Display

The multi-function information display has the
following functions.

■ Display Function

Runtime Engine Data Tri-Screen

037635-00X00

Figure 6

This screen displays real time engine data and
alarm indications.

Alarm Indicators

Diag Codes Screen

Diag codes

PORT

STBD

037635-02X00

Figure 8

Alarm Indicator Functions

The alarm indicators and buzzer are activated
when sensors detect an abnormality during engine
operation. The alarm indicators are off during
normal operation, but are activated as follows when
an abnormality arises:

• The coolant temperature alarm indicator activates
when the coolant gets too hot.

• The engine oil pressure alarm indicator activates
when the engine oil pressure drops.

ALARM!

MAINTENANCE ENGINE

OK

CANCEL

037635-01X00

Figure 7

The alarm window appears with an audible alarm
when abnormal engine activity occurs.

Note: When starting the engine, make it a rule to

check that when the switch panel is pressed
to the power switch, the welcome screen
appears on the display and goes out. If the
system does not function normally, contact
your authorized Yanmar Marine dealer or
distributor and ask for diagnostics.

• The electric charge alarm indicator activates
when there is a charging failure.

8LV Series Operation Manual

17

PRODUCT OVERVIEW

NOTICE

■ Switch Panel

(to start and stop the engine)

The switch panel has the following functions.

Eng.START/STOPswitch

CheckEng.indicator

Emergencystopswitch

Powerswitch

037627-00E04

Figure 9

To start and stop the engine:

Press the START/STOP switch.

■ Emergency Stop Switch

Use this switch only in an emergency.

Under normal circumstances, do not use the
Emergency stop switch to stop the engine.
The engine shuts down suddenly when the
Emergency stop switch is pressed.
After the engine has stopped, press the Emergency
stop switch to release the emergency stop.

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8LV Series Operation Manual

8LV Series Operation Manual

BEFORE YOU

OPERATE

This section of the Operation Manual describes the
diesel fuel, engine oil, and engine coolant
specifications and how to replenish them. It also
describes the daily engine checks.

Before performing any operations within this
section, review the Safety section on page 3.

8LV Series Operation Manual

19

BEFORE YOU OPERATE

DANGER

NOTICE

CAUTION

DIESEL FUEL

Diesel fuel is flammable and explosive under
certain conditions. See Safety on page 3.

Diesel Fuel Specifications

Only use diesel fuels recommended by Yanmar
Marine for the best engine performance, to prevent
engine damage and to comply with EPA warranty
requirements. Only use clean diesel fuel.

Diesel fuel should comply with the following
specifications. The table lists several worldwide
specifications for diesel fuels.

Diesel Fuel Specification Location

No. 2-D, No. 1-D, ASTM D975 USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

B5 diesel fuels must meet certain specifications

The biodiesel fuels must meet the minimum
specifications for the country in which they are
used:

• In Europe, biodiesel fuels must comply with the
European Standard EN14214.

• In the United States, biodiesel fuels must comply
with the American Standard ASTM D-6751.

Biodiesel should be purchased only from
recognized and authorized diesel fuel suppliers.

Precautions and concerns regarding the use of
bio-fuels:

• Biodiesel fuels have a higher content of
methyl-esters, which may deteriorate certain
metal, rubber and plastic components of the fuel
system. The customer and/or boat builder are
responsible to verify the usage of biodiesel
compatible components on the vessel fuel supply
and return systems.

• Free water in biodiesel may result in plugging of
fuel filters and increased bacterial growth.

• High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.

■ Bio-Diesel Fuels

Yanmar approves the use of biodiesel fuels that do
not exceed a blend of 5 % non-mineral oil based
fuel with 95 % standard diesel fuel. Such biodiesel
fuels are known in the marketplace as B5 biodiesel
fuels. B5 biodiesel fuel can reduce particulate
matter and the emission of “greenhouse” gases
compared to standard diesel fuel.

If the B5 biodiesel fuel used does not meet the
approved specifications, it will cause abnormal
wear of injectors, reduce the life of the engine
and it may affect the warranty coverage of your
engine.

• Biodiesel may have adverse effects on some
elastomers (seal materials) and may result in fuel
leakage and dilution of the engine lubricating oil.

• Even biodiesel fuels that comply with a suitable
standard as delivered, will require additional care
and attention to maintain the quality of the fuel in
the equipment or other fuel tanks. It is important
to maintain a supply of clean, fresh fuel. Regular
flushing of the fuel system, and/or fuel storage
containers, may be necessary.

• The use of biodiesel fuels that do not comply with
the standards as agreed to by the diesel engine
manufacturers and the diesel fuel injection
equipment manufacturers, or biodiesel fuels that
have degraded as per the precautions and
concerns above, may affect the warranty
coverage of your engine.

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8LV Series Operation Manual