6LPA series OPERATION MANUAL 6LPA-STP2 6LPA-STZP2 P/N: 0A6LP-G00101 MARINE ENGINES
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.
TABLE OF CONTENTS Page Introduction .............................................................. 1 Record of Ownership .............................................. 2 Safety ....................................................................... 3 Safety Precautions ................................................. General Information ......................................... Before You Operate ......................................... During Operation and Maintenance .....................
TABLE OF CONTENTS Checking the Engine Oil .................................. 31 Adding Engine Oil .......................................... 31 Marine Drive Oil .................................................... 32 Mercruiser Bravo Stern Drive Oil Specifications ................................................ 32 Checking and Adding Marine Drive Oil ................ 32 Checking and Adding Power Steering Oil (6LPASTZP2 Models) ............................................. 32 Engine Coolant ................
TABLE OF CONTENTS Tightening Fasteners ...................................... 51 EPA Maintenance Requirements .............................. 52 EPA Requirements for USA and Other Applicable Countries ..................................................... 52 EPA Requirements ......................................... 52 Conditions to Ensure Compliance with EPA Emission Standards ........................................ 52 Inspection and Maintenance .............................
TABLE OF CONTENTS Your Warranty Rights and Obligations: ................ 93 Warranty Period: ............................................ 94 Warranty Coverage: ........................................ 94 Exclusions: ................................................... 94 Owner’s Responsibility: ................................... 95 Customer Assistance: ..................................... 95 Maintenance Log ...........................................
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.
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.
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’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged.
SAFETY 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.
SAFETY Sever Hazard ! WARNING The safety messages that follow have WARNING level hazards. 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. Rotating parts can cause severe injury or death.
SAFETY ! WARNING ! CAUTION Piercing Hazard Avoid skin contact with highpressure 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. Have your authorized Yanmar marine dealer or distributor repair the damage.
SAFETY NOTICE The safety messages that follow have NOTICE level hazards. 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. See your authorized Yanmar marine dealer or distributor if you need to operate the engine at high altitudes.
SAFETY LOCATION OF SAFETY DECALS Figure 1 shows the location of safety decals on Yanmar 6LPA series marine engines. (1) (2) (3) (4) (5) 0004813 1 – Part Number: 120324-07240 2 – Part Number: 128296-07260 3 – Part Number: 119773-07280 Figure 1 4 – Part Number: 128296–07300 5 – Part Number: 128296–07360 Note: Figure 1 shows an overhead view of the 6LPA engine.
PRODUCT OVERVIEW YANMAR 6LPA FEATURES AND APPLICATIONS The 6LPA series are 6-cylinder, 4-stroke direct injection diesel engines equipped with liquid coolant systems. The 6LPA-STP2 engines are equipped with a marine gear (ZF63A1 or KMH50A). The 6LPA-STZP2 engines are equipped with a stern drive (Mercruiser Bravo). These engines are designed for pleasure craft use.
PRODUCT OVERVIEW 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. Perform this procedure in open waters: During the break-in period, the engine coolant temperature gauge should be monitored, temperature should be between 71˚ - 87˚C (160˚ - 190˚F).
PRODUCT OVERVIEW COMPONENT IDENTIFICATION Service Side (Left Side as Viewed from Propeller) Note: 6LPA-STZP2 with stern drive shown. Components marked with an * are for 6LPA-STZP2 only.
PRODUCT OVERVIEW Non-Service Side (3) (2) (1) (4*) (5) (6) (11) (7*) (10) (9) (8) 0004885 1– 2– 3– 4– 5– 6– 12 Figure 2 Turbocharger Engine Nameplate (on rocker arm cover) Fresh Water (Coolant) Tank Power Steering Oil Tank* Fresh Water Filler Cap Engine Oil Filler Cap 7 – Power Steering Oil Pump* 8 – Alternator 9 – Engine Oil Dipstick 10 – Fresh Water Cooler 11 – V-Belt 6LPA Series Operation Manual © 2007 Yanmar Marine International
PRODUCT OVERVIEW ENGINE NAMEPLATE Model Gear Model // Continuous power kW min-1 min-1 Speed of prop,shaf t // Fuel stop power kW min-1 ENG.No. 0004574 Figure 3 The nameplate of Yanmar 6LPA series engines is shown in Figure 3. The nameplate is located on the engine rocker arm cover. Check the engine's model, output, rpm and serial number on the nameplate. Replace if damaged or lost.
PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter Removes dirt and water from the fuel. The filter is a cartridge type, and the inner element should be replaced before clogging occurs. A water separator is on the bottom of the filter and should be drained periodically. Fuel Feed Pump A mechanical pump that pumps fuel from the tank to the fuel injection pump. It is built in to the fuel injection pump. Fuel Bleed Pump This is a manual fuel pump.
PRODUCT OVERVIEW CONTROL EQUIPMENT The control equipment at the helm makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the remote control (throttle) handle, which is connected by control cables to the engine control lever. Instrument Panel (Optional) Equipment and Functions The instrument panel has the following gauges and alarm devices.
PRODUCT OVERVIEW (1) (2) New B-Type (3) (4) (5) (8) 1– 2– 3– 4– Warning Indicator Display Tachometer Alarm Stop Switch Panel Illumination Switch (1) (2) (7) Figure 4 (6) 5– 6– 7– 8– 0003281_m1 Engine Stop Button Starter (Key) Switch Alarm Hourmeter New C-Type (3) (4) (5) (6) (7) (10) 1– 2– 3– 4– 5– 16 (9) Figure 5 Engine Oil Pressure Gauge Fresh Water (Coolant) Temperature Gauge Tachometer Alarm Stop Switch Panel Illumination Switch (8) 0003282_m1 6 – Engine Stop Button 7 – Start (Ke
PRODUCT OVERVIEW (1) (2) New D-Type (3) (4) (5) (12) (11) (10) (9) (6) (7) (8) 0003283_m1 1– 2– 3– 4– 5– 6– Figure 6 Turbocharger Boost Pressure Gauge Engine Oil Pressure Gauge Fresh Water (Coolant) Temperature Gauge Tachometer Alarm Stop Switch Panel Illumination Switch 7 – Engine Stop Button 8 – Start (Key) Switch 9 – Alarm 10 – Hourmeter 11 – Clock 12 – Warning Indicator Display 6LPA Series Operation Manual © 2007 Yanmar Marine International 17
PRODUCT OVERVIEW Available Alarm Switches and Meter Senders 6LPA-STP2 6LPA-STZP2 Switches Senders Battery Not Charging ○ Fresh Water (Coolant) Temperature Too High ○ Engine (Lube) Oil Pressure Too Low ○ Fresh Water (Coolant) Level Too Low □ Exhaust (Cooling Seawater Flow) Restriction □ Gear Oil (Stern Drive Models Only) □ Fuel Filter ○ Tachometer ○ Fresh Water (Coolant) Temperature □ Engine (Lube) Oil Pressure □ Boost Pressure □ Fresh Water (Coolant) Temperature Engine (Lube) Oil Pr
PRODUCT OVERVIEW Switches and Gauges Switch or Gauge Function OFF (2): The key can be inserted or removed from switch. All power is turned off. * (1) ON (3): For engine operation. Gauges and alarms are operational. (2) (3) START (4): For starting engine. When key is released after engine starts, key automatically moves to ON position. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat. (4) GLOW (1): For air heater (optional).
PRODUCT OVERVIEW Warning Devices When a sensor detects a problem during operation, the indicator on the instrument panel will light and an alarm will sound. Indicators are located on the instrument panel, the alarm is located on the back of the panel. Under normal operating conditions, the indicators are off. • Alarm (Buzzer): If a warning lamp illuminates, the alarm will sound. However, no alarm will sound when the battery charging lamp illuminates.
PRODUCT OVERVIEW Figure 11 Fuel Filter (Water Separator) (Figure 11) When the water level inside the water separator becomes too high, the sensor will send a signal to the indicator causing it to light. Drain the water separator. If operation is continued without draining the water separator, fuel feed to the engine is restricted and may cause damage to the engine or fuel injection pump.
PRODUCT OVERVIEW Alarms Check that indicators and alarms are working normally when the key is turned to ON.
PRODUCT OVERVIEW Engine Stop Button (1) Figure 15 0004881 Push and hold the stop button (Figure 15, (1)) on the instrument panel to stop the engine. When the stop button is pushed, the solenoid valve on the fuel injection pumps stops the fuel supply to the engine. Press and hold the engine stop button until the engine has come to a complete stop. NOTICE: Releasing the engine stop button before the engine has stopped rotating will cause the engine to continue to run.
PRODUCT OVERVIEW Remote Control (Throttle) Handle MV Side Mount The engine is controlled by the remote control handle located in the cockpit. The speed control lever on the engine and clutch lever on the marine drive are connected by remote control cables. There are various models of remote control handles available. When using a model other than shown below, consult the manufacturer's documentation for more information.
PRODUCT OVERVIEW Reverse Move the handle from NEUTRAL to REV (reverse). This engages the clutch in reverse and simultaneously increases the engine speed. Pushing the handle further in the same direction increases engine speed to full speed. MV (3) (2) Free Throttle Operation When the boat is stopped (clutch is in NEUTRAL) the idling speed of the engine can be increased in the following manner: 1. 2. (1) 0004889 Figure 19 Ensure the handle is in NEUTRAL.
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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. DIESEL FUEL Diesel Fuel Specifications Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels. DIESEL FUEL SPECIFICATION LOCATION ASTM D975 No. 2-D, No.
BEFORE YOU OPERATE Additional Technical Fuel Requirements 2. • The fuel cetane number should be equal to 45 or higher. • The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred. • NEVER mix kerosene, used engine oil, or residual fuels with the diesel fuel. • Water and sediment in the fuel should not exceed 0.05% by volume. • Keep the fuel tank and fuel-handling equipment clean at all times. • Ash content not to exceed 0.01% by volume. • Carbon residue content not to exceed 0.
BEFORE YOU OPERATE Bleeding the Fuel System Fuel System (1) Bleeding must be done if any fuel system maintenance has been performed (replacement of fuel filter, etc.) or if the engine does not start after several attempts. (8) (2) (7) (3) (1) (4) Figure 3 (5) (6) 0004489 (2) 1– 2– 3– 4– 5– Fuel Filter To Fuel Injection Pump Less than 500 mm (20 in.) Fuel Cock 20 - 30 mm (0.75 - 1.125 in.
BEFORE YOU OPERATE ENGINE OIL Engine Oil Viscosity Engine (Lube) Oil Specifications Use an engine oil that meets or exceeds the following guidelines and classifications: SAE 10W-30 SAE 15W-40 API Service Categories CD or higher Recommended SAE Oil Viscosity: 10W30 or 15W40 Note: 1. Be sure the engine oil, engine oil storage containers and engine oil filling equipment are free of sediment or water. 2. Change the engine oil after the first 50 hours of operation and then at every 125 hours thereafter. 3.
BEFORE YOU OPERATE Checking the Engine Oil Adding Engine Oil (4) 1. (5) (1) 2. (2) (3) 0004902 Figure 6 1. 2. 3. 4. 5. 6. It is recommended that the engine be as level as possible before checking the oil. Remove dipstick (Figure 6, (1)) and wipe with clean cloth. Fully reinsert dipstick. Remove dipstick. The oil level should be between upper (Figure 6, (2)) and lower (Figure 6, (3)) lines on the dipstick. Add oil if necessary. See Adding Engine Oil on page 31.
BEFORE YOU OPERATE MARINE DRIVE OIL Checking and Adding Marine Drive Oil Note: Refer to the marine gear manufacturer's operation manual for the marine gear oil specifications. Refer to the manufacturer's operation manual for marine gear or stern drive oil specifications. Note: Refer to the manufacturer's operation manual for the proper procedure to check and fill the marine drive oil.
BEFORE YOU OPERATE ENGINE COOLANT Note: In the U.S., LLC is required for the warranty to be valid. Engine Coolant Specifications Engine Coolant • Texaco Long Life Coolant (LLC), both standard and premixed, product code 7997 and 7998. • Havoline Extended Life Antifreeze / Coolant, product code 7994. NOTICE: Always add LLC to soft water - especially when operating in cold weather. Without LLC, cooling performance will decrease due to scale and rust in the cooling system.
BEFORE YOU OPERATE Checking and Adding Engine Coolant 5. (4) (1) (1) (2) FULL (3) LOW 0004493 Figure 9 0004910 Figure 8 1. 2. 3. 4. 34 Ensure all drain cocks are closed. WARNING! NEVER remove the filler cap while the engine is hot. Serious burns may result. Loosen the filler cap of the coolant tank to relieve the pressure, then remove the filler cap (Figure 8, (1)). Pour coolant slowly into the coolant tank to avoid air bubbles. Fill until coolant overflows from the filler port.
BEFORE YOU OPERATE CRANKING THE ENGINE 7. When performing engine break-in or if the engine has not been used for a long period of time, engine oil will not be distributed to all of the operating parts. Using the engine in this condition will lead to seizure. After a long period of non-use, distribute engine oil to each part by cranking the engine. Perform the following procedure before beginning operation: 1. 2. 3. 4. When the key is in the START position, the engine will begin cranking.
BEFORE YOU OPERATE DAILY CHECKS Checking Diesel Fuel, Engine Oil and Engine Coolant Levels Before you start for the day, make sure the Yanmar engine is in good operating condition. CAUTION! It is important to perform daily checks as listed in this 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.
BEFORE YOU OPERATE Checking the Wiring Connectors See your authorized Yanmar marine dealer or distributor. Tightening All Major Nuts and Bolts See Tightening Fasteners on page 51 or see your authorized Yanmar marine dealer or distributor.
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ENGINE OPERATION Exhaust Hazard ! WARNING Fire and Explosion Hazard 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. 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.
ENGINE OPERATION STARTING THE ENGINE NOTICE 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. If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is in the ON position, see your authorized Yanmar marine dealer or distributor for service before operating the engine.
ENGINE OPERATION 6. 7. Turn the key switch to START (Figure 1, (4)). Release the key switch when the engine has started. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat. The alarm should stop and the indicators should go out. NOTICE: If any indicator fails to illuminate when the key switch is in the ON position, see your authorized Yanmar marine dealer or distributor for service before operating the engine.
ENGINE OPERATION Restarting After Starting Failure After the Engine Has Started Before turning the key switch again, ensure the engine has stopped completely. If an attempt to restart is made while the engine is running, the pinion gear of the starter motor will be damaged. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat. 1. After the engine has started, ensure the remote control handle is in NEUTRAL.
ENGINE OPERATION 2. 3. 4. MT-3: Pull out the handle lever (Figure 3, (4)) and adjust the speed to no more than 1500 rpm and run the engine at low speed with no load. MV: Pull out the free throttle button (Figure 4, (4)) and adjust the speed to no more than 1500 rpm and run the engine at low speed with no load. Allow engine to run for approximately 5 minutes. Check the following items at a low engine speed: • Check that the gauges, indicators and alarm are normal.
ENGINE OPERATION REMOTE CONTROL HANDLE OPERATION MV Side Mount (4) (3) Acceleration and Deceleration MT-3 Top Mount (4) (5) (3) (5) (6) (2) (6) (2) (1) (7) (1) (7) 0004887 Figure 6 0004886 Figure 5 1– 2– 3– 4– 5– 6– 7– Reverse High Speed Reverse Low Speed Reverse Neutral Forward Forward Low Speed Forward High Speed 1– 2– 3– 4– 5– 6– 7– Forward High Speed Forward Low Speed Forward Neutral Reverse Reverse Low Speed Reverse High Speed Note: Direction of travel will vary depending on installatio
ENGINE OPERATION 2. NOTICE: NEVER shift the marine gear at high engine speed. During normal operation, the marine gear should only be shifted with the engine at idle. When moving the handle between FORWARD and REVERSE, bring the clutch to NEUTRAL and pause before slowly shifting to the desired position. Do not shift abruptly from FORWARD to REVERSE or vice versa. Morse Remote Control Handle (Optional) • Move the handle to the NEUTRAL (middle) position to stop the boat. The engine will idle at low speed.
ENGINE OPERATION 7. 8. 9. 46 Turn off the battery master switch (if equipped). Close the fuel cock. Close the seacock (if equipped). NOTICE: Be sure to close the seacock. Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink.
PERIODIC MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. SAFETY PRECAUTIONS ! WARNING Crush Hazard If you need to transport an engine 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.
PERIODIC MAINTENANCE Shock Hazard ! WARNING Welding Hazard Make welding repairs safely. • 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. • Remove the multi-pin connectors to the engine electronics or engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point.
PERIODIC MAINTENANCE PRECAUTIONS NOTICE 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.
PERIODIC MAINTENANCE Keep a Log of Engine Hours and Daily Checks Keep a log of the number of hours the engine is run each day and a log of the daily checks performed. Also note the date, type of repair (e.g., replaced alternator), and parts used for any service needed between the periodic maintenance intervals. Periodic maintenance intervals are every 50, 125, 250, 500, 1000 and 1250 engine hours. Failure to perform periodic maintenance will shorten the life of the engine.
PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. NOTICE: The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7” head (JIS strength classification: 7T). Apply 60% torque to bolts that are not listed. Apply 80% torque when tightened to aluminum alloy.
PERIODIC MAINTENANCE EPA MAINTENANCE REQUIREMENTS The operating conditions should be as follows: To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential that you follow the Periodic Maintenance Schedule on page 54 and the Periodic Maintenance Procedures on page 59. EPA Requirements for USA and Other Applicable Countries The following are the requirements for the EPA.
PERIODIC MAINTENANCE Inspection and Maintenance See Inspection and Maintenance of EPA Emission-Related Parts on page 58 for the EPA emission-related parts. Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission-Related Parts section are covered in Periodic Maintenance Schedule on page 54. This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty period.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline.
PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Lubricating System Every 50 hours or monthly whichever comes first Every 125 hours or 6 months whichever comes first Change the engine oil ◊ Initial 50 ◊ Replace the engine oil filter element ◊ Initial 50 ◊ Check the engine oil level Every 250 hours or one year whichever comes first Every 500 hours or 2 years whichever comes first Eve
PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Seawater Cooling System Check seawater outlet discharge Every 50 hours or monthly whichever comes first Every 125 hours or 6 months whichever comes first Every 250 hours or one year whichever comes first Every 500 hours or 2 years whichever comes first ● Check or replace the zinc anodes ◊ Check and clean the seawater passage Electrical
PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Remote Control Handle Intake and Exhaust System Check and lubricate the remote control cable operation Every 50 hours or monthly whichever comes first Every 125 hours or 6 months whichever comes first Every 250 hours or one year whichever comes first Every 500 hours or 2 years whichever comes first Every 1250 hours or 5 years whichever com
PERIODIC MAINTENANCE Inspection and Maintenance of EPA Emission-Related Parts Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle (adjustment) Check fuel injection pump adjustment 3000 hours Check turbocharger adjustment Check electronic engine control unit and its associated sensors and actuators Note: The inspection and maintenance items shown above to be performed at your Yanmar dealer or distributor.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES 2. After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. • Changing the Engine Oil and Replacing the Engine Oil Filter Element • Changing the Fuel Filter Element Changing the Engine Oil and Replacing the Engine Oil Filter Element The engine oil on a new engine becomes contaminated from the initial break-in of internal parts.
PERIODIC MAINTENANCE 10. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low. 11. Dispose of waste properly. Replacing the Fuel Filter Element (5) (4) (3) (2) (1) 0004915 Figure 3 60 1– 2– 3– 4– 5– Mounting Screw (2 used) Housing Alarm Switch O-Ring Filter Element 1. Close the fuel cock of the fuel tank.
PERIODIC MAINTENANCE 2. 3. 4. Remove the two mounting screws (Figure 3, (1)) and the housing (Figure 3, (2)). Drain the fuel from the fuel drain cock on the bottom of the fuel / water separator. Disconnect the alarm switch harness. Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter or monthly, whichever comes first.
PERIODIC MAINTENANCE Draining Fuel Filter / Water Separator Water and sediment can clog the fuel filter and impair the function of the fuel injection pump and valve. If heavy deposits of water and sediment are drained, also drain the fuel tank. NOTICE: NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electric system will result. Note: Battery fluid tends to evaporate in high temperatures, especially in summer.
PERIODIC MAINTENANCE Every 125 Hours of Operation Perform the following maintenance every 125 hours of operation or 6 months, whichever comes first. • Changing the Engine Oil and Replacing the Engine Oil Filter Changing the Engine Oil and Replacing the Engine Oil Filter See Changing the Engine Oil and Replacing the Engine Oil Filter Element on page 59. After Initial 250 Hours of Operation Perform the following maintenance after the initial 250 hours of operation.
PERIODIC MAINTENANCE Every 250 Hours of Operation Perform the following maintenance every 250 hours or one year of operation, whichever comes first. • Replacing the Fuel Filter Element • Changing the Coolant • Checking or Replacing the Zinc Anodes • Adjusting the Remote Control Cable • Cleaning the Turbocharger • Cleaning the Air Cleaner Replacing the Fuel Filter Element 3. 4. 5. 6. 7.
PERIODIC MAINTENANCE Fresh Water Cooler (4) 0004917 Figure 11 Intercooler (2) Location Part Number Qty. Dimensions DxL Fuel Cooler 119574– 44150 1 0.5 x 1.0 in. Engine Oil Cooler 119574– 44150 2 0.5 x 1.0 in. Fresh Water Cooler 119574– 44150 1 0.5 x 1.0 in. Intercooler 119574– 18790 2 0.5 x 1.0 in. Note: Some marine drives have additional zinc anodes. Check the manufacturer's documentation for location and other information.
PERIODIC MAINTENANCE Cleaning the Air Cleaner Every 500 Hours of Operation (1) 0004911 Figure 14 1. 2. 3. Slide air cleaner (Figure 14, (1)) off air inlet. Clean the air cleaner with detergent. Allow to air dry and install on the air inlet. NOTICE: Replace the air cleaner if unable to clean or if damaged. Perform the following maintenance every 500 hours or 2 years of operation, whichever comes first.
PERIODIC MAINTENANCE (2) Checking and Adjusting the Alternator V-Belt Tension (3) (1) (4) (1) (2) 0004913 Figure 16 1. 0004903 Figure 15 NOTICE: NEVER get any oil on the belt(s). Oil on the belt causes slipping and stretching. Replace the belt if it is damaged. NEVER over-tighten the belt(s). Engine damage will result. 1. 2. 3. Check the belt by pushing on the middle of the belt (Figure 15, (1)) with your finger. With proper tension, the belt should deflect 8 - 10 mm (approximately 3/8 in.).
PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or 4 years of operation, whichever comes first.
PERIODIC MAINTENANCE 7. NOTICE: Replace the seawater pump impeller every 1000 hours even if no damage is apparent. When replacement is required, see your authorized Yanmar marine dealer or distributor. Adjusting Intake / Exhaust Valve Clearance See your authorized Yanmar marine dealer or distributor. Lapping the Intake and Exhaust Valve See your authorized Yanmar marine dealer or distributor.
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TROUBLESHOOTING If a problem occurs, stop the engine immediately. Refer to the SYMPTOM column in the Troubleshooting Chart to identify the problem. TROUBLESHOOTING AFTER STARTING Just after the engine has started, check the following items at a low engine speed: Is sufficient water being discharged from the seawater outlet pipe? • If the discharge is low, stop the engine immediately. Identify the cause and repair.
TROUBLESHOOTING Periodically operate the engine near maximum speed while underway. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintain engine performance and prolong the life of the engine. Are there abnormal vibrations or noise? • Depending on the hull structure, engine and hull resonance may suddenly increase at certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed range.
TROUBLESHOOTING TROUBLESHOOTING CHART Symptom Probable Cause Measure Indicators light on the instrument panel and alarm sounds during operation Shift to low speed operation immediately, and check which indicator has come on. Stop the engine and inspect. If no abnormality is identified and there is no problem with operation, return to port at lowest speed and request repairs. • Engine oil low pressure alarm indicator comes on Engine oil level is low. Check engine oil level. Add or replace.
TROUBLESHOOTING Symptom Probable Cause Measure Reference • When key is turned ON • When any trouble occurs (oil pressure etc.) No electrical current available. Circuit broken or lamp burned out. See your authorized Yanmar marine dealer or distributor. - • One of the indicators does not go out Sensor switch is faulty. See your authorized Yanmar marine dealer or distributor. - • Battery low charge indicator does not go out during operation V-belt is loose or broken.
TROUBLESHOOTING Symptom Probable Cause Measure Reference No fuel. Add fuel. Bleed fuel system. See Filling the Fuel Tank on page 29 and See Bleeding the Fuel System on page 29 Air in fuel line. Bleed fuel system. See Bleeding the Fuel System on page 29 Fuel filter is clogged. Replace filter element. See Replacing the Fuel Filter Element on page 60 Improper fuel. Replace with recommended fuel. See Diesel Fuel Specifications on page 27 Problem with fuel injection.
TROUBLESHOOTING Symptom Probable Cause Measure Reference Overload Reduce load. - Improper propeller matching. See your authorized Yanmar marine dealer or distributor. - Dirty air cleaner. Clean air cleaner. See Cleaning the Air Cleaner on page 66 Improper fuel. Replace with recommended fuel. See Diesel Fuel Specifications on page 27 Faulty spraying of fuel injector. See your authorized Yanmar marine dealer or distributor. - Low boost pressure.
TROUBLESHOOTING TROUBLESHOOTING INFORMATION If the engine does not operate properly, refer to the Troubleshooting Chart on page 73 or see your authorized Yanmar marine dealer or distributor.
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LONG-TERM STORAGE If the engine will not be used for an extended period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting. The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized Yanmar marine dealer or distributor.
LONG-TERM STORAGE DRAINING THE FRESH WATER AND SEAWATER COOLING SYSTEM (1) (4) (2) 0004906 Figure 3 0004904 Figure 1 (5) (3) 0004907 Figure 4 0004905 Figure 2 1– 2– 3– 4– 5– Seawater Drain Cock Fresh Water Drain Cock Fresh Water Drain Cock Seawater Pump Cover Seawater Drain Cock Draining the Fresh Water Cooling System 1. 2. 3. 80 Open the fresh water drain cocks and drain the fresh water into an appropriate container. Close the drain cocks after draining the water. Dispose of waste properly.
LONG-TERM STORAGE Draining Seawater Cooling System NOTICE: If seawater is left inside, it may freeze and damage parts of the cooling system (fresh water cooler, seawater pump, etc.) when ambient temperature is below 0°C (32°F). 1. 2. 3. 4. 5. REMOVING THE ENGINE FROM LONG-TERM STORAGE When using the engine after a long period of storage, prepare for operation in the same manner for a new engine. See Before You Operate on page 27. Close the seacock. Open the seawater drain cocks and drain off the seawater.
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SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS Specification 6LPA-STP2 Type 6LPA-STZP2 Vertical water-cooled 4–cycle diesel engine Number of cylinders 6 Bore x stroke 94 mm x 100 mm 3.7 in. x 3.94 in. Displacement 4.164 L Continuous power at crankshaft 211 kW (286 hp) / 3682 rpm Maximum output rating* 232 kW (315 hp) / 3800 rpm* High idle 4280 ± 25 rpm Low idle 750 + 25 / 0 Combustion system Direct injection Starting system Electric start (12 V - 2.
SPECIFICATIONS * Density of fuel: 0.840 g/cm3 at 15˚C. Fuel temperature 25°C at the inlet of the fuel injection pump. Rating condition: ISO 3046-1, 8665. Note: 1 hp metric = 0.7355 kW Output Power Fuel Temperature 84 Specific Gravity 25°C 77°F 40°C 104°F 0.860 323 306 0.
SPECIFICATIONS Marine Drive Specifications (Optional) Model Type Applicable engine Reduction ratio ZF63A1: Ahead / Astern Bravo X-1, 2, 3: Both Ahead / Astern Hurth Kanzaki ZF63A1 KMH50A Mercruiser Bravo X-1 Bravo X-2 8° down Hydraulic Stern Drive 6LPA-STP2 6LPA-STZP2 Bravo X-3 1.22 / 1.21 1.67 / 1.67 1.36 1.50 1.36 1.56 / 1.58 2.13 / 2.13 1.50 1.65 1.50 2.04 / 2.10 2.43 / 2.43 - 1.81 1.65 2.52 / 2.53 - - 2.00 1.81 See manufacturer's documentation for additional information.
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SYSTEM DIAGRAMS PIPING DIAGRAMS Contact your authorized Yanmar dealer for current diagrams.
SYSTEM DIAGRAMS - - 0004891 6LPA-STP2 Figure 1 88 6LPA Series Operation Manual © 2007 Yanmar Marine International
SYSTEM DIAGRAMS Power Power Power - - 0004892 6LPA-STZP2 Figure 2 6LPA Series Operation Manual © 2007 Yanmar Marine International 89
SYSTEM DIAGRAMS WIRING DIAGRAMS 0004893 B-Type Instrument Panel Figure 3 90 6LPA Series Operation Manual © 2007 Yanmar Marine International
SYSTEM DIAGRAMS 0004894 C/D-Type x B-Type Instrument Panel Figure 4 6LPA Series Operation Manual © 2007 Yanmar Marine International 91
SYSTEM DIAGRAMS 0004895 C/D-Type x C-Type Instrument Panel Figure 5 92 6LPA Series Operation Manual © 2007 Yanmar Marine International
EPA WARRANTY USA ONLY YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR 94 AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES. Note: Please refer to Yanmar's Limited Warranty Handbook for a description of the normal (non-EPA) warranty.
EPA WARRANTY USA ONLY It is recommended that any replacement parts used for maintenance, repair or replacement of emission control systems are Yanmar parts. The owner may elect to have maintenance, replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance, replacement or repair.
EPA WARRANTY USA ONLY Owner’s Responsibility: Customer Assistance: As the Yanmar marine engine owner, you are responsible for the performance of the required maintenance listed in your Operation Manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your marine engine, but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
Maintenance Log Date 96 Operating Hours Maintenance Performed Dealer Name 6LPA Series Operation Manual © 2007 Yanmar Marine International Stamp or Signature
Date Operating Hours Maintenance Performed 6LPA Series Operation Manual © 2007 Yanmar Marine International Dealer Name Stamp or Signature 97
98 6LPA Series Operation Manual © 2007 Yanmar Marine International
