Yanmar 6LPA-STP2 User manual

6LPA
series
6LPA Service Manual
SERVICE MANUAL
6LPA-STP2
6LPA-STZP2
P/N: 0B6LP-U00101
MARINE
ENGINES

ii NOV 2007 (Rev. 01) 6LPA Service Manual
© 2007 Yanmar Marine International
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind
and may not contain the necessary detail or safety statements that may be required for a non-professional to
perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service
professional before working on your Yanmar product.
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.
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 Marine International.
© 2007 Yanmar Marine International.
1207

6LPA Service Manual 1-1
© 2007 Yanmar Marine International
6LPA Service Manual Section 1
INTRODUCTION
This manual gives specific instructions for the
proper repair of Yanmar 6LPA-STP2/STZP2 series
marine engines.
Please follow the procedures carefully to ensure
quality service.
Yanmar recommends that you read this Service
Manual completely before starting with repairs.
Along with standard tools, Yanmar recommends the
use of special tools, necessary to perform repairs
correctly.
Yanmar products are continuously undergoing
improvement. This Service Manual has been
checked carefully in order to avoid errors. However
Yanmar is not liable, for any misrepresentations,
errors of description or omissions. Contact an
authorized Yanmar marine dealer or distributor for
any questions you have regarding this Service
Manual.

INTRODUCTION Revision History
1-2 NOV 2007 (Rev. 01) 6LPA Service Manual
© 2007 Yanmar Marine International
REVISION HISTORY
This manual is a living document. Periodic manual
revisions are published to document product
improvements and changes. This practice ensures
the manual has the most current information.
As manual revisions become necessary, individual
pages are prepared and sent to those who need
the information. If a page, or number of pages
should be replaced, the replacement information is
sent along with a revised Revision Control Table.
Discard the older, obsolete information.
At times, the revision involves inserting additional
pages in one or more sections. Replace the
Revision Control Table and insert the new pages.
This method of revision control represents the most
cost-effective solution to providing current, updated
information as needed.
Revision Control Table
Revision Date
Revision Number
New Page Numbers
Involved Remarks Initiating
Dept.
Jun 2007
Rev. 0
ALL Initial Release YMI
Nov 2007
Rev. 01
3-18
3.32
4-5
Fixed Nameplate
Units of measure
EPA Update
YMI

GENERAL SERVICE INFORMATION
Front Power Take-Off (PTO) Output
12/05
6LPA Service Manual 3-17
© 2007 Yanmar Marine International
Method for Front PTO
1. Use type "A" (Belt drive with no outside
bearing). NEVER use other types of PTO.
2. NEVER engage the UP-pull drive. Use the side
pull belt drive.
3. Use a single V-drive, type "A."
4. The PTO pulley should be aluminum. The
outside diameter should be maximum 170 mm
(6.69 in.) and the overhang within
25 mm (0.98 in.).
5. Install the pulley to the exterior of the viscous
damper and tighten the pulley and damper with
the damper fixing bolts (M8 x (6 Qty.)) and the
washers. (Torque: 3.8 ± 0.2 kg·m,
37.27 ± 1.96 N·m (27.4 ± 1.4 lb-ft))
Note: The crankshaft may break if the front
PTO output exceeds the allowable
output.
Figure 3-14V-Pulley Overhang
Figure 3-14
1 – Pulley Thickness Should be
10 mm (0.393 in.)
2 – Viscous Damper
3 – Crankshaft
4 – PTO Pulley (Aluminum)
Figure 3-15V-Pulley Drawing
Figure 3-15
• "A"-Type V Belt Style: A Material: Aluminum
equivalent inertia weight 0.065 kg·cm sec2
(0.63 N·cm sec2)
(3)
(2)
(1)
(4) 0005552
0005553

GENERAL SERVICE INFORMATION Location of Nameplate
3-18 NOV 2007 (Rev. 01) 6LPA Service Manual
© 2007 Yanmar Marine International
LOCATION OF NAMEPLATE
The nameplate of the Yanmar 6LPA series engines
is shown in Figure 3-16. The nameplate is located
on the engine rocker arm cover.
Engine Nameplate (Typical)
Figure 3-166LPA-STP2/STZP2 Engines
Figure 3-16
DIESEL FUEL
Diesel Fuel Specifications
CAUTION! Only use diesel fuels recommended
by Yanmar 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.
Additional Technical Fuel Requirements
• 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.
• Water and sediment in the fuel should not exceed
0.05% by volume.
• Ash content not to exceed 0.01% by volume.
• Carbon residue content not to exceed 0.35% by
volume. Less than 0.1% is preferred.
• Total aromatics content should not exceed 35%
by volume. Less than 30% is preferred.
• PAH (polycyclic aromatic hydrocarbons) content
should be below 10% by volume.
• NEVER mix kerosene, used engine oil, or
residual fuels with the diesel fuel.
• NEVER use Biocide or mix winter and summer
fuels.
Gear Model
ENG.No.
Model
min
-1
min-1
min-1
Speed of prop shaft
Fuel stop power kW
Continuous power kW
/
/
0004574
DIESEL FUEL
SPECIFICATION LOCATION
No. 2-D, No. 1-D,
ASTM D975-94
USA
EN590:96 European
Union
ISO 8217 DMX International
BS 2869-A1 or A2 United
Kingdom
JIS K2204 Grade No. 2 Japan

GENERAL SERVICE INFORMATION
Abbreviations and Symbols
12/05
6LPA Service Manual 3-31
© 2007 Yanmar Marine International
ABBREVIATIONS AND
SYMBOLS
Abbreviations
Symbols
Aampere
AC alternating current
ACEA Association des Constructeurs
Ah ampere-hour
API American Petroleum Institute
ARB Air Resources Board
ATDC after top dead center
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
CARB California Air Resources Board
CCA cold cranking amp
cfm cubic feet per minute
cm centimeter
cm³ cubic centimeter
cm³/min cubic centimeter per minute
cu in. cubic inch
Ddiameter
DC direct current
DI direct injection
DVA direct volt adapter
EPA Environmental Protection
ESG electronic speed governor
°F degree Fahrenheit
fl oz fluid ounce (U.S.)
fl oz/min fluid ounce (U.S.) per minute
ft foot
ft-lb foot pound*
ft-lbf/min foot pound force per minute
ggram
gal gallon (U.S.)
gal/hr gallon (U.S.) per hour
gal/min gallon (U.S.) per minute
GL gear lubricant
hp horsepower (metric)
hr hour
I.D. inside diameter
ID identification
IDI indirect injection
in. inch
in.Aq inches Aqueous (water)
in.Hg inches Mercury
in-lb inch pound**
Jjoule
JASO Japanese Automobile
Kkelvin
kg kilogram
kgf/cm² kilogram force per square
kgf/m kilogram force per meter
km kilometers
kPa kilopascal
kW kilowatt
Lliter
L/hr liter per hour
lb pound
lbf pound force
lb-ft pound foot (Tightening Torque)
lb-in pound inch (Tightening Torque)
mmeter
mL milliliter
mm millimeter
mmAq millimeter Aqueous (water)
MPa megapascal
mV millivolt
Nnewton
N·m newton meter
No. number
O.D. outside diameter
oz ounce
Pa pascal
PS horsepower (metric)
psi pound per square inch
qt quart (U.S.)
Rradius
rpm revolutions per minute
SAE Society of Automotive
sec. second
tshort ton 2000 lb
TBN total base number
TDC top dead center
Vvolt
VAC volt alternating current
VDC volt direct current
Wwatt
°degree
+plus
-minus
±plus or minus
Ωohm
μmicro
%percent
* Work torque such as engine torque
** Work torque such as starter motor torque

GENERAL SERVICE INFORMATION Unit Conversions
3-32 NOV 2007 (Rev. 01) 6LPA Service Manual
© 2007 Yanmar Marine International
UNIT CONVERSIONS
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
centi c x 0.01
milli m x 0.001
micro μx 0.000001
mile x 1.6090 = km
ft x 0.3050 = m
in. x 2.5400 = cm
in. x 25.4000 = mm
km x 0.6210 = mile
m x 3.2810 = ft
cm x 0.3940 = in.
mm x 0.0394 = in.
gal (U.S.) x 3.78540 = L
qt (U.S.) x 0.94635 = L
cu in. x 0.01639 = L
cu in. x 16.38700 = mL
fl oz (U.S.) x 0.02957 = L
fl oz (U.S.) x 29.57000 = mL
cm³ x 1.00000 = mL
cm³ x 0.03382 = fl oz (U.S.)
lb x 0.45360 = kg
oz x 28.35000 = g
kg x 2.20500 = lb
g x 0.03527 = oz
lbf x 4.4480 = N
lbf x 0.4536 = kgf
N x 0.2248 = lbf
N x 0.1020 = kgf
kgf x 2.2050 = lbf
kgf x 9.8070 = N
ft-lb x 0.1383 = kgf/m
in.-lb x 0.0115 = kgf/m
lb-ft x 1.3558 = N·m
lb-ft x 0.1383 = kgf/m
lb-in. x 0.1130 = N·m
lb-in. x 0.0115 = kgf/m
kgf/m x 7.2330 = ft-lb
kgf/m x 86.8000 = in.-lb
kgf/m x 9.8070 = N·m
N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
N·m x 0.1020 = kgf/m
psi x 0.0689 = bar
psi x 6.8950 = kPa
psi x 0.0703 = kgf/cm²
bar x 14.5030 = psi
bar x 100.0000 = kPa
bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
kPa x 0.0100 = bar
kPa x 0.0102 = kgf/cm²
kgf/cm² x 98.0700 = psi
kgf/cm² x 0.9807 = bar
kgf/cm² x 14.2200 = kPa
in.Hg (60°) x 0.0333 = bar
in.Hg (60°) x 3.3770 = kPa
in.Hg (60°) x 0.0344 = kgf/cm²
mmAq x 0.0394 = in.Aq
hp (metric
or PS)
x 0.9863201 = hp SAE
hp (metric
or PS)
x 0.7354988 = kW
hp SAE x 1.0138697 = hp (metric or PS)
hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
kW x 1.3410221 = hp SAE
°F = (1.8 x °C) + 32
°C = 0.556 x (°F - 32)

PERIODIC MAINTENANCE
EPA Requirements
12/05
6LPA Service Manual NOV 2007 (Rev. 01) 4-5
© 2007 Yanmar Marine International
Conditions to Ensure Compliance
with EPA Emission Standards
The following are the conditions that must be met in
order to ensure that the emissions during operation
meet the EPA standards:
• Ambient temperature: -20 to 40°C (-4 to 104°F)
• Relative humidity: 80% or lower
The diesel fuel should be:
• ASTM D975 No. 1-D or No. 2-D, or equivalent
(minimum of cetane No. 45)
The lubricating oil should be:
• Type API, Class CD or higher
Perform inspections as outlined in Periodic
Maintenance Procedures on page 4-9 and keep a
record of the results.
Pay particular attention to these important points:
• Replacing the engine oil
• Replacing the oil filter
• Replacing the fuel filter
• Cleaning the air cleaner
Note: Inspections are divided into two sections
in accordance with who is responsible for
performing the inspection: the user or the
manufacturer.
Inspection and Maintenance
See Inspection and Maintenance of EPA
Emission-Related Parts on page 4-8. 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 4-6.
This maintenance must be performed to keep the
emission values of your engine in the standard
values during the warranty period. The warranty
period is determined by the age of the engine or the
number of hours of operation.

PERIODIC MAINTENANCE Periodic Maintenance Schedule
4-6 6LPA Service Manual
© 2007 Yanmar Marine International
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. CAUTION! Establish a periodic maintenance
plan according to the engine application and make sure to perform the required periodic
maintenance at intervals indicated. Failure to follow these guidelines will impair the engines safety
and performance characteristics, shorten the engines life and may affect the warranty coverage of
the engine.
Note: The following procedures are considered normal maintenance and are performed at the owner’s
expense.
* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 4-8.
c: Check or Clean : Replace
System Item
Periodic Maintenance Interval
Daily
Every
50 hours or
one month
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 500
hours or 2
years
whichever
comes first
Every 1250
hours or 5
years
whichever
comes first
Whole Visual inspection of
engine exterior
c
Fuel System
Check the fuel level
and refill if necessary
c
Drain water and
sediment from the
fuel tank
c
Drain the fuel / water
separator
c
Replace the fuel filter
element

Initial 50

Check the fuel
injection timing
c
Check the fuel
injector pressure and
nozzle spray
pattern*
c
Lubricating
System
Check the engine oil
level
c
Change the engine
oil

Initial 50

Replace the engine
oil filter element

Initial 50

Wash the engine oil
cooler
c