Yanmar 6LPA-STP2 User manual

en
English
MARINE ENGINE
OPERATION MANUAL
6LPA-STP2
6LPA-STZP2

MODEL
OPERATION MANUAL CODE
All Rights Reserved, Copyright
6LPA-STP2, 6LPA-STZP2
0A6LP-G00103
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 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.

6LPA Series Operation Manual i
TABLE OF
CONTENTS
Page
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 ............................ 8
PRODUCT OVERVIEW ................................................... 9
YANMAR 6LPA SERIES FEATURES AND
APPLICATIONS......................................................... 9
New Engine Break-In......................................... 10
COMPONENT IDENTIFICATION ............................ 11
Service Side
(Left Side as Viewed from Propeller)................. 11
Non-Service Side............................................... 12
NAMEPLATES ......................................................... 13
FUNCTION OF MAJOR COMPONENTS ................ 14
CONTROL EQUIPMENT ......................................... 15
Instrument Panel (Optional)............................... 15
Remote Control (Throttle) Handle...................... 21
BEFORE YOU OPERATE ............................................. 25
INTRODUCTION...................................................... 25
SAFETY PRECAUTIONS ........................................ 25

TABLE OF CONTENTS
ii 6LPA Series Operation Manual
DIESEL FUEL........................................................... 26
Diesel Fuel Specifications .................................. 26
Handling of Diesel Fuel ...................................... 27
Fuel Tank (Optional) .......................................... 28
Fuel System ....................................................... 28
Filling the Fuel Tank........................................... 28
Bleeding the Fuel System .................................. 29
ENGINE OIL ............................................................. 30
Engine Oil Specifications .................................. 30
Engine Oil Viscosity ........................................... 31
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
(6LPA-STZP2 Models) ....................................... 33
ENGINE COOLANT ................................................. 33
Engine Coolant Specifications ........................... 33
Coolant (Closed Cooling System) ...................... 34
Checking and Adding Coolant............................ 34
CRANKING THE ENGINE ....................................... 36
ENGINE OPERATION .................................................... 37
INTRODUCTION ...................................................... 37
SAFETY PRECAUTIONS......................................... 37
STARTING THE ENGINE ........................................ 39
If the Engine Fails to Start.................................. 40
Starting at Low Temperatures............................ 41
After the Engine has Started .............................. 42
REMOTE CONTROL HANDLE OPERATION.......... 43
Acceleration and Deceleration ........................... 43
Shifting the Engine............................................. 44
CAUTIONS DURING OPERATION.......................... 45
SHUTTING DOWN THE ENGINE............................ 46
Normal Shutdown............................................... 46
CHECKING THE ENGINE AFTER OPERATION..... 47
PERIODIC MAINTENANCE ........................................... 49
INTRODUCTION ...................................................... 49
SAFETY PRECAUTIONS......................................... 49

TABLE OF CONTENTS
6LPA Series Operation Manual iii
12/05
PRECAUTIONS ....................................................... 51
The Importance of Periodic Maintenance.......... 51
Performing Periodic Maintenance ..................... 51
The Importance of Daily Checks ....................... 51
Keep a Log of Engine Hours and Daily Checks 51
Yanmar Replacement Parts .............................. 51
Tools Required .................................................. 51
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help............................................. 51
Tightening Fasteners......................................... 52
PERIODIC MAINTENANCE SCHEDULE ................ 53
PERIODIC MAINTENANCE PROCEDURES .......... 56
Daily Checks...................................................... 56
After Initial 50 Hours of Operation ..................... 57
Every 50 Hours of Operation ............................. 60
Every 125 Hours of Operation ........................... 62
After Initial 250 Hours of Operation ................... 62
Every 250 Hours of Operation ........................... 63
Every 500 Hours of Operation ........................... 65
Every 1000 Hours of Operation ......................... 67
Every 1250 Hours of Operation ......................... 68
TROUBLESHOOTING ................................................... 69
SAFETY PRECAUTIONS ........................................ 69
TROUBLESHOOTING AFTER STARTING ............. 69
TROUBLESHOOTING INFORMATION................... 70
TROUBLESHOOTING CHART................................ 71
LONG-TERM STORAGE ............................................... 73
PREPARE ENGINE FOR LONG-TERM STORAGE 73
DRAIN SEAWATER COOLING SYSTEM ............... 74
RETURNING THE ENGINE TO SERVICE .............. 75
SPECIFICATIONS ......................................................... 77
PRINCIPAL ENGINE SPECIFICATIONS ................ 78
Marine Drive Specifications (Optional) .............. 79
SYSTEM DIAGRAMS .................................................... 81
PIPING DIAGRAMS................................................. 81
WIRING DIAGRAMS................................................ 87

TABLE OF CONTENTS
iv 6LPA Series Operation Manual
This Page Intentionally Left Blank

6LPA Series Operation Manual 1
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 6LPA
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.
•IfthisOperation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• 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.

INTRODUCTION
26LPA Series Operation Manual
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:___________________________________________________________

6LPA Series Operation Manual 3
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.
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.
A
This safety alert symbol
appears with most safety
statements. It means
attention, become alert,
your safety is involved!
Please read and abide by
the message that follows
the safety alert symbol.

SAFETY
46LPA Series Operation Manual
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
DANGER
The safety messages that follow have
DANGER level hazards.
NEVER permit anyone to
install or operate the engine
without proper training.
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.
•See your authorized Yanmar Marine
dealer or distributor for additional
training.
During Operation and
Maintenance
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.
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.
Fire Hazard
Undersized wiring systems
can cause an electrical fire.
Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.
Store any equipment in a designated
area away from moving parts.
NEVER use the engine compartment for
storage.

SAFETY
6LPA Series Operation Manual 5
12/05
WARNING
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.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.
Exposure Hazard
ALWAYS wear personal
protective equipment
including appropriate
clothing, gloves, work
shoes, and eye and hearing protection
as required by the task at hand.
Sudden Movement Hazard
NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the warning signals.
Burn Hazard
Some of the engine
surfaces become very hot
during operation and
shortly after shutdown.
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.

SAFETY
66LPA Series Operation Manual
CAUTION
The safety messages that follow have
CAUTION level hazards.
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.
Coolant Hazard
Wear eye protection and
rubber gloves when you
handle engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.
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. 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 your
country’s 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.
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.

SAFETY
6LPA Series Operation Manual 7
12/05
NOTICE
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,
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). See 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,
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 speed,
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.
NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.

SAFETY
86LPA Series Operation Manual
LOCATION OF SAFETY DECALS
Figure 1 show the location of safety decals on Yanmar 6LPA series marine engines.
6LPA Engines
Figure 1
1 – Part Number: 120324-07240
2 – Part Number: 128296-07260
3 – Part Number: 119773-07280
4 – Part Number: 128296–07300
5 – Part Number: 128296–07360
0004813
NEVER pour the
engine oil across
the full line.
119773-07280
DANGER
FULL
LOW
(1) (2) (3) (4)
(5)

6LPA Series Operation Manual 9
PRODUCT OVERVIEW
YANMAR 6LPA SERIES
FEATURES AND
APPLICATIONS
The 6LPA series are four-stroke direct
injection diesel engines equipped with
liquid coolant systems.
The 6LPA-STP2 engines are equipped
with a marine gear (ZF63A1 or KMH50A,
KMH50V).
The 6LPA-STZP2 engines are equipped
with a stern drive (ZT370, Mercruiser
Bravo).
These engines are designed for pleasure
craft use.
The engines are equipped with a marine
gear or sail drive unit.
These engines are designed for pleasure
craft use.
It is recommended that new vessels be
propped so the engines can operate at 50
to 100 min-1 above the fuel stop power
engine speed to allow for some added
weight and hull resistance.
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 inboard
equipment, always observe the
instructions and cautions given in the
operation manuals supplied by the
shipyard and equipment manufacturers.
The 6LPA series engines are designed to
be operated at maximum throttle
(3800 min-1) for less than 5% of total
engine time (30 minutes out of every 10
hours) and cruising speed (2800 min-1 or
less) for less than 90% of 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
Yanmars local subsidiary in your region or
your authorized Yanmar Marine dealer or
distributor.

PRODUCT OVERVIEW
10 6LPA Series Operation Manual
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
between 71° and 87°C (160° and 190°F).
During the first 10 hours of operation, the
engine should be run at maximum engine
speed minus 400 to 500 min-1
(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.
NOTICE
Do not operate at WOT (wide open throttle)
for more than a minute at a time during the
first 10 hours of operation.
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 engine 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 race the engine to clean the
carbon from the cylinders and fuel injection
valve.
Perform this procedure in open waters:
• With the clutch 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 at maximum speed
minus 400 min-1 most of the time
(approximately 70% load), with a 10
minute run at maximum minus 200 min-1
(approximately 80% load) every
30 minutes and a 4 to 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 race the
engine.
To complete engine break-in, perform After
Initial 50 Hours of Operation maintenance
procedures. See After Initial 50 Hours of
Operation on page 57.

PRODUCT OVERVIEW
6LPA Series Operation Manual 11
12/05
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.
Figure 1
Figure 1
1–FuelCooler
2 – Fuel Filter
3 – Power Steering Oil Cooler*
4 – Engine Oil Filter
5 – Intercooler
6 – Mixing Elbow
7 – Engine Oil Cooler
8–Starter
9 – Engine Oil Cooler
10 – Fuel Injection Pump
11 – Seawater Pump
12–Stern Drive
(1)
(2)
(3)
(4)
(5) (6)
(12)
(11) (10)
(9) (8)(7)
0004884

PRODUCT OVERVIEW
12 6LPA Series Operation Manual
Non-Service Side
Figure 2
Figure 2
1 – Turbocharger
2 – Engine Nameplate (on rocker
arm cover)
3 – Fresh Water (Coolant) Tank
4 – Power Steering Oil Tank*
5 – Fresh Water Filler Cap
6 – Engine Oil Filler Cap
7 – Power Steering Oil Pump*
8–Alternator
9 – Engine Oil Dipstick
10 – Fresh Water Cooler
11–V-Belt
(1) (2) (3)(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
0004885

PRODUCT OVERVIEW
6LPA Series Operation Manual 13
12/05
NAMEPLATES
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.
Figure 3
Gear Model
ENG.No.
Model
min-1
min-1
min-1
Speed of prop shaft
Fuel stop power kW
Continuous power kW
/
/
0004574

PRODUCT OVERVIEW
14 6LPA Series Operation Manual
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. 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.
Engine Oil Filler Port Filler port for engine oil.
Engine Oil Filter 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 should
be replaced periodically.
Engine Oil Dipstick Gauge stick for checking the engine oil level.
Marine Gear Oil Filler Port (If
Equipped)
Filler port for marine gear lube oil. Located on top of the marine gear case.
Cooling System There are two cooling systems: coolant and seawater.
• Coolant Tank
• Heat Exchanger
• Coolant Pump
The tank stores the coolant and is connected to the heat exchanger. Cooling
seawater passes through the heat exchanger to cool the coolant by heat
exchange. After cooling, the coolant is fed by the coolant pump to the inside of
the engine, around the combustion chamber, turbocharger and then returned to
the tank.
Filler Cap Located on the top of the coolant tank. It has two pressure regulating valves
(release and retraction valves). When the coolant temperature rises, the
pressure inside the coolant tank increases causing the release valve in the filler
cap to open.
Reservoir Hot water and steam pass through a rubber hose to the reservoir for cooling. (The
filler port and the reservoir are connected by a rubber hose.) When the load is
reduced and the coolant temperature falls, the pressure in the coolant tank is
lowered, activating the retraction valve in the filler cap. This causes the coolant
in the reservoir to return to the coolant tank. This process reduces the
consumption of coolant.
Turbocharger A pressurized intake air feeding device. The exhaust gas turbine is rotated by the
exhaust gas and the power is used to rotate the blower. This pressurizes the
intake air for sending to the cylinder.
Charge air cooler This heat exchanger cools the pressurized charging air from the turbocharger
with water.
Zinc Anode The metal area of the seawater cooling system is prone to galvanic corrosion.
The zinc anode is installed in the various coolers to prevent this. When the zinc
anode becomes worn, components in the fresh water cooler, oil cooler, etc. will
corrode. Periodic replacement of the zinc anode is necessary.
Nameplates Nameplates are provided on the engine and have the model, serial number and
other data.
Starter A DC motor for starting the engine. Electric current causes the pinion gear to
engage with the ring gear on the flywheel to start the engine.
Alternator This generator rotates by a V-belt drive to charge the battery during operation.