Yanmar 6LPA-STP2 Operation Manual Download Page 83

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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.

Supply the authorized Yanmar Marine

dealer or distributor with the following

information:

• Model name and serial number of your

engine

• Boat model, hull material, size (tons)
• Use, type of boating, number of hours run
• Total number of operation hours (refer to

hourmeter), age of boat

• The operating conditions when the

problem occurs:

• Engine rpm
• Color of exhaust smoke
• Type of diesel fuel
• Type of engine oil
• Any abnormal noises or vibration
• Operating environment such as high

altitude or extreme ambient

temperatures, etc.

• Engine maintenance history and

previous problems

• Other factors that contribute to the

problem

TROUBLESHOOTING

6LPA Series Operation Manual

Summary of Contents for 6LPA-STP2

Page 1: ...6LPA series OPERATION MANUAL 6LPA STP2 6LPA STZP2 P N 0A6LP G00102 MARINE ENGINES ...

Page 2: ...roduct 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 ...

Page 3: ...ent Identification 11 Service Side Left Side as Viewed from Propeller 11 Non Service Side 12 Engine Nameplate 13 Function of Major Components 14 Control Equipment 15 Instrument Panel Optional 15 Remote Control Throttle Handle 23 Before You Operate 27 Diesel Fuel 27 Diesel Fuel Specifications 27 Filling the Fuel Tank 29 Bleeding the Fuel System 30 Engine Oil 30 Engine Lube Oil Specifications 30 Eng...

Page 4: ...Handle 37 Checking the Alarm Indicators 37 Preparing Fuel Oil and Coolant in Reserve 37 Engine Operation 39 Starting the Engine 40 Starting at Low Temperatures 41 Restarting After Starting Failure 42 After the Engine Has Started 42 Remote Control Handle Operation 44 Acceleration and Deceleration 44 Shifting the Marine Drive 45 Shutting Down the Engine 46 Periodic Maintenance 47 Safety Precautions ...

Page 5: ...f Operation 68 Every 1250 Hours of Operation 69 Troubleshooting 71 Troubleshooting After Starting 71 Troubleshooting Chart 73 Troubleshooting Information 77 Long Term Storage 79 Prepare Engine for Long Term Storage 79 Draining the Fresh Water and Seawater Cooling System 80 Draining the Fresh Water Cooling System 81 Draining Seawater Cooling System 81 Removing the Engine from Long Term Storage 81 S...

Page 6: ...rranty Period 98 Warranty Coverage 98 Exclusions 98 Owner s Responsibility 99 Customer Assistance 99 Maintenance Log 100 TABLE OF CONTENTS vi 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 7: ...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 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 ...

Page 8: ...nts 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 INTRODUCTION 2 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 9: ... time 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 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 CAU...

Page 10: ...messages that follow have WARNING 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...

Page 11: ...AYS 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 feeling ill Exposure Hazard To avoid injury ALWAYS wear personal protective equipment including appropriate clothing gloves work shoes eye and hearing p...

Page 12: ...ne 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 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 Tool Hazard ALWAYS use to...

Page 13: ...ld 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 ...

Page 14: ...ne oil across the full line 119773 07280 DANGER FULL LOW 1 2 3 4 5 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 Note Figure 1 shows an overhead view of the 6LPA engine SAFETY 8 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 15: ... 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 The 6LPA series engines are designed to be op...

Page 16: ... 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 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 spee...

Page 17: ...PA STZP2 only 1 2 3 4 5 6 12 11 10 9 8 7 0004884 Figure 1 1 Fuel Cooler 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 PRODUCT OVERVIEW 6LPA Series Operation Manual 11 2007 Yanmar Marine International ...

Page 18: ...n 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 PRODUCT OVERVIEW 12 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 19: ... 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 6LPA Series Operation Manual 13 2007 Yanmar Marine International ...

Page 20: ...top of the fresh water recovery tank It has two pressure regulating valves release and retraction valves When the cooling water tempereature rises the pressure inside the fresh water tank increases causing the release valve in the filler cap to open Coolant Recovery Tank Hot water and steam pass through a rubber hose to the subtank for cooling The filler port and the subtank are connected by a rub...

Page 21: ...er Switch X X X Engine Stop Button X X X Alarm Buzzer X X X Alarm Buzzer Stop Switch X X X Backlight Switch for Gauges X X X Warning Indicators Battery Low Charge X X X Fresh Water Coolant High Temperature X X X Engine Lube Oil Low Pressure X X X Fresh Water Coolant Level X X Exhaust Cooling Seawater Flow X X X Fuel Filter Water Separator X X X Gear Oil 6LPA STZP2 Only X X Gauges Tachometer with H...

Page 22: ...tch 7 Alarm 8 Hourmeter New C Type 1 2 3 4 5 6 7 8 9 10 0003282_m1 Figure 5 1 Engine Oil Pressure Gauge 2 Fresh Water Coolant Temperature Gauge 3 Tachometer 4 Alarm Stop Switch 5 Panel Illumination Switch 6 Engine Stop Button 7 Start Key Switch 8 Alarm 9 Hourmeter 10 Warning Indicator Display PRODUCT OVERVIEW 16 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 23: ...e Oil Pressure Gauge 3 Fresh Water Coolant Temperature Gauge 4 Tachometer 5 Alarm Stop Switch 6 Panel Illumination Switch 7 Engine Stop Button 8 Start Key Switch 9 Alarm 10 Hourmeter 11 Clock 12 Warning Indicator Display PRODUCT OVERVIEW 6LPA Series Operation Manual 17 2007 Yanmar Marine International ...

Page 24: ...ter Coolant Level Too Low Exhaust Cooling Seawater Flow Restriction Gear Oil Stern Drive Models Only Fuel Filter Senders Tachometer Fresh Water Coolant Temperature Engine Lube Oil Pressure Boost Pressure Fresh Water Coolant Temperature For two stations Engine Lube Oil Pressure Standard Optional PRODUCT OVERVIEW 18 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 25: ...larm off temporarily Turn the alarm buzzer OFF when inspecting for cause WARNING Inspect and repair the abnormality immediately Backlight Switch Turns instrument panel backlighting OFF or ON Hourmeter Shows the total number of operating hours Can be used as a guide for periodic maintenance checks The hourmeter is located at the bottom of the tachometer Engine Lube Oil Pressure Gauge Shows the engi...

Page 26: ...ning indicator to light Figure 7 Battery Low Charge Indicator Figure 7 When the alternator output is too low the indicator will light When charging begins the indicator will turn off No alarm will sound for low battery charge Figure 8 Fresh Water Coolant High Temperature Indicator and Alarm Figure 8 When the coolant temperature reaches the maximum allowable temperature 95 C 203 F or higher the ind...

Page 27: ...ntinued without draining the water separator fuel feed to the engine is restricted and may cause damage to the engine or fuel injection pump Figure 12 Exhaust Cooling Seawater Flow Restriction Figure 12 When the amount of cooling seawater being discharged is too low the sensor will activate the warning indicator Stop operation immediately to avoid damage to the engine Check the seawater cooling sy...

Page 28: ...to the air heater if equipped is turned on The START position Figure 14 4 allows current to the starting motor When starting the engine move the key to the START position and release The key will automatically move to the ON position NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat When the key is in the OFF position Figure 14 2 the elec...

Page 29: ...ted 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 Morse Remote Control Handle Optional This is a single lever remote control handle connected by a remot...

Page 30: ...eously increases the engine speed Pushing the handle further in the same direction increases engine speed to full speed 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 Free Throttle Operation When the boat is stopped clutch is in...

Page 31: ...dle When the handle or button is pulled out move the handle to either FORWARD or REVERSE to increase the idling speed Returning to Normal Operation MT 3 Move the throttle handle to NEUTRAL Figure 18 1 The lever will automatically return to the normal position MV Move throttle handle to NEUTRAL Figure 19 3 Push the free throttle button in PRODUCT OVERVIEW 6LPA Series Operation Manual 25 2007 Yanmar...

Page 32: ...This Page Intentionally Left Blank PRODUCT OVERVIEW 26 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 33: ...mar 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 ASTM D975 No 2 D No 1 D USA EN590 European Union ISO 8217 DMX International BS 2869 A1 or A2 United Kingdo...

Page 34: ...dling of Diesel Fuel 0004512 Figure 1 1 Water and dust in the fuel may cause engine failure When fuel is stored be sure that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain 2 Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to extract the clear filtered fuel fr...

Page 35: ...engine compartment after refueling Never operate bilge blower while refueling Doing so can pump explosive fumes into the engine compartment and result in an explosion 1 Clean the area around the fuel cap 2 Remove the fuel cap from the fuel tank 3 Fill the tank with clean fuel free of oil and dirt WARNING Hold the hose nozzle firmly against the filler port while filling This prevents static electri...

Page 36: ...g guidelines and classifications 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 Select the oil viscosity based on the ambient temperature wh...

Page 37: ...ine Oil 5 1 4 2 3 0004902 Figure 6 1 It is recommended that the engine be aslevelaspossiblebeforecheckingthe oil 2 Remove dipstick Figure 6 1 and wipe with clean cloth 3 Fully reinsert dipstick 4 Remove dipstick The oil level should be between upper Figure 6 2 and lower Figure 6 3 lines on the dipstick 5 Add oil if necessary See Adding Engine Oil on page 32 NOTICE NEVER overfill the engine with oi...

Page 38: ...y by hand 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 Mercruiser Bravo Stern Drive Oil Specifications Use marine gear oil that meets or exceeds the following guidelines and classifications Drive Oil QuickSilver 1 High Performance G...

Page 39: ...commendations use a proper LLC which will not have any adverse effects on the materials cast iron aluminum copper etc of the engine s cooling system See Engine Coolant Specifications on page 33 ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range NOTICE ALWAYS add LLC to soft water especially when operating in cold weather NEVER use hard water Water shoul...

Page 40: ...ater may spray out if it is not closed tightly 5 LOW FULL 4 1 2 3 0004493 Figure 9 Check the coolant level in the coolant recovery tank The level should be at the FULL mark Figure 9 2 Add coolant if necessary NOTICE NEVER pour cold coolant into a hot engine 6 Remove coolant recovery tank cap Figure 9 4 to add coolant if necessary Do not add water 7 Replace filler cap and tighten it firmly Failure ...

Page 41: ...warning indicators to light during cranking Note If the engine has not been operated for a long period of time check that the key can be moved from START to ON positions smoothly 6 While pushing the STOP button Figure 10 1 turn the key to the START position Figure 10 2 NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 7 When the key is in...

Page 42: ...ater separator See Draining Fuel Filter Water Separator on page 62 If you have to drain the fuel filter water separator frequently drainthefueltankandcheck for water in your fuel supply See Draining Water From the Fuel Tank on page 61 CAUTION If any problem is noted during the visual check the necessary corrective action must be taken before you operate the engine Checking Diesel Fuel Engine Oil a...

Page 43: ... the instruments and alarm indicators at regular intervals Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the day s operation Always store engine oil and coolant in reserve for at least one refill on board to be ready for emergencies Checking the Wiring Connectors See your authorized Yanmar Marine dealer or distributor Tightening All Major Nuts and Bolts See Tightening Faste...

Page 44: ...This Page Intentionally Left Blank BEFORE YOU OPERATE 38 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 45: ...pment 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 Sever Hazard Keep children and pets away while the engine is operating 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...

Page 46: ...er 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 STARTING THE ENGINE NOTICE If the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the eng...

Page 47: ...ing temperature A light load on a cold engine provides better combustion and faster engine warm up than no load Avoid running the engine at idling speed any longer than necessary Starting with Air Heater If Equipped 1 Open the seacock if equipped 2 Open the fuel cock 3 Put remote control handle in NEUTRAL 4 Turn the battery master switch if equipped ON 5 0003622 1 2 3 4 Figure 2 Turn key switch to...

Page 48: ...ge will occur Air Bleeding the Fuel System After Starting Failure If the engine does not start after several attempts there may be air in the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Bleed the air out of the system See Bleeding the Fuel System on page 30 After the Engine Has Started 1 After the engine has started ensure the remote control handle is in NEUT...

Page 49: ...e immediately Identify the cause and repair NOTICE The engine will seize if it is operated when cooling seawater discharge is inadequate or if load is applied without any warm up operation For troubleshooting assistance see Troubleshooting After Starting on page 71 or Troubleshooting Chart on page 73 If necessary see your authorized Yanmar dealer or distributor When operating the engine at low spe...

Page 50: ...V Side Mount 1 2 3 4 5 6 7 0004887 Figure 6 1 Forward High Speed 2 Forward Low Speed 3 Forward 4 Neutral 5 Reverse 6 Reverse Low Speed 7 Reverse High Speed Note Direction of travel will vary depending on installation location Use the remote control throttle handle to control acceleration and deceleration Move the handle slowly and smoothly ENGINE OPERATION 44 6LPA Series Operation Manual 2007 Yanm...

Page 51: ...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 Move the h...

Page 52: ...oximately 1000 rpm without load for 5 minutes 4 With the key in the ON position push and hold the stop button Figure 7 1 until the engine is off Note Continue to hold the stop button in until the engine is completely stopped If the button is released before the engine has completely stopped it may restart 5 After the engine has stopped turn the key switch to OFF Figure 7 4 Note If the engine does ...

Page 53: ...r 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 6LPA Series Operation Manual 47 200...

Page 54: ... leads to the alternator and engine electronics or engine control unit prior to reconnecting the batteries Exhaust Hazard 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 Shock Hazard ALWAYS ...

Page 55: ...nts due to poor engine performance and helps extend the life of the engine Performing Periodic Maintenance WARNING 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 Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connecti...

Page 56: ...rten the life of the engine Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks Ask Your Authorized Yanmar Marine Dealer or Distributor For Help...

Page 57: ...h a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy Bolt diameter x pitch mm M6 x 1 0 M8 x 1 25 M10 x 1 5 M12 x 1 75 M14 x 1 5 M16 x 1 5 Tightening Torque N m 11 0 1 0 26 0 3 0 50 0 5 0 90 0 10 0 140 0 10 0 230 0 10 0 kgf m 1 1 0 1 2 7 0 3 5 1 0 5 9 2 1 0 14 3 1 0 23 5 1 0 lb ft 19 0 2 1 37 3 6 66 0 7 2 103 7 2 170...

Page 58: ...sist you in specified compliance Conditions to Ensure Compliance with EPA Emission Standards Thefollowingaretheconditionsthatmustbe 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 sho...

Page 59: ...e of EPA Emission Related Parts on page 58 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 The warranty period is determined by the age of the engine or the number of hours of operation PERIODIC MAINTENANCE 6LPA Series Operation Manual 53 2007 Yanmar Marin...

Page 60: ...ngine See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a Check or Clean Replace Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 hours or monthly which ever comes first Every 125 hours or 6 months which ever comes first Every 250 hours or one year which ever comes first Every 5...

Page 61: ...t Every 1250 hours or 5 years which ever comes first Lubricating System Check the engine oil level Change the engine oil Initial 50 Replace the engine oil filter element Initial 50 Wash the engine oil cooler Marine Drive System Check marine drive oil Refer to the marine drive system operation manual Check power steering oil Check power trim oil Check drive oil Fresh Water Cooling System Check cool...

Page 62: ...rst Every 1250 hours or 5 years which ever comes first Seawater Cooling System Check seawater outlet discharge During Oper ation Check or replace the seawater pump impeller Check or replace the zinc anodes Check and clean the seawater passage Piping Clean or replace the exhaust water mixing elbow Check or replace fuel line and rubber hoses Electrical System Check the alarm and indicators Check the...

Page 63: ...heck and lubricate the remote control cable operation Adjust the remote control cable Intake and Exhaust System Wash turbo charger blower Clean air cleaner Adjust the intake and exhaust valve clearance Initial 250 Lap the intake and exhaust valves Miscel laneous Check and adjust the power steering oil pump belt 6LPA STZP2 only Replace the timing belt Replace the front rubber damper For EPA require...

Page 64: ...t 3000 hours Check fuel injection pump adjustment 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 58 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 65: ...ting engine oil Carefully clean the dipstick and the surrounding area before you remove the dipstick Remove the engine oil dipstick Attach the oil drain pump if equipped and pump out the oil For easier draining remove the engine oil fill cap 3 Turn the engine oil filter Figure 1 1 counterclockwise with a wrench 4 Remove the engine oil filter 5 Applyasmallamountofengineoiltothe seal of the new filt...

Page 66: ... 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 1 Mounting Screw 2 used 2 Housing 3 Alarm Switch 4 O Ring 5 Filter Element PERIODIC MAINTENANCE 60 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 67: ...t 11 Connect the alarm switch harness 12 Install the housing and mounting screws 13 Bleed the fuel system See Bleeding the Fuel System on page 30 Dispose of waste properly 14 Start engine and check for leaks 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 Draining W...

Page 68: ...n immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment 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 In such conditions inspect the battery earlier than specified 1 Turn th...

Page 69: ...hecking the Fuel Injector Spray Pattern Inspecting and Adjusting Intake Exhaust Valve Clearance Checking the Fuel Injector Spray Pattern See your authorized Yanmar Marine dealer or distributor Inspecting and Adjusting Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisi...

Page 70: ...age 34 Checking or Replacing Zinc Anodes Inspect and replace the zinc anodes periodically NOTICE If zinc anodes are not replaced periodically corrosion and engine damage will result 1 Close the seacock 2 Draintheseawatercoolingsystem See Draining Seawater Cooling System on page 81 1 0004896 Figure 8 3 Remove all the plugs Figure 9 1 Figure 10 3 Figure 11 4 Figure 12 2 and Figure 13 2 labeled ZINC ...

Page 71: ...rol Cables Note Never adjust the high speed stop bolt on the governor This will void the engine warranty Adjusting Engine Speed Governor Remote Control Cable See your authorized Yanmar dealer or distributor Adjusting Clutch Remote Control Cable Refer to the manufacturer s documentation Cleaning the Turbocharger Contamination of the turbocharger causes revolutions to drop and engine output to fall ...

Page 72: ...t Cleaning or Replacing Exhaust Water Mixing Elbow Replacing Fuel Line and Rubber Hoses Adjusting or Replacing the Alternator V Belt Checking and Adjusting the Power Steering Oil Pump Belt 6LPA STZP2 Models Cleaning or Replacing Exhaust Water Mixing Elbow See your authorized Yanmar dealer or distributor Replacing Fuel Line and Rubber Hoses Replace fuel line and rubber hoses every 500 hours or 2 ye...

Page 73: ...umber 119775 77260 Checking and Adjusting the Power Steering Oil Pump Belt 6LPA STZP2 Models 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 3 4 1 2 0004913 Figure 16 1 Checkthebeltbypushingonthemiddle of the belt Figure 16 3 with your finger With proper tension the belt ...

Page 74: ...awater Cooling System on page 81 3 Loosen the cover bolts and remove the cover and O ring 4 Inspect the inside of the seawater pump with a flashlight If any of the following are found disassembly and maintenance are required Impeller blades are cracked or nicked Edges or surfaces of the blades are marred or scratched Wear plate is damaged 5 If no damage is found when inspecting the inside of the p...

Page 75: ...or distributor Cleaning and Checking the Seawater Passage See your authorized Yanmar Marine dealer or distributor Cleaning and Checking the Fresh Water Cooling Water Passage See your authorized Yanmar Marine dealer or distributor Adjusting the Tension of the Alternator V Belt See Checking and Adjusting the Alternator V Belt Tension on page 67 Replacing the Timing Belt See your authorized Yanmar Ma...

Page 76: ...This Page Intentionally Left Blank PERIODIC MAINTENANCE 70 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 77: ...mal The continuous emission of black exhaust smoke indicates engine overloading This shortens the engine s life and should be avoided When operating the engine at low speed for long periods of time race the engine once every 2 hours Racing the engine with the clutch in NEUTRAL accelerate from the low speed position to the high speed position and repeat this process about five times This is done to...

Page 78: ...If any abnormal sounds are heard stop the engine and inspect for cause Alarm sounds during operation If the alarm sounds during operation lower the engine speed immediately check the warning lamps and stop the engine for repairs Is there water oil or fuel leakage Are there any loose bolts or connections Check the engine room daily for any leaks or loose connections Is there sufficient fuel in the ...

Page 79: ...lant fresh water in coolant recovery tank is low Check coolant level and refill See Checking and Adding Engine Coolant on page 34 Leakage in fresh water cooling system causing temperature to rise See your authorized Yanmar Marine dealer or distributor Contamination inside cooling system See your authorized Yanmar Marine dealer or distributor Fresh water cooling pump damaged See your authorized Yan...

Page 80: ...dealer or distributor Battery low charge indicator does not go out during operation V belt is loose or broken Replace V belt or adjust tension See Checking and Adjusting the Alternator V Belt Tension on page 67 Battery is defective Check battery fluid level specific gravity or replace battery See Checking the Battery Electrolyte Level Serviceable Batteries Only on page 62 Alternator power generati...

Page 81: ...rine dealer or distributor Starterdoesnotturnor turns slowly engine can be turned manually Faulty clutch position Shift to NEUTRAL and start Insufficient battery charge Check fluid level Recharge Replace See Checking the Battery Electrolyte Level Serviceable Batteries Only on page 62 Cable terminal contact failure Remove corrosion from terminals Tighten battery cables Faulty safety switch device S...

Page 82: ...ributor Low boost pressure See your authorized Yanmar Marine dealer or distributor Incorrect intake exhaust valve clearance See your authorized Yanmar Marine dealer or distributor White smoke 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 Fuel injection timing off See you...

Page 83: ...rial size tons Use type of boating number of hours run Total number of operation hours refer to hourmeter age of boat The operating conditions when the problem occurs Engine rpm Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment such as high altitude or extreme ambient temperatures etc Engine maintenance history and previous problem...

Page 84: ...This Page Intentionally Left Blank TROUBLESHOOTING 78 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 85: ...ting the engine into long term storage 1 Wipe off any dust or oil from the outside of engine 2 Drain water from fuel filters 3 Drain fuel tank completely or fill the tank to prevent condensation 4 Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle 5 Seal the intake silencer exhaust pipe etc to prevent moisture or contamination from enteri...

Page 86: ... Figure 1 3 0004905 Figure 2 4 0004906 Figure 3 5 0004907 Figure 4 1 Seawater Drain Cock 2 Fresh Water Drain Cock 3 Fresh Water Drain Cock 4 Seawater Pump Cover 5 Seawater Drain Cock LONG TERM STORAGE 80 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 87: ...ze and damage parts of the cooling system fresh water cooler seawater pump etc when ambient temperature is below 0 C 32 F 1 Close the seacock 2 Open the seawater drain cocks and drain off the seawater 3 Remove the four bolts attaching the seawater pump cover Remove the cover and drain the seawater 4 Install cover and tighten bolts 5 Close all the drain cocks REMOVING THE ENGINE FROM LONG TERM STOR...

Page 88: ...This Page Intentionally Left Blank LONG TERM STORAGE 82 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 89: ...el Cooling system Constant high temperature fresh water cooling 2 systems seawater and fresh water cooling Cooling water capacity 13 5 L 14 3 qt engine 1 6 L 1 7 qt coolant recovery tank Lubrication system Forced lubrication system with trochoid gear pump Engine lube oil capacity Total 10 5 L 11 0 qt Oil Pan 8 4 L 8 9 qt Turbocharger Model RHE62W IHI made Type Water cooled turbine housing Dimensio...

Page 90: ...Optional Model Hurth Kanzaki Mercruiser ZF63A1 KMH50A Bravo X 1 Bravo X 2 Bravo X 3 Type 8 down Hydraulic Stern Drive Applicable engine 6LPA STP2 6LPA STZP2 Reduction ratio ZF63A1 Ahead Astern Bravo X 1 2 3 Both Ahead Astern 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 informa...

Page 91: ...SYSTEM DIAGRAMS PIPING DIAGRAMS Contact your authorized Yanmar dealer for current diagrams 6LPA Series Operation Manual 85 2007 Yanmar Marine International ...

Page 92: ...6LPA STP2 7 6 5 4 3 2 1 8 11 10 13 12 15 14 17 20 22 24 16 9 18 19 21 23 25 0006321 Figure 1 SYSTEM DIAGRAMS 86 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 93: ...ipe to Fuel Tank 13 Diesel Fuel Cooler 14 Diesel Fuel Inlet from Fuel Tank 15 Diesel Fuel Filter 16 Coolant Temperature Sender Optional 17 Coolant Temperature Switch 18 Coolant Outlet to Heater 19 Engine Oil Cooler Relief Valves 20 Safety Valve 21 Coolant Pump 22 Engine Oil Pump 23 Engine Oil Inlet Filter 24 Coolant Inlet from Heater 25 Thermostat SYSTEM DIAGRAMS 6LPA Series Operation Manual 87 20...

Page 94: ...6LPA STZP2 10 9 8 7 6 5 4 3 1 2 11 15 14 17 16 19 18 21 24 26 28 20 13 22 23 25 27 29 12 0006322 Figure 2 SYSTEM DIAGRAMS 88 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 95: ...ea Water Inlet from Seacock 15 Seawater Pump 16 Diesel Fuel Return Pipe to Fuel Tank 17 Diesel Fuel Cooler 18 Diesel Fuel Inlet from Fuel Tank 19 Diesel Fuel Filter 20 Coolant Temperature Sender Optional 21 Coolant Temperature Switch 22 Coolant Outlet to Heater 23 Engine Oil Cooler Relief Valves 24 Safety Valve 25 Coolant Pump 26 Engine Oil Pump 27 Engine Oil Inlet Filter 28 Coolant Inlet from Hea...

Page 96: ... Type Instrument Panel 1 2 4 6 10 11 9 8 3 5 7 12 13 15 19 21 20 18 16 14 17 17 22 23 35 34 33 32 31 30 29 28 27 26 25 24 0006324 Figure 3 SYSTEM DIAGRAMS 90 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 97: ...Coolant Temperature Sender 15 Tachometer Sensor 16 Engine Oil Pressure Sensor 17 Timer Controller 18 Boost Sender 19 Coolant Level Switch 20 Fuel Filter Switch 21 Boost Switch 22 Wire Harness Option 23 Starter Switch 24 Fuel Filter 25 Boost 26 Exhaust 27 Coolant Temperature 28 Engine Oil Pressure 29 Charge 30 Starter Switch 31 Tachometer with Hour Meter 32 Buzzer 33 Buzzer Stop 34 Illuminate 35 St...

Page 98: ...6 15 18 17 14 19 12 13 20 21 22 23 24 27 31 30 29 32 34 28 26 25 33 35 36 42 47 57 37 38 39 40 41 43 44 45 60 58 59 4 55 53 52 54 56 61 62 63 64 65 46 50 51 49 48 0006325 Figure 4 SYSTEM DIAGRAMS 92 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 99: ...For 6LPA DTZP STZP STZP2 30 6LPA DTZP STZP STZP2 31 Coolant Level Switch 32 Drive Trim Sender 33 Timer Controller 34 Fuel Filter Switch 35 Wire Harness for 2 panel 36 Wire Harness 37 Starter Switch 38 Stop Switch 39 Illuminate 40 Buzzer Stop 41 Buzzer 42 Tachometer with Hour Meter 43 Coolant Temperature Meter 44 Engine Oil Pressure Meter 45 Charge 46 Starter Switch 47 Gear Oil 48 Fuel Emp 49 Fuel ...

Page 100: ...7 9 10 11 14 15 20 21 22 12 13 18 23 16 17 24 25 26 27 28 29 30 32 31 35 39 34 33 36 38 37 40 41 63 42 43 46 47 49 50 51 64 62 65 66 48 45 44 19 4 3 2 1 68 70 72 74 67 69 71 73 75 0006323 Figure 5 SYSTEM DIAGRAMS 94 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 101: ... STZP2 34 6LPA DTZP STZP STZP2 35 Coolant Level Switch 36 Drive Trim Sender 37 Timer Controller 38 Fuel Filter Switch 39 Boost 40 Wire Harness for 2 Panel 41 Wire Harness 42 Starter Switch 43 Stop Switch 44 Illuminate 45 Instrument Panel No 2 Station Option 46 Buzzer Stop 47 Buzzer 48 Tachometer with Hour Meter 49 Coolant Temperature Meter 50 Engine Oil Pressure Meter 51 Charge 52 Engine Oil Press...

Page 102: ...This Page Intentionally Left Blank SYSTEM DIAGRAMS 96 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 103: ...to Yanmar installation requirements and there has been no abuse neglect or improper maintenance of your Yanmar Marine engine Yanmar warrants that the engine is designed built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U S Environmental Protection Agency and is free from defects in material and workmanship which would cause this engin...

Page 104: ... distributor This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following 1 Fuel Injection System 2 Turbocharger System 3 Aftercooler 4 Electronic Engine Control Units and its associated Sensor and Actuators Exclusions Failures oth...

Page 105: ... in your engine no longer operating in compliance with applicable emission requirements You are responsible for initiating the warranty process You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authori...

Page 106: ...Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature 100 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 107: ...Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature 6LPA Series Operation Manual 101 2007 Yanmar Marine International ...

Page 108: ...102 6LPA Series Operation Manual 2007 Yanmar Marine International ...

Page 109: ...6LPA Series Operation Manual 103 2007 Yanmar Marine International ...

Page 110: ...This Page Intentionally Left Blank 104 6LPA Series Operation Manual 2007 Yanmar Marine International ...

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