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

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.

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.

1207

6LPA Service Manual 1-1

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

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

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

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

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

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

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

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

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

Fuel System

Check the fuel level

and refill if necessary

Drain water and

sediment from the

fuel tank

Drain the fuel / water

separator

Replace the fuel filter

element



Initial 50



Check the fuel

injection timing

Check the fuel

injector pressure and

nozzle spray

pattern*

c

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

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