6LPA-STP2 6LPA 6LPA-STZP2rhinomarineboats.com/PDF/6LPA-Operation.Manual.pdf · 6LPA-STP2 6LPA-STZP2 P/N: 0A6LP-G00101 MARINE ENGINES. Disclaimers: All information, illustrations and

6LPAseries

OPERATION MANUAL6LPA-STP2

6LPA-STZP2

P/N: 0A6LP-G00101

MARINEENGINES

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.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 storageand retrieval systems - without the written permission of Yanmar Marine International.© 2007 Yanmar Marine International

0407

ii 6LPA Series Operation Manual© 2007 Yanmar Marine International

TABLE OFCONTENTS

PageIntroduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 4

Location of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Product Overview ...................................................... 9

Yanmar 6LPA Features and Applications . . . . . . . . . . . . . . . . . . . . 9New Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Service Side (Left Side as Viewed fromPropeller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Non-Service Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Function of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Instrument Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Remote Control (Throttle) Handle . . . . . . . . . . . . . . . . . . . . . . 24

Before You Operate .................................................. 27Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Diesel Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Engine (Lube) Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . 30Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6LPA Series Operation Manual iii© 2007 Yanmar Marine International

Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Marine Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Mercruiser Bravo Stern Drive OilSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Checking and Adding Marine Drive Oil . . . . . . . . . . . . . . . . 32Checking and Adding Power Steering Oil (6LPA-STZP2 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Engine Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Checking and Adding Engine Coolant . . . . . . . . . . . . . . . . . 34

Cranking the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Checking Diesel Fuel, Engine Oil and EngineCoolant Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Checking and Refilling Marine Drive Oil . . . . . . . . . . . . . . . 36Checking the Battery Electrolyte Level . . . . . . . . . . . . . . . . 36Checking the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Checking the Remote Control Handle . . . . . . . . . . . . . . . . . 36Checking the Alarm Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Preparing Fuel, Oil and Coolant in Reserve . . . . . . . . . . 36

Engine Operation ...................................................... 39Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Starting at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Restarting After Starting Failure . . . . . . . . . . . . . . . . . . . . . . . . . 42After the Engine Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remote Control Handle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 44Shifting the Marine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Periodic Maintenance ................................................ 47

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

The Importance of Periodic Maintenance . . . . . . . . . . . . . 49Performing Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . 49The Importance of Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . 49Keep a Log of Engine Hours and Daily Checks . . . . . 50Yanmar Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Ask Your Authorized Yanmar Marine Dealer orDistributor For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

TABLE OF CONTENTS

iv 6LPA Series Operation Manual© 2007 Yanmar Marine International

Tightening Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51EPA Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

EPA Requirements for USA and Other ApplicableCountries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52EPA Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Conditions to Ensure Compliance with EPAEmission Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Inspection and Maintenance of EPA Emission-Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59After Initial 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . 59Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Every 125 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 63After Initial 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . 63Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Every 1000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 68Every 1250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 69

Troubleshooting ....................................................... 71Troubleshooting After Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Long-Term Storage ................................................... 79Prepare Engine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . 79Draining the Fresh Water and Seawater CoolingSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Draining the Fresh Water Cooling System . . . . . . . . . . . . 80Draining Seawater Cooling System . . . . . . . . . . . . . . . . . . . . 81

Removing the Engine from Long-Term Storage . . . . . . . . . . . 81Specifications .......................................................... 83

Principal Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Marine Drive Specifications (Optional) . . . . . . . . . . . . . . . . 85

System Diagrams ..................................................... 87Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

EPA Warranty USA Only ............................................ 93Yanmar Co., Ltd. Limited Emission Control SystemWarranty - USA Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

TABLE OF CONTENTS

6LPA Series Operation Manual v© 2007 Yanmar Marine International

Your Warranty Rights and Obligations: . . . . . . . . . . . . . . . . 93Warranty Period: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Warranty Coverage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Exclusions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Owner’s Responsibility: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Customer Assistance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

TABLE OF CONTENTS

vi 6LPA Series Operation Manual© 2007 Yanmar Marine International

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, and fromcruisers to mega yachts. In marine leisureboating, the worldwide reputation of YanmarMarine is second to none. We design ourengines to respect nature. This meansquieter engines, with minimal vibrations,cleaner than ever. All of our engines meetapplicable regulations, including emissions,at the time of manufacture.To help you enjoy your Yanmar 6LPA seriesengine for many years to come, pleasefollow these recommendations:

• Read and understand this OperationManual before you operate the engine toensure that you follow safe operatingpractices and maintenance procedures.

• Keep this Operation Manual in aconvenient place for easy access.

• If this Operation Manual is lost ordamaged, order a new one from yourauthorized Yanmar marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theengine and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour engine. If you have any questionsabout these differences, please contactyour authorized Yanmar marine dealer ordistributor.

• The specifications and components(instrument panel, fuel tank, etc.)described in this manual may differ fromones installed on your vessel. Please referto the manual provided by themanufacturer of these components.

• Refer to the Yanmar Limited WarrantyHandbook for a complete warrantydescription.

6LPA Series Operation Manual 1© 2007 Yanmar Marine International

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Engine Model:

Engine Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 6LPA Series Operation Manual© 2007 Yanmar Marine International

SAFETYYanmar considers safety of greatimportance and recommends that anyonethat comes into close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts exercise care, common sense andcomply with the safety information in thismanual and on the engine’s safety decals.Keep the decals from becoming dirty or tornand replace them if they are lost ordamaged. Also, if you need to replace a partthat has a decal attached to it, make sureyou order the new part and decal at the sametime.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

! DANGERIndicates a hazardous situation which, ifnot avoided, will result in death orserious injury.

! WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which can causedamage to the engine, personal propertyand / or the environment or cause theequipment to operate improperly.


SAFETY PRECAUTIONSGeneral InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.Before You Operate

! DANGERThe safety messages that follow haveWARNING level hazards.

NEVER permit anyone toinstall or operate theengine without propertraining.

• Read and understand this OperationManual before you operate or service theengine to ensure that you follow safeoperating practices and maintenanceprocedures.

• Safety signs and labels are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar marinedealer or distributor for additional training.

During Operation andMaintenance

! DANGERThe safety message that follows hasDANGER level hazards.

Crush HazardNEVER stand under hoistedengine. If the hoist mechanismfails, the engine will fall on you.

SAFETY


! WARNINGThe safety messages that follow haveWARNING level hazards.

Explosion HazardWhile the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area around

the battery well-ventilated and keep sparks,open flames and any other form of ignitionout of the area.

Fire and Explosion HazardDiesel fuel is flammable and explosiveunder certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in awell-ventilated area, away from anycombustibles or sources of ignition.

Fire HazardUndersized wiring systemscan cause an electrical fire.

Sever HazardRotating parts can causesevere injury or death. NEVERwear jewelry, unbuttonedcuffs, ties or loose fittingclothing and ALWAYS tie long

hair back when working near moving /rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or feeling ill.

Exposure HazardTo avoid injury, ALWAYSwear personal protectiveequipment includingappropriate clothing, gloves,work shoes, eye and hearing

protection as required by the task at hand.

Entanglement HazardNEVER leave the key in thekey switch when you areservicing the engine.Someone may accidentallystart the engine and not realize

you are servicing it.

NEVER operate the engine while wearing aheadset to listen to music or radio becauseit will be difficult to hear the warning signals.

Stop the engine before you begin to serviceit.

If you must service the engine while it isoperating, remove all jewelry, tie back longhair, and keep your hands, other body partsand clothing away from moving / rotatingparts.

SAFETY


! WARNINGPiercing Hazard

Avoid skin contact with high-pressure diesel fuel spraycaused by a fuel system leaksuch as a broken fuel injectionline. High-pressure fuel can

penetrate your skin and result in seriousinjury. If you are exposed to high-pressurefuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with yourhands. ALWAYS use a piece of wood orcardboard. Have your authorized Yanmarmarine dealer or distributor repair thedamage.

Burn HazardSome of the engine surfacesbecome very hot duringoperation and shortly aftershut-down. Keep hands andother body parts away fromhot engine surfaces.

Sudden Movement HazardALWAYS stop the engine before beginningservice.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.

! CAUTIONThe safety messages that follow haveCAUTION level hazards.

Poor Lighting HazardEnsure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool HazardALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening engine parts.

Flying Object HazardALWAYS wear eye protection whenservicing the engine or when usingcompressed air or high-pressure water.Dust, flying debris, compressed air,pressurized water or steam may injure youreyes.

Coolant HazardWear eye protection andrubber gloves when youhandle Long Life enginecoolant. If contact with theeyes or skin should occur,

flush eyes and wash immediately with cleanwater.

SAFETY


NOTICEThe safety messages that follow haveNOTICE level hazards.

It is important to perform daily checks aslisted in the Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.

See your authorized Yanmar marine dealeror distributor if you need to operate theengine at high altitudes. At high altitudes theengine will lose power, run rough andproduce exhaust gases that exceed thedesign specifications.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such asengine oil, diesel fuel and engine coolant.Consult the local authorities or reclamationfacility.NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

If a Yanmar Marine Engine is installed at anangle that exceeds the specifications statedin the Yanmar Marine Installation manuals,engine oil may enter the combustionchamber causing excessive engine speed,white exhaust smoke and serious enginedamage. This applies to engines that runcontinuously or those that run for shortperiods of time.

If you have an installation with two or threeengines and only one engine is operating,the water pickup (thru-hull) of the non-running engine(s) should be closed. This willprevent water from being forced past theseawater pump and eventually finding itsway into the engine. The result of waterentering the engine could cause seizure orother serious problems.

If you have an installation with two or threeengines, and only one engine is operating,please note that if the propeller shaft thru-hull (stuffing box) is lubricated by enginewater pressure and the engines areinterconnected, care must be taken thatwater from the running engine does notenter the exhaust of the non-runningengine(s). This water could cause seizure ofthe non-running engine(s). See yourauthorized Yanmar marine dealer ordistributor for a complete explanation of thiscondition.

If you have an installation with two or threeengines, and only one engine is operating,it is important to limit the amount of throttleapplied to the running engine. If you observeblack smoke or movement of the throttledoes not increase engine rpm, you areoverloading the engine that is running.Immediately throttle back to approximately2/3 throttle or to a setting where the engineperforms normally. Failure to do so maycause the running engine to overheat orcause excess carbon buildup which mayshorten the engine's life.

NEVER attempt to adjust the low or high idlespeed limit screw. This may impair thesafety and performance of the engine andshorten its life. Modifications of this type mayvoid the warranty. If adjustment is everrequired, contact your authorized Yanmarmarine dealer or distributor.

SAFETY


LOCATION OF SAFETY DECALSFigure 1 shows the location of safety decals on Yanmar 6LPA series marine engines.

(1) (2) (3) (4)

(5)

0004813

Figure 11 – Part Number: 120324-072402 – Part Number: 128296-072603 – Part Number: 119773-07280

4 – Part Number: 128296–073005 – Part Number: 128296–07360

Note: Figure 1 shows an overhead view of the 6LPA engine.

SAFETY


PRODUCT OVERVIEWYANMAR 6LPA FEATURESAND APPLICATIONSThe 6LPA series are 6-cylinder, 4-strokedirect injection diesel engines equipped withliquid coolant systems.The 6LPA-STP2 engines are equipped witha marine gear (ZF63A1 or KMH50A).The 6LPA-STZP2 engines are equippedwith a stern drive (Mercruiser Bravo).These engines are designed for pleasurecraft use.It is recommended that new vessels bepropped so the engines can operate at100 - 200 rpm above the rated power output(3800 rpm) to allow for future added weightand hull resistance. The engine must beable to reach the rated power output rpmunder full load at all times.Failure to do so can lead to reduced vesselperformance, lead to increased smokelevels and cause permanent damage to yourengine.

The engine must be installed correctly withcoolant lines, exhaust gas lines andelectrical wiring. Any auxiliary equipmentattached to the engine should be easy to useand accessible for service. To handle thedrive equipment, propulsion systems(including the propeller) and other onboardequipment, always observe the instructionsand cautions given in the operation manualssupplied by the shipyard and equipmentmanufacturers.The 6LPA series engines are designed to beoperated at maximum throttle (3800 rpm) forless than 5% of total engine time (30 minutesout of every 10 hours) and cruising speed(2800 - 3600 rpm or less) for less than 90%of total engine time (9 hours out of every 10hours).The laws of some countries may require hulland engine inspections, depending on theuse, size and cruising area of the boat. Theinstallation, fitting and surveying of thisengine all require specialized knowledgeand engineering skills. See Yanmar's localsubsidiary in your region or your authorizedYanmar marine dealer or distributor.New Engine Break-InAs with all reciprocating engines, the wayyour engine is operated during its first 50hours of operation plays a very significantrole in determining how long it will last andhow well the engine will perform over itslifetime.


A new Yanmar diesel engine must beoperated at suitable speeds and powersettings during the break-in period to makethe sliding parts, such as piston rings, breakin properly and to stabilize enginecombustion.During the break-in period, the enginecoolant temperature gauge should bemonitored, temperature should be between71˚ - 87˚C (160˚ - 190˚F).During the first 10 hours of operation, theengine should be run at maximum rpmminus 400 - 500 rpm (approximately60 - 70% of load) most of the time. This willensure the sliding parts break in properly.During this period, avoid operating atmaximum engine speed and load to avoiddamaging or scoring sliding parts.Do not operate the engine at low idle or atlow speed and light load for more than30 minutes at a time. Since unburned fueland engine oil will adhere to the piston ringswhen operating at low speeds for longperiods, this will interfere with propermovement of the rings and the lube oilconsumption may increase. Low idle speeddoes not allow break-in of sliding parts.If operating engine at low speed and lightload, you must race the engine to clean thecarbon from the cylinders and fuel injectionvalve.

Perform this procedure in open waters:• With the clutch in NEUTRAL, accelerate

from the low speed position to the highspeed position briefly.

• Repeat this process five times.Once past the initial 10 hours until 50 hours,the engine should be used over its fulloperating range, with special emphasis onrunning at relatively high power settings.This is not the time for an extended cruise atidle or low speed. The boat should be run atmaximum speed minus 400 rpm most of thetime (approximately 70% load), with a 10minute run at maximum minus 200 - 300 rpm(approximately 80% load) every 30 minutesand a 4 - 5 minute period of operation atWOT (wide open throttle) once each 30minutes. During this period, be sure not tooperate your engine at low speed and lightload for more than 30 minutes. If operatingengine at low speed and light load bynecessity, just after the low idle operation,be sure to race the engine.To complete engine break-in, perform AfterInitial 50 Hours maintenance procedures.See Periodic Maintenance Schedule onpage 54.

PRODUCT OVERVIEW


COMPONENT IDENTIFICATIONService Side (Left Side as Viewed from Propeller)Note: 6LPA-STZP2 with stern drive shown. Components marked with an * are for6LPA-STZP2 only.

(1)

(2)(3*)

(4)

(5) (6)

(12)

(11) (10)(9) (8) (7)

0004884

Figure 11 – Fuel Cooler2 – Fuel Filter3 – Power Steering Oil Cooler*4 – Engine Oil Filter5 – Intercooler6 – Mixing Elbow

7 – Engine Oil Cooler8 – Starter9 – Engine Oil Cooler10 – Fuel Injection Pump11 – Seawater Pump12 – Stern Drive

PRODUCT OVERVIEW


Non-Service Side

(1) (2)(3)

(4*)(5)

(6)

(7*)

(8)(9)(10)

(11)

0004885

Figure 21 – Turbocharger2 – Engine Nameplate (on rocker arm cover)3 – Fresh Water (Coolant) Tank4 – Power Steering Oil Tank*5 – Fresh Water Filler Cap6 – Engine Oil Filler Cap

7 – Power Steering Oil Pump*8 – Alternator9 – Engine Oil Dipstick10 – Fresh Water Cooler11 – V-Belt

PRODUCT OVERVIEW


ENGINE NAMEPLATE

//

Gear Model

ENG.No.

//

Model

min-1

min-1

min-1

Continuous power kW

Speed of prop,shaf t

Fuel stop power kW

0004574

Figure 3The nameplate of Yanmar 6LPA seriesengines is shown in Figure 3. Thenameplate is located on the engine rockerarm cover. Check the engine's model,output, rpm and serial number on thenameplate. Replace if damaged or lost.

PRODUCT OVERVIEW


FUNCTION OF MAJOR COMPONENTSName of Component FunctionFuel 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 separatoris 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 filterfeeds 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 spin-on type andthe inner element should be replaced periodically.

Engine Oil Dipstick Gauge stick for checking the engine oil level.Marine Gear Oil Filler Port (IfEquipped)

Filler port for marine gear lube oil. Located on top of the marine gear case.

Cooling System There are two cooling systems: fresh water and seawater. • Fresh Water (Coolant)

Tank• Fresh Water Cooler• Cooling Water Pump

The tank stores the fresh cooling water and is connected to the fresh watercooler. Cooling seawater passes through the fresh water cooler to cool thefresh water by heat exchange. After cooling, the cooled fresh water is fedby the cooling water pump to the inside of the engine, around the combustionchamber, turbocharger and then returned to the tank.

Filler Cap Located on the top of the fresh water recovery tank. It has two pressureregulating valves (release and retraction valves). When the cooling watertempereature rises, the pressure inside the fresh water tank increasescausing 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 rubber hose.) When theload is reduced and the cooling water temperature falls, the pressure in thefresh water tank is lowered, activating the retraction valve in the filler cap.This causes the cool water in the subtank to return to the fresh water recoverytank. This process reduces the consumption of cooling water.

Turbocharger A pressurized intake air feeding device. The exhaust gas turbine is rotatedby the exhaust gas and the power is used to rotate the blower. Thispressurizes the intake air for sending to the cylinder.

Intercooler This heat exchanger cools the pressurized charging air from theturbocharger with water.

Zinc Anode The metal area of the seawater cooling system is prone to galvaniccorrosion. 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 isnecessary.

Nameplates Nameplates are provided on the engine and have the model, serial numberand other data.

Starter A DC motor for starting the engine. Electric current causes the pinion gearto 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 duringoperation.

PRODUCT OVERVIEW


CONTROL EQUIPMENTThe control equipment at the helm makes remote control operation possible. It consists ofthe instrument panel, which is connected to the engine by a wire harness, and the remotecontrol (throttle) handle, which is connected by control cables to the engine control lever.Instrument Panel (Optional)Equipment and FunctionsThe instrument panel has the following gauges and alarm devices.

Gauge or Switch New B-TypePanel

See Figure 4New C-Type

PanelSee Figure 5

New D-TypePanel

See Figure 6

Switches

Key (Starter) Switch X X XEngine Stop Button X X XAlarm (Buzzer) X X XAlarm (Buzzer) StopSwitch

X X X

Backlight Switch forGauges

X X X

WarningIndicators

Battery Low Charge X X XFresh Water(Coolant) HighTemperature

X X X

Engine (Lube) OilLow Pressure

X X X

Fresh Water(Coolant) Level

— X X

Exhaust (CoolingSeawater Flow)

X X X

Fuel Filter (WaterSeparator)

X X X

Gear Oil (6LPA-STZP2 Only)

— X X

Gauges

Tachometer withHourmeter

X X X

Engine (Lube) OilPressure Gauge

— X X

Fresh Water(Coolant)Temperature Gauge

— X X

Turbocharger BoostPressure Gauge

— — X

Clock Quartz Clock X(Option)

X(Option)

X

Indicator Preheat Indicator X(Option)

X(Option)

X

X = Available — = Not Available

PRODUCT OVERVIEW


New B-Type(1) (2) (3) (4)

(5)

(6)(7)(8)0003281_m1

Figure 41 – Warning Indicator Display2 – Tachometer3 – Alarm Stop Switch4 – Panel Illumination Switch

5 – Engine Stop Button6 – Starter (Key) Switch7 – Alarm8 – Hourmeter

New C-Type(1) (2) (3) (4) (5)

(6)

(7)

(8)(9)(10) 0003282_m1

Figure 51 – Engine Oil Pressure Gauge2 – Fresh Water (Coolant) Temperature Gauge3 – Tachometer4 – Alarm Stop Switch5 – Panel Illumination Switch

6 – Engine Stop Button7 – Start (Key) Switch8 – Alarm9 – Hourmeter10 – Warning Indicator Display

PRODUCT OVERVIEW


New D-Type(1) (2) (3) (4) (5) (6) (7)

(8)(9)(10)(11)(12)0003283_m1

Figure 61 – Turbocharger Boost Pressure Gauge2 – Engine Oil Pressure Gauge3 – Fresh Water (Coolant) Temperature Gauge4 – Tachometer5 – Alarm Stop Switch6 – Panel Illumination Switch

7 – Engine Stop Button8 – Start (Key) Switch9 – Alarm10 – Hourmeter11 – Clock12 – Warning Indicator Display

PRODUCT OVERVIEW


Available Alarm Switches and Meter Senders 6LPA-STP2

6LPA-STZP2

Switches

Battery Not Charging ○Fresh Water (Coolant) Temperature TooHigh

○

Engine (Lube) Oil Pressure Too Low ○Fresh Water (Coolant) Level Too Low □Exhaust (Cooling Seawater Flow)Restriction

□

Gear Oil (Stern Drive Models Only) □Fuel Filter ○

Senders

Tachometer ○Fresh Water (Coolant) Temperature □Engine (Lube) Oil Pressure □Boost Pressure □Fresh Water (Coolant)Temperature For two

stations

□

Engine (Lube) OilPressure

□

○ = Standard □ = Optional

PRODUCT OVERVIEW


Switches and GaugesSwitch or Gauge Function

0003622

(1)(2)

(3)

(4)

Starter (Key) Switch

OFF (2): The key can be inserted or removed from switch. Allpower is turned off. *

ON (3): For engine operation. Gauges and alarms areoperational.START (4): For starting engine. When key is released afterengine starts, key automatically moves to ON position. NOTICE:NEVER hold the key in the START position for longer than15 seconds or the starter motor will overheat.GLOW (1): For air heater (optional).

Engine Stop Button Press the button to stop the engine by cutting off the fuel flow.Continue to press the button until the engine has stopped. **

Warning Alarm (Buzzer) The alarm sounds if an abnormality is detected. See WarningDevices on page 20.

Warning Indicators The lamps illuminate when an abnormaility is detected. SeeWarning Devices on page 20.

Alarm (Buzzer) Stop Switch The switch is used to shut the alarm off temporarily. Turn thealarm (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 islocated at the bottom of the tachometer.

Engine (Lube) Oil Pressure Gauge Shows the engine (lube) oil pressure.Fresh Water (Coolant) Temperature Gauge Shows the cooling fresh water temperature.Turbocharger Boost Pressure Gauge Shows the intake air pressure (intake air boost pressure of

turbocharger).Preheat Indicator (If equipped) Illuminates when the air heater is heating up for easier starting

in cold temperatures. Indicator is located in the warning lampcluster.

* The engine cannot be stopped by the starter (key) switch. Use the engine stop button to turn engine OFF.** Releasing the engine stop button before the engine has stopped rotating will cause the engine to continue to

run.

PRODUCT OVERVIEW


Warning DevicesWhen a sensor detects a problem duringoperation, the indicator on the instrumentpanel will light and an alarm will sound.Indicators are located on the instrumentpanel, the alarm is located on the back of thepanel. Under normal operating conditions,the indicators are off.• Alarm (Buzzer): If a warning lamp

illuminates, the alarm will sound.However, no alarm will sound when thebattery charging lamp illuminates.

• Alarm (Buzzer) Stop Switch: Wheninvestigating the cause of an alarm, pressthe alarm (buzzer) stop switch.WARNING! The switch is used to shutthe alarm off temporarily. Turn thealarm (buzzer) OFF when inspectingfor cause. Inspect and repair theabnormality immediately.

• Warning Indicators: When operation isnormal, the warning indicators are OFF. Ifan abnormality is detected, the sensor willtrigger the appropriate warning indicatorto light.

Figure 7Battery Low Charge Indicator(Figure 7) - When the alternator output istoo low, the indicator will light. Whencharging begins, the indicator will turn off.No alarm will sound for low battery charge.

Figure 8Fresh Water (Coolant) High TemperatureIndicator and Alarm (Figure 8) - When thecoolant temperature reaches the maximumallowable temperature (95˚C [203˚F] orhigher), the indicator will light and the alarmwill sound. Continuing operation attemperatures exceeding the maximum limitwill result in damage and seizure. Check theload and troubleshoot the fresh watercooling system.

Figure 9Engine (Lube) Oil Low Pressure Indicatorand Alarm (Figure 9) - When the engine oilpressure falls below the specified level, theoil pressure sensor will send a signal to theindicator causing it to light and the alarm tosound. Stop operation immediately to avoiddamage to the engine. Check the oil leveland troubleshoot the lubrication system.

0004882

Figure 10Fresh Water (Coolant) Level Indicator andAlarm (Figure 10) - When the amount ofcooling water in the fresh water recoverytank falls below normal, the sensor will senda signal to the indicator causing it to light andthe alarm to sound. Stop operationimmediately to avoid damage to the engine.Check the water level in the cooling waterrecovery tank and troubleshoot the coolingsystem.

PRODUCT OVERVIEW


Figure 11Fuel Filter (Water Separator) (Figure 11) -When the water level inside the waterseparator becomes too high, the sensor willsend a signal to the indicator causing it tolight. Drain the water separator. If operationis continued without draining the waterseparator, fuel feed to the engine isrestricted and may cause damage to theengine or fuel injection pump.

Figure 12Exhaust (Cooling Seawater Flow)Restriction (Figure 12) - When the amountof cooling seawater being discharged is toolow, the sensor will activate the warningindicator. Stop operation immediately toavoid damage to the engine. Check theseawater cooling system for restriction ordamage.

Figure 13Gear Oil Level (6LPA-STZP2 Only)(Figure 13) - When the amount of gear oilfalls below normal, the sensor will send asignal to the indicator causing it to light andthe alarm to sound. Stop engineimmediately to avoid damage to the geardevice. Check the oil level in the gear andtroubleshoot the gear system.

PRODUCT OVERVIEW


AlarmsCheck that indicators and alarms are working normally when the key is turned to ON.

Key Switch OFF ⇒ ON START ⇒ ONEngine Before starting RunningAlarm ON OFFIndicators Battery Low Charge Indicator ON OFF

Fresh Water (Coolant) High TemperatureIndicator

OFF OFF

Engine (Lube) Oil Low Pressure Indicator ON OFFFresh Water (Coolant) Level Indicator OFF OFFFuel Filter (Water Separator) Indicator OFF OFFExhaust (Cooling Seawater Flow) RestrictionIndicator

ON OFF

Gear Oil Level (6LPA-STZP2 Only) OFF OFF

Key (Starter) Switch

0003622

(1)(2)

(3)

(4)

Figure 14The GLOW position (Figure 14, (1)) is thestart aid position. Electric current to the airheater (if equipped) is turned on.The START position (Figure 14, (4)) allowscurrent to the starting motor. When startingthe engine, move the key to the STARTposition and release. The key willautomatically move to the ON position.NOTICE: NEVER hold the key in theSTART position for longer than 15seconds or the starter motor willoverheat.

When the key is in the OFF position(Figure 14, (2)) the electric current is off.The key can be inserted or removed in thisposition.The ON position (Figure 14, (3)) allowselectrical current to the controls andequipment and allows the engine to keeprunning. To stop the engine, keep the keyswitch in the ON position and push theengine stop button. After stopping theengine, turn key to OFF position.

PRODUCT OVERVIEW


Engine Stop Button

(1)

0004881

Figure 15Push and hold the stop button(Figure 15, (1)) on the instrument panel tostop the engine. When the stop button ispushed, the solenoid valve on the fuelinjection pumps stops the fuel supply to theengine.Press and hold the engine stop button untilthe engine has come to a complete stop.NOTICE: Releasing the engine stopbutton before the engine has stoppedrotating will cause the engine tocontinue to run.

PRODUCT OVERVIEW


Remote Control (Throttle) HandleThe engine is controlled by the remotecontrol handle located in the cockpit. Thespeed control lever on the engine and clutchlever on the marine drive are connected byremote control cables. There are variousmodels of remote control handles available.When using a model other than shownbelow, consult the manufacturer'sdocumentation for more information.Morse Remote Control Handle(Optional)This is a single-lever remote control handleconnected by a remote cable. It operates theclutch to NEUTRAL, FORWARD andREVERSE and controls the engine speed.

MT-3 Top Mount

(1)

(2)

(3)(4)

(5)(6)

(7)

0004886

Figure 161 – Reverse High Speed2 – Reverse Low Speed3 – Reverse4 – Neutral5 – Forward6 – Forward Low Speed7 – Forward High Speed

MV Side Mount

(1)

(2)

(3)

(4)

(5)

(6)

(7)0004887

Figure 171 – Forward High Speed2 – Forward Low Speed3 – Forward4 – Neutral5 – Reverse6 – Reverse Low Speed7 – Reverse High SpeedThe operation labels on the handle are:• FWD - Forward• NEU - Neutral (Clutch Disengaged)• Throttle - Position to reduce engine speed• REV - Reverse

Starting and StoppingPut the handle in NEUTRAL. This puts theclutch in the disengaged position and theengine at a low speed.ForwardMove the handle from NEUTRAL to FWD(forward). This engages the clutch inforward and simultaneously increases theengine speed. Pushing the handle further inthe same direction increases engine speedto full speed.

PRODUCT OVERVIEW


ReverseMove the handle from NEUTRAL to REV(reverse). This engages the clutch inreverse and simultaneously increases theengine speed. Pushing the handle further inthe same direction increases engine speedto full speed.Free Throttle OperationWhen the boat is stopped (clutch is inNEUTRAL) the idling speed of the enginecan be increased in the following manner:1. Ensure the handle is in NEUTRAL.2. Disengage the clutch:

MT-3

(4)

(1)

(2)

(3)

0004888

Figure 181 – Neutral2 – Low Speed3 – High Speed4 – Remote Control (Throttle)

Handle

MV

(1)

(2)

(3)

(4)

0004889

Figure 191 – High Speed2 – Low Speed3 – Neutral4 – Free Throttle Button

3. • MT-3: Pull the throttle handle(Figure 18, (4)) all the way out.

• MV: Pull out the free throttle button(Figure 19, (4)), located next to thehandle.

When the handle or button is pulled out,move the handle to either FORWARDor REVERSE to increase the idlingspeed.

Returning to Normal Operation• MT-3: Move the throttle handle to

NEUTRAL (Figure 18, (1)). The lever willautomatically return to the normalposition.

• MV: Move throttle handle to NEUTRAL(Figure 19, (3)). Push the free throttlebutton in.

PRODUCT OVERVIEW


This Page Intentionally Left Blank

PRODUCT OVERVIEW


BEFORE YOU OPERATEThis section of the Operation Manualdescribes the diesel fuel, engine oil andengine coolant specifications and how toreplenish them. It also describes the dailyengine checks.

DIESEL FUELDiesel Fuel SpecificationsDiesel fuel should comply with the followingspecifications. The table lists severalworldwide specifications for diesel fuels.

DIESEL FUELSPECIFICATION

LOCATION

ASTM D975 No. 2-D,No. 1-D

USA

EN590 European UnionISO 8217 DMX InternationalBS 2869-A1 or A2 United KingdomJIS K2204 Japan


Additional Technical FuelRequirements• The fuel cetane number should be equal

to 45 or higher.• The sulfur content must not exceed 0.5%

by volume. Less than 0.05% is preferred.• NEVER mix kerosene, used engine oil, or

residual fuels with the diesel fuel.• Water and sediment in the fuel should not

exceed 0.05% by volume.• Keep the fuel tank and fuel-handling

equipment clean at all times.• Ash content not to exceed 0.01% by

volume.• Carbon residue content not to exceed

0.35% by volume. Less than 0.1% ispreferred.

• Total aromatics content should notexceed 35% by volume. Less than 30% ispreferred.

• PAH (polycyclic aromatic hydrocarbons)content should be below 10% by volume.

• Do not use Biocide.• Do not use kerosene or residual fuels.Handling of Diesel Fuel

0004512

Figure 11. Water and dust in the fuel may cause

engine failure. When fuel is stored, besure that the inside of the storagecontainer is clean and dry, and that thefuel is stored away from dirt or rain.

2. Keep the fuel container stationary forseveral hours to allow any dirt or waterto settle to the bottom of the container.Use a pump to extract the clear, filteredfuel from the top of the container(Figure 1).

Fuel TankNote: Optional fuel tank style shown.

(1)

(2)

(3)

0004898

Figure 21 – Sediment Bowl2 – Drain Cock3 – Fuel Line To EngineInstall a drain cock (Figure 2, (2)) at thebottom of the fuel tank to remove water andcontaminants from the sediment bowl(Figure 2, (1)).The fuel outlet should be positioned 20 - 30mm (0.75 - 1.125 in.) above the bottom ofthe tank so that only clean fuel is distributedto the engine.

BEFORE YOU OPERATE


Fuel System

0004489

(1)

(2)

(3)

(4)(5)

(6)

(7)

(8)

Figure 31 – Fuel Filter2 – To Fuel Injection Pump3 – Less than 500 mm (20 in.)4 – Fuel Cock5 – 20 - 30 mm (0.75 - 1.125 in.)

Approximately6 – Drain Cock7 – Fuel Tank8 – Fuel Return LineInstall a fuel line from the fuel tank to the fuelpump. See Figure 3.Filling the Fuel TankBefore filling fuel tank for the firsttime:Rinse fuel tank with kerosene or diesel fuel.Dispose of waste properly.To fill the fuel tank: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 hosenozzle firmly against the filler portwhile filling. This prevents staticelectricity buildup which couldcause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows thefuel tank is full. NOTICE: NEVERoverfill the fuel tank.

5. Replace the fuel cap and hand-tighten.Over-tightening the fuel cap willdamage it.

Bleeding the Fuel SystemBleeding must be done if any fuel systemmaintenance has been performed(replacement of fuel filter, etc.) or if theengine does not start after several attempts.

(1)

(2)

0004908

Figure 41. Check the fuel level in the fuel tank.

Refill if necessary.2. Open the fuel cock of the fuel tank.

WARNING! ALWAYS wear safetyglasses when bleeding the fuelsystem.

3. Loosen the air bleed screw(Figure 4, (2)) 2 - 3 turns.

4. Push up and down on the priming pump(Figure 4, (1)) to release air out of theair bleed screw.

5. Continue pumping until a solid streamof fuel with no air bubbles begins toflow.

6. Tighten the air bleed screw.

BEFORE YOU OPERATE


ENGINE OILEngine (Lube) Oil SpecificationsUse an engine oil that meets or exceeds thefollowing guidelines and classifications:API Service Categories CD or higherRecommended SAE Oil Viscosity: 10W30or 15W40Note:1. Be sure the engine oil, engine oil

storage containers and engine oil fillingequipment are free of sediment orwater.

2. Change the engine oil after the first 50hours of operation and then at every125 hours thereafter.

3. Select the oil viscosity based on theambient temperature where the engineis being operated. See the SAE ServiceGrade Viscosity Chart (Figure 5).

4. Yanmar does not recommend the useof engine oil “additives.”

Handling Engine Oil1. When handling and storing engine oil,

be careful not to allow dust and water tocontaminate the oil. Clean around thefiller port before filling.

2. Do not mix lube oils of different types orbrands. Mixing may cause the chemicalcharacteristics of the oil to change andlubricating performance to decrease,reducing the engine's life.

3. Engine oil should be changed at thespecified intervals, regardless if theengine has been operated.

Engine Oil Viscosity

-4°F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

Figure 5If you operate your equipment attemperatures outside the limits shown,consult your authorized Yanmar dealer ordistributor for special lubricants or startingaids.

BEFORE YOU OPERATE


Checking the Engine Oil

(5)

(1)

(4)

(2)(3)

0004902

Figure 61. It is recommended that the engine be

as level as possible before checking theoil.

2. Remove dipstick (Figure 6, (1)) andwipe with clean cloth.

3. Fully reinsert dipstick.4. Remove dipstick. The oil level should

be between upper (Figure 6, (2)) andlower (Figure 6, (3)) lines on thedipstick.

5. Add oil if necessary. See AddingEngine Oil on page 31. NOTICE:NEVER overfill the engine with oil.

6. Fully reinsert dipstick.

Adding Engine Oil1. NOTICE: Prevent dirt and debris

from contaminating engine oil.Carefully clean the dipstick and thesurrounding area before youremove the cap. Remove the oil fillerport cap (Figure 6, (4)) from filler port(Figure 6, (5)) and fill with engine oil.

2. Fill with oil to the upper limit on thedipstick (Figure 6, (2)). NOTICE:NEVER overfill the engine withengine oil.

3. Insert the dipstick fully to check thelevel. NOTICE: ALWAYS keep the oillevel between upper and lower lineson the oil cap / dipstick.

4. Tighten the filler port cap securely byhand.

BEFORE YOU OPERATE


MARINE DRIVE OILNote: Refer to the marine gearmanufacturer's operation manual for themarine gear oil specifications. Refer to themanufacturer's operation manual for marinegear or stern drive oil specifications.Mercruiser® Bravo Stern DriveOil SpecificationsUse marine gear oil that meets or exceedsthe following guidelines and classifications:Drive Oil• QuickSilver® 1 High Performance Gear

Lube.Power Steering Oil (6LPA-STZP2 Only)• Quicksilver® Power Trim and Steering

Fluid or Dexlone-IIPower Trim Oil• Quicksilver® Power Trim and Steering

Fluid or SAE 10W-30 or 10W-40 EngineOil

Checking and Adding MarineDrive OilNote: Refer to the manufacturer's operationmanual for the proper procedure to checkand fill the marine drive oil.Checking and Adding PowerSteering Oil (6LPA-STZP2Models)

(1)

(4)

(3)(2)

0004912

Figure 71. Remove the filler cap / dipstick

(Figure 7, (4)) from the power steeringoil service tank (Figure 7, (1)) and wipewith a clean cloth.

2. Fully reinsert dipstick.3. Remove dipstick. The oil level should

be between upper (Figure 7, (3)) andlower (Figure 7, (2)) lines on thedipstick.

4. Fill with oil to the upper limit on thedipstick. See Mercruiser® Bravo SternDrive Oil Specifications on page 32.NOTICE: NEVER overfill the powersteering system with oil.

5. Fully reinsert dipstick and tighten.

1 QuickSilver is a registered trademark of Brunswick Corporation.

BEFORE YOU OPERATE


ENGINE COOLANTEngine Coolant Specifications• Texaco Long Life Coolant (LLC), both

standard and premixed, product code7997 and 7998.

• Havoline Extended LifeAntifreeze / Coolant, product code 7994.

Note: In the U.S., LLC is required for thewarranty to be valid.Engine CoolantNOTICE: Always add LLC to softwater - especially when operating incold weather. Without LLC, coolingperformance will decrease due to scaleand rust in the cooling system. Wateralone may freeze and form ice; itexpands approximately 9% in volume.Use the proper amount of coolantconcentrate for the ambienttemperature as specified by the LLCmanufacturer. LLC concentrationshould be a minimum of 30% to amaximum of 60%. Too much LLC willdecrease the cooling efficiency also. Donot mix different types or brands of LLCor a harmful sludge may form. Do notuse hard water. Water should be cleanand free from sludge or particles.Following the manufacturer’srecommendations, use a proper LLCwhich will not have any adverse effectson the materials (cast iron, aluminum,copper, etc.) of the engine’s fresh watercooling system. See Engine CoolantSpecifications on page 33.Excessive use of antifreeze also lowersthe cooling efficiency of the engine. Besure to use the mixing ratios specifiedby the antifreeze manufacturer for thetemperature range.Replace engine coolant periodically,according to the maintenance schedulein this Operation Manual.Remove scale from the cooling systemperiodically by flushing the system.Do not mix different brands ofantifreeze. Chemical reactions maymake the antifreeze useless and engineproblems may result.

BEFORE YOU OPERATE


Checking and Adding EngineCoolant

0004910

(1)

Figure 81. Ensure all drain cocks are closed.2. WARNING! NEVER remove the filler

cap while the engine is hot. Seriousburns may result. Loosen the filler capof the coolant tank to relieve thepressure, then remove the filler cap(Figure 8, (1)).

3. Pour coolant slowly into the coolanttank to avoid air bubbles. Fill untilcoolant overflows from the filler port.

4. Align filler cap tabs with filler portnotches and tighten filler cap.WARNING! ALWAYS tighten thefiller cap. Steam or scalding watermay spray out if it is not closedtightly.

5.

LOW

FULL

(4)(1)

(2)

(3)

0004493

Figure 9Check the coolant level in the coolantrecovery tank. The level should be atthe FULL mark (Figure 9, (2)). Addcoolant if necessary. NOTICE: NEVERpour cold coolant into a hot engine.

6. Remove coolant recovery tank cap(Figure 9, (4)) to add coolant ifnecessary. Do not add water.

7. Replace filler cap and tighten it firmly.Failure to do so will cause waterleakage.

8. Check the rubber hose (Figure 9, (1))connecting the coolant recovery tank tothe coolant tank / heat exchanger.Replace if damaged.

Note: If the coolant runs low too often or onlythe coolant level in the coolant tank dropswithout any change in the level in the coolantrecovery tank, there may be water or airleaks in the cooling system. See yourauthorized Yanmar dealer or distributor.

BEFORE YOU OPERATE


CRANKING THE ENGINEWhen performing engine break-in or if theengine has not been used for a long periodof time, engine oil will not be distributed toall of the operating parts. Using the enginein this condition will lead to seizure.After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:1. Open seacock (if equipped).2. Open fuel cock.3. Put remote control shift lever in

NEUTRAL.4. Turn battery switch to ON (if equipped).

(1)

(2)

(3)(4)

(5)

0004890

Figure 105. Turn key to ON (Figure 10, (3)). It is

normal for the alarm to sound and thewarning indicators to light duringcranking.

Note: If the engine has not been operated fora long period of time, check that the key canbe moved from START to ON positionssmoothly.6. While pushing the STOP button

(Figure 10, (1)), turn the key to theSTART position (Figure 10, (2)).NOTICE: NEVER hold the key in theSTART position for longer than 15seconds or the starter motor willoverheat.

7. When the key is in the START position,the engine will begin cranking.Continue cranking for about 5 secondsand listen for abnormal noise duringthat time.

Note: If the STOP button is released duringthe cranking procedure, the engine will start.Do not start the engine in this mode.8. Move key to OFF position

(Figure 10, (4)). The engine will stopcranking.

BEFORE YOU OPERATE


DAILY CHECKSBefore you start for the day, make sure theYanmar engine is in good operatingcondition. CAUTION! It is important toperform daily checks as listed in thisOperation Manual. Periodicmaintenance prevents unexpecteddowntime, reduces the number ofaccidents due to poor engineperformance and helps extend the life ofthe engine. Make sure you check thefollowing items:Visual Checks1. Check for engine oil leaks.2. Check for fuel leaks.3. Check for engine coolant leaks.4. Check for damaged or missing parts.5. Check for loose, missing or damaged

fasteners.6. Check the electrical harnesses for

cracks, abrasions, and damaged orcorroded connectors.

7. Check hoses for cracks, abrasions anddamaged, loose or corroded clamps.

8. Check the fuel filter / water separator forpresence of water and contaminants. Ifyou find any water or contaminants,drain the fuel filter / water separator.See Draining Fuel Filter / WaterSeparator on page 62. If you have todrain the fuel filter / water separatorfrequently, drain the fuel tank and checkfor water in your fuel supply. SeeDraining Water From the Fuel Tank onpage 61.

CAUTION! If any problem is notedduring the visual check, the necessarycorrective action must be taken beforeyou operate the engine.

Checking Diesel Fuel, Engine Oiland Engine Coolant LevelsFollow the procedures in Filling the FuelTank on page 29, Checking the Engine Oilon page 31 and Checking and AddingEngine Coolant on page 34 to check theselevels.Checking and Refilling MarineDrive OilSee Checking and Adding Marine Drive Oilon page 32.Checking the Battery ElectrolyteLevelCheck the battery electrolyte level beforeuse. See Checking the Battery ElectrolyteLevel (Serviceable Batteries Only) on page62.Checking the Alternator BeltCheck the belt tension before use. SeeChecking and Adjusting the Alternator V-Belt Tension on page 67 .Checking the Remote ControlHandleCheck the operation of the remote controlhandle and ensure it moves smoothly. If it ishard to operate, grease the joints of theremote control cable and lever bearings. Ifthe lever is too loose, adjust the remotecontrol cable. See Checking and AdjustingRemote Control Cables on page 65.Checking the Alarm IndicatorsCheck the instruments and alarm indicatorsat regular intervals.Preparing Fuel, Oil and Coolant inReservePrepare sufficient fuel for the day’soperation. Always store engine oil andcoolant in reserve (for at least one refill) onboard, to be ready for emergencies.

BEFORE YOU OPERATE


Checking the Wiring ConnectorsSee your authorized Yanmar marine dealeror distributor.Tightening All Major Nuts and BoltsSee Tightening Fasteners on page 51 orsee your authorized Yanmar marine dealeror distributor.

BEFORE YOU OPERATE



BEFORE YOU OPERATE


ENGINE OPERATION ! WARNING

Fire and Explosion HazardNEVER jump-start the engine.Sparks caused by shorting thebattery to the starter terminalsmay cause a fire or explosion.ONLY use the key switch to

start the engine.

Sudden Movement HazardBe sure the boat is in open water away fromother boats, docks or other obstructionsbefore increasing rpm. Avoid unexpectedequipment movement. Shift the marine gearinto the NEUTRAL position any time theengine is at idle.

To prevent accidental equipmentmovement, NEVER start the engine in gear.

Sever HazardKeep children and pets awaywhile the engine is operating.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.


NOTICEIf any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair the problembefore you continue to operate the engine.If the alarm window with audible alarm failsto display and go out about 3 seconds laterwhen the ignition switch is in the ONposition, see your authorized Yanmarmarine dealer or distributor for servicebefore operating the engine.

Observe the following environmentaloperating conditions to maintain engineperformance and avoid premature enginewear:• Avoid operating in extremely dusty

conditions.• Avoid operating in the presence of

chemical gases or fumes.• NEVER run the engine if the ambient

temperature is above +40˚C (+104˚F) orbelow -16˚C (+5˚F).

• If the ambient temperature exceeds+40˚C (+104˚F), the engine may overheatand cause the engine oil to break down.

• If the ambient temperature is below -16˚C(+5˚F), rubber components such asgaskets and seals will harden causingpremature engine wear and damage.

• Contact your authorized Yanmar marineengine dealer or distributor if the enginewill be operated outside of this standardtemperature range.

NEVER engage the starter motor while theengine is running. Damage to the startermotor pinion and / or ring gear will result.

STARTING THE ENGINENOTICE: If the vessel is equipped with awater lift (water lock) muffler, excessivecranking could cause seawater to enterthe cylinders and damage the engine. Ifthe engine does not start after crankingfor 10 seconds, close the seacock toavoid filling the muffler with water.Crank for 10 seconds or until the enginestarts. When the engines does start,stop the engine immediately.1. Open the seacock (if equipped).2. Open the fuel cock.3. Put the remote control handle in

NEUTRAL.Note: Safety equipment should make itimpossible to start the engine in any otherposition than NEUTRAL.4. Turn the battery master switch (if

equipped) to ON.

0003622

(1)(2)

(3)

(4)

Figure 15. Turn key switch to ON (Figure 1, (3)).

Ensure that the instrument panelindicators light and the alarm sounds.This indicates that indicators and alarmare working correctly.

Note: The coolant high temperature alarmindicator does not come on during start-up.

ENGINE OPERATION


6. Turn the key switch to START(Figure 1, (4)). Release the key switchwhen the engine has started. NOTICE:NEVER hold the key in the STARTposition for longer than 15 secondsor the starter motor will overheat.

7. The alarm should stop and theindicators should go out. NOTICE: Ifany indicator fails to illuminatewhen the key switch is in the ONposition, see your authorizedYanmar marine dealer or distributorfor service before operating theengine.

Note: When the engine has not been usedfor a long period of time, check that the keycan move from the START position to theON position smoothly.Starting at Low TemperaturesComply with local environmentalrequirements. Use air heaters (if equipped)to avoid starting problems and white smoke.NOTICE: NEVER use an engine startingaid such as ether. Engine damage willresult.To limit white smoke, run the engine at lowspeed and under moderate load until theengine reaches normal operatingtemperature. A light load on a cold engineprovides better combustion and fasterengine warm-up than no load.Avoid running the engine at idling speed anylonger than necessary.Starting with Air Heater (IfEquipped)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 2Turn key switch to GLOW(Figure 2, (1)) for 15 seconds.NOTICE: NEVER run the air heater(GLOW position) for more than 20seconds at a time or engine damagewill result.

6. Turn key switch to ON (Figure 2, (3)).Ensure that the instrument panelindicators light and the alarm sounds.This shows that indicators and alarmare working correctly.

Note: The coolant high temperature alarmindicator does not come on during start-up.7. Turn key switch to START

(Figure 2, (4)). Release the key switchwhen the engine has started. The alarmshould stop and the indicators shouldgo out. NOTICE: NEVER hold the keyin the START position for longerthan 15 seconds or the startermotor will overheat.

ENGINE OPERATION


Restarting After Starting FailureBefore turning the key switch again, ensurethe engine has stopped completely. If anattempt to restart is made while the engineis running, the pinion gear of the startermotor will be damaged. NOTICE: NEVERhold the key in the START position forlonger than 15 seconds or the startermotor will overheat.NOTICE: NEVER attempt to restart theengine if the engine has not stoppedcompletely. Pinion gear and startermotor damage will occur.Air Bleeding the Fuel System AfterStarting FailureIf the engine does not start after severalattempts, there may be air in the fuel system.If air is in the fuel system, fuel cannot reachthe fuel injection pump. Bleed the air out ofthe system. See Bleeding the Fuel Systemon page 29.

After the Engine Has Started1. After the engine has started, ensure the

remote control handle is in NEUTRAL.MT-3

(4)

(1)

(2)

(3)

0004888

Figure 31 – Neutral2 – Low Speed3 – High Speed4 – Throttle Handle

MV

(1)

(2)

(3)

(4)

0004889

Figure 41 – High Speed2 – Low Speed3 – Neutral4 – Free Throttle Button

ENGINE OPERATION


2. MT-3: Pull out the handle lever(Figure 3, (4)) and adjust the speed tono more than 1500 rpm and run theengine at low speed with no load.

3. MV: Pull out the free throttle button(Figure 4, (4)) and adjust the speed tono more than 1500 rpm and run theengine at low speed with no load.

4. Allow engine to run for approximately 5minutes.

Check the following items at a low enginespeed:• Check that the gauges, indicators and

alarm are normal.• Check for water, fuel or oil leakage from

the engine.• Check that the exhaust color, engine

vibration and sound are normal.• When there are no problems, keep the

engine at low speed with the boat stillstopped to distribute engine oil to all partsof the engine.

• Check that sufficient cooling water isdischarged from the seawater outlet pipe.Operation with inadequate seawaterdischarge will damage the impeller of theseawater pump. If seawater discharge istoo low, stop the engine immediately.Identify the cause and repair. NOTICE:The engine will seize if it is operatedwhen cooling seawater discharge isinadequate or if load is appliedwithout any warm-up operation.For troubleshooting assistance, seeTroubleshooting After Starting on page71 or Troubleshooting Chart on page73.If necessary, see your authorized Yanmardealer or distributor.

When operating the engine at low speedfor long periods of time, race the engineonce every 2 hours. Racing the engine:with the clutch in NEUTRAL, acceleratefrom the low speed position to the highspeed position and repeat this processabout five times. This is done to cleanout carbon from the cylinders and thefuel injection valves. NOTICE:Neglecting the race the engine willresult in poor exhaust color and reduceengine performance.Periodically operate the engine nearmaximum speed while underway. Thiswill generate higher exhausttemperatures, which will help clean outhard carbon deposits, maintain engineperformance and prolong the life of theengine.

ENGINE OPERATION


REMOTE CONTROLHANDLE OPERATIONAcceleration and Deceleration

MT-3 Top Mount

(1)

(2)

(3)(4)

(5)(6)

(7)

0004886

Figure 51 – Reverse High Speed2 – Reverse Low Speed3 – Reverse4 – Neutral5 – Forward6 – Forward Low Speed7 – Forward High Speed

MV Side Mount

(1)

(2)

(3)

(4)

(5)

(6)

(7)0004887

Figure 61 – Forward High Speed2 – Forward Low Speed3 – Forward4 – Neutral5 – Reverse6 – Reverse Low Speed7 – Reverse High Speed

Note: Direction of travel will vary dependingon installation location.Use the remote control (throttle) handle tocontrol acceleration and deceleration. Movethe handle slowly and smoothly.Shifting the Marine DriveNOTICE: Shifting the marine drive whileoperating at high speed or not pushingthe handle fully into position (partialengagement) will result in damage tomarine drive parts and abnormal wear.1. Before using the marine gear, be sure

to move the throttle handle to a low idleposition (less than 1000 rpm). Move thethrottle handle slowly to a higher speedposition after completing clutchengagement.

ENGINE OPERATION


2. NOTICE: NEVER shift the marinegear at high engine speed. Duringnormal operation, the marine gearshould only be shifted with theengine at idle. When moving thehandle between FORWARD andREVERSE, bring the clutch toNEUTRAL and pause before slowlyshifting to the desired position. Do notshift abruptly from FORWARD toREVERSE or vice versa.

Morse Remote Control Handle(Optional)• Move the handle to the NEUTRAL

(middle) position to stop the boat. Theengine will idle at low speed.

• Move the handle to the FORWARDposition to go forward. When the clutch isengaged in forward, the speed willincrease.

• Move the handle to the REVERSEposition to go in reverse. When the clutchis engaged in reverse, the speed willincrease.

SHUTTING DOWN THEENGINENOTICE: Do not stop engine abruptlyduring operation. Yanmar recommendsthat when shutting the engine down,allow the engine to run, without load, for5 minutes. This will allow the enginecomponents that operate at hightemperatures, such as the exhaustsystem, to cool slightly before theengine itself is shut down.1. Reduce engine speed to low idle and

put remote control handle inNEUTRAL.

2. Accelerate from low speed to highspeed and repeat five times. This willclean out the carbon from the cylindersand the fuel injection nozzles.

(1)

(2)

(3)(4)

(5)

0004890

Figure 73. Allow engine to run at low speed

(approximately 1000 rpm) without loadfor 5 minutes.

4. With the key in the ON position, pushand hold the stop button(Figure 7, (1)) until the engine is off.

Note: Continue to hold the stop button inuntil the engine is completely stopped. If thebutton is released before the engine hascompletely stopped, it may restart.5. After the engine has stopped, turn the

key switch to OFF (Figure 7, (4)).Note: If the engine does not shut off whenthe engine stop button is pushed, close thefuel cock on the fuel tank.6. Remove the key.

ENGINE OPERATION


7. Turn off the battery master switch (ifequipped).

8. Close the fuel cock.9. Close the seacock (if equipped).

NOTICE: Be sure to close theseacock. Neglecting to close theseacock could allow water to leakinto the boat and may cause it tosink.

ENGINE OPERATION


PERIODIC MAINTENANCEThis section of the Operation Manualdescribes the procedures for proper careand maintenance of the engine.

SAFETY PRECAUTIONS ! WARNING

Crush HazardIf you need to transport anengine for repair, have ahelper assist you attach itto a hoist and load it on atruck.

The engine lifting eyes are engineered to liftthe weight of the marine engine only.ALWAYS use the engine lifting eyes whenlifting the engine.

Additional equipment is necessary to lift themarine engine and marine gear together.ALWAYS use lifting equipment withsufficient capacity to lift the marine engine.


! WARNINGWelding Hazard

Make welding repairs safely.• ALWAYS turn off the battery switch (if

equipped) or disconnect the negativebattery cable and the leads to thealternator when welding on theequipment.

• Remove the multi-pin connectors to theengine electronics or engine control unit.Connect the weld clamp to thecomponent to be welded and as close aspossible to the welding point.

• NEVER connect the weld clamp to theengine or in a manner which would allowcurrent to pass through a mountingbracket.

• When welding is completed, reconnectthe leads to the alternator and engineelectronics or engine control unit prior toreconnecting the batteries.

Exhaust HazardALWAYS ensure that allconnections are tightened tospecifications after repair ismade to the exhaust system.All internal combustion

engines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.

Shock HazardALWAYS turn off thebattery switch (ifequipped) or disconnectthe negative battery cablebefore servicing the

equipment.

ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

PERIODIC MAINTENANCE


NOTICEAny part which is found defective as a resultof inspection, or any part whose measuredvalue does not satisfy the standard or limit,must be replaced.

Modifications may impair the engine’ssafety and performance characteristics andshorten the engine’s life. Any alterations tothis engine may void its warranty. Be sure touse Yanmar genuine replacement parts.

PRECAUTIONSThe Importance of PeriodicMaintenanceEngine deterioration and wear occur inproportion to the length of time the enginehas been in service and the conditions theengine is subjected to during operation.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.Performing PeriodicMaintenanceWARNING! NEVER block windows,vents, or other means of ventilation ifthe engine is operating in an enclosedarea. All internal combustion enginescreate carbon monoxide gas duringoperation. Accumulation of this gaswithin an enclosure could cause illnessor even death. Make sure that allconnections are tightened tospecifications after repair is made to theexhaust system. Failure to comply couldresult in death or serious injury.The Importance of Daily ChecksThe Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make it a habitof performing daily checks before the startof each operating day. See Daily Checks onpage 36.



Keep a Log of Engine Hours andDaily ChecksKeep a log of the number of hours the engineis run each day and a log of the daily checksperformed. Also note the date, type of repair(e.g., replaced alternator), and parts usedfor any service needed between the periodicmaintenance intervals. Periodicmaintenance intervals are every 50, 125,250, 500, 1000 and 1250 engine hours.Failure to perform periodic maintenance willshorten the life of the engine.Yanmar Replacement PartsYanmar recommends that you use genuineYanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.Tools RequiredBefore you start any periodic maintenanceprocedure, make sure you have the toolsyou need to perform all of the required tasks.Ask Your Authorized YanmarMarine Dealer or Distributor ForHelpOur professional service technicians havethe expertise and skills to help you with anymaintenance or service related procedures.



Tightening FastenersUse the correct amount of torque when you tighten fasteners. Applying excessive torque maydamage the fastener or component and not enough torque may cause a leak or componentfailure.NOTICE: The tightening torque in the Standard Torque Chart should be applied only

to the bolts with a “7” head (JIS strength classification: 7T). Apply 60%torque to bolts that are not listed. Apply 80% torque when tightened toaluminum 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

TighteningTorque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0kgf-m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0lb-ft – 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2lb-in. 96 ± 9.0 – – – – –



EPA MAINTENANCEREQUIREMENTSTo maintain optimum engine performanceand compliance with the EnvironmentalProtection Agency (EPA) Regulations forEngines, it is essential that you follow thePeriodic Maintenance Schedule on page54 and the Periodic MaintenanceProcedures on page 59.EPA Requirements for USA andOther Applicable CountriesThe following are the requirements for theEPA. Unless these requirements are met,the exhaust gas emissions will not be withinthe limits specified by the EPA.See Conditions to Ensure Compliance withEPA Emission Standards on page 52.Clean or replace the air cleaner element ifthe air intake restriction exceeds thereferenced specifications.EPA RequirementsThe EPA emission regulation is applicableonly in the USA and other countries thathave adapted the EPA requirements in partor in whole. Determine and follow theemission regulations in the country whereyour engine will be operating to assist you inspecified compliance.Conditions to EnsureCompliance with EPA EmissionStandardsThe following are the conditions that must bemet in order to ensure that the emissionsduring operation meet the EPA standards.

The operating conditions should be asfollows:• Ambient temperature: -20˚ to +40˚C

(-4˚ to +104˚F)• Relative humidity: 80% or lower• Permissible value for intake negative

pressure: 204 mmAq (8 in.Aq) or lower• Permissible value for exhaust back

pressure: 1999 mmAq (78.7 in.Aq) orlower

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 higherBe sure to perform inspections as outlinedin Periodic Maintenance Procedures onpage 59 and keep a record of the results.Pay particular attention to these importantpoints:• Replacing the engine oil• Replacing the engine oil filter• Replacing the fuel filterNote: Inspections are divided into twosections in accordance with who isresponsible for performing the inspection:the user or the maker.



Inspection and MaintenanceSee Inspection and Maintenance of EPAEmission-Related Parts on page 58 for theEPA emission-related parts. Inspection andmaintenance procedures not shown in theInspection and Maintenance of EPAEmission-Related Parts section are coveredin Periodic Maintenance Schedule on page54.This maintenance must be performed tokeep the emission values of your engine inthe standard values during the warrantyperiod. The warranty period is determinedby the age of the engine or the number ofhours of operation.



PERIODIC MAINTENANCE SCHEDULEDaily 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. Periodicmaintenance intervals vary depending on engine application, loads, diesel fuel and engineoil used and are hard to establish definitively. The following should be treated only as ageneral guideline. CAUTION! Establish a periodic maintenance plan according to theengine application and make sure you perform the required periodic maintenanceat intervals indicated. Failure to follow these guidelines will impair the engine’ssafety and performance characteristics, shorten the engine’s life and may affect thewarranty coverage on your engine. See your authorized Yanmar marine dealer ordistributor for assistance when checking items marked with a ●.

○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributorSystem Item Periodic Maintenance Interval

Daily Every 50hours ormonthlywhich-

evercomes

first

Every125

hours or6

monthswhich-

evercomes

first

Every250

hoursor oneyear

which-ever

comesfirst

Every500

hoursor 2

yearswhich-

evercomes

first

Every1000hoursor 4

yearswhich-

evercomes

first

Every1250hoursor 5

yearswhich-

evercomes

firstWhole Visual

inspectionof engineexterior

○

FuelSystem

Check thefuel leveland refill ifnecessary

○

Drainwater andsedimentfrom fueltank

○

Drain thefuel / waterseparator

○

Replacethe fuelfilterelement

◊Initial 50

◊

Check thefuelinjectiontiming *

●*

Check thefuelinjectorpressureand nozzlespraypattern*

●Initial250

●*





evercomes

first

Every125

hours or6

monthswhich-

evercomes

first

Every250

hoursor oneyear

which-ever

comesfirst

Every500

hoursor 2

yearswhich-

evercomes

first

Every1000hoursor 4

yearswhich-

evercomes

first

Every1250hoursor 5

yearswhich-

evercomes

firstLubricatingSystem

Check theengine oillevel

○

Changethe engineoil

◊Initial 50

◊

Replacethe engineoil filterelement

◊Initial 50

◊

Wash theengine oilcooler

●

MarineDriveSystem

Checkmarinedrive oil

○

Refer to the marine drive system operation manual.

Checkpowersteering oil

○

Checkpower trimoil

○

Checkdrive oil

○

FreshWaterCoolingSystem

Checkcoolantlevel

○

Changecoolant

◊

Clean andcheck thecoolingwaterpassage

●

Clean thecoolingwatersystem

●





evercomes

first

Every125

hours or6

monthswhich-

evercomes

first

Every250

hoursor oneyear

which-ever

comesfirst

Every500

hoursor 2

yearswhich-

evercomes

first

Every1000hoursor 4

yearswhich-

evercomes

first

Every1250hoursor 5

yearswhich-

evercomes

firstSeawaterCoolingSystem

Checkseawateroutletdischarge

○DuringOper-ation

Check orreplace theseawaterpumpimpeller

●

Check orreplace thezincanodes

◊

Check andclean theseawaterpassage

●

Piping Clean orreplace theexhaust /watermixingelbow

●

Check orreplacefuel lineand rubberhoses

○ ●

ElectricalSystem

Check thealarm andindicators

○

Check theelectrolytelevel in thebattery

○

Adjust thetension ofthealternatorV-belt orreplace V-belt

○ ●





evercomes

first

Every125

hours or6

monthswhich-

evercomes

first

Every250

hoursor oneyear

which-ever

comesfirst

Every500

hoursor 2

yearswhich-

evercomes

first

Every1000hoursor 4

yearswhich-

evercomes

first

Every1250hoursor 5

yearswhich-

evercomes

firstRemoteControlHandle

Check andlubricatethe remotecontrolcableoperation

○

Adjust theremotecontrolcable

○

Intake andExhaustSystem

Washturbo-chargerblower

●

Clean aircleaner

○

Adjust theintake andexhaustvalveclearance

●Initial250

●

Lap theintake andexhaustvalves

●

Miscel-laneous

Check andadjust thepowersteering oilpump belt(6LPA-STZP2only)

○

Replacethe timingbelt

●

* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 58.Note: These procedures are considered normal maintenance and are performed at theowner’s expense.



Inspection and Maintenance of EPA Emission-Related PartsParts IntervalClean fuel injection nozzle 1500 hoursCheck fuel injection nozzle (adjustment)

3000 hoursCheck fuel injection pump adjustmentCheck turbocharger adjustmentCheck electronic engine control unit and its associated sensors and actuators

Note: The inspection and maintenance items shown above to be performed at your Yanmardealer or distributor.



PERIODIC MAINTENANCEPROCEDURESAfter Initial 50 Hours ofOperation

Perform the following maintenance after theinitial 50 hours of operation.• Changing the Engine Oil and

Replacing the Engine Oil FilterElement

• Changing the Fuel Filter ElementChanging the Engine Oil andReplacing the Engine Oil FilterElementThe engine oil on a new engine becomescontaminated from the initial break-in ofinternal parts. It is very important that theinitial oil replacement is performed asscheduled.It is easiest and most effective to drain theengine oil after operation while the engine isstill warm. WARNING! If you must drainthe engine oil while it is still hot, stayclear of the hot engine oil to avoid beingburned. ALWAYS wear eye protection.

(1)

0004899

Figure 11. Turn the engine OFF.

2. NOTICE: Prevent dirt and debrisfrom contaminating engine oil.Carefully clean the dipstick and thesurrounding area before youremove the dipstick. Remove theengine oil dipstick. Attach the oil drainpump (if equipped) and pump out theoil.For easier draining, remove the engineoil fill cap.

3. Turn the engine oil filter(Figure 1, (1)) counterclockwise with awrench.

4. Remove the engine oil filter.5. Apply a small amount of engine oil to the

seal of the new filter.6. Install a new filter element and tighten

by hand until the seal touches thehousing.

7. Turn filter an additional 3/4 turn with afilter wrench.

(1)

0004900

Figure 28. Remove filler cap (Figure 2, (1)) and

fill with new engine oil through filler port.See Adding Engine Oil on page 31.NOTICE: NEVER mix different typesof engine oil. This may adverselyaffect the lubricating properties ofthe engine oil. NEVER overfill.Overfilling may result in whiteexhaust smoke, engine overspeedor internal damage.

9. Perform a trial run and check for oilleaks.



10. Approximately 10 minutes afterstopping the engine, remove the oildipstick and check the oil level. Add oilif the level is too low.

11. Dispose of waste properly.

Replacing the Fuel Filter Element

(5)

(4)

(3)

(2)

(1)

0004915

Figure 31 – Mounting Screw (2 used)2 – Housing3 – Alarm Switch4 – O-Ring5 – Filter Element1. Close the fuel cock of the fuel tank.



2. Remove the two mounting screws(Figure 3, (1)) and the housing(Figure 3, (2)).

3. Drain the fuel from the fuel drain cockon the bottom of the fuel / waterseparator.

4. Disconnect the alarm switch harness.

0004897

Figure 45. Remove the alarm switch (Figure 4)

with a wrench.6. Remove the filter element

(Figure 3, (5)) with a filter wrench.7. Install the alarm switch to the new fuel

filter.Component Part No.Fuel Filter Element 119773-55710

8. Apply a thin film of clean diesel fuel tothe sealing surface of the new filtergasket.

9. Install new filter and tighten hand-tight.Use a filter wrench and tighten to14.7 - 19.6 N·m (130.1 - 173.5 in.-lb).

10. Install filter and tighten hand-tight.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 29. Disposeof waste properly.

14. Start engine and check for leaks.

Every 50 Hours of OperationAfter you complete the initial 50 hourmaintenance procedures, perform thefollowing procedures every 50 hoursthereafter or monthly, whichever comesfirst.• Draining Water From the Fuel Tank• Draining Fuel Filter / Water Separator• Checking Battery Electrolyte LevelDraining Water From the Fuel Tank

(1)

(2)

(3)

0004898

Figure 51 – Sediment Bowl2 – Drain Cock3 – Fuel Line To Engine1. Put a pan under the drain cock

(Figure 5, (2)) to catch fuel.2. Open the drain cock and drain water

and sediment. Close the drain cockwhen the fuel is clean and free of airbubbles. NOTICE: Dispose of wasteproperly.



Draining Fuel Filter / WaterSeparatorWater and sediment can clog the fuel filterand impair the function of the fuel injectionpump and valve. If heavy deposits of waterand sediment are drained, also drain the fueltank.

(1)

(2)

0004916

Figure 61. Close the fuel cock of the fuel tank.2. Remove the two mounting screws

(Figure 6, (1)) and remove the housing(Figure 6, (2)).

3. Put a pan under the drain cock.4. Loosen the drain cock of the water

separator and drain off any water or dirtcollected inside.

5. Install housing and mounting screws.6. Bleed air from the fuel system. See

Bleeding the Fuel System on page 29.Checking the Battery ElectrolyteLevel (Serviceable Batteries Only)WARNING! Batteries contain sulfuricacid. NEVER allow battery fluid to comein contact with clothing, skin or eyes.Severe burns could result. ALWAYSwear safety goggles and protectiveclothing when servicing the battery. Ifbattery fluid contacts the eyes and / orskin, immediately flush the affected areawith a large amount of clean water andobtain prompt medical treatment.

NOTICE: NEVER turn off the batteryswitch (if equipped) or short the batterycables during operation. Damage to theelectric system will result.Note: Battery fluid tends to evaporate in hightemperatures, especially in summer. In suchconditions, inspect the battery earlier thanspecified.1. Turn the battery master switch to OFF

(if equipped) or disconnect the negative(-) battery cable.

2. Do not operate with insufficient batteryelectrolyte as the battery will bedestroyed.

3. Remove the plugs and check theelectrolyte level in all cells. NOTICE:NEVER attempt to remove thecovers or fill a maintenance-freebattery.

4. If the level is lower than the minimum filllevel (Figure 7, (1)), fill with distilledwater (Figure 7, (2)) (available in thegrocery store) up to the upper limit(Figure 7, (3)) of the battery.

UPPER LEVEL LOWER LEVEL

(2)

(3)

(1)

0004566

Figure 7Note: The maximum fill level isapproximately 10 - 15 mm(3/8 - 9/16 in.) above the plates.



Every 125 Hours of OperationPerform the following maintenance every125 hours of operation or 6 months,whichever comes first.• Changing the Engine Oil and

Replacing the Engine Oil FilterChanging the Engine Oil andReplacing the Engine Oil FilterSee Changing the Engine Oil and Replacingthe Engine Oil Filter Element on page 59.

After Initial 250 Hours ofOperation

Perform the following maintenance after theinitial 250 hours of operation.• Checking the Fuel Injector Spray

Pattern• Inspecting and Adjusting

Intake / Exhaust Valve ClearanceChecking the Fuel Injector SprayPatternSee your authorized Yanmar marine dealeror distributor.Inspecting and AdjustingIntake / Exhaust Valve ClearanceProper adjustment is necessary to maintainthe correct timing for opening and closingthe valves. Improper adjustment will causethe engine to run noisily, resulting in poorengine performance and engine damage.See your authorized Yanmar marine dealeror distributor to adjust the intake / exhaustvalve clearance.



Every 250 Hours of OperationPerform the following maintenance every250 hours or one year of operation,whichever comes first.• Replacing the Fuel Filter Element• Changing the Coolant• Checking or Replacing the Zinc

Anodes• Adjusting the Remote Control Cable• Cleaning the Turbocharger• Cleaning the Air CleanerReplacing the Fuel Filter ElementSee Replacing the Fuel Filter Element onpage 60.Changing the CoolantReplace the coolant every year.Note: If Long Life coolant is used, replacecoolant every 2 years.1. Drain the fresh water cooling system.

See Draining the Fresh Water CoolingSystem on page 80.

2. Fill the cooling system with cleancoolant. See Checking and AddingEngine Coolant on page 34.

Checking or Replacing Zinc AnodesInspect and replace the zinc anodesperiodically. NOTICE: If zinc anodes arenot replaced periodically, corrosion andengine damage will result.1. Close the seacock.2. Drain the seawater cooling system. See

Draining Seawater Cooling System onpage 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 (Figure 8, (1)).

4. Measure the remaining zinc in the plug.Replace the zinc anode when it is lessthan one-half its original size. See chartfor sizes.

5. Install a new zinc in a new plug.NOTICE: NEVER use sealing tape toinstall the zinc anode. The anodemust make metal-to-metal contact.

6. Install plug.7. Open the seacock and check for leaks.

Fuel Cooler

(1)

0004918

Figure 9Engine Oil Cooler

(3)

(3)

0004919

Figure 10



Fresh Water Cooler

(4)

0004917

Figure 11Intercooler

(2)

0004920

Figure 12Intercooler

(2)

0004921

Figure 13

Location PartNumber

Qty. DimensionsD x L

FuelCooler

119574–44150

1 0.5 x 1.0 in.

EngineOil Cooler

119574–44150

2 0.5 x 1.0 in.

FreshWaterCooler

119574–44150

1 0.5 x 1.0 in.

Inter-cooler

119574–18790

2 0.5 x 1.0 in.

Note: Some marine drives have additionalzinc anodes. Check the manufacturer'sdocumentation for location and otherinformation.Checking and Adjusting RemoteControl CablesNote: Never adjust the high speed stop bolton the governor. This will void the enginewarranty.Adjusting Engine Speed (Governor)Remote Control CableSee your authorized Yanmar dealer ordistributor.Adjusting Clutch Remote Control CableRefer to the manufacturer's documentation.Cleaning the TurbochargerContamination of the turbocharger causesrevolutions to drop and engine output to fall.If a significant drop in engine output is noted(10% or more), clean the turbocharger.This should be done only by a trained andqualified technician. See your authorizedYanmar marine dealer or distributor.



Cleaning the Air Cleaner

(1)

0004911

Figure 141. Slide air cleaner (Figure 14, (1)) off air

inlet.2. Clean the air cleaner with detergent.3. Allow to air dry and install on the air

inlet. NOTICE: Replace the aircleaner if unable to clean or ifdamaged.

Every 500 Hours of OperationPerform the following maintenance every500 hours or 2 years of operation, whichevercomes first.• 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-STZP2Models)

Cleaning or ReplacingExhaust / Water Mixing ElbowSee your authorized Yanmar dealer ordistributor.Replacing Fuel Line and RubberHosesReplace fuel line and rubber hoses every500 hours or 2 years, whichever comes first.See your authorized Yanmar marine dealeror distributor.



Checking and Adjusting theAlternator V-Belt Tension

(1)

(2)

0004903

Figure 15NOTICE: NEVER get any oil on thebelt(s). Oil on the belt causes slippingand stretching. Replace the belt if it isdamaged. NEVER over-tighten thebelt(s). Engine damage will result.1. Check the belt by pushing on the middle

of the belt (Figure 15, (1)) with yourfinger.With proper tension, the belt shoulddeflect 8 - 10 mm (approximately3/8 in.).

2. Loosen the alternator bolt(Figure 15, (2)) and move thealternator to adjust the V-belt tension.

3. Replace the V-belt if required.Alternator V-Belt

Part Number119775–77260

Checking and Adjusting the PowerSteering Oil Pump Belt (6LPA-STZP2Models)NOTICE: NEVER get any oil on thebelt(s). Oil on the belt causes slippingand stretching. Replace the belt if it isdamaged. NEVER over-tighten thebelt(s). Engine damage will result.

(3)

(4)

(1)

(2)

0004913

Figure 161. Check the belt by pushing on the middle

of the belt (Figure 16, (3)) with yourfinger.With proper tension, the belt shoulddeflect 8 - 10 mm (approximately3/8 in.) (Figure 16, (4)).

2. Loosen the power steering pump bolt(Figure 16, (2)) and move the oil pump(Figure 16, (1)) to adjust the belttension.

3. Replace the belt if required.Power Steering Oil Pump Belt Part

Number (6LPA-STZP2 only)119787–26540



Every 1000 Hours of OperationPerform the following maintenance every1000 hours or 4 years of operation,whichever comes first.• Checking the Fuel Injection Timing• Checking the Fuel Injector Pressure

and Nozzle Spray Pattern• Replacing the Seawater Pump

Impeller• Adjusting Intake / Exhaust Valve

Clearance• Lapping the Intake and Exhaust

ValvesChecking the Fuel Injection TimingSee your authorized Yanmar marine dealeror distributor.Checking the Fuel Injector Pressureand Nozzle Spray PatternSee your authorized Yanmar marine dealeror distributor.

Checking or Replacing SeawaterPump Impeller

(4)

(3)

(1)(2)

0004914

Figure 171 – Impeller2 – O-Ring3 – Cover4 – Cover Bolts1. Close the seacock.2. Drain the seawater cooling system. See

Draining Seawater Cooling System onpage 81.

3. Loosen the cover bolts and remove thecover and O-ring.

4. Inspect the inside of the seawater pumpwith a flashlight. If any of the followingare found, disassembly andmaintenance are required:• Impeller blades are cracked or

nicked. Edges or surfaces of theblades are marred or scratched.

• Wear plate is damaged.5. If no damage is found when inspecting

the inside of the pump, install the O-ringand cover.

6. If a large amount of water leakscontinuously from the water drain linebelow the seawater pump duringoperation, replace the mechanical seal.See your authorized Yanmar marinedealer or distributor.



7. NOTICE: Replace the seawaterpump impeller every 1000 hourseven if no damage is apparent.When replacement is required, seeyour authorized Yanmar marine dealeror distributor.

Adjusting Intake / Exhaust ValveClearanceSee your authorized Yanmar marine dealeror distributor.Lapping the Intake and ExhaustValveSee your authorized Yanmar marine dealeror distributor.

Every 1250 Hours of OperationPerform the following maintenanceprocedures every 1250 hours of operationor 5 years, whichever comes first.• Cleaning the Cooling Water System• Cleaning and Checking the Seawater

Passage• Cleaning and Checking the Fresh

Water Cooling Water Passage• Adjusting the Tension of the

Alternator V-Belt• Replacing the Timing Belt• Washing Engine Oil CoolerCleaning the Cooling Water SystemSee your authorized Yanmar marine dealeror distributor.Cleaning and Checking theSeawater PassageSee your authorized Yanmar marine dealeror distributor.Cleaning and Checking the FreshWater Cooling Water PassageSee your authorized Yanmar marine dealeror distributor.Adjusting the Tension of theAlternator V-BeltSee Checking and Adjusting the AlternatorV-Belt Tension on page 67.Replacing the Timing BeltSee your authorized Yanmar marine dealeror distributor.Washing the Engine CoolerSee your authorized Yanmar marine dealeror distributor.






TROUBLESHOOTINGIf a problem occurs, stop the engineimmediately. Refer to the SYMPTOMcolumn in the Troubleshooting Chart toidentify the problem.

TROUBLESHOOTINGAFTER STARTINGJust after the engine has started, check thefollowing items at a low engine speed:Is sufficient water being dischargedfrom the seawater outlet pipe?• If the discharge is low, stop the engine

immediately. Identify the cause andrepair.

Is the exhaust color normal?• The continuous emission of black exhaust

smoke indicates engine overloading. Thisshortens the engine's life and should beavoided.

When operating the engine at low speedfor long periods of time, race the engineonce every 2 hours. Racing the engine:with the clutch in NEUTRAL, acceleratefrom the low speed position to the highspeed position and repeat this processabout five times. This is done to cleanout carbon from the cylinders and thefuel injection valves. NOTICE:Neglecting the race the engine willresult in poor exhaust color and reduceengine performance.


Periodically operate the engine nearmaximum speed while underway. Thiswill generate higher exhausttemperatures, which will help clean outhard carbon deposits, maintain engineperformance and prolong the life of theengine.Are there abnormal vibrations or noise?• Depending on the hull structure, engine

and hull resonance may suddenlyincrease at certain engine speed ranges,causing heavy vibrations. Avoid operationin this speed range. If any abnormalsounds are heard, stop the engine andinspect for cause.

Alarm sounds during operation.• If the alarm sounds during operation,

lower the engine speed immediately,check the warning lamps and stop theengine for repairs.

Is there water, oil or fuel leakage? Arethere any loose bolts or connections?• Check the engine room daily for any leaks

or loose connections.Is there sufficient fuel in the fuel tank?• Refill fuel in advance to avoid running out

of fuel. If the tank runs out of fuel, bleedthe fuel system. See Bleeding the FuelSystem on page 29.

TROUBLESHOOTING


TROUBLESHOOTING CHARTSymptom Probable Cause Measure ReferenceIndicators light on theinstrument panel andalarm sounds duringoperation

Shift to low speed operation immediately, and check which indicator has come on.Stop the engine and inspect. If no abnormality is identified and there is no problemwith operation, return to port at lowest speed and request repairs.

• Engine oil lowpressure alarmindicator comes on

Engine oil level is low. Check engine oil level.Add or replace.

See Checkingthe Engine Oil on

page 31Engine oil filter clogged. Replace engine oil filter.

Replace engine oil.See Changingthe Engine Oiland Replacingthe Engine Oil

Filter Element onpage 59

• Fresh water (coolant)level alarm comes on

Coolant / fresh water in coolantrecovery tank is low.

Check coolant level andrefill.

See Checkingand Adding

Engine Coolanton page 34

• Fresh water (coolant)high temperaturealarm comes on

Coolant / fresh water in coolantrecovery tank is low.

Check coolant level andrefill.

See Checkingand Adding

Engine Coolanton page 34

Leakage in fresh water coolingsystem causing temperature torise.

See your authorizedYanmar marine dealer ordistributor.

-

Contamination inside coolingsystem.


-

Fresh water cooling pumpdamaged.


• Gear oil alarm comeson

Insufficient drive oil. Check oil level and refill. See Marine DriveOil on page 32

• Fuel filter alarm comeson

Water level in fuel / waterseparator too high.

Drain. See DrainingFuel Filter /

Water Separatoron page 62

• Exhaust alarm comeson

Insufficient discharge of coolingseawater.Check that seacock is open.Damaged seawater pump.


-

Faulty Warning Devices Do not operate the engine if alarm devices are not repaired. Serious accidents mayresult if abnormalities are not identified due to faulty indicators or alarm.

TROUBLESHOOTING


Symptom Probable Cause Measure ReferenceIndicators Do Not Go On:• When key is turned

ON• When any trouble

occurs (oil pressureetc.)

No electrical current available.Circuit broken or lamp burnedout.


-

• One of the indicatorsdoes not go out

Sensor switch is faulty. See your authorizedYanmar marine dealer ordistributor.

-

• Battery low chargeindicator does not goout during operation

V-belt is loose or broken. Replace V-belt or adjusttension.

See Checkingand Adjusting theAlternator V-BeltTension on page

67Battery is defective. Check battery fluid level,

specific gravity orreplace battery.

See Checkingthe Battery

Electrolyte Level(Serviceable

Batteries Only)on page 62

Alternator power generationfailure.


-

TROUBLESHOOTING


Symptom Probable Cause Measure ReferenceStarting Failures:• Starter turns but

engine does not startNo fuel. Add fuel. Bleed fuel

system.See Filling theFuel Tank on

page 29 and SeeBleeding the

Fuel System onpage 29

Air in fuel line. Bleed fuel system. See Bleeding theFuel System on

page 29Fuel filter is clogged. Replace filter element. See Replacing

the Fuel FilterElement on page

60Improper fuel. Replace with

recommended fuel.See Diesel Fuel

Specifications onpage 27

Problem with fuel injection. See your authorizedYanmar marine dealer ordistributor.

-

Compression leakage fromintake / exhaust valve.


-

• Starter does not turn orturns slowly (enginecan be turnedmanually)

Faulty clutch position. Shift to NEUTRAL andstart.

-

Insufficient battery charge. Check fluid level.Recharge. Replace.

See Checkingthe Battery

Electrolyte Level(Serviceable

Batteries Only)on page 62

Cable terminal contact failure. Remove corrosion fromterminals. Tightenbattery cables.

-

Faulty safety switch device. See your authorizedYanmar marine dealer ordistributor.

-

Faulty starter switch. See your authorizedYanmar marine dealer ordistributor.

-

Power lacking due to accessorydrive being engaged.


-

• Engine cannot beturned manually

Internal parts seized. See your authorizedYanmar marine dealer ordistributor.

-

TROUBLESHOOTING


Symptom Probable Cause Measure ReferenceAbnormal Exhaust Color:• Black smoke Overload Reduce load. -

Improper propeller matching. See your authorizedYanmar marine dealer ordistributor.

-

Dirty air cleaner. Clean air cleaner. See Cleaning theAir Cleaner on

page 66Improper fuel. Replace with

recommended fuel.See Diesel Fuel

Specifications onpage 27

Faulty spraying of fuel injector. See your authorizedYanmar marine dealer ordistributor.

-

Low boost pressure. See your authorizedYanmar marine dealer ordistributor.

-

Incorrect intake / exhaust valveclearance.


-

• White smoke Improper fuel. Replace withrecommended fuel.

See Diesel FuelSpecifications on

page 27Faulty spraying of fuel injector. See your authorized

Yanmar marine dealer ordistributor.

-

Fuel injection timing off. See your authorizedYanmar marine dealer ordistributor.

-

Engine burning oil (excessiveconsumption).


-

TROUBLESHOOTING


TROUBLESHOOTINGINFORMATIONIf the engine does not operate properly, referto the Troubleshooting Chart on page 73 orsee your authorized Yanmar marine dealeror distributor.Supply the authorized Yanmar marinedealer or distributor with the followinginformation:• 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 ambienttemperatures, etc.

• Engine maintenance history andprevious problems

• Other factors that contribute to theproblem

TROUBLESHOOTING



TROUBLESHOOTING


LONG-TERM STORAGEIf the engine will not be used for an extendedperiod of time, special measures should betaken to protect the cooling system, fuelsystem and combustion chamber fromcorrosion and the exterior from rusting.The engine can normally stand idle for up to6 months. If it remains unused for longerthan this, please contact your authorizedYanmar marine dealer or distributor.

PREPARE ENGINE FORLONG-TERM STORAGENote: If the engine is close to a periodicmaintenance interval, perform thosemaintenance procedures before putting theengine 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 thebearings of the remote control handle.

5. Seal the intake silencer, exhaust pipe,etc. to prevent moisture orcontamination from entering engine.

6. Completely drain bilge in hull bottom.7. Waterproof the engine room to prevent

rain or seawater from entering.8. Charge the battery once a month to

compensate for battery’s self-discharge.

9. Remove key from key switch and coverthe key switch with moisture cap.


DRAINING THE FRESHWATER AND SEAWATERCOOLING SYSTEM

(2)

(1)

0004904

Figure 1

(3)

0004905

Figure 2

(4)0004906

Figure 3

(5)

0004907

Figure 41 – Seawater Drain Cock2 – Fresh Water Drain Cock3 – Fresh Water Drain Cock4 – Seawater Pump Cover5 – Seawater Drain Cock

Draining the Fresh Water CoolingSystem1. Open the fresh water drain cocks and

drain the fresh water into an appropriatecontainer.

2. Close the drain cocks after draining thewater.

3. Dispose of waste properly.

LONG-TERM STORAGE


Draining Seawater CoolingSystemNOTICE: If seawater is left inside, it mayfreeze and damage parts of the coolingsystem (fresh water cooler, seawaterpump, etc.) when ambient temperatureis below0°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 thecover and drain the seawater.

4. Install cover and tighten bolts.5. Close all the drain cocks.

REMOVING THE ENGINEFROM LONG-TERMSTORAGEWhen using the engine after a long period ofstorage, prepare for operation in the samemanner for a new engine. See Before YouOperate on page 27.

LONG-TERM STORAGE



LONG-TERM STORAGE


SPECIFICATIONSPRINCIPAL ENGINE SPECIFICATIONS

Specification 6LPA-STP2 6LPA-STZP2Type Vertical water-cooled 4–cycle diesel engineNumber of cylinders 6Bore x stroke 94 mm x 100 mm

3.7 in. x 3.94 in.Displacement 4.164 LContinuous power at crankshaft 211 kW (286 hp) / 3682 rpmMaximum output rating* 232 kW (315 hp) / 3800 rpm*

High idle 4280 ± 25 rpmLow idle 750 + 25 / 0Combustion system Direct injectionStarting system Electric start (12 V - 2.5 kW)Charging system Alternator with built-in regulator 12V DC - 80ADirection of rotation Counterclockwise (viewed from flywheel)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 tankLubrication system Forced lubrication system with trochoid gear pump• Engine (lube) oilcapacity

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

Dimensions (lessgear)

L x W x H 1065 x 671 x 729 mm41.9 x 26.4 x 28.7 in.

1145 x 752 x 799 mm45.1 x 29.6 x 31.5 in.

Weight (less gear) 408 kg (899 lb) 428 kg (944 lb)Recommended battery capacity 12V x 120 AhRecommended remote controlhandle

Single lever-type only

Engine installation Flexible engine mount


* Density of fuel: 0.840 g/cm3 at 15˚C. Fuel temperature 25°C at the inlet of the fuel injection pump. Ratingcondition: ISO 3046-1, 8665.

Note: 1 hp metric = 0.7355 kWOutput Power

Fuel TemperatureSpecificGravity

25°C77°F

40°C104°F

0.860 323 3060.840 315 299

SPECIFICATIONS


Marine Drive Specifications (Optional)Model Hurth Kanzaki Mercruiser

ZF63A1 KMH50A Bravo X-1 Bravo X-2 Bravo X-3Type 8° down Hydraulic Stern DriveApplicableengine

6LPA-STP2 6LPA-STZP2

Reduction ratioZF63A1:Ahead / AsternBravo X-1, 2, 3:Both Ahead /Astern

1.22 / 1.21 1.67 / 1.67 1.36 1.50 1.361.56 / 1.58 2.13 / 2.13 1.50 1.65 1.502.04 / 2.10 2.43 / 2.43 - 1.81 1.652.52 / 2.53 - - 2.00 1.81

See manufacturer's documentation for additional information.

SPECIFICATIONS



SPECIFICATIONS


SYSTEM DIAGRAMSPIPING DIAGRAMSContact your authorized Yanmar dealer forcurrent diagrams.


6LPA-STP2

-- -

0004

891

Figure 1

SYSTEM DIAGRAMS


6LPA-STZP2Po

wer

Pow

er

Pow

er

-

- -

0004

892

Figure 2

SYSTEM DIAGRAMS


WIRING DIAGRAMSB-Type Instrument Panel

0004

893

Figure 3

SYSTEM DIAGRAMS


C/D-Type x B-Type Instrument Panel

0004

894

Figure 4

SYSTEM DIAGRAMS


C/D-Type x C-Type Instrument Panel

0004

895

Figure 5

SYSTEM DIAGRAMS


EPA WARRANTYUSA ONLY

YANMAR CO., LTD. LIMITEDEMISSION CONTROLSYSTEM WARRANTY - USAONLY

0005438

THIS EMISSION WARRANTY APPLIES TOTHE ENGINES CERTIFIED TO UNITEDSTATES EPA 40 CFR 94 AND SOLD BYYANMAR THAT ARE INSTALLED INVESSELS FLAGGED OR REGISTERED INTHE UNITED STATES.Note: Please refer to Yanmar's LimitedWarranty Handbook for a description of thenormal (non-EPA) warranty.Your Warranty Rights andObligations:Yanmar warrants to the first user and eachsubsequent purchaser the emission controlsystem on your engine for periods of timelisted below provided the engine has beeninstalled according to Yanmar installationrequirements and there has been no abuse,neglect, or improper maintenance of yourYanmar marine engine.Yanmar warrants that the engine isdesigned, built and tested using genuineparts and equipped so as to conform to allapplicable emission requirements of theU.S. Environmental Protection Agency andis free from defects in material andworkmanship which would cause thisengine to fail to conform to the applicableemission regulations over its limitedemission control system warranty period.Where a warrantable emissions conditionexists, Yanmar will repair your engine at nocharge to you for diagnosis, parts, and labor.Warranty service or repair will be providedat authorized Yanmar marine dealers ordistributors.


It is recommended that any replacementparts used for maintenance, repair orreplacement of emission control systemsare Yanmar parts. The owner may elect tohave maintenance, replacement or repair ofthe emission control components andsystems performed by any repairestablishment or individual and may elect touse parts other than Yanmar parts for suchmaintenance, replacement or repair.However, the cost of such service or partsand subsequent failures from such serviceor parts will not be covered under thisemission control system warranty:Warranty Period:The warranty starts on either the date ofdelivery to the first end-user.For Pleasure Use: The warranty period isfive (5) years or 2000 hours of use,whichever occurs first. In the absence of adevice to measure hours of use, the enginehas a warranty period of five (5) years.

Warranty Coverage:Repair or replacement of any warrantedparts will be performed at an authorizedYanmar dealer or distributor. This limitedemission control system warranty coversengine components that are a part of theemission control system of the engine asdelivered by Yanmar to the original retailpurchaser. Such components may includethe following:1. Fuel Injection System2. Turbocharger System3. Aftercooler4. Electronic Engine Control Units and its

associated Sensor and ActuatorsExclusions:Failures other than those arising fromdefects in material and / or workmanship arenot covered by this limited emissionswarranty. This warranty does not extend tothe following: malfunction caused by abuse,misuse, improper adjustment, modification,alteration, tampering, disconnection,improper or inadequate maintenance,improper storage or use of non-recommended fuels and lubricating oils,accident-caused damage, and replacementof expendable and / or consumable itemsmade in connection with scheduledmaintenance.Yanmar disclaims any responsibility forincidental or consequential damages suchas loss of time, inconvenience, loss of useof marine vessel / engine or commercialloss.

EPA WARRANTY USA ONLY


Owner’s Responsibility:As the Yanmar marine engine owner, youare responsible for the performance of therequired maintenance listed in yourOperation Manual. Yanmar recommendsthat you retain all documentation, includingreceipts, covering maintenance on yourmarine engine, but Yanmar cannot denywarranty solely for the lack of receipts or foryour failure to ensure the performance of allscheduled maintenance.Your engine is designed to operate on dieselfuel only. Use of any other fuel may result inyour engine no longer operating incompliance with applicable emissionrequirements. You are responsible forinitiating the warranty process. You mustpresent your marine engine to an authorizedYanmar dealer or distributor as soon as aproblem exists.

Customer Assistance:If you have any questions regarding yourwarranty rights and responsibilities or wouldlike information on the nearest authorizedYanmar dealer or distributor, you shouldcontact Yanmar Marine USA Corporation forassistance.Yanmar Marine USA Corporation101 International ParkwayAdairsville, GA 30103 USATelephone: 770-877-9894Fax: 770-877-7567

EPA WARRANTY USA ONLY


Maintenance LogDate Operating

HoursMaintenance Performed Dealer Name Stamp or

Signature


Date OperatingHours

Maintenance Performed Dealer Name Stamp orSignature



Documents

6LPA-STP2 6LPA 6LPA-STZP2rhinomarineboats.com/PDF/6LPA-Operation.Manual.pdf · 6LPA-STP2 6LPA-STZP2 P/N: 0A6LP-G00101 MARINE ENGINES. Disclaimers: All information, illustrations and