Yanmar 6LPA-STP2, 6LPA-STZP2 Operation Manual
OPERATION MANUAL
MARINE ENGINE
6LPA-STP2
6LPA-STZP2
en
English
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual
are intended as representative reference views only. Moreover, because of our
continuous product improvement policy, we may modify information, illustrations
and/or specifications to explain and/or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time without notice.
Yanmar and are registered trademarks of YANMAR CO., LTD. in
Japan and/or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means graphic, electronic, or mechanical, including photocopying, recording, taping, or
information storage and retrieval systems - without the written permission of
YANMAR CO., LTD.
OPERATION MANUAL
MODEL
CODE
6LPA-STP2, 6LPA-STZP2
0A6LP-G00103
All Rights Reserved, Copyright
TABLE OF
CONTENTS
INTRODUCTION .............................................................. 1
Record of Ownership ................................................. 2
SAFETY ........................................................................... 3
SAFETY PRECAUTIONS .......................................... 4
General Information ............................................. 4
Before You Operate............................................. 4
During Operation and Maintenance..................... 4
LOCATION OF SAFETY DECALS ............................ 8
PRODUCT OVERVIEW ................................................... 9
YANMAR 6LPA SERIES FEATURES AND
APPLICATIONS......................................................... 9
New Engine Break-In......................................... 10
COMPONENT IDENTIFICATION ............................ 11
Service Side
(Left Side as Viewed from Propeller)................. 11
Non-Service Side............................................... 12
NAMEPLATES ......................................................... 13
FUNCTION OF MAJOR COMPONENTS ................ 14
CONTROL EQUIPMENT ......................................... 15
Instrument Panel (Optional)............................... 15
Remote Control (Throttle) Handle...................... 21
Page
BEFORE YOU OPERATE ............................................. 25
INTRODUCTION...................................................... 25
SAFETY PRECAUTIONS ........................................ 25
6LPA Series Operation Manual i
TABLE OF CONTENTS
DIESEL FUEL........................................................... 26
Diesel Fuel Specifications .................................. 26
Handling of Diesel Fuel ...................................... 27
Fuel Tank (Optional) .......................................... 28
Fuel System ....................................................... 28
Filling the Fuel Tank........................................... 28
Bleeding the Fuel System .................................. 29
ENGINE OIL ............................................................. 30
Engine Oil Specifications .................................. 30
Engine Oil Viscosity ........................................... 31
Checking the Engine Oil..................................... 31
Adding Engine Oil .............................................. 31
MARINE DRIVE OIL................................................. 32
Mercruiser® Bravo Stern Drive Oil
Specifications ..................................................... 32
Checking and Adding Marine Drive Oil .............. 32
Checking and Adding Power Steering Oil
(6LPA-STZP2 Models) ....................................... 33
ENGINE COOLANT ................................................. 33
Engine Coolant Specifications ........................... 33
Coolant (Closed Cooling System) ...................... 34
Checking and Adding Coolant............................ 34
CRANKING THE ENGINE ....................................... 36
ENGINE OPERATION .................................................... 37
INTRODUCTION ...................................................... 37
SAFETY PRECAUTIONS......................................... 37
STARTING THE ENGINE ........................................ 39
If the Engine Fails to Start.................................. 40
Starting at Low Temperatures............................ 41
After the Engine has Started .............................. 42
REMOTE CONTROL HANDLE OPERATION.......... 43
Acceleration and Deceleration ........................... 43
Shifting the Engine ............................................. 44
CAUTIONS DURING OPERATION.......................... 45
SHUTTING DOWN THE ENGINE............................ 46
Normal Shutdown............................................... 46
CHECKING THE ENGINE AFTER OPERATION..... 47
PERIODIC MAINTENANCE ........................................... 49
INTRODUCTION ...................................................... 49
SAFETY PRECAUTIONS......................................... 49
ii 6LPA Series Operation Manual
12/05
TABLE OF CONTENTS
PRECAUTIONS ....................................................... 51
The Importance of Periodic Maintenance.......... 51
Performing Periodic Maintenance ..................... 51
The Importance of Daily Checks ....................... 51
Keep a Log of Engine Hours and Daily Checks 51
Yanmar Replacement Parts .............................. 51
Tools Required .................................................. 51
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help............................................. 51
Tightening Fasteners ......................................... 52
PERIODIC MAINTENANCE SCHEDULE ................ 53
PERIODIC MAINTENANCE PROCEDURES .......... 56
Daily Checks...................................................... 56
After Initial 50 Hours of Operation ..................... 57
Every 50 Hours of Operation ............................. 60
Every 125 Hours of Operation ........................... 62
After Initial 250 Hours of Operation ................... 62
Every 250 Hours of Operation ........................... 63
Every 500 Hours of Operation ........................... 65
Every 1000 Hours of Operation ......................... 67
Every 1250 Hours of Operation ......................... 68
TROUBLESHOOTING ................................................... 69
SAFETY PRECAUTIONS ........................................ 69
TROUBLESHOOTING AFTER STARTING ............. 69
TROUBLESHOOTING INFORMATION................... 70
TROUBLESHOOTING CHART................................ 71
LONG-TERM STORAGE ............................................... 73
PREPARE ENGINE FOR LONG-TERM STORAGE 73
DRAIN SEAWATER COOLING SYSTEM ............... 74
RETURNING THE ENGINE TO SERVICE .............. 75
SPECIFICATIONS ......................................................... 77
PRINCIPAL ENGINE SPECIFICATIONS ................ 78
Marine Drive Specifications (Optional) .............. 79
SYSTEM DIAGRAMS .................................................... 81
PIPING DIAGRAMS................................................. 81
WIRING DIAGRAMS................................................ 87
6LPA Series Operation Manual iii
TABLE OF CONTENTS
This Page Intentionally Left Blank
iv 6LPA Series Operation Manual
INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We
design our engines to respect nature. This
means quieter engines, with minimal
vibrations, cleaner than ever. All of our
engines meet applicable regulations,
including emissions, at the time of
manufacture.
To help you enjoy your Yanmar 6LPA
series engine for many years to come,
please follow these recommendations:
• Read and understand this Operation
Manual before you operate the machine
to ensure that you follow safe operating
practices and maintenance procedures.
• Keep this Operation Manual in a
convenient place for easy access.
•If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your engine. If you have any
questions about these differences,
please contact your authorized Yanmar
Marine dealer or distributor.
• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please
refer to the manual provided by the
manufacturer of these components.
• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.
6LPA Series Operation Manual 1
INTRODUCTION
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.
Engine Model: __________________________________________________________
Engine Serial No.: _______________________________________________________
Date Purchased:_________________________________________________________
Dealer:_________________________________________________________________
Dealer Phone:___________________________________________________________
2 6LPA Series Operation Manual
SAFETY
DANGER
WARNING
CAUTION
NOTICE
Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
decals. Keep the labels from becoming
dirty or torn and replace them if they are
lost or damaged. Also, if you need to
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time.
This safety alert symbol
appears with most safety
statements. It means
attention, become alert,
A
your safety is involved!
Please read and abide by
the message that follows
the safety alert symbol.
Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment, or cause the
equipment to operate improperly.
6LPA Series Operation Manual 3
SAFETY
DANGER
WARNING
SAFETY PRECAUTIONS
General Information
There is no substitute for common sense
and careful practices. Improper practices
or carelessness can cause burns, cuts,
mutilation, asphyxiation, other bodily injury
or death. This information contains general
safety precautions and guidelines that
must be followed to reduce risk to personal
safety. Special safety precautions are
listed in specific procedures. Read and
understand all of the safety precautions
before operation or performing repairs or
maintenance.
Before You Operate
The safety messages that follow have
DANGER level hazards.
NEVER permit anyone to
install or operate the engine
without proper training.
Read and understand this
Operation Manual before you operate or
service the engine to ensure that you
follow safe operating practices and
maintenance procedures.
• Safety signs and labels are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar Marine
dealer or distributor for additional
training.
During Operation and Maintenance
The safety messages that follow have
WARNING level hazards.
Explosion Hazard
While the engine is running
or the battery is charging,
hydrogen gas is being
produced and can be easily
ignited. Keep the area
around the battery
well-ventilated and keep sparks, open
flames and any other form of ignition
out of the area.
Fire and Explosion Hazard
Diesel fuel is flammable and explosive
under certain conditions.
NEVER use a shop rag to catch the fuel.
Wipe up all spills immediately.
NEVER refuel with the engine running.
Fire Hazard
Undersized wiring systems
can cause an electrical fire.
Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.
Store any equipment in a designated
area away from moving parts.
NEVER use the engine compartment for
storage.
4 6LPA Series Operation Manual
12/05
WARNING
Sever Hazard
Rotating parts can cause
severe injury or death.
NEVER wear jewelry,
unbuttoned cuffs, ties or
loose-fitting clothing and
ALWAYS tie long hair back when
working near moving / rotating parts
such as the flywheel or PTO shaft. Keep
hands, feet and tools away from all
moving parts.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.
Exposure Hazard
ALWAYS wear personal
protective equipment
including appropriate
clothing, gloves, work
shoes, and eye and hearing protection
as required by the task at hand.
SAFETY
Exhaust Hazard
NEVER block windows,
vents or other means of
ventilation if the engine is
operating in an enclosed
area. All internal combustion engines
create carbon monoxide gas during
operation and special precautions are
required to avoid carbon monoxide
poisoning.
Sudden Movement Hazard
NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the warning signals.
Burn Hazard
Some of the engine
surfaces become very hot
during operation and
shortly after shutdown.
Keep hands and other body
parts away from hot engine surfaces.
6LPA Series Operation Manual 5
SAFETY
CAUTION
NOTICE
The safety messages that follow have
CAUTION level hazards.
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages
on portable safety lamps.
Too l Ha z a r d
ALWAYS use tools appropriate for the
task at hand and use the correct size
tool for loosening or tightening
machine parts.
Flying Object Hazard
ALWAYS wear eye protection when
servicing the engine or when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure
your eyes.
Coolant Hazard
Wear eye protection and
rubber gloves when you
handle engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.
The safety messages that follow have
NOTICE level hazards.
It is important to perform daily checks as
listed in the Operation Manual. Periodic
maintenance prevents unexpected
downtime, reduces the number of
accidents due to poor engine performance
and helps extend the life of the engine.
See your authorized Yanmar Marine dealer
or distributor if you need to operate the
engine at high altitudes. At high altitudes
the engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.
ALWAYS be environmentally
responsible.
Follow the guidelines of your
country’s governmental
agencies for the proper disposal of
hazardous materials such as engine oil,
diesel fuel and engine coolant. Consult the
local authorities or reclamation facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground,
or into ground water or waterways.
If a Yanmar Marine Engine is installed at
an angle that exceeds the specifications
stated in the Yanmar Marine Installation
Manuals, engine oil may enter the
combustion chamber causing excessive
engine speed, white exhaust smoke and
serious engine damage. This applies to
engines that run continuously or those that
run for short periods of time.
6 6LPA Series Operation Manual
12/05
NOTICE
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the
non-running engine(s) should be closed.
This will prevent water from being forced
past the seawater pump and eventually
finding its way into the engine. The result
of water entering the engine could cause
seizure or other serious problems.
If you have an installation with two or three
engines, and only one engine is operating,
please note that if the propeller shaft
thru-hull (stuffing box) is lubricated by
engine water pressure and the engines are
interconnected, care must be taken that
water from the running engine does not
enter the exhaust of the non-running
engine(s). This water could cause seizure
of the non-running engine(s). See your
authorized Yanmar Marine dealer or
distributor for a complete explanation of
this condition.
SAFETY
If you have an installation with two or three
engines, and only one engine is operating,
it is important to limit the amount of throttle
applied to the running engine. If you
observe black smoke or movement of the
throttle does not increase engine speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 throttle or to a setting
where the engine performs normally.
Failure to do so may cause the running
engine to overheat or cause excess carbon
buildup which may shorten the engine’s
life.
NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.
6LPA Series Operation Manual 7
SAFETY
LOCATION OF SAFETY DECALS
Figure 1 show the location of safety decals on Yanmar 6LPA series marine engines.
6LPA Engines
(1) (2) (3) (4)
DANGER
NEVER pour the
FULL
engine oil across
LOW
the full line.
119773-07280
(5)
Figure 1
1 – Part Number: 120324-07240
2 – Part Number: 128296-07260
4 – Part Number: 128296–07300
5 – Part Number: 128296–07360
3 – Part Number: 119773-07280
8 6LPA Series Operation Manual
0004813
PRODUCT OVERVIEW
YANMAR 6LPA SERIES FEATURES AND APPLICATIONS
The 6LPA series are four-stroke direct
injection diesel engines equipped with
liquid coolant systems.
The 6LPA-STP2 engines are equipped
with a marine gear (ZF63A1 or KMH50A,
KMH50V).
The 6LPA-STZP2 engines are equipped
with a stern drive (ZT370, Mercruiser
Bravo).
These engines are designed for pleasure
craft use.
The engines are equipped with a marine
gear or sail drive unit.
These engines are designed for pleasure
craft use.
It is recommended that new vessels be
propped so the engines can operate at 50
to 100 min
engine speed to allow for some added
weight and hull resistance.
Failure to do so can lead to reduced vessel
performance, lead to increased smoke
levels and cause permanent damage to
your engine.
-1
above the fuel stop power
The engine must be installed correctly with
coolant lines, exhaust gas lines and
electrical wiring. Any auxiliary equipment
attached to the engine should be easy to
use and accessible for service. To handle
the drive equipment, propulsion systems
(including the propeller) and other inboard
equipment, always observe the
instructions and cautions given in the
operation manuals supplied by the
shipyard and equipment manufacturers.
The 6LPA series engines are designed to
be operated at maximum throttle
(3800 min
engine time (30 minutes out of every 10
hours) and cruising speed (2800 min
less) for less than 90% of total engine time
(9 hours out of every 10 hours).
The laws of some countries may require
hull and engine inspections, depending on
the use, size and cruising area of the boat.
The installation, fitting and surveying of
this engine all require specialized
knowledge and engineering skills. See
Yanmars local subsidiary in your region or
your authorized Yanmar Marine dealer or
distributor.
-1
) for less than 5% of total
-1
or
6LPA Series Operation Manual 9
PRODUCT OVERVIEW
NOTICE
New Engine Break-In
As with all reciprocating engines, the way
your engine is operated during its first 50
hours of operation plays a very significant
role in determining how long it will last and
how well the engine will perform over its
lifetime.
A new Yanmar diesel engine must be
operated at suitable speeds and power
settings during the break-in period to make
the sliding parts, such as piston rings,
break-in properly and to stabilize engine
combustion.
During the break-in period, the engine
coolant temperature gauge should be
monitored; temperature should be
between 71° and 87°C (160° and 190°F).
During the first 10 hours of operation, the
engine should be run at maximum engine
speed minus 400 to 500 min
(approximately 60 to 70% of load) most of
the time. This will ensure the sliding parts
break in properly. During this period, avoid
operating at maximum engine speed and
load to avoid damaging or scoring sliding
parts.
Do not operate at WOT (wide open throttle)
for more than a minute at a time during the
first 10 hours of operation.
Do not operate the engine at low idle or at
low speed and light load for more than
30 minutes at a time. Since unburned fuel
and engine oil will adhere to the piston
rings when operating at low speeds for
long periods, this will interfere with proper
movement of the rings and the engine oil
consumption may increase. Low idle
speed does not allow break-in of sliding
parts.
-1
If operating engine at low speed and light
load, you must race the engine to clean the
carbon from the cylinders and fuel injection
valve.
Perform this procedure in open waters:
• With the clutch in NEUTRAL, accelerate
from the low-speed position to the
high-speed position briefly.
• Repeat this process five times.
Once past the initial 10 hours until 50
hours, the engine should be used over its
full operating range, with special emphasis
on running at relatively high power
settings. This is not the time for an
extended cruise at idle or low speed. The
boat should be run at maximum speed
minus 400 min
(approximately 70% load), with a 10
minute run at maximum minus 200 min
(approximately 80% load) every
30 minutes and a 4 to 5 minute period of
operation at WOT (wide open throttle)
once each 30 minutes. During this period,
be sure not to operate your engine at low
speed and light load for more than
30 minutes. If operating engine at low
speed and light load by necessity, just after
the low idle operation, be sure to race the
engine.
To complete engine break-in, perform After
Initial 50 Hours of Operation maintenance
procedures. See After Initial 50 Hours of
Operation on page 57.
-1
most of the time
-1
10 6LPA Series Operation Manual
12/05
(1)
(2)
(3)
(4)
(5)
(6)
(12)
(11)
(10)
(9)
(8)
(7)
0004884
PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
Service Side (Left Side as Viewed from Propeller)
Note: 6LPA-STZP2 with stern drive shown. Components marked with an * are for
6LPA-STZP2 only.
Figure 1
1–Fuel Cooler
2 – Fuel Filter
3 – Power Steering Oil Cooler*
4 – Engine Oil Filter
5 – Intercooler
6 – Mixing Elbow
6LPA Series Operation Manual 11
Figure 1
7 – Engine Oil Cooler
8–Starter
9 – Engine Oil Cooler
10 – Fuel Injection Pump
11 – Seawater Pump
12–Stern Drive
PRODUCT OVERVIEW
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
0004885
Non-Service Side
Figure 2
Figure 2
1 – Turbocharger
2 – Engine Nameplate (on rocker
arm cover)
3 – Fresh Water (Coolant) Tank
4 – Power Steering Oil Tank*
5 – Fresh Water Filler Cap
6 – Engine Oil Filler Cap
7 – Power Steering Oil Pump*
8–Alternator
9 – Engine Oil Dipstick
10 – Fresh Water Cooler
11–V-Belt
12 6LPA Series Operation Manual
12/05
Gear Model
ENG.No.
Model
min
-1
min
-1
min
-1
Speed of prop shaft
Fuel stop power kW
Continuous power kW
/
/
0004574
NAMEPLATES
The nameplate of Yanmar 6LPA series
engines is shown in Figure 3. The
nameplate is located on the engine rocker
arm cover. Check the engine's model,
output, rpm and serial number on the
nameplate. Replace if damaged or lost.
Figure 3
PRODUCT OVERVIEW
6LPA Series Operation Manual 13
PRODUCT OVERVIEW
FUNCTION OF MAJOR COMPONENTS
Name of Component Function
Fuel Filter Removes dirt and water from the fuel. The filter is a cartridge type, and the inner
element should be replaced before clogging occurs. A water separator is on the
bottom of the filter and should be drained periodically.
Fuel Feed Pump A mechanical pump that pumps fuel from the tank to the fuel injection pump. It is
Fuel Bleed Pump This is a manual fuel pump. Pushing the knob on the top of the fuel filter feeds
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
Engine Oil Dipstick Gauge stick for checking the engine oil level.
Marine Gear Oil Filler Port (If
Equipped)
Cooling System There are two cooling systems: coolant and seawater.
• Coolant Tank
• Heat Exchanger
• Coolant Pump
Filler Cap Located on the top of the coolant tank. It has two pressure regulating valves
Reservoir Hot water and steam pass through a rubber hose to the reservoir for cooling. (The
Turbocharger A pressurized intake air feeding device. The exhaust gas turbine is rotated by the
Charge air cooler This heat exchanger cools the pressurized charging air from the turbocharger
Zinc Anode The metal area of the seawater cooling system is prone to galvanic corrosion.
Nameplates Nameplates are provided on the engine and have the model, serial number and
Starter A DC motor for starting the engine. Electric current causes the pinion gear to
Alternator This generator rotates by a V-belt drive to charge the battery during operation.
built in to the fuel injection pump.
the fuel. The pump is also used to bleed air from the fuel system.
distributed to the engine’s moving parts. The filter is a cartridge type and should
be replaced periodically.
Filler port for marine gear lube oil. Located on top of the marine gear case.
The tank stores the coolant and is connected to the heat exchanger. Cooling
seawater passes through the heat exchanger to cool the coolant by heat
exchange. After cooling, the coolant is fed by the coolant pump to the inside of
the engine, around the combustion chamber, turbocharger and then returned to
the tank.
(release and retraction valves). When the coolant temperature rises, the
pressure inside the coolant tank increases causing the release valve in the filler
cap to open.
filler port and the reservoir are connected by a rubber hose.) When the load is
reduced and the coolant temperature falls, the pressure in the coolant tank is
lowered, activating the retraction valve in the filler cap. This causes the coolant
in the reservoir to return to the coolant tank. This process reduces the
consumption of coolant.
exhaust gas and the power is used to rotate the blower. This pressurizes the
intake air for sending to the cylinder.
with water.
The zinc anode is installed in the various coolers to prevent this. When the zinc
anode becomes worn, components in the fresh water cooler, oil cooler, etc. will
corrode. Periodic replacement of the zinc anode is necessary.
other data.
engage with the ring gear on the flywheel to start the engine.
14 6LPA Series Operation Manual
12/05
PRODUCT OVERVIEW
CONTROL EQUIPMENT
The control equipment at the helm makes remote control operation possible. It consists of
the instrument panel, which is connected to the engine by a wire harness, and the remote
control (throttle) handle, which is connected by control cables to the engine control lever.
Instrument Panel (Optional)
Equipment and Functions
The instrument panel has the following gauges and alarm devices.
c = Available, — = Not Available
Gauge or Switch
Key (Starter) Switch
Engine Stop Button ccc
Switches
Warning
Indicators
Gauges
Clock Quartz Clock
Indicator Preheat Indicator
Alarm (Buzzer) ccc
Alarm (Buzzer) Stop
Switch
Backlight Switch for
Gauges
Battery Low Charge
Fresh Water
(Coolant) High
Temperature
Engine (Lube) Oil
Low Pressure
Fresh Water
(Coolant) Level
Exhaust (Cooling
Seawater Flow)
Fuel Filter (Water
Separator)
Gear Oil
(6LPA-STZP2 Only)
Tachometer with
Hourmeter
Engine (Lube) Oil
Pressure Gauge
Fresh Water
(Coolant)
Temperature Gauge
Turbocharger Boost
Pressure Gauge
New B-Type
Panel See
(Figure 3)
ccc
ccc
ccc
ccc
ccc
ccc
—
ccc
ccc
—
ccc
— cc
—
——
c
(Option)
c
(Option)
New C-Type
Panel See
(Figure 4)
New D-Type
Panel See
(Figure 5)
cc
cc
cc
c
c
(Option)
c
(Option)
c
c
6LPA Series Operation Manual 15
PRODUCT OVERVIEW
(1) (2) (3) (4)
(5)
(6)(7)(8)
0003281_m1
Figure 3
1 – Warning Indicator Display
2–Tachometer
3 – Alarm Stop Switch
4 – Panel Illumination Switch
Figure 4
(1) (2) (3) (4) (5)
New B-Type
Figure 4
5 – Engine Stop Button
6 – Starter (Key) Switch
7–Alarm
8 – Hourmeter
New C-Type
(8)(9)(10)
0003282_m1
Figure 5
1 – Engine Oil Pressure Gauge
2 – Fresh Water (Coolant)
Temperature Gauge
3–Tachometer
4 – Alarm Stop Switch
5 – Panel Illumination Switch
6 – Engine Stop Button
7 – Start (Key) Switch
8–Alarm
9 – Hourmeter
10 – Warning Indicator Display
16 6LPA Series Operation Manual
(6)
(7)
12/05
(1) (2) (3) (4) (5) (6) (7)
(8)(9)(10)(11)(12)
0003283_m1
Figure 5
New D-Type
PRODUCT OVERVIEW
Figure 6
1 – Turbocharger Boost Pressure
Gauge
2 – Engine Oil Pressure Gauge
3 – Fresh Water (Coolant)
Temperature Gauge
4–Tachometer
5 – Alarm Stop Switch
Available Alarm Switches and Meter Senders
Battery Not Charging
Fresh Water (Coolant) Temperature Too High c
Engine (Lube) Oil Pressure Too Low c
Switches
Senders
Fresh Water (Coolant) Level Too Low
Exhaust (Cooling Seawater Flow) Restriction
Gear Oil (Stern Drive Models Only)
Fuel Filter
Tachometer
Fresh Water (Coolant) Temperature
Engine (Lube) Oil Pressure
Boost Pressure
Fresh Water (Coolant) Temperature
Engine (Lube) Oil Pressure
6 – Panel Illumination Switch
7 – Engine Stop Button
8 – Start (Key) Switch
9–Alarm
10–Hourmeter
11–Clock
12 – Warning Indicator Display
c = Standard, = Optional
6LPA-STP2, 6LPA-STZP2
c
c
c
For two
stations
6LPA Series Operation Manual 17
PRODUCT OVERVIEW
NOTICE
WARNING
0003622
(1)
(2)
(3)
(4)
Switches and Gauges
Switch or Gauge Function
OFF (2): The key can be inserted or removed from switch. All
power is turned off. *
ON (3): For engine operation. Gauges and alarms are
operational.
START (4): For starting engine. When key is released after
engine starts, key automatically moves to ON position.
NEVER hold the key in the START position for longer than 15
seconds or the starter motor will overheat.
GLOW (1): For air heater (optional).
Starter (Key) Switch
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 Warning
Devices on page 19.
Warning Indicators The lamps illuminate when an abnormality is detected. See
Warning Devices on page 19.
Alarm (Buzzer) Stop Switch The switch is used to shut the alarm off temporarily. Turn the
alarm (buzzer) OFF when inspecting for cause.
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
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
Preheat Indicator (If equipped) Illuminates when the air heater is heating up for easier starting
* 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.
guide for periodic maintenance checks. The hourmeter is
located at the bottom of the tachometer.
turbocharger).
in cold temperatures. Indicator is located in the warning lamp
cluster.
18 6LPA Series Operation Manual
12/05
WARNING
PRODUCT OVERVIEW
Warning Devices
When a sensor detects a problem during operation, the indicator on the instrument panel
will light and an alarm will sound. Indicators are located on the instrument panel, the alarm
is located on the back of the panel. 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 the battery charging lamp illuminates.
• Alarm (Buzzer) Stop Switch: When investigating the cause of an alarm, press the alarm
(buzzer) stop switch.
The switch is used to shut the alarm off temporarily. Turn the alarm (buzzer) OFF when
inspecting for cause. Inspect and repair the abnormality immediately.
• Warning Indicators: When operation is normal, the warning indicators are OFF. If an
abnormality is detected, the sensor will trigger the appropriate warning indicator to light.
Battery Low Charge Indicator
When the alternator output is too low, the indicator will light. When
charging begins, the indicator will turn off. No alarm will sound for low
battery charge.
Fresh Water (Coolant) High Temperature Indicator and Alarm
When the coolant temperature reaches the maximum allowable
temperature (95°C [203°F] or higher), the indicator will light and the alarm
will sound. Continuing operation at temperatures exceeding the maximum
limit will result in damage and seizure. Check the load and troubleshoot the
fresh water cooling system.
Engine (Lube) Oil Low Pressure Indicator and Alarm
When the engine oil pressure falls below the specified level, the oil
pressure sensor will send a signal to the indicator causing it to light and the
alarm to sound. Stop operation immediately to avoid damage to the
engine. Check the oil level and troubleshoot the lubrication system.
6LPA Series Operation Manual 19
PRODUCT OVERVIEW
0004882
Fresh Water (Coolant) Level Indicator and Alarm
When the amount of cooling water in the fresh water recovery tank falls
below normal, the sensor will send a signal to the indicator causing it to
light and the alarm to sound. Stop operation immediately to avoid damage
to the engine. Check the water level in the cooling water recovery tank and
troubleshoot the cooling system.
Fuel Filter (Water Separator)
When the water level inside the water separator becomes too high, the
sensor will send a signal to the indicator causing it to light. Drain the water
separator. If operation is continued without draining the water separator,
fuel feed to the engine is restricted and may cause damage to the engine
or fuel injection pump.
Exhaust (Cooling Seawater Flow) Restriction
When the amount of cooling seawater being discharged is too low, the
sensor will activate the warning indicator. Stop operation immediately to
avoid damage to the engine. Check the seawater cooling system for
restriction or damage.
Gear Oil Level (6LPA-STZP2 Only)
When the amount of gear oil falls below normal, the sensor will send a
signal to the indicator causing it to light and the alarm to sound. Stop
engine immediately to avoid damage to the gear device. Check the oil level
in the gear and troubleshoot the gear system.
Alarms
Check that indicators and alarms are working normally when the key is turned to ON.
Key Switch OFF ⇒ ON START ⇒ ON
Engine Before starting Running
Alarm ON OFF
Indicators Battery Low Charge Indicator ON OFF
Fresh Water (Coolant) High Temperature Indicator OFF OFF
Engine (Lube) Oil Low Pressure Indicator ON OFF
Fresh Water (Coolant) Level Indicator OFF OFF
Fuel Filter (Water Separator) Indicator OFF OFF
Exhaust (Cooling Seawater Flow) Restriction Indicator ON OFF
Gear Oil Level (6LPA-STZP2 Only) OFF OFF
20 6LPA Series Operation Manual
12/05
NOTICE
NOTICE
0003622
(1)
(2)
(3)
(4)
(1)
0004881
Key (Starter) Switch
Figure 6
PRODUCT OVERVIEW
Engine Stop Button
Figure 7
Figure 8
Figure 7
The GLOW position (Figure 7, (1)) is the
start aid position. Electric current to the air
heater (if equipped) is turned on.
The START position (Figure 7, (4)) allows
current to the starting motor. When starting
the engine, move the key to the START
position and release. The key will
automatically move to the ON position.
NEVER hold the key in the START position
for longer than 15 seconds or the starter
motor will overheat.
When the key is in the OFF position
(Figure 7, (2)) the electric current is off.
The key can be inserted or removed in this
position.
The ON position (Figure 7, (3)) allows
electrical current to the controls and
equipment and allows the engine to keep
running. To stop the engine, keep the key
switch in the ON position and push the
engine stop button. After stopping the
engine, turn key to OFF position.
Push and hold the stop button
(Figure 8, (1)) on the instrument panel to
stop the engine. When the stop button is
pushed, the solenoid valve on the fuel
injection pumps stops the fuel supply to
the engine.
Press and hold the engine stop button until
the engine has come to a complete stop.
Releasing the engine stop button before
the engine has stopped rotating will cause
the engine to continue to run.
Remote Control (Throttle) Handle
The engine is controlled by the remote
control handle located in the cockpit. The
speed control lever on the engine and
clutch lever on the marine drive are
connected by remote control cables. There
are various models of remote control
handles available. When using a model
other than shown below, consult the
manufacturer's documentation for more
information.
6LPA Series Operation Manual 21
PRODUCT OVERVIEW
(1)
(2)
(3)
(4)
(5)
(6)
(7)
0004887
Morse Remote Control Handle (Optional)
This is a single-lever remote control handle
connected by a remote cable. It operates
the clutch to NEUTRAL, FORWARD and
REVERSE and controls the engine speed.
Figure 8
(2)
(1)
1 – Reverse High Speed
2 – Reverse Low Speed
3–Reverse
4–Neutral
5–Forward
6 – Forward Low Speed
7 – Forward High Speed
MT-3 Top Mount
(4)
(3)
Figure 9
(5)
(6)
(7)
0004886
Figure 9
MV Side Mount
Figure 10
1 – Forward High Speed
2 – Forward Low Speed
3–Forward
4–Neutral
5 – Reverse
6 – Reverse Low Speed
7 – Reverse High Speed
The operation labels on the handle are:
• FWD - Forward
• NEU - Neutral (Clutch Disengaged)
• Throttle - Position to reduce engine
speed
• REV - Reverse
Starting and Stopping
Put the handle in NEUTRAL. This puts the
clutch in the disengaged position and the
engine at a low speed.
Forward
Move the handle from NEUTRAL to FWD
(forward). This engages the clutch in
forward and simultaneously increases the
22 6LPA Series Operation Manual
engine speed. Pushing the handle further
in the same direction increases engine
speed to full speed.
12/05
(4)
(1)
(2)
(3)
0004888
(1)
(2)
(3)
(4)
Reverse
Move the handle from NEUTRAL to REV
(reverse). This engages the clutch in
reverse and simultaneously increases the
engine speed. Pushing the handle further
in the same direction increases engine
speed to full speed.
Free Throttle Operation
When the boat is stopped (clutch is in
NEUTRAL) the idling speed of the engine
can be increased in the following manner:
PRODUCT OVERVIEW
Figure 11
MV
1. Ensure the handle is in NEUTRAL.
2. Disengage the clutch:
Figure 10
1–Neutral
MT-3
Figure 11
2–Low Speed
3 – High Speed
4 – Remote Control (Throttle)
Handle
Figure 12
1 – High Speed
2–Low Speed
3–Neutral
4 – Free Throttle Button
3.
• MT-3: Pull the throttle handle
(Figure 11, (4)) all the way out.
• MV: Pull out the free throttle button
(Figure 12, (4)), located next to the
handle.
When the handle or button is pulled out,
move the handle to either FORWARD or
REVERSE to increase the idling speed.
Returning to Normal Operation
• MT-3: Move the throttle handle to
NEUTRAL (Figure 11, (1)). The lever
will automatically return to the normal
position.
• MV: Move throttle handle to NEUTRAL
(Figure 12, (3)). Push the free throttle
button in.
6LPA Series Operation Manual 23
PRODUCT OVERVIEW
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24 6LPA Series Operation Manual
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