Yanmar 6LPA Series Marine Diesel Engine Repair Service Manual

(6LPA-STP2, 6LPA-STZP2)
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This Workshop Service Repair manual PDF download for the 6LPA-STP2/STZP2 Series Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar Marine Diesel Engine

6LPA-STP2
6LPA-STZP2


TABLE OF CONTENTS :

Introduction
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication
Turbocharger
Starter Motor
Alternator
Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 086LP-G00101
Total Pages : 319


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Statements
Safety Precautions
General Service Information
Safety Precautions
Location of Safety Decals
Component Identification
Engine Piping Diagrams
6LPA-STP2
6LPA-STZP2
External Views
6LPA-STP2
Engine Sender and Switch Locations
Instrument Panel (Optional)
B-Type Panel (119773-91131)
C-Type Panel (119773-91162)
D-Type Panel (119773-91192)
Performance Curve Charts
Front Power Take-Off (PTO) Output
Front PTO Diagram
Method for Front PTO
Location of Nameplate
Engine Nameplate (Typical)
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Handling Diesel Fuel
Diesel Fuel Lines
Fuel Tank
Filling the Fuel Tank
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Additional Technical Engine Oil Requirements:
Engine Oil Viscosity
Handling Oil
Checking the Engine Oil
Adding Engine Oil
Marine Drive Oil
Mercruiser® Bravo Stern Drive Oil Specifications
Checking and Adding Marine Drive Oil
Checking and Adding Power Steering Oil (6LPA-STZP2 Models)
Engine Coolant
Engine Coolant Specifications
Checking and Adding Engine Coolant
Draining the Freshwater and Seawater Cooling System
Draining the Freshwater Cooling System
Draining Seawater Cooling System
Principal Engine Specifications
Marine Gear (Optional)
Special Torque Chart
Tightening Torques for Standard Bolts and Nuts
Tightening Fasteners
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Special Service Tools
Equipment (Locally Available)
Measuring Instruments
Special Service Materials (Locally Available)
Special Service Materials Reference (Locally Available)
Wiring Diagrams
B-Type Instrument Panel
C/D-Type x B-Type Instrument Panel
C/D-Type x C-Type Instrument Panel
Periodic Maintenance
Safety Precautions
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Tools Required
EPA Requirements
EPA Requirements for USA and Other Applicable Countries
Conditions to Ensure Compliance with EPA Emission Standards
Inspection and Maintenance
Periodic Maintenance Schedule
Inspection and Maintenance of EPA Emission-Related Parts
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Changing the Engine Oil and Replacing the Engine Oil Filter Element
Replacing the Fuel Filter Element
Every 50 Hours of Operation
Draining Water from the Fuel Tank
Draining Fuel Filter / Water Separator
Checking the Battery Electrolyte Level (Serviceable Batteries Only)
Every 125 Hours of Operation
Changing the Engine Oil and Replacing the Engine Oil Filter
After Initial 250 Hours of Operation
Checking the Fuel Injector Spray Pattern
Inspecting and Adjusting Intake / Exhaust Valve Clearance
Every 250 Hours of Operation
Replacing the Fuel Filter Element
Changing the Coolant
Checking or Replacing Zinc Anodes
Checking and Adjusting Remote Control Cables
Cleaning the Turbocharger
Cleaning the Air Cleaner
Every 500 Hours of Operation
Cleaning or Replacing Exhaust / Water Mixing Elbow
Replacing Fuel Line and Rubber Hoses
Checking and Adjusting the Alternator V-Belt Tension
Checking and Adjusting the Power Steering Oil Pump Belt (6LPA-STZP2 Models)
Every 1000 Hours of Operation
Checking the Fuel Injection Timing
Checking the Fuel Injector Pressure and Nozzle Spray Pattern
Checking or Replacing Seawater Pump Impeller
Adjusting Intake / Exhaust Valve Clearance
Lapping the Intake and Exhaust Valve
Every 1250 Hours of Operation
Cleaning the Cooling Water System
Cleaning and Checking the Seawater Cooling Passage
Cleaning and Checking the Freshwater Cooling Water Passage
Adjusting the Tension of the Alternator V-Belt
Replacing the Timing Belt
Washing Engine Oil Cooler
Replacing the Front Rubber Damper
Engine
Safety Precautions
Introduction
Specifications
Principal Engine Specifications
Engine Service Standards
Special Torque Chart
Cylinder Head
Component Views
Cylinder Head and Camshaft
Cylinder Head Assembly
Cylinder Head Removal
Cylinder Head Disassembly
Cleaning, Inspection and Servicing
Cylinder Head Cleaning and Inspection
Intake and Exhaust Valve Cleaning and Inspection
Valve Seat Inspection and Servicing
Valve Spring Inspection
Valve Rocker Arm and Shaft Inspection
Camshaft and Bearing Inspection
Camshaft Oil Seal Replacement
Cylinder Head Assembly
Cylinder Head Installation
Camshaft Installation
Camshaft Oil Seal Retainer Installation
Final Assembly
Cylinder Block
Components
Preparation for Disassembly
Cylinder Block Disassembly
Cylinder Block Inspection
Piston and Connecting Rod Disassembly
Piston and Connecting Rod Inspection
Inspection and Servicing of Crankshaft
Crankshaft Oil Seal Replacement
Piston and Connecting Rod Assembly
Cylinder Block Assembly
Rear Crankshaft Oil Seal Installation
Final Engine Assembly and Adjustments
Timing Belt
Components
Timing Belt Removal
Timing Belt Inspection
Timing Belt
Idler Pulley
Tension Spring and Tensioner
Timing Belt Installation
Timing Gear
Components
Timing Gear Removal
Timing Gear Inspection
Front Crankshaft Oil Seal Replacement
Fuel Injection Pump Drive Gear Oil Seal Replacement
Timing Gear Installation
Valve Clearance Inspection and Adjustment
Valve Clearance Inspection
Valve Clearance Adjustment
Injection Timing Inspection and Adjustment
Inspection of Injection Timing
Adjustment of Injection Timing
Fuel System
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Fuel Injection Pump Specifications
Injection Characteristics
Timer Characteristics
BCS Characteristics
Fuel Filter Replacement
Fuel Injection Nozzle
Components
Fuel Injection Nozzle Removal
Fuel Injection Nozzle Testing
Leak Test
Spray Test
Fuel Injection Nozzle Components
Fuel Injection Nozzle Disassembly and Inspection
Fuel Injection Nozzle Adjustment
Pre-lift Adjustment
Checking No. 2 Opening Pressure
Adjusting No. 1 Opening Pressure
Fuel Injection Nozzle Installation
Fuel Injection Pump
Components
Fuel Injection Pump Removal
Components
COMPONENTS - Continued
Fuel Injection Pump Installation
Cooling System
Safety Precautions
Introduction
Cooling System
Freshwater Pump Related Components
Freshwater Pump Removal
Freshwater Pump Installation
Seawater Pump Components
Seawater Pump Disassembly
Seawater Pump Reassembly
Thermostat Components
Thermostat Removal
Thermostat Installation
Components Related to Cooling System
Freshwater Tank
Freshwater Cooler
Coolant Recovery Tank
Coolant Recovery Tank Installation
Seacock (Optional)
Lubrication
Safety Precautions
Introduction
Specifications
Testing Oil Pressure
Oil Pump
Components
Oil Pump Removal
Oil Pump Disassembly and Inspection
Oil Pump Reassembly
Oil Pump Installation
Oil Cooler
Components
Oil Cooler Removal
Oil Cooler Disassembly and Inspection
Oil Cooler Installation
Piston Cooling Oil Nozzle
Components
Oil Nozzle Disassembly and Inspection
Oil Nozzle Installation
Turbocharger
Safety Precautions
Introduction
Turbocharger
Components and Operation
Turbine
Blower
Thrust Bearing
Radial Bearing
Sealing Structure at Blower Side
Sectional View (RHE6W Model)
Components (RHE6W Turbocharger)
Service Specifications
Service Standards
Special Torque Chart
Special Tools
Periodic Inspection
Inspection Intervals
Inspection Procedure
Disassembly
Component Identification (RHE6W Turbocharger)
Inspection Before Disassembly
Disassembly
Inspection and Cleaning
Component Identification (RHE6W Turbocharger)
Cleaning
Component Inspection
Reassembly
Component Identification (RHE6W Turbocharger)
Installation
Lubrication path
Intake path
Exhaust path
Starter Motor
Safety Precautions
Introduction
Starter Specifications
Starter
Components
Starter Disassembly
Starter Inspection and Testing
Armature
Field Coil Frame
Brushes
Clutch and Gear
Bearing
Magnetic Switch
Starter Reassembly
Performance Testing
Pull In Test
Hold In Test
Check Return of the Clutch Pinion Gear
No Load Performance Test
Alternator
Safety Precautions
Introduction
Specifications
Components
Wiring Diagram
Test and Inspection
Drive Belt Inspection
General Inspection
Check Discharge Warning Light Circuit
Check Charging Circuit Under No Load
Check Charging Circuit Under Load
Alternator Service
Disassembly
Inspection and Testing
Rotor Circuit and Slip Rings
Stator Drive End Frame
Brushes
Rectifier
Bearing Service
Assembly
Troubleshooting
Safety Precautions
Introduction
Troubleshooting Chart

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