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Related Manuals for Hyundai Seasall H380 Series
Summary of Contents for Hyundai Seasall H380 Series
- Page 1 INSTALLATION & OPERATION MANUAL H380 Series...
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Page 2: Table Of Contents
INSTALLATION & OPERATION MANUAL H380 Series TABLE OF CONTENTS ABOUT THIS MANUAL …………………………………………………………………..… CHAPTER 1 ENGINE OVERVIEW ……………………………………………………………… CHAPTER 2 ENGINE OPERATION.………………………………………………………. CHAPTER 3 COOLING SYSTEM …………………………………………………………. CHAPTER 4 FUEL SYSTEM ………………………………………………………………. CHAPTER 5 INTAKE & EXHAUST SYSTEM ……………………………………………. CHAPTER 6 LUBRICATION SYSTEM ……………………………………………………... -
Page 3: About This Manual
This engine installation and operation manual is provided as guidance for the installation of Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide technical information to aid in performing an effective engine installation so as to achieve both maximum performance and service life. -
Page 4: Safety Precautions
Wait until the engine is fully cool to do inspection and maintenance. • Do not use the engine for a purpose other than what is intended by Hyundai SeasAll. REFUELING Do not modify the performance of the... - Page 5 INSTALLATION & OPERATION MANUAL H380 Series ENGINE BREAK-IN INITIAL BREAK-IN PROCEDURE The first 20 hours of operation is the engine break-in period. During this period, it is important that the engine is operated as outlined below. • DO NOT operate engine at idle rpm for extended periods of time during the first 10 hours.
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Page 6: Chapter 1 Engine Overview
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 1 ENGINE OVERVIEW ENGINE COMPONENTS ① ⑦ FUEL FILTER ENGINE MOUNTING BRACKETS ② ⑧ SWITCH BOX OIL FILTER ③ ⑨ SEAWATER PUMP WATER PUMP ④ ⑩ AIR INTAKE MANIFOLD EXPANSION TANK ⑤ ⑪... - Page 7 INSTALLATION & OPERATION MANUAL H380 Series ① ⑧ INTERCOOLER COOLANT PIPE (HEAT EXCHANGER OUTLET) ② ⑨ DRY EXHAUST PIPE JUNCTION BOX ③ ⑩ TURBO-CHARGER OUTLET PIPE ENGINE MOUNTING BRACKET ④ ⑪ LIFTING EYES HEAT EXCHANGER ⑤ ⑫ EXHAUST MANIFOLD AIR FILTER ⑥...
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Page 8: Technical Data
INSTALLATION & OPERATION MANUAL H380 Series TECHNICAL DATA H380 Engine type 4-stroke, 4-valve After-cooled, EUI, Turbocharger Output ps (kW) 380ps (280) rpm at full load 1800 Cylinders Ignition sequence 1-5-3-6-2-4 Displacement [cm 9,960 Bore [mm] Stroke [mm] Compression ratio 16.0 : 1 Max. - Page 9 INSTALLATION & OPERATION MANUAL H380 Series PERFORMANCE CURVES • H380 - 8 -...
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Page 10: Engine Identification
INSTALLATION & OPERATION MANUAL H380 Series ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the JUNCTION box (See figure). • SERIAL NUMBER ON THE ENGINE BLOCK FORMAT : D6HAXXXXXX • ENGINE NAME PLATE - 9 -... - Page 11 INSTALLATION & OPERATION MANUAL H380 Series ENGINE SUSPENSION EYES • To lift the engine, use the three engine eyes (see figure). • To avoid engine damage, take care that engine lift chains or belts do not hit or touch surrounding parts during engine lifting.
- Page 12 INSTALLATION & OPERATION MANUAL H380 Series ENGIEN DIMENSIONS • H380 - 11 -...
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Page 13: Chapter 2 Engine Operation
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 2 ENGINE OPERATION STARTING ENGINE STOPPING ENGINE • Before starting the engine, you should • The engine should be run for a few minutes check engine oil, coolant, gearbox oil, fuel at idle ( in neutral ) before turning it off. This... - Page 14 INSTALLATION & OPERATION MANUAL H380 Series EMERGENCY STOP • You can stop the engine by pushing this button. After releasing the switch by twisting the button, you can start the engine again. (Normally, the button should be in the “out” position.) •...
- Page 15 INSTALLATION & OPERATION MANUAL H380 Series WINTER OPERATION AND STORAGE • When using or storing your engine under 0°C, protect parts exposed seawater (seawater pump, intercooler, heat exchanger, cooling lines, seawater strainer, valves and hoses) from freezing. • The battery capacity decreases temperature drops.
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Page 16: Chapter 3 Cooling System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 3 COOLING SYSTEM SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT EXHAUST MANIFOLD AIRFILTER COOLANT PUMP HEATER CONNECTOR TURBOCHARGER THERMOSTAT INTAKE MANIFOLD EXHAUST PIPE HOUSING EXPANSION TANK HEAT EXCHANGER INTERCOOLER SEAWATER INTAKE AIR SEA WATER PUMP... - Page 17 INSTALLATION & OPERATION MANUAL H380 Series SEAWATER FLOW – OPEN COOLING CIRCUIT Water strainer ← Water valve ← Water pickup ↓ Seawater pump ↓ Intercooler ↓ Heat exchanger ↓ Seawater WATER PICKUP • Water pickup should be installed in an area where it won’t pick up air bubbles and will access...
- Page 18 INSTALLATION & OPERATION MANUAL H380 Series CLEAN STRAINER FILTER • Stop the engine and close the water valve. • Remove the filter cap. • Remove the filter element, flush it thoroughly with clean water or compressed air. • Insert the cleaned filter element and screw on the filter cap.
- Page 19 INSTALLATION & OPERATION MANUAL H380 Series CHECKING SEAWATER PUMP & IMPELLER • Stop the engine and close the water valve. • Remove the impeller housing cover. • Remove the impeller from inside the seawater pump. • Check the condition of impeller and bushing.
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Page 20: Engine Coolant
INSTALLATION & OPERATION MANUAL H380 Series ENGINE COOLANT FLOW ( CLOSED COOLING CIRCUIT) 1. Engine Block Coolant Outlet ↓ 2. Exhaust manifold ↓ Turbocharger 3. Thermostat housing ↓ 4. Heat exchanger ↓ 5. coolant pump ENGINE COOLANT • The high-pressure cooling system has a reservoir filled with year-round antifreeze coolant. - Page 21 INSTALLATION & OPERATION MANUAL H380 Series ENGINE COOLANT • If the coolant level is below level ‘Low’, add Mixture Percentage(volume) Ambient enough specified coolant to provide protection Temperature Antifreeze Water against freezing and corrosion. Coolant level should be between the MAX and MIN. But do -15℃...
- Page 22 INSTALLATION & OPERATION MANUAL H380 Series REMOVING AIR BUBBLES IN COOLANT • Start the engine and warm it up at a low rpm. • Stop the engine and allow the engine to cool, and then open the cap of the expansion tank carefully.
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Page 23: Chapter 4 Fuel System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 4 FUEL SYSTEM The unit injector consists of a pumping element (A), a controlling component (B), and a nozzle (C) as shown in the illustration. The pumping element (A) generates the fuel pressure as the force from the cam drives the plunger via the rocker arm. - Page 24 INSTALLATION & OPERATION MANUAL H380 Series FUEL SUPPLY SYSTEM • The fuel system consists of control an unit, an unit injector, a fuel pump, fuel line, fuel filter, overflow valve, and a fuel tank etc. • Fuel flows into the fuel filter from the pump.
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Page 25: Recommended Fuel Quality
2) After water is drained, securely tighten the drain plug. CAUTION CAUTION HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS (HIGH CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO THE... - Page 26 INSTALLATION & OPERATION MANUAL H380 Series CHANGING FUEL FILTER AND FUEL CHARGING When replacing a fuel filter element • Clean around the fuel filter. PRIMING PUMP • Loosen air vent bolt on fuel filter and relieve the pressure in the fuel line.
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Page 27: Chapter 5 Intake & Exhaust System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 5 INTAKE & EXHAUST SYSTEM The intake air system of this engine is optimized by EVGT and a highly efficient intercooler system. The pressure of the air system is up to about abs. 2.7 bar in order to optimize engine combustion. - Page 28 INSTALLATION & OPERATION MANUAL H380 Series CHECK AIRFILTER • The original Hyundai SeasAll air cleaner may be cleaned and reused. • If the air filter is very dirty, it can increase airflow resistance and reduce flow of air to the engine.
- Page 29 Exhaust Pipe CAUTION CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION, PLEASE IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION, PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER. CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER. - 28 -...
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Page 30: Chapter 6 Lubrication System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 6 LUBRICATION SYSTEM LUBRICATION COMPONENTS - 29 -... -
Page 31: Engine Oil Level Checks
INSTALLATION & OPERATION MANUAL H380 Series ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular intervals. • Be sure the boat is level. • Start the engine and allow it to reach normal operating temperature. • Turn the engine off and wait about 5 minutes, until the oil has returned to the oil pan. - Page 32 INSTALLATION & OPERATION MANUAL H380 Series ENGINE OIL EXTACTION PUMP • Allow the engine to warm up at least 5 minutes then turn off engine. • Remove the engine oil filler cap and oil filter. • The oil drain hose is connected to the oil extraction pump ①.
- Page 33 INSTALLATION & OPERATION MANUAL H380 Series REPLACING FULL FLOW OIL FILTER • Remove the drain plug(A) at the lower part of oil filter and drain the engine oil. • Remove the cap of oil filter upper part and remove the oil filter.
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Page 34: Chapter 7 Electrical System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 7 ELECTRICAL SYSTEM BATTERY CABLE CONNECTIONS 1) The diameter of battery cable should be at least 40mm within a length of 4m. 2) And it should be at least 50mm if the cable is longer than 4m. - Page 35 INSTALLATION & OPERATION MANUAL H380 Series ACCELERATION SENSOR AND CONTROL LEVER • When installing control lever cable to acceleration 40 mm sensor, be sure that the acceleration sensor lever is fully released to the idle position and fully pulled to the full-load position. The swing distance of lever between idle and full-load position is 40mm.
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Page 36: Battery Checks
INSTALLATION & OPERATION MANUAL H380 Series BATTERY CHECKS Battery inspection is very important in electronically controlled engines: You must check the battery condition regularly. LOAD TEST • Perform the following steps to complete the load Voltage Temperature test procedure for maintenance-free batteries. - Page 37 • If the replacement fuse blows, this indicates an electrical problem. Avoid using the system involved immediately consult authorized Hyundai SeasAll dealer. FUSE BOX1 • Ignition power : 5 Amp • VGT power : 15 Amp • Main power : 20 Amp •...
- Page 38 INSTALLATION & OPERATION MANUAL H380 Series RELAY • Oil pump_20Amp • Air heater_20Amp • Starter sol_20Amp • Main_20Amp • Fuel heater_20Amp • VGT power_20Amp • Using an ohmmeter, check that there is Terminal Continuity continuity between each terminal. 30 - 87 85 - 86 •...
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Page 39: Chapter 8 Instrument System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 8 EOI SYSTEM The Engine Operating Indicator (EOI) system gives you a lot of information about the engine’s current workings. You can hear alarm beeps, or see information including RPM, coolant temperature, warning lamps, error codes and engine working time. If the switch is on, warning lamps for battery, engine oil and so on are flashed on. - Page 40 INSTALLATION & OPERATION MANUAL H380 Series WARNING LAMP Alarm would sound when alarm lamps flicker. HIGH COOLANT TEMP. ENGINE OIL PRESSURE LOW • This lamp informs you of engine coolant • This lamp informs you of the engine oil high abnormally (110℃).
- Page 41 INSTALLATION & OPERATION MANUAL H380 Series SWITCHS 1) Function switch - use to change the information display on the LCD. 2) PTO/IDLE on switch – use to enable PTO/IDLE RPM adjustment function 3) UP/DOWN switch – use to inc/dec PTO/IDLE RPM.
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Page 42: Rpm Gauge
INSTALLATION & OPERATION MANUAL H380 Series RPM GAUGE 1) When the key is at ignition ON position, this gauge will work. 2) This gauge indicates real-time engine rpm. 3) Avoid max. rpm and WOT (Wide Open Throttle) before a cold engine is fully warmed up, as it can harm the engine. - Page 43 INSTALLATION & OPERATION MANUAL H380 Series EOI FUNCTION 1) RPM gauge 7) Coolant high temperature warning lamp 2) Key switch 8) LCD information 3) OBD connector 9) Function switch 4) Check engine lamp 10) PTO/IDLE ON switch 5) Charging warning lamp...
- Page 44 INSTALLATION & OPERATION MANUAL H380 Series EOI BOX ( INSIDE ) MAIN ① Connection Plug – CN1 (Engine Main Connector) ② Connection Plug – CN2 (Inspect Terminal) ③ Connection Plug – CN3 (Key Switch) ④ Connection Plug – CN4 (RPM Gauge-Main) ⑤...
- Page 45 INSTALLATION & OPERATION MANUAL H380 Series EOI PIN ASSIGNMENT CN1 (ENGINE MAIN CONNECTOR) NEUTRAL SWITCH2 FOOT BREAK SWITCH CAN1_L CRS/PTO/RSG LAMP GEARBOX OIL PRESSURE OIL PRESSURE SENDER START SWITCH OIL PRESSURE SWITCH CHARGE WARNING LAMP CLUTCH SWITCH CC/ENG PTO ENABLE...
- Page 46 INSTALLATION & OPERATION MANUAL H380 Series CN3 (KEY SWITCH) KEY SWITCH START SWITCH BATTERY+ CN4 (RPM Gauge-Main) BATTERY+ NOT USED KEY SWITCH DIMMER CAN1_H CAN1_L NOT USED CN5 (RPM Gauge-Aux) NOT USED BUZZER OIL PRESSURE SENDER NOT USED GEARBOX OIL PRESSURE...
- Page 47 (diagnosis trouble code) will give you information about it. The DTC display is only for initial assistance and to aid communication with a Hyundai SeasAll dealer if there is an emergency. You should contact your nearest Hyundai SeasAll dealer as soon as possible if a system problem arises.
- Page 48 INSTALLATION & OPERATION MANUAL H380 Series Fuel Pressure Level 1 Derate P1087 Fuel Pump Fuel Pressure Level 2 Derate P1088 ○ ○ Engine Power Limitation Fuel Pressure Level 3 Dreate P1089 ○ ○ Fuel Temperature Sensor "A" Circuit Low Input P0182 Sensor Default Value : 40 ℃...
- Page 49 INSTALLATION & OPERATION MANUAL H380 Series Injector Spill "1" High side circuit Low - Cylinder 1 P1229 ○ ○ Injector Spill "1" High side circuit High - Cylinder 1 P1230 ○ ○ No Injection Injector Spill "1" Low side circuit Low - Cylinder 1 P1231 ○...
- Page 50 INSTALLATION & OPERATION MANUAL H380 Series Turbocharger Turbine Overspeed P0049 Engine Power Limitation ○ ○ TURBO CHARGER SPEED Turbocharger speed sensor circuit Low P2580 ○ ○ Sensor Default Value : 100000RPM Turbocharger speed sensor circuit high P2581 ○ ○ VGT initialize Error P1045 ○...
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Page 51: Chapter 9 Anti Corrosion System
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 9 ANTI CORROSION SYSTEM ANODE INTERCOOLER HEAT EXCHANGER The sacrificial anode must be replaced when more than 50% of it has been used. Check especially frequently when used in saltwater. It is recommended to replace the sacrificial anode at the start of each season. -
Page 52: Chapter 10 Engine Storage
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 10 ENGINE STORAGE The major consideration in preparing your engine for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your engine for out-of-season... -
Page 53: Chapter 11 Maintenance
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 11 MAINTENANCE PREDELIVERY INSPECTION CHECK LIST BEFORE THE WATER TEST ON THE WATER TEST Boat drain plug in place Seawater inlet valve open (Check before putting boat in water) Engine coolant level Seawater pump operation... -
Page 54: Maintenance Schedule
INSTALLATION & OPERATION MANUAL H380 Series MAINTENANCE SCHEDULE Whichever comes first Maintenance Maintenance intervals 200h / 400h / Daily item 1year 2years Check the coolant level and for leaks ● Replace the seawater pump impeller ● Cooling system Clean the heat exchanger tube bundle ●... - Page 55 INSTALLATION & OPERATION MANUAL H380 Series MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS - 54 -...
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Page 56: Chapter 12 Troubleshooting Guide
INSTALLATION & OPERATION MANUAL H380 Series CHAPTER 12 TROUBLESHOOTING GUIDE ■ Starter motor does not crank the engine Possible Causes •Engine stop switch is not “ON” position •Engine is not shifted to neutral position •Safety stop switch activated •Wrong neutral switch connection to EOI •Weak battery or battery connections are loose... - Page 57 INSTALLATION & OPERATION MANUAL H380 Series ■ Engine rattling, noisy engine Possible Causes •Compensation of individual injector not •No engine coolant temperature sensor signal adapted •Low compression pressure •Clogged injector return line •No rail pressure sensor signal •Faulty injector •Poor injector O-ring •Carbon deposit on the injector...
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Page 58: Chapter 13 Warranty
CHAPTER 13 WARRANTY WHAT IS COVERED Hyundai SeasAll warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for one (1) year from the date the product is first sold to a retail purchaser or when the Product has been operated for 1000 hours, whichever occurs first. - Page 59 Warranty coverage is available only to retail customers who purchase from a dealer authorized by Hyundai SeasAll to distribute the product in the country in which the sale occurred, and then only after the Hyundai SeasAll specified pre-delivery inspection process is completed and documented.
- Page 60 • All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner’s responsibility. • Use of other than Hyundai SeasAll genuine replacement parts when making warranty repairs. • Participating in or preparing for racing or other competitive activity.
- Page 61 Text, figures and standards in this guide are based on information current at the time of printing. Reprinting, reproduction or translation, in whole or in part, is not permitted without the written approval of HYUNDAI SEASALL. All rights according to the applicable copyright laws are expressly reserved for HYUNDAI SEASALL. Subject to alterations.
- Page 62 INSTALLATION & OPERATION MANUAL H380 Series...
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