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Hyundai Seasall G7 Series Installation & Operation Manual

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INSTALLATION & OPERATION MANUAL
G7 Series
G7 Series Engines

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Summary of Contents for Hyundai Seasall G7 Series

  • Page 1 INSTALLATION & OPERATION MANUAL G7 Series G7 Series Engines...

  • Page 2: Table Of Contents

    INSTALLATION & OPERATION MANUAL G7 Series TABLE OF CONTENTS ABOUT THIS MANUAL …………………………………………………….…………..……..……….. SAFETY PRECAUTIONS ……………………………………………….………………..……………… ENGINE BREAK-IN …………………………………………………………………………………..APPROXIMATE STANDARD CONVERSIONS …………..…………………………………………… CHAPTER 1 ENGINE OVERVIEW ………………………………………..………...….…….……… ENGINE COMPONENTS ……………………………………..………….…………… TECHNICAL DATA ……………………………………………..……….…………….. PERFORMANCE CURVES……………………………………..…….………..…….. ENGIEN IDENTIFICATION……………………………………..……….…………..ENGIEN HANGER …..……………………………………………..……....
  • Page 3 INSTALLATION & OPERATION MANUAL G7 Series TABLE OF CONTENTS CHAPTER 7 ELECTRICAL SYSTEM ………………………………………………………………… BATTERY CABLE CONNECTIONS ……………………………..……..……….. ACCELERATION SENSOR & CONTROL LEVER…………….………………… PROCEDURES FOR CONTROL LEVER INSTALLATION………………………… BATTERY CHECKS………..………………………………………...……….…..LOAD TEST……………………………………………………………………………… JUNCTION BOX & FUSES………………….………………………..……………… CHAPTER 8 EOI SYSTEM …………………………………………..……………………………...…...

  • Page 4: 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 5: 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. Do REFUELING not modify the performance of the supplied engine without the express permission of •...

  • Page 6: Engine Break-In

    • The first 20 hours of operation is the engine performed using the special tools and break-in period. During this period, it is procedures specified by Hyundai SeasAll. important that the engine is operated as outlined below. • The limited warranty does not apply to any •...

  • Page 7: Approximate Standard Conversions

    INSTALLATION & OPERATION MANUAL G7 Series APPROXIMATE STANDARD CONVERSIONS MULTIPLY MULTIPLY SYMBOL SYMBOL SYMBOL SYMBOL 0.039 inch inch 25.4 LENGTH inch LENGTH inch 2.54 3.28 0.3048 0.0016 645.2 AREA AREA 10.764 0.093 in ³ 0.061 in³ 16.388 0.06 61.023 in³...

  • Page 8: Chapter 1 Engine Overview

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 1 ENGINE OVERVIEW ENGINE COMPONENTS ⑧ ① FUEL FILTER TURBOCHARGER ② ⑨ JUNCTION BOX (Switch Attached) ③ ⑩ SEAWATER PUMP (Inlet) EXPANSION TANK ④ ⑪ INTERCOOLER FUEL PUMP ⑤ OIL EXTRACTION PUMP OIL FILLER CAP ⑥...
  • Page 9 INSTALLATION & OPERATION MANUAL G7 Series EXHAUST MANIFOLD OIL FILTER & OIL COOLER EXHAUST ELBOW OIL SEPARATOR HEAT EXCHANGER COOLANT FILLER CAP THERMOSTAT HOUSING EMERGENCY SWITCH ALTERNATER OIL EXTRACTION SWITCH STARTER MOTOR OIL LEVEL GAUGE WATER PUMP AIR HEATER RELAY...

  • Page 10: Technical Data

    INSTALLATION & OPERATION MANUAL G7 Series TECHNICAL DATA G300 G300A G350 4-stroke, 4-valve per cylinder Engine type After cooled, direct injection, water cooling 300 (221) 350 (257) Output PS (kW) 2,500 2,800 rpm at full load Cylinders 1-5-3-6-2-4 Ignition sequence...

  • Page 11: Performance Curves

    INSTALLATION & OPERATION MANUAL G7 Series PERFORMANCE CURVES - 10 -...
  • Page 12 INSTALLATION & OPERATION MANUAL G7 Series ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the JUNCTION box (See figure). • SERIAL NUMBER ON THE ENGINE BLOCK FORMAT : D6GBXXXXXXXX ENGINE FRONT • ENGINE NAME PLATE Engine Family...
  • Page 13 INSTALLATION & OPERATION MANUAL G7 Series ENGINE HANGER • To lift the engine, use the two 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 14: Engien Dimensions

    INSTALLATION & OPERATION MANUAL G7 Series ENGIEN DIMENSIONS T/M ASSEMBLY BOLT PATTERN • BELL-HOUSING : SAE 2 • FLYWHEEL : SAE 11-1/2 TOP VIEW SIDE VIEW FRONT VIEW BELT INSTALLATION MODEL : G7 ALTERNATOR DRIVE PULLEY IDLER PULLEY TENSIONER PULLEY...

  • Page 15: Chapter 2 Engine Operation

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 2 ENGINE OPERATION STARTING ENGINE • Before starting the engine, you should • The engine room requires a constant supply check engine oil, coolant, gearbox oil, fuel of fresh air. gauge, seawater pump, battery, water •...

  • Page 16: Emergency Stop

    INSTALLATION & OPERATION MANUAL G7 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 Emergency Stop Switch button should be in the ‘out’ position.) •...

  • Page 17: Chapter 3 Cooling System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 3 COOLING SYSTEM SCHEMATIC DIAGRAM OF ENGINE COOLING INTERCOOLER SEA WATER PUMP COOLANT EXPANSION TANK INTAKE MANIFOLD AIRFILTER PUMP TURBOCHARGER BLOCK → HEAD OIL COOLER WET EXHAUST PIPE EXHAUST MANIFOLD Opened DRY EXHAUST PIPE...

  • Page 18: Seawater Flow - Opened Circuit

    INSTALLATION & OPERATION MANUAL G7 Series SEAWATER FLOW – opened circuit Water strainer ← Water valve ← Water pickup ↓ Seawater pump ↓ Intercooler ↓ Heat exchanger ↓ Exhaust pipe ↓ Discharge Seawater WATER PICKUP • Water pickup should be installed in an area where it won’t pick up air bubbles and will access...

  • Page 19: Water Strainer

    INSTALLATION & OPERATION MANUAL G7 Series WATER STRAINER • Strainer should be located in an area where it will be easily accessible for periodic seawater flow inspection and cleaning. • The size of strainer must be of sufficient capacity to pass the seawater (a flow rate over 400 liters per minute flow rate).

  • Page 20: Seawater Pump

    INSTALLATION & OPERATION MANUAL G7 Series SEAWATER PUMP • The inner diameter of hose connected to seawater pump inlet should be PF 1-1/2 inch. • The cross section of the hose may shrink due to inlet pressure drop. Therefore, the hose from water pickup in the boat’s hull to the seawater pump inlet should be as short as possible and...

  • Page 21: Checking Seawater Pump & Impeller

    INSTALLATION & OPERATION MANUAL G7 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.

  • Page 22: Engine Coolant Flow - Closed Circuit

    INSTALLATION & OPERATION MANUAL G7 Series ENGINE COOLANT FLOW - closed circuit MAX Level MIN Level ENGINE COOLANT • Engine coolant must be maintained at the “MIN” level marked on the side of the expansion tank when the engine is cold.

  • Page 23: Supplemental Engine Coolant

    INSTALLATION & OPERATION MANUAL G7 Series SUPPLEMENTAL ENGINE COOLANT • If the coolant level is below level ‘Low’, add Mixture Percentage(volume) enough specified coolant to provide protection Ambient against freezing and corrosion. Coolant level Temperature Antifreeze Water should be between the MAX and MIN. But do not exceed level ‘MAX’.

  • Page 24: Removing Air Bubbles In Coolant

    • Contact your Hyundai SeasAll dealer if you need nipples for cabin heater connection. To cabin heater ※HOSE inner diameter: Φ17...

  • Page 25: Chapter 4 Fuel System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 4 FUEL SYSTEM The fuel supply system of this engine is diesel common rail direction injection. In order to optimize engine combustion, its maximum injection pressure is up to 2,000bar. Multi-injection is possible thanks to the quick response of the solenoid type injector.

  • Page 26: Fuel Flow

    INSTALLATION & OPERATION MANUAL G7 Series FUEL FLOW Fuel tank ↓ Primary fuel filter with water detection sensor (Separate Item) ↓ High pressure pump (Built-in low pressure fuel pump function) ↓ Main Fuel filter ↓ High pressure pump (High pressure fuel) ↓...

  • Page 27: Recommended Fuel Quality

    2) After water is drained, securely tighten the drain plug. CAUTION HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO THE USE OF UNQUALIFIED FUELS.

  • Page 28: Changing Fuel Filter Cartridge

    INSTALLATION & OPERATION MANUAL G7 Series CHANGING FUEL FILTER CARTRIDGE < MAIN FILTER > When replacing a fuel filter element • Clean around the fuel filter. • Loosen air vent bolt ‘A’ on fuel filter and relieve the pressure in the fuel line.

  • Page 29: Chapter 5 Intake & Exhaust System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 5 INTAKE & EXHAUST SYSTEM The intake air system of this engine is optimized by EWGT 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 30 INSTALLATION & OPERATION MANUAL G7 Series ENGINE AIR CONSUMPTION -. Engine need to proper intake air for combustion this requires a minimum inner area of air supply ducting the area can be calculated by using the formula <TABLE1> Number of...

  • Page 31: Check Air Filter

    INSTALLATION & OPERATION MANUAL G7 Series CHECK AIR FILTER • 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 32: Exhaust System

    • The exhaust gas pressure should not exceed 110± 10 mmHg @ 2,500 / 2,800 rpm for the best performance of the engine. Be sure that rain does not fall into the exhaust elbow. CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION, PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER. - 31 -...

  • Page 33: Chapter 6 Lubrication System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 6 LUBRICATION SYSTEM SCHEMATIC DIAGRAM OF ENGINE LUBRICATION - 32 -...
  • Page 34 INSTALLATION & OPERATION MANUAL G7 Series ENGINE OIL LEVEL CHECKS • The engine oil level must be checked at regular intervals. • The F, L positions of the dipstick are the same when the engine is horizontal or tilted (approx. 7 °) (see figure).

  • Page 35: Engine Oil Extaction Pump

    INSTALLATION & OPERATION MANUAL G7 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. Route the loose end of the hose into the container being used for the oil change.

  • Page 36: Replacing Oil Filter

    USED OIL MUST BE STORED IN A SAFE PLACE AWAY FROM CHILDREN AND SOURCES OF IGNITION. IF YOU HAVE A USED OIL DISPOSAL PROBLEM, PLEASE HAVE THE ENGINE OIL CHANGED BY YOUR NEAREST HYUNDAI SEASALL SERVICE DEALER. ① Cylinder block ⑧...

  • Page 37: Chapter 7 Electrical System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 7 ELECTRICAL SYSTEM BATTERY CABLE CONNECTIONS 1) The cross-section of the battery cables should be at least 40mm and no longer than 4m. 2) If the cable is longer than 4m, the cross-section should be at least 50mm 3) Recommended battery capacity is over 100 amperes.

  • Page 38: Acceleration Sensor & Control Lever

    INSTALLATION & OPERATION MANUAL G7 Series ACCELERATION SENSOR AND CONTROL LEVER When installing control lever cable to acceleration 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.

  • Page 39: Battery Checks

    INSTALLATION & OPERATION MANUAL G7 Series BATTERY CHECKS Battery inspection is very important in electronically controlled engines. You must check the battery condition regularly. LOAD TEST • Connect the load tester clamps to the terminals and proceed with the test as follows.
  • Page 40 INSTALLATION & OPERATION MANUAL G7 Series JUNCTION BOX ( Relays and fuse ) Name Fuse information Relay1_Spare 1. Startor_30A Glow_sub 2. Fuel heater_25A Main 3. Main relay_25A Start 4. Main filter_20A Main_filter 5. Ignition_5A Oil_pump Midi fuse1 ALT_40A Midi fuse2 ALT_40A...

  • Page 41: Chapter 8 Eoi System

    When the engine starts normally, all the lamps turn off. If there is a problem, the specific lamp will come on. In this case, contact your Hyundai SeasAll dealer and have the engine checked as soon as possible.
  • Page 42 INSTALLATION & OPERATION MANUAL G7 Series EOI BOX ( inside ) & HARNESS Neutral SW1 Neutral SW2 SPARE OP_UNIT TERMINAL Spare terminal info. RPM, IG+, GND, Dimmer, Buzzer OP_UNIT KEY_IG Neutral SW1 KEY_START Neutral SW2 EOI Wiring 00740-6L1H9 KEY_PER+ SPARE TERMINAL...

  • Page 43: Eoi Function

    INSTALLATION & OPERATION MANUAL G7 Series EOI FUNCTION Key switch PTO Up / Down switch PTO / IDLE select switch Diagnosis Port Ø 5.2 EOI Button function Engi ne Speed 0 RPM Symbol color Cool ant Temp. Bat t er y Vol t age 0 ℃...
  • Page 44 INSTALLATION & OPERATION MANUAL G7 Series Hot key button function 5s long button press 5s long button press Engi ne Speed Engi ne Speed Button Sound 0 RPM Running Time 0 RPM !!! Fault !!!! Cool ant Temp. Bat t er y Vol t age Cool ant Temp.
  • Page 45 INSTALLATION & OPERATION MANUAL G7 Series Engine monitoring parameter 1page PTO Mode G,H,L Series Part Description Engine parameters name Prameters data value G, H, L Series PTO mode indicate ⓑ 3page Layout TRIPLE: 2page Layout TRIPLE : External Sensor data...
  • Page 46 INSTALLATION & OPERATION MANUAL G7 Series System settings Engi ne Speed Engi ne Speed Engine Type Language Fault Shutdown Button Sound 0 RPM 0 RPM Serial No. Over Speed DTC List Coolant Warning Cool ant Temp. Bat t er y Vol t age Cool ant Temp.
  • Page 47 Save & Exit VDO_P28 Exit Exit VDO_P10 ** Via ECU CAN message “ G7 series” ** External sensor type user any vendors ** For example sensor image None Analog Sensor type fuel range empty “240 Ω” ~ Full “33 Ω” range...
  • Page 48 INSTALLATION & OPERATION MANUAL G7 Series Alarm management Fault display and alarm Engi ne Speed Engi ne Speed 0 RPM 0 RPM !!! Fault !!!! !!! Fault !!!! Cool ant Temp. Bat t er y Vol t age Cool ant Temp.
  • Page 49 INSTALLATION & OPERATION MANUAL G7 Series Chart 1 ( Default setting value of Engine model ) Engine type G300 G350 H380 H410 L500 L600 L700 Parameter Fault shutdown <- <- <- <- <- <- <- <- Serial No. DTC List ENG Oil&Filter Exchange...

  • Page 50: Warning Lamp

    (dip stick). If the oil is low, refill it. If you refill • Neutral switch state lamp the oil and the lamp still does not turn off, you if neutral s/w turn on, you check NEUTRAL should ask your Hyundai SeasAll dealer for position . maintenance. CAN STATE •...

  • Page 51: Switches

    INSTALLATION & OPERATION MANUAL G7 Series SWITCHES 1) Function switch - use to change the information display on the LCD. 2) PTO / IDLE change switch – use to enable PTO / IDLE RPM adjustment function 3) UP / DOWN switch – use to raise or lower PTO / IDLE RPM.

  • Page 52: G-Scan

    INSTALLATION & OPERATION MANUAL G7 Series G-SCAN G-scan is a diagnostic tool which can perform the functions of DTC analysis, fault code searching, data analysis and ECU upgrading. G-SCAN CONNECTIONS The G-scan can be connected to the diagnostic connector of the EOI (1), as well as to the G-scan connector in the junction box (2).
  • Page 53 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 54 INSTALLATION & OPERATION MANUAL G7 Series ● ● P0201 TWV1 output open load (Injector coil open) ● ● P0202 TWV5 output open load (Injector coil open) ● ● P0203 TWV3 output open load (Injector coil open) ● ● P0204 TWV6 output open load (Injector coil open) ●...
  • Page 55 INSTALLATION & OPERATION MANUAL G7 Series P0562 Battery Voltage Too Low ● ● Battery Voltage Too High P0563 ● ● P009C VDIC2#1 communication Failuer P009D VDIC2#2 communication Failuer ● ● P0601 check sum error - Flash area of Main-CPU Max torque limit 50% ●...

  • Page 56: Chapter 9 Anti Corrosion System

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 9 ANTI CORROSION SYSTEM INTERCOOLER HEAT EXCHANGER ANODE 1) ANODE for corrosion protection. Must be replaced every 250 hours. 2) When used in salt or brackish water, regular inspection is required. It is strongly recommended to replace the sacrificial anode at the start of each season.

  • Page 57: Chapter 10 Engine Storage

    INSTALLATION & OPERATION MANUAL G7 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 58: Winter Storage

    INSTALLATION & OPERATION MANUAL G7 Series WINTER STORAGE Protect your engine from freezing and corrosion damage by following the procedures indicated below. • COOLING SYSTEM • LUBRICATION SYSTEM -. If the seawater system is not filled with an -. Start the engine and allow it to reach normal antifreeze solution as per the instructions above, operating temperature.

  • Page 59: Long Term Storage

    INSTALLATION & OPERATION MANUAL G7 Series LONG TERM STORAGE These instructions must be followed in order to obtain warranty coverage for long term storage engines. These procedures are intended to prevent oxidation and deterioration of engine and fuel system components.

  • Page 60: Chapter 11 Maintenance

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 11 MAINTENANCE THE INITIAL RUNNING CHECK BEFORE THE WATER TEST ON THE WATER TEST Seawater inlet valve open Seawater pump operating properly Engine coolant level Seawater strainer correctly mounted , Clean and tightly closed...

  • Page 61: Maintenance Schedule

    INSTALLATION & OPERATION MANUAL G7 Series MAINTENANCE SCHEDULE ○ : Check/Clean, ◇ : Check (Replace if Necessary), ● : Replace Minimun 1 y Daily 250h 600h 1000h /Necessary ○ Check coolant level and check for leaks ○ Clean Seawater strainer ○...

  • Page 62: A/S Part Number

    INSTALLATION & OPERATION MANUAL G7 Series A/S PART NUMBER DESCRIPTION Remarks 26325-52003 OIL FILTER ELEMENT SERVICE KIT 31965-52800 FILTER CATRIDGE-FUEL 00360-6L171 ELEMENT-PRIMARY FILTER 00500-4H170 AIR FILTER 00400-4G160 SEAWATER PUMP ASSEMBLY IMPELLER KIT MINOR KIT-SEAWATER PUMP MAJOR KIT-SEAWATER PUMP 00100-4H102 ANODE...

  • Page 63: Maintenance Log

    INSTALLATION & OPERATION MANUAL G7 Series MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS - 62 -...

  • Page 64: Chapter 12 Troubleshooting Guide

    INSTALLATION & OPERATION MANUAL G7 Series CHAPTER 12 TROUBLESHOOTING GUIDE ■ Starter motor does not crank the engine Possible Causes •Engine stop switch is not in the “ON” position •Engine is not shifted to neutral position (Switch is pressed) •Weak battery or battery connections are loose •Starter motor solenoid or slave solenoid failure...
  • Page 65 INSTALLATION & OPERATION MANUAL G7 Series ■ Engine rattling, noisy engine Possible Causes •Incorrect compensation of individual injectors •No engine coolant temperature sensor signal •Low compression pressure •Clogged injector return line •No rail pressure sensor signal •Faulty injector •Poor injector O-ring •Carbon deposit on the injector...

  • Page 66: Chapter 13 Warranty

    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 67 INSTALLATION & OPERATION MANUAL G7 Series DURATION OF WARRANTY Leisure Applications Extended Major Components Base Engine (Includes Base Engine Warranty) Engine Rating year hour year hour S270/D170/R200 1,000 2,000 /U125 **H380/L500/ 5,000 G300 ** Operating less than 1,500 hours per year and Full Power operation < 10% of total use period •...
  • Page 68 WARRANTY REGISTRATION Warranty Registration Card must be submitted to Hyundai SeasAll within 30 days of the Warranty Starting Date. The Warranty Registration Card identifies information on customer and product, models and serial numbers, date of sale, type of use and the selling dealer etc. If the ‘Warranty Registration Card’...
  • Page 69 Hyundai SeasAll will verify the warranty registration of the new owner. WHAT HYUNDAI SEASALL WILL DO Hyundai SeasAll will pay for all parts and labor needed to repair the damage to the product resulting from a defect in materials or factory workmanship.
  • Page 70 INSTALLATION & OPERATION MANUAL G7 Series WHAT IS COVERED Hyundai SeasAll warrants its products to be free of defects in material and workmanship during the warranty period. LIMITATIONS – EXPENDABLE PARTS Not included are the following expendable parts: • Filters : fuel filter, engine oil filter, air filter •...

  • Page 71: Warranty Registration Card

    WARRANTY REGISTRATION CARD Date of sale This card is essential for registration of the customer’s warranty. Month Year Please fill out the following registration card in English. If Warranty Transfer , Check box ■OWNER’S INFORMATION Name or Company E-Mail Address Country State / Province / City Operating Location...
  • Page 72 INSTALLATION & OPERATION MANUAL G7 Series...

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