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Related Manuals for Hyundai Seasall S250
Summary of Contents for Hyundai Seasall S250
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Page 2: Table Of Contents
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines TABLE OF CONTENTS PAGE NUMBER ABOUT THIS MANUAL …………………………………………………………………..…. ……………………………………………………………… CHAPTER 1 ENGINE OVERVIEW ……………………………………………………… 1. ENGINE COMPONENTS ……………………………………………….. 2. ENGINE SUSPENSION EYES ……………………………………………………. 3. ENGINE IDENTIFICATION 4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE …….. - Page 3 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines TABLE OF CONTENTS PAGE NUMBER CHAPTER 7 ELECTRICAL SYSTEM ……………………………………………………. 1. BATTERY CABLE CONNECTIONS ……………………………...……. 2. BATTERY CHECKS ………………………………………………..……. 3. FUSE AND RELAY …………………………………………………...….. CHAPTER 8 INSTRUMENT SYSTEM ……………………...………………………..1. INSTRUMENTS CONNECTION …………..……………………………...
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Page 4: About This Manual
This engine installation and operation manual is provided as guidance for the installation of Hyundai SeasAll engine to 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: Chapter 1 Engine Overview
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 1 ENGINE OVERVIEW 1. ENGINE COMPONENTS 1. ECU Box 7. Engine Oil Gauge 2. Coolant Expansion Tank 8. Acceleration Lever Sensor 3. Engine Oil Cap 9. Seawater Pump 4. Engine Oil Filter 10. -
Page 6: Engine Suspension Eyes
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE SUSPENSION EYES 1) To lift the engine, first remove the engine cover. You will find three engine eyes (see figure). 2) To avoid engine damage, take care that engine lift chains or belts do not hit or touch surrounding parts during engine lifting. -
Page 7: Engine Identification
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the ECU box (see figure). § SERIAL NUMBER ON THE ENGINE BLOCK § NAME PLATE ON THE ECU BOX... -
Page 8: Schematic Diagram Of Common Rail Diesel Engine
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE - 7 -... -
Page 9: Technical Data
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 5. TECHNICAL DATA S250 / 220S S250 / 220P S250J 4-stroke, 4-valve Engine type After-cooled, direct-injection, water cooling Output ps(kW) 250ps (184) / 220ps (162) rpm at full load 3800/3200 Cylinders... -
Page 10: Performance Curve
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 6. PERFORMANCE CURVE § S250S & S250P MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 9 -... - Page 11 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines § S250J MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 10 -...
- Page 12 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines § S220S & S220P MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 11 -...
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Page 13: Engine Dimensions
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 7. ENGINE DIMENSIONS § MerCruiser Bravo One X Diesel Front view Side view § MerCruiser Bravo Two X Diesel Front view Side view - 12 -... - Page 14 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines § MerCruiser Bravo Three X Diesel Front view Side view § ZF 63 A Front view Side view - 13 -...
- Page 15 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines § ZF 63 C Front view Side view § Waterjet adapter without ZF 45C / ZF 63C Front view Side view - 14 -...
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Page 16: Chapter 2 Engine Mount System
2. ENGINE MOUNT DIMENSIONS CAUTION CAUTION USE ONLY THE ORIGINAL HYUNDAI SEASALL MOUNTINGS THAT WERE USE ONLY THE ORIGINAL HYUNDAI SEASALL MOUNTINGS THAT WERE SUPPLIED WITH THE INITIAL PURCHASE. SUPPLIED WITH THE INITIAL PURCHASE. AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE, MAKE SURE AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE, MAKE SURE THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN. -
Page 17: Engine Mount Tool For Sterndrive Model
MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE. IF IN ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE. IF IN DOUBT ABOUT ENGINE INSTALLATION, PLEASE CONTACT YOUR DOUBT ABOUT ENGINE INSTALLATION, PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER. -
Page 18: Chapter 3 Cooling & Exhaust System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 3 COOLING & EXHAUST SYSTEM 1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT EX-MANIFOLD CABIN HEATER AIR FILTER CONNECTOR TURBO CHARGER THERMOSTAT COOLANT PUMP EXHAUST ELBOW EX-MANIFOLD OIL COOLER EXPANSION TANK... -
Page 19: The Flow Of Seawater
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. THE FLOW OF SEAWATER – OPEN COOLING CIRCUIT Water strainer ← Water valve ← Water pickup ↓ ① Seawater pump ↓ ② Intercooler ↓ ③ Heat exchange ⑤ EVGT cooler ↓... -
Page 20: Seawater Pump
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4) To 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 •... - Page 21 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines • Apply soapy water to impeller when assembling, and reassemble towards rotation direction • Replace of the O-ring on the impeller housing cover • Open the water valve • Start the engine and check if there is water leakage...
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Page 22: The Flow Of Engine Coolant
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. THE FLOW OF ENGINE COOLANT – CLOSED COOLING CIRCUIT § THERMOSTAT CLOSED CONDITION ① Coolant engine outlet ↓ ① ① ② Exhaust manifold ↓ ③ ③ Thermostat closed (opening temp 82℃) ↓... - Page 23 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines If the coolant level is low, add enough specified coolant to provide protection against freezing and corrosion. Bring the level to MAX, but do not overfill. If frequent additions are required, see an authorized dealer for a cooling system inspection.
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Page 24: Removing Air Bubble
1) In order to use cabin heater, an extra coolant circulation pump is needed. 2) After connecting cabin heater lines, engine coolant must be refilled and checked. 3) Please check coolant flow direction, as shown in figure. 4) If in doubt, please contact your nearest Hyundai SeasAll dealer. From heater To heater * Outer diameter of line is Ø17.3 mm... -
Page 25: Exhaust System
S250 and S220 Series Engines 4. EXHAUST SYSTEM 1) Your Hyundai Seasall engine’s exhaust system consists of a coolant-cooled exhaust manifold and a seawater-cooled exhaust elbow (water injected wet exhaust system). 2) The vessel’s exhaust pipe line should not be made too long or to bend. The maximum back pressure of the exhaust gas should be under 360 mbar. -
Page 26: Chapter 4 Fuel System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 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 1600 bar. Multi-injection is possible thanks to the quick response of the piezo type injector. -
Page 27: The Flow Of Fuel
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1. THE FLOW OF FUEL Fuel tank ↓ Auxiliary fuel filter ↓ ① Fuel pump (low pressure) ↓ ② Fuel filter with water detection sensor ↓ ③ High pressure pump ↓... -
Page 28: Acceleration Sensor And Control Lever
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. ACCELERATION SENSOR AND CONTROL LEVER 65 mm 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. -
Page 29: Recommended Fuel Quality
CAUTION CAUTION HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO THE FUEL INJECTON COMPONENTS CASES WHERE DAMAGE TO THE FUEL INJECTON COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO... -
Page 30: Chapter 5 Air Intake System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 5 AIR INTAKE 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. 2.5 bar in order to optimize engine combustion. -
Page 31: Air Filter Maintenance
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines AIR FILTER MAINTENANCE 1) The air filter must be cleaned regularly. If the engine is operated in a dirty environment, clean the filter more frequently. 2) Blow out the air filter from the inside toward the outside with max. 2.0 bar compressed air. -
Page 32: Chapter 6 Lubrication System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 6 LUBRICATION SYSTEM 1. THE FLOW OF ENGINE OIL - 31 -... -
Page 33: Engine Oil Level Checks
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular intervals. l Be sure the boat is level. l Start the engine and allow it to reach normal operating temperature. -
Page 34: Engine Oil Extaction Pump
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. ENGINE OIL EXTACTION PUMP 1) Allow the engine to warm up at least 5 minutes. 2) Remove the engine oil inlet cap and oil filter. 3) The supplied oil change hose is connected on to the oil extraction pump ①, and you must route the other end of the hose into the container being used for the oil change②. -
Page 35: Chapter 7 Electrical System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 7 ELECTRICAL SYSTEM 1. 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 36: Battery Checks
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. BATTERY CHECKS Battery inspection is very important in electronic control engines: You must check the battery condition regularly. LOAD TEST 1) Perform the following steps to complete the load test procedure for maintenance-free batteries. -
Page 37: Fuse And Relay
ECU box. Always replace a blown fuse with one of the same rating. If the replacement fuse blows, this indicates an electrical problem. Avoid using the system involved and immediately consult an authorized Hyundai SeasAll dealer. Fuses in the ECU Box System Power_30Amp... - Page 38 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3.2 RELAY Relay in the ECU Box 1) Main Relay_30Amp 2) Oil Extract Relay_30Amp 3) Fuel Pump Relay Power_30Amp 4) Spare_30Amp 5) Start Sol. Relay_30Amp 6) Fuel Heater Relay _30Amp Using an ohmmeter, check that there is continuity between each terminal.
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Page 39: Chapter 8 Instrument System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 8 INSTRUMENT SYSTEM 1. INSTRUMENTS CONNECTION gauges only available for dual EOI application ※ For information about the installation and operation of the EOI (Engine Operating Indicator) system, please refer to Chapter 9. - Page 40 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.1 Standard instrumentation Ø 5 RPM Gauge Coolant Temperature Gauge Battery Volt Meter Gauge Ignition Key switch 1.2 COOLANT TEMPERATURE GAUGE 1) When the key is at ignition ON position, this gauge will work.
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Page 41: Cut-Out For Gauge
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.3 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 42: Chapter 9 Eoi System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 9 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. -
Page 43: Switches
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.2 SWITCHES 1) Buzzer Reset Switch - This switch is used for turning off the alarm temporarily. 2) Dimmer Switch - This switch is used for controlling brightness of the other gauges connected to the EOI. -
Page 44: Eoi Connections
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines EOI CONNECTIONS Rear view 1. Connection plug – CN1 (from engine) 6. Connection plug – CN6 (service tool) 2. Connection plug – CN2 (to dual EOI) 7. Connection plug – CN7 (external) 3. -
Page 45: Eoi Pin Assignment
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. EOI PIN ASSIGNMENT CN1 (MAIN EOI CONNECTOR FROM ENGINE) 1. Ignition power 13. RPM signal 2. Main relay power 14. Spare 3. Permanent power 15. Spare 4. Not used 16. Spare 5. - Page 46 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CN3 (TACHOMETER) Main relay power RPM signal illumination illumination CAN_H CAN_L Not used CN4 (COOLANT TEMP. GAUGE) Coolant temperature signal Ignition power illumination illumination Not used CN5 (VOLT GAUGE) Ignition power...
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Page 47: Neutral Switch And Dual Eoi Connection
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CN8 (KEY BOX) 1. Ignition power 2. Start power 3. Permanent power 4. NEUTRAL SWITCH AND DUAL EOI CONNECTION 1) Neutral switch wires should be connected at pin #4 and #5 of the external connector of the EOI. -
Page 48: Alarm And Dtc(Diagnosis Trouble Code)
(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 49 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines Fail safety Alarm Item Description Expectation Cause(s) Fuel cut Note 1) Lamp Buzzer RPM limit ○ P0203 Open load P0267 Short circuit ground √ • Injector circuit √ √ Cylinder3 injector...
- Page 50 Coolant temperature high (above 110℃) temp. Blinking • Cooling line check temp. sensor Note 1) RPM Limit : ● ( Rated rpm - 500rpm), ○ (Rated rpm - 800rpm) Note 2),3) would be applied to S250/220 models - 49 -...
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Page 51: Dtc(Diagnosis Trouble Code) List
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 5.2 DTC(DIAGNOSIS TROUBLE CODE) LIST P code DESCRIPTION Crankshaft Position – Camshaft Position Correlation P0016 P0047 Turbocharger Boost Control Solenoid Circuit Low P0048 Turbocharger Boost Control Solenoid Circuit High Manifold Absolute Pressure – Barometric Pressure Correlation... - Page 52 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P0232 Fuel Pump Secondary Circuit High P0234 Turbocharger Over boost Condition P0237 Turbocharger Boost Sensor "A" Circuit Low P0238 Turbocharger Boost Sensor "A" Circuit High P0252 Pump Pressure Regulation Valve Circuit...
- Page 53 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P0341 Camshaft Position Sensor A Circuit Range/Performance P0381 Glow Plug/Heater Indicator Circuit P0562 System Voltage Low P0563 System Voltage High P0601 Internal Control Module Memory Check Sum Error...
- Page 54 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P1171 Minimum Rail Pressure Exceeded P1172 Maximum Rail Pressure Exceeded P1173 Set Value of PCV not in Plausibility Range P1185 Maximum Pressure Exceeded P1186 Minimum Pressure at Engine Speed Too Low...
- Page 55 Turbocharger Boost Control Position Sensor "A" Circuit High *P2566 Turbocharger Boost Control Position Sensor "A" Circuit Intermittent U0001 High Speed CAN Communication Bus U0100 Faults in CAN a Transmit Messages *Pxxxx codes would be applied to only S250/220 models - 54 -...
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Page 56: Chapter 10 Anti Corrosion System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 10 ANTI CORROSION SYSTEM Intercooler Heat exchanger Sacrificial anodes The sacrificial anode must be replaced when more than 60% 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 57: Chapter 11 Engine Operation
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 11 ENGINE OPERATION 1. ENGINE ON/OFF 1) Before starting the engine, you should check engine oil, coolant, gearbox oil, fuel gauge, raw water pump, battery, and so on. 2) When you start the engine, check that the engine throttle lever① is at neutral position. If not, the engine may not start or there is possibility of shooting off. -
Page 58: Emergency Stop
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. EMERGENCY STOP 1) You can stop the engine by pushing this switch. After releasing the switch, you can start the engine again. 2) When the switch is pressed or it doesn’t work normally, the engine doesn’t crank. We recommend that you check this switch first if there is any cranking problem. -
Page 59: Chapter 12 Engine Storage
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 12 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 60: Chapter 13 Maintenance
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 13 MAINTENANCE 1. PREDELIVERY INSPECTION CHECK LIST 1.1 BEFORE THE WATER TEST 1.2 ON THE WATER TEST -ENGINE CHECKS -ENGINE CHECKS Boat drain plug in place Seawater inlet valve open... -
Page 61: Main Check List
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. MAINTENANCE SCHEDULE Whichever comes first Maintenance Maintenance intervals 200h / 400h / Daily item 1year 2years ● Check the coolant level and leakage ● Replace the seawater pump Impeller ●... -
Page 62: Maintenance Log
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS - 61 -... -
Page 63: Chapter 14 Troubleshooting Guide
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 14 TROUBLESHOOTING GUIDE ■ Starter motor does not crank the engine Possible Causes •Engine is not shifted to neutral position •Engine stop switch “ON” position •Wrong neutral switch connection to EOI •Weak battery or battery connections are loose... - Page 64 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines ■ 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...
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Page 65: Chapter 15 Warranty
CHAPTER 15 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 two (2) years from the date the product is first sold to a recreational use retail purchaser or when the Product has been operated for 1000 hours, whichever occurs first. - Page 66 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 • 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 68 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.