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Related Manuals for Hyundai L500 SERIES
Summary of Contents for Hyundai L500 SERIES
- Page 1 INSTALLATION & OPERATION MANUAL L500 Series...
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Page 2: Table Of Contents
INSTALLATION & OPERATION MANUAL L500 Series TABLE OF CONTENTS ABOUT THIS MANUAL ………………………………………………………………..……..……….. SAFETY PRECAUTIONS ………………………………………………………….……..……………… APPROXIMATE CONVERSIONS FROM STANDARD……………………………………………… ENGINE OVERVIEW ……………………………………………..…...….…….……… CHAPTER 1 ENGINE COMPONENTS ………………………………………..……….…………… TECHNICAL DATA ………………………………………………..…….…………….. PERFORMANCE CURVES…………………………………………….………..…….. ENGINE IDENTIFICATION……………………………………..……….…………..ENGINE SUSPENSION.…………………………………………….……..……... ENGINE DIMENSIONS………………………………………….………..…..…….. ENGINE OPERATION ………………………………………………………….……….. - Page 3 INSTALLATION & OPERATION MANUAL L500 Series TABLE OF CONTENTS RECOMMENDED OIL QUALITY………………………..……………..…...…..ENGINE OIL EXTACTION PUMP…………………………….…………...…………. CHECKING BYPASS AND OIL FILTER………………………………..….………… ELECTRICAL SYSTEM ………………………………………………..……………… CHAPTER 7 BATTERY CABLE CONNECTIONS ………………………………..………….. ACCELERATION SENSOR AND CONTROL LEVER…………….…………..…… PROCEDURES FOR CONTROL LEVER INSTALLATION…………………..……...
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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 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. REFUELING Do not modify the performance of the... - Page 6 During this period, procedures specified by Hyundai SeasAll. it is important that the engine is operated as outlined below. • The limited warranty does not apply to any • DO NOT operate engine at idle rpm for...
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Page 7: Approximate Conversions From Standard
INSTALLATION & OPERATION MANUAL L500 Series APPROXIMATE CONVERSIONS FROM STANDARD 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: Engine Overview
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 1 ENGINE OVERVIEW ENGINE COMPONENTS ① ENGINE MOUNTING BRACKETS FUEL FILTER ② JUNCTION BOX OIL FILTER ③ SEAWATER PUMP BYPASS OIL FILTER ④ WATER PUMP ⑤ WATER SEPARATOR EXPANSION TANK ⑥ OIL EXTRACTION PUMP C.C.P.C.V. - Page 9 INSTALLATION & OPERATION MANUAL L500 Series INTERCOOLER COOLANT PIPE (HEAT EXCHANGER OUTLET) DRY EXHAUST PIPE STARTER MOTOR TURBO-CHARGER OUTLET PIPE ENGINE MOUNTING BRACKET LIFTING EYES HEAT EXCHANGER AIR FILTER EXHAUST MANIFOLD AIR FILTER CONNECTOR ALTERNATOR - 8 -...
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Page 10: Technical Data
INSTALLATION & OPERATION MANUAL L500 Series TECHNICAL DATA L500 4-stroke, 4-valve Engine type After-cooled, Electronic Unit Injector (EUI), Turbocharger Output ps (kW) 500PS (368kW) rpm at full load 1800 rpm Cylinders Ignition sequence 1-5-3-6-2-4 Displacement [cm 12,736 Bore [mm] Stroke [mm] Compression ratio 16.0 : 1... -
Page 11: Performance Curves
INSTALLATION & OPERATION MANUAL L500 Series PERFORMANCE CURVES - 10 -... -
Page 12: Engine Identification
INSTALLATION & OPERATION MANUAL L500 Series ENGINE IDENTIFICATION Engine identification is affixed to the engine block . (See figure). • SERIAL NUMBER ON THE ENGINE BLOCK FORMAT : D6CEXXXXXX • ENGINE NAME PLATE - 11 -... -
Page 13: Engine Suspension
INSTALLATION & OPERATION MANUAL L500 Series ENGINE SUSPENSION • To lift the engine, use the four lifting eyes (see illustration). • To avoid engine damage, take care that engine lifting chains or belts do not hit or touch surrounding parts during engine lifting. -
Page 14: Engine Dimensions
INSTALLATION & OPERATION MANUAL L500 Series ENGINE DIMENSIONS Side Front - 13 -... - Page 15 PTO PULLEY REFER DRAWING <CRANK PULLEY > T/M ASSEMBLY BOLT PATTERN • BELL HOUSING : SAE 1 • FLYWHEEL : SAE 14 BELT INSTALLATION MODEL : L500 ALTERNATOR DRIVE PULLEY IDLER PULLEY TENSIONER PULLEY WATER PUMP PULLEY - 14 -...
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Page 16: Chapter 2 Engine Operation
INSTALLATION & OPERATION MANUAL L500 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. Be sure that... -
Page 17: Emergency Stop
INSTALLATION & OPERATION MANUAL L500 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 18: Chapter 3 Cooling System
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 3 COOLING SYSTEM SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT EXHAUST MANIFOLD COOLANT AIRFILTER PUMP HEATER CONNECTOR TURBOCHARGER INTAKE MANIFOLD EXHAUST PIPE EXPANSION TANK HEAT EXCHANGER INTERCOOLER SEAWATER SEA WATER INTAKE AIR PUMP EXHAUST GAS... -
Page 19: Seawater Flow - Open Cooling Circuit
INSTALLATION & OPERATION MANUAL L500 Series SEAWATER FLOW – OPEN COOLING CIRCUIT Water strainer ← Water valve ← Water pickup ↓ Seawater pump ↓ Intercooler ↓ Heat exchanger ↓ Discharge Seawater WATER PICKUP • Water pickup should be installed in an area where it won’t pick up air bubbles and will access... -
Page 20: Cleaning Strainer Filter
INSTALLATION & OPERATION MANUAL L500 Series CLEANING 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 21: Automatic Drain Valve
INSTALLATION & OPERATION MANUAL L500 Series AUTOMATIC DRAIN VALVE • The Automatic Drain Valve allows condensed water in the intercooler to drain when the engine is a idle or is stopped. CHECKING AUTOMATIC DRAIN VALVE • Stop the engine and remove the Automatic Condensate water Emission from intercooler. -
Page 22: Seawater Pump
INSTALLATION & OPERATION MANUAL L500 Series SEAWATER PUMP • The internal diameter of hose connected to seawater pump inlet should be 50.8mm (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... -
Page 23: Checking Seawater Pump & Impeller
INSTALLATION & OPERATION MANUAL L500 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 24: Engine Coolant
INSTALLATION & OPERATION MANUAL L500 Series ENGINE COOLANT FLOW(CLOSED CIRCUIT) 1. Engine block coolant outlet(L) 5. Exhaust manifold 2. Heat exchanger 4. Engine block coolant outlet(S) Coolant pump 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 25: Draining Coolant
INSTALLATION & OPERATION MANUAL L500 Series SUPPLEMENTAL ENGINE COOLANT • If the coolant level is below level ‘Low’, add Mixture Percentage(volume) Ambient enough specified coolant to provide protection Temperature against freezing and corrosion. Coolant level Antifreeze Water should be between the MAX and MIN. But do -15℃... -
Page 26: Removing Air Bubbles In Coolant
To heater ※HOSE IN DIAMETER Φ17 • Contact your Hyundai SeasAll dealer if you have From heater any concerns. WARNING NEVER OPEN THE EXPANSION TANK CAP WHEN THE ENGINE IS OPERATING OR HOT. -
Page 27: Chapter 4 Fuel System
INSTALLATION & OPERATION MANUAL L500 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 28: Fuel Supply System
INSTALLATION & OPERATION MANUAL L500 Series FUEL SUPPLY SYSTEM • The fuel system consists of an electronic control unit (ECU), unit injectors, a fuel pump, fuel lines, a fuel filter, an overflow valve, a fuel tank etc. • Fuel from the fuel filter is supplied into the fuel gallery in the cylinder head. -
Page 29: 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 INJECTION COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO THE USE OF UNQUALIFIED FUELS. -
Page 30: Changing Fuel Filter
INSTALLATION & OPERATION MANUAL L500 Series CHANGING FUEL 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. • Replace the filter element. -
Page 31: Intake & Exhaust System
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 5 INTAKE & EXHAUST SYSTEM The turbo-charger uses the exhaust gas to increase the output of the engine by supplying compressed air to the combustion chamber. filter Boost Pressure & ATS#1 Cam position... -
Page 32: Check Air Filter
INSTALLATION & OPERATION MANUAL L500 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 the flow of air to the engine. -
Page 33: Exhaust System
• The exhaust pipe can be rotated per the installation requirements. Tighten the exhaust pipe to the support bracket to prevent damage from vibration. CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION, PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER. - 32 -... -
Page 34: Lubrication System
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 6 LUBRICATION SYSTEM LUBRICATION COMPONENTS 5. Plate Cylinder block 6. Oil cooler assembly 2. Gasket 7. Oil filter 3. Oil pump assembly 8. Bypass filter 4. Oil fan - 33 -... -
Page 35: Engine Oil Level Checks
INSTALLATION & OPERATION MANUAL L500 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 36: Engine Oil Extaction Pump
INSTALLATION & OPERATION MANUAL L500 Series ENGINE OIL EXTRACTION 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 37 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. - 36 -...
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Page 38: Chapter 7 Electrical System
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 7 ELECTRICAL SYSTEM BATTERY CABLE CONNECTIONS 1) The cross-section of the battery cables should be at least 40 mm and no longer than 4 m. 2) If the cable is longer than 4m, the cross-section should be at least 50 mm 3) Recommended battery capacity is over 100 amperes. -
Page 39: Acceleration Sensor And Control Lever
INSTALLATION & OPERATION MANUAL L500 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. -
Page 40: Battery Checks
INSTALLATION & OPERATION MANUAL L500 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: ①... -
Page 41: Fuses And Relays
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 a Hyundai SeasAll dealer. - 40 -... -
Page 42: Relays
INSTALLATION & OPERATION MANUAL L500 Series RELAYS ① ⑦ Reserve-20Amp Air heater-20Amp ② Main-20Amp ⑧ Starter solenoid-20Amp ③ ⑨ Fuel heater-20Amp Power key-20Amp(5Pin) ④ Oil pump-20Amp • Using an ohmmeter, check that there is Terminal Continuity continuity between each terminal. -
Page 43: 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 44: Rpm Gauge
INSTALLATION & OPERATION MANUAL L500 Series RPM GAUGE 1) When the ignition key is in the ON position, this gauge will work. 2) This gauge indicates real-time engine rpm. 3) Avoid maximum rpm and Wide Open Throttle (WOT) before a cold engine is fully warmed up as it can harm the engine. -
Page 45: Eoi Function
INSTALLATION & OPERATION MANUAL L500 Series EOI FUNCTION 1) RPM gauge 7) Coolant high temperature warning lamp 2) Key switch 8) LCD information 3) G scan terminal port 9) Function switch 4) Check engine lamp 10) PTO/IDLE Change switch 5) Charging warning lamp... -
Page 46: Warning Lamp
INSTALLATION & OPERATION MANUAL L500 Series WARNING LAMPS Alarm will sound when alarm lamps flicker. CHECK ENGINE OIL PRESSURE WARNING • This lamp informs you that the engine has • This lamp informs you if the engine oil a serious problem. -
Page 47: Switches
5) Adjustable RPM area : 600RPM ~ 800RPM. If you need to change the IDLE RPM value in the range of 600 RPM to 500 RPM, the value can be changed using the G-SCAN. Contact your Hyundai-SeasAll dealer. - 46 -... -
Page 48: Eoi Box ( Inside )
INSTALLATION & OPERATION MANUAL L500 Series EOI BOX ( INSIDE ) 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 49: Eoi Pin Assignment
INSTALLATION & OPERATION MANUAL L500 Series EOI PIN ASSIGNMENT CN1 (ENGINE MAIN CONNECTOR) GROUND NEUTRAL SWITCH 2 CAN 1-L IDLE SWITCH GEARBOX OIL PRESSURE PTO LAMP START SWITCH OIL PRESSURE SENDER CHARGE WARNING LAMP OIL PRESSURE SWITCH PTO SWITCH CLUTCH SWITCH... - Page 50 INSTALLATION & OPERATION MANUAL L500 Series CN3 (KEY SWITCH) KEY SWITCH START SWITCH BATTERY + CN4 (RPM Gauge-Main) BATTERY + NOT USED GROUND KEY SWITCH DIMMER CAN 1-H CAN 1-L NOT USED CN5 (RPM Gauge-Aux) NOT USED BUZZER OIL PRESSURE SENDER...
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Page 51: G-Scan
INSTALLATION & OPERATION MANUAL L500 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 52: Dtc (Diagnosis Trouble Code) And Alarm List
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 53 INSTALLATION & OPERATION MANUAL L500 Series FAIL SAFE & DEFAULT WARNING ITEM DTC DISRIPTION P-CODE BUZZER VALUE LAMP Engine Coolant Temperature Circuit Low Input P0117 ▪ Sensor Default Value - Key on & Starting : - 10℃ Engine Coolant Temperature Circuit High Input...
- Page 54 INSTALLATION & OPERATION MANUAL L500 Series FAIL SAFE & DEFAULT WARNING ITEM DTC DISRIPTION P-CODE BUZZER LAMP VALUE Injector Needle "5" High side circuit Low – Cylinder 2 P1217 ○ ○ Injector Needle "5" High side circuit High - Cylinder 2 P1218 ○...
- Page 55 INSTALLATION & OPERATION MANUAL L500 Series FAIL SAFE & DEFAULT WARNING ITEM DTC DISRIPTION P-CODE BUZZER LAMP VALUE ○ ○ Injector Spill "5" High side circuit Low - Cylinder 2 P1245 ○ ○ Injector Spill "5" High side circuit High - Cylinder 2...
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Page 56: Chapter 9 Anti Corrosion System
INSTALLATION & OPERATION MANUAL L500 Series CHAPTER 9 ANTI CORROSION SYSTEM ANODE INTERCOOLER HEAT EXCHANGER 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 L500 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 L500 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: Chapter 11 Maintenance
INSTALLATION & OPERATION MANUAL L500 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 60: Maintenance Schedule
INSTALLATION & OPERATION MANUAL L500 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 1) ○ ○ Clean Seawater strainer ○... -
Page 61: After Sales Part Number
INSTALLATION & OPERATION MANUAL L500 Series A/S PART NUMBER DESCRIPTION Remarks 26325-84700 ELEMENT-OIL FILTER 31945-82000 FILTER CATRIDGE-FUEL 31945-7L002 ELEMENT-WATER SEPARATOR 00500-6L170 AIR FILTER 00400-6L160 SEAWATER PUMP ASSEMBLY 00400-6L290 IMPELLER KIT 00400-6L298 MINOR KIT-SEAWATER PUMP 00400-6L299 MAJOR KIT-SEAWATER PUMP 00100-5S117 ANODE... -
Page 62: Maintenance Log
INSTALLATION & OPERATION MANUAL L500 Series MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS - 61 -... -
Page 63: Chapter 12 Troubleshooting Guide
INSTALLATION & OPERATION MANUAL L500 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 64 INSTALLATION & OPERATION MANUAL L500 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...
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Page 65: 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 66 Pump Housing and Oil Pan. • Cylinder Liner or Cylinder Bore scratches are not included in extended major part warranty coverage. Hyundai SeasAll Rating Categories For Marine Auxiliary Engine (Ratings in accordance with ISO 8528 ) Standby Power 1) Operating less than 500 hours per year with average 90% load of the declared Standby Power 2) No overload capability is available for this rating.
- Page 67 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 68 INSTALLATION & OPERATION MANUAL L500 Series OWNER’S OBLIGATIONS It is the owner’s obligation to install, operate, maintain and care for Hyundai SeasAll engines in accordance with the instructions and requirements stated in the Installation and Operation Manual. The owner is responsible for providing enough time and cooperation to get the engine repaired by an authorized dealer, and to deliver it to a proper facility for repair.
- Page 69 Transmissions and drive systems (ZF Marine, Mercury etc.) are covered under separate warranties, provided and serviced by those companies. For information on those warranties, please see the separate booklets included in the original packaging of your Hyundai SeasAll purchase. - 68 -...
- Page 70 Dealer’s Instructions: Dealers must complete this card to register the warranty. Please return the copy to your national Importer/Distributor immediately. Unregistered engines are subject to warranty rejection. REMARKS SIGNATURE : ___________________________ 37,Cheoldobangmulgwan-ro Uiwang-Si, Gyeonggi-Do, Korea ｜TEL : +82-70-8620-8035 ｜FAX : +82-70-8244-8555 ｜www.hyundai-seasall.com...
- Page 71 INSTALLATION & OPERATION MANUAL L500 Series...