Hyundai Seasall S250S series Installation & Operation Manual
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Related Manuals for Hyundai Seasall S250S series
Summary of Contents for Hyundai Seasall S250S series
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Page 2: Table Of Contents
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines TABLE OF CONTENTS ABOUT THIS MANUAL …………………………………………………………………..…. SAFETY PRECAUTIONS ……………………………………………………...……………… APPROXIMATE CONVERSIONS FROM STANDARD…………………………………….. ……………………………………………………………… CHAPTER 1 ENGINE OVERVIEW ……………………………………………………… 1. ENGINE COMPONENTS 2. ENGINE SUSPENSION ………. ……………………………………………….. ……………………………………………………. 3. ENGINE IDENTIFICATION 4. - Page 3 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines TABLE OF CONTENTS CHAPTER 7 ELECTRICAL SYSTEM ……………………………………………………. 1. BATTERY CABLE CONNECTIONS ……………………………...……. 2. BATTERY CHECKS ………………………………………………..……. 3. FUSE AND RELAY …………………………………………………...….. CHAPTER 8 INSTRUMENT SYSTEM ……………………...………………………..1. INSTRUMENT CONNECTIONS …………..……………………….…… 2.
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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: 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: Approximate Conversions From Standard
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 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... -
Page 7: 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 8: Engine Suspension
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE SUSPENSION 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 9: 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 Worldwide Only USA - 8 -... -
Page 10: Schematic Diagram Of Common Rail Diesel Engine
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE - 9 -... -
Page 11: 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 Ignition sequence 1-2-3-4-5-6 Displacement [cm... -
Page 12: Performance Curves
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 6. PERFORMANCE CURVE S250S & S250P MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 11 -... - Page 13 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines S250J MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 12 -...
- Page 14 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines S220S & S220P MODEL *BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption - 13 -...
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Page 15: Belt Installation & Engine Dimesions
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 7. BELT INSTALLATION & ENGINE DIMENSIONS V-RIBBED BELT INSTALLATION MODEL : S-ENG SERIES AN ALTERNATOR DP DRIVE PULLEY IDLER PULLEY PS POWER STEERING TP TENSIONER PULLEY WP WATER PUMP PULLEY ... - Page 16 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines MerCruiser Bravo Three X Diesel Front view Side view ZF 63 A Front view Side view - 15 -...
- Page 17 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 - 16 -...
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Page 18: Chapter 2 Engine Mount System
2. ENGINE MOUNT DIMENSIONS CAUTION USE ONLY THE ORIGINAL HYUNDAI SEASALL MOUNTINGS THAT WERE SUPPLIED WITH THE INITIAL PURCHASE. AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE, MAKE SURE THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN. - Page 19 FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE. HYUNDAI SEASALL ENGINES MUST BE USE THE GENUINE ALIGNMENT TOOL OF HYUNDAI SEASALL OTHER THE DRIVE COUPLER WILL BE DAMAGED. - 18 -...
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Page 20: Chapter 3 Cooling & Exhaust System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 3 COOLING SYSTEM & 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 HEAT EXCHANGER E-VGT COOLER INTERCOOLER... -
Page 21: Water Pickup
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 22: 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 23 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHECKING SEA WATER 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 24: 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 25 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3) 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. 4) If frequent additions are required, see an authorized dealer for a cooling system inspection.
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Page 26: Removing Air Bubbles
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 Ø... -
Page 27: 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 28: 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 29: Low Pressure Fuel Line
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 ↓ ④... -
Page 30: 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 31: Recommended Fuel Quality
• After starting the engine, check to make certain the fuel filter warning light is off CAUTION HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO THE FUEL INJECTON COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO THE USE OF UNQUALIFIED FUELS. -
Page 32: 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 33: Air Filter Maintenance
S250 and S220 Series Engines AIR FILTER MAINTENANCE • 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 34: Chapter 6 Lubrication System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 6 LUBRICATION SYSTEM 1. ENGINE OIL FLOW - 33 -... -
Page 35: 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. Be sure the boat is level. Start the engine and allow it to reach normal operating temperature. -
Page 36: 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 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 change②. -
Page 37: Chapter 7 Electrical System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 7 ELECTRICAL SYSTEM 1. BATTERY CABLE CONNECTIONS 1) The size of battery cable should be at least 40mm and no longer than 4m. 2) If the cable is longer than 4m. the size should be at least 50mm 3) Recommended battery capacity is over 200 amperes. -
Page 38: 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 39: 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 40 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3.2 RELAYS Relays in the ECU Box 1) Main Relay: 30 Amp 2) Oil Extraction Pump Relay: 30 Amp 3) Fuel Pump Relay : 30 Amp 4) Spare : 30 Amp * Two Pole System : Cut-off solenoid relay (30 Amp) 5) Start Solenoid Relay: 30 Amp 6) Fuel Heater Relay: 30 Amp...
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Page 46: Chapter 9 Eoi System
When the engine starts normally, the lamps all go off. If there is a problem, the specific lamp will come on. You should contact your nearest Hyundai SeasAll dealer and have the engine checked as soon as possible. 1. OVERVIEW OF EOI SYSTEM 1.1 INFORMATION LCD ITEM... -
Page 47: Switches
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.2 SWITCHES • Buzzer Reset Switch - This switch is used for turning off the alarm temporarily. • Dimmer Switch - This switch is used for controlling brightness of the other gauges connected to the EOI. -
Page 48: Eoi Connections
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. 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 49: 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 50 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CN3 (TACHOMETER) Main relay power RPM signal Ground illumination illumination CAN_H CAN_L Not used CN4 (COOLANT TEMP. GAUGE) Coolant temperature signal Ignition power Ground illumination illumination Not used CN5 (VOLTMETER) Ignition power Ground illumination illumination...
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Page 52: Trim Wiring Connection Diagram
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 5. TRIM WIRING CONNECTION DIAGRAM TRIM LIMITE TRIM SENDER TRIM PUMP REMOTE CONTROL TRANSOM PLATE TRAILER S/W (SIDE TYPE ONLY) GEAR LUBE MONITOR GAUGE-TRIM GAUGE-VOLT BATTERY E O I GAUGE & LAMP POWER BUZZER (DRIVE OIL) - 50 -... -
Page 53: G-Scan
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 6. G-SCAN G-scan is diagnosis tool have function the DTC analysis, fault code searching, data analysis and ECU upgrade. 6-1. G-SCAN CONNECTIONS G-scan can be connected to the CN6 connector of EOI, as well as G-scan connector in the ECU box. -
Page 54: 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 55 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines - 53 -...
- Page 56 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines - 54 -...
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Page 57: Dtc(Diagnosis Trouble Code) List
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 7.2 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 P0069 P0087 Fuel Rail/System Pressure - Too Low... - Page 58 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 P0253 Pump Pressure Regulation Valve Circuit Low P0254...
- Page 59 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 P0602 Control Module Programming Error P0604...
- Page 60 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 P1187 Regulator Valve Stick P1188...
- Page 61 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION Throttle/Pedal Position Sensor/Switch “D” / “E” Voltage Correlation P2138 P2228 Barometric Pressure Circuit Low Input P2229 Barometric Pressure Circuit High Input P2262 Turbocharger Boost Pressure Not Detected - Mechanical P2263/5/6/7/8 Turbocharger Boost System Performance P2264...
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Page 62: Chapter 10 Anti Corrosion System
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 10 ANTI CORROSION SYSTEM Intercooler Heat exchanger Sacrificial anodes 1) Sacrificial anode must be replace every 250hr The sacrificial anode check especially frequently when used in saltwater. It is recommended to replace the sacrificial anode at the start of each season. -
Page 64: Engine Break-In
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. 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. 1) DO NOT operate engine at idle rpm for extended periods of time during the first 10 hours. -
Page 65: Emergency Stop
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. 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 66: 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 storage or prolonged storage (two months or longer and winter storage) : CHECK LIST •... -
Page 67: Winter Storage
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 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 -. -
Page 68: Chapter 13 Maintenance
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 13 MAINTENANCE 1. THE INITIAL RUNNING CHECK - BEFORE THE WATER TEST - ON THE WATER TEST Seawater inlet valve open Boat drain plug in place (Check before putting boat in water) Engine coolant level Seawater pump operation Cooling system hose clamps tight... -
Page 69: Maintenance Schedule
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. MAINTENANCE SCHEDULE ○ : Check/Clean, ◇ : Check ( Replace if necessary), ● : Replace Which ever comes first Interval Every Every 250 Every 500 Every 1,000 1,500 Item Daily Hours Hours Hours... -
Page 70: Sterndrive & Transmission Maintenance Schedule
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. STERNDRIVE & TRANSMISSION MAINTENANCE SCHEDULE Whichever comes first Maintenance Maintenance 100h / intervals Daily 1year item ● Check sterndrive unit oil level (Transmission) ● Trim pump oil level ● Steering fluid level ●... -
Page 71: Maintenance Log
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS - 69 -... -
Page 72: 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 •... - Page 73 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 •...
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Page 74: Chapter 15 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 75 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 76 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 77 INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 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.
- Page 78 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. - 76 -...
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Page 79: 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...
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