Hyundai Seasall G7 Series User manual

INSTALLATION & OPERATION MANUAL
G7 Series
G7 Series Engines

INSTALLATION & OPERATION MANUAL
G7 Series
- 1 -
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 …..……………………………………………..……....................
ENGIEN DIMENSIONS…………………………………………….……..….....……..
CHAPTER 2 ENGINE OPERATION …………………………………………………..…….………..
STARTING AND STOPPING ENGINE……………………………..…….………….
EMERGENCY STOP …………………..…………………………………..…………..
INTAKE AIR HEATER…………………………………………………….….………..
CHAPTER 3 COOLING SYSTEM ……………………………………………………….…….……...
SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..……….............
SEAWATER FLOW - opened circuit…………………………………..……….…….
WATER PICKUP……………………………………………………….…..…….……..
WATER STRAINER………………………………………………….……...……..…….
CLEANING STRAINER FILTER………………………………….………….…..………
SEAWATER PUMP………………………………………………………..…..……….
CHECKING SEAWATER PUMP & IMPELLER…………………..……..……..……..
ENGINE COOLANT FLOW – closed circuit…..…………………………………….
ENGINE COOLANT………………………………………………….…….…….…….
SUPPLEMENTAL ENGINE COOLANT……………………………….………….….
DRAINING COOLANT……………………………………………………..…….…….
REMOVING AIR BUBBLES IN COOLANT……………………………..….….……..
CABIN HEATER CONNECTION……………………………………….………..……
CHAPTER 4 FUEL SYSTEM …………………………………………………………..….…………..
FUEL FLOW ………………………………………………………….……….………..
RECOMMENDED FUEL QUALITY ………………....……………….…….……..….
DRAINING WATER FROM FUEL FILTER ………………………….…….……..….
CHANGING FUEL FILTER CARTRIDGE …………………….……..…….………..
CHAPTER 5 INTAKE & EXHAUST SYSTEM ……………….………………………….….………..
ENGINE AIR CONSUMPTION & ROOM VENTILATION …………………........
CHECK AIR FILTER …………………..……………………..…………..….….……..
CLEANING AIR FILTER ……………………………………..……………….….……
EXHAUST SYSTEM………………………………………………………...….………
CHAPTER 6 LUBRICATION SYSTEM …………………………………….……………….…………
SCHEMATIC DIAGRAM OF ENGINE LUBRICATION…………………………….
ENGINE OIL LEVEL CHECKS & RECOMMENDED OIL QUALITY …...…….
ENGINE OIL EXTACTION PUMP ………………………………………………………
REPLACING OIL FILTER ...…..………………………………………………………….
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INSTALLATION & OPERATION MANUAL
G7 Series
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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 …………………………………………..……………………………...…
INSTRUMENT CONNECTIONS………………………………………………………
EOI FUNCTION…………..……………………………......………………..……...….
EOI DISPLAY INFORMATION……………………………………………………………
WARNING LAMP…………..………………………………………………………..….
SWITCHES …………………………………………………………………..……........
PTO MODE………………………………………………………………………………
IDLE SETTING MODE……………………………………………………...………….
EOI BOX ( INSIDE )………………………………………………………….……….…
G-SCAN……………………………………………………………….……..………..…
G-SCAN CONNECTIONS………………………………………………….…………..
CHAPTER 9 ANTI CORROSION SYSTEM ……………………………………………….…..……..
CHAPTER 10 ENGINE STORAGE ……………………………………………………..…..………......
WINTER STORAGE …..…………..……………………........…………..…………...
LONG TERM STORAGE……………………………………………………………….
CHAPTER 11 MAINTENANCE ……………………………………………………………..…..……….
THE INITIAL RUNNING CHECK……………………....……………..………..………….
MAINTENANCE SCHEDULE ………………………………………..….…...…….....
A/S PART NUMBER……………...………………………………………..….………..
MAINTENANCE LOG………………………………………………………....………..
CHAPTER 12 TROUBLESHOOTING GUIDE …………………………………………………...........
CHAPTER 13 WARRANTY ……………………………………………………………….……..….......
WARRANTY REGISTRATION CARD ………………………………………………..
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INSTALLATION & OPERATION MANUAL
G7 Series
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ABOUT THIS MANUAL
This engine installation and operation manual is provided as guidance for the installation of
Hyundai SeasAll engine inaboat, 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.
Hyundai SeasAll is committed to making clear and accurate information available for those who
maintain, own and repair the H380 Series engines.Hyundai SeasAll values your input regarding
revisions and additional information for our manuals.
WARNING
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO PERSONAL INJURY OR DEATH TO
OPERATORS AND NEARBY PERSONNEL.
CAUTION
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO IMPROPER OPERATION, DAMAGE OR
DESTRUCTION OF THE ENGINE.
•The manufacturer is not liable for any damages or losses caused by faulty installation, wrong
handling of the equipment and/or deficient maintenance.
•The operator is responsible for the correct and safe operation of the engine and safety of its
occupants and general public.
•It is strongly recommended that each operator read and understand this manual before
installing and operating the engine.
•This manual as well as safety labels posted on the engine use the following safety alerts to
draw your attention to special safety instructions that should be followed.
•This manual able to changed without notice

INSTALLATION & OPERATION MANUAL
G7 Series
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SAFETY PRECAUTIONS
HOT SURFACES AND FLUIDS
•There is always a risk of burns when working
with a hot engine. Be aware of hot parts like
the turbocharger system, the exhaust system,
hot coolant hoses, etc. Wait until the engine
is fully cool to do inspection and maintenance.
REFUELING
• Refuel only after the engine completely stops.
•Use only the recommended fuel. The wrong
grade of fuel can cause operating problems,
can cause the engine to stop and can cause
engine damage.
•Pay special attention to safe practices when
refueling.
PAINT DAMAGE
•Damage of the engine or parts paint during
maintenance and inspection can cause
corrosion. Any damage must be repainted
after inspection and maintenance.
WELDING ON ENGINE
•Welding directly on the engine block can
cause damage to the engine control systems.
The ECU and related electronic devices must
be disconnected and removed if unavoidable
welding is needed.
•Read and understand this operator’s manual
as well as other information supplied by
Hyundai SeasAll for safer use of these
products. Be sure to check your engine
regularly.
•Do not use the engine for a purpose other
than what is intended by Hyundai SeasAll. Do
not modify the performance of the supplied
engine without the express permission of
Hyundai SeasAll. This can be dangerous, can
shorten the life of your engine and can
invalidate your warranty.
•Original and genuine parts supplied from
Hyundai SeasAll must be used for inspections
and maintenance. Hyundai SeasAll does not
guarantee any damage caused by the use of
imitation parts.
•Engine inspection and maintenance should
be carried out by properly trained and factory
approved service engineers.
•The engine should be inspected if the
electronic engine control unit shuts down the
engine.
•If you don’t use the studs for PTO pulley,
remove them for safety.

INSTALLATION & OPERATION MANUAL
G7 Series
- 5 -
ENGINE BREAK-IN
WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.
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.
•DO NOT operate at any one constant speed
for extended periods of time.
•DO NOT exceed 75% of full throttle during the
first 10 hours except during the engine initial
Break-In Procedure. During the next 10 hours,
occasional operating at full throttle (5 minutes
at a time maximum) is permissible.
•AVOID full throttle accelerations from neutral
position.
DO NOT operate at all full throttle until engine
reaches normal operating temperature. (40℃)
•FREQUENTLY CHECK engine oil level and
add oil if necessary.
USING AND ASSEMBLING GENUINE PARTS
•Installation must be done and repairs must be
performed using the special tools and
procedures specified by Hyundai SeasAll.
•The limited warranty does not apply to any
damage to our products caused by the
installation or use of parts and accessories
which are not manufactured or sold by us.
•Check for compliance with torque tightening
requirements. (Contact your Hyundai SeasAll
dealer or refer to the manual)
•Any gaskets, O-rings, seals or other sealing
parts should be replaced with new parts during
repairs.

INSTALLATION & OPERATION MANUAL
G7 Series
- 6 -
APPROXIMATE STANDARD CONVERSIONS
SYMBOL MULTIPLY
BY SYMBOL SYMBOL MULTIPLY BY SYMBOL
LENGTH
mm 0.039 inch
LENGTH
inch 25.4 mm
cm 0.4 inch inch 2.54 cm
m3.28 ft ft 0.3048 m
AREA mm20.0016 in2AREA in2645.2 mm2
m210.764 ft2ft20.093 m2
VOLUME
cm30.061 in³
VOLUME
in³ 16.388 cm3
mL 0.06 in3in316 mL
Ldm361.023 in³ in³ 0.016 Ldm3
Ldm30.22 imp.gallon imp.gallon 4.545 Ldm3
Ldm30.264 U.S.gallon U.S.gallon 3.785 Ldm3
m30.76 yd3yd31.3 m3
m335.315 ft³ ft³ 0.028 m3
FORCE kgf 2.204 lbf FORCE lbf 0.453 kgf
N0.224 lbf lbf 4.448 N
TEMP. oF=9/5x℃+32 TEMP. oC=5/9x(℉-32)
PRESSURE
Bar 14.5 psi
PRESSURE
psi 0.068 Bar
MPa 145 psi psi 0.0068 MPa
Pa 0.102 mmWc mmWc 9.807 Pa
Pa 0.004 inWc inWc 249.098 Pa
KPa 4inWc inWc 0.249 KPa
mWg 39.37 inWc inWc 0.025 mWg
TORQUE Nm 0.738 lbf ft TORQUE lbf ft 1.356 Nm
WEIGHT kg 2.205 lb WEIGHT lb 0.454 kg
kg 35.273 oz oz 0.028 kg
WORK
kJ/kWh 0.43 BTU/lb
WORK
BTU/lb 2.326 kJ/kWh
MJ/kg 430 BTU/lb BTU/lb 0.0023 MJ/kg
kJ/kg 0.24 Kcal/kg Kcal/kg 4.184 kJ/kg
ENERGY kJ/kg 0.697 BTU/hph ENERGY BTU/hph 1.435 kJ/kg
FUEL
CONSUMP.
g/kWh 0.736 g/hph FUEL
CONSUMP.
g/hph 1.36 g/kWh
g/kWh 0.0016 lb/hph lb/hph 616.78 g/kWh
FLOW RATE
(GAS) m3/h 0.588 ft³/min FLOW RATE
(GAS) ft³/min 1.699 m3/h
FLOW RATE
(LIQUID) m3/h 4.403 US gal/min FLOW RATE
(LIQUID) US gal/min 0.2271 m3/h
SPEED
m/s 3.281 ft/s
SPEED
ft/s 0.3048 m/s
kph 0.539 knots knots 1.852 kph
mph 0.869 knots knots 1.1508 mph
kph 0.62 mph mph 1.61 kph

INSTALLATION & OPERATION MANUAL
G7 Series
- 7 -
CHAPTER 1
ENGINE OVERVIEW
ENGINE COMPONENTS
①
②
⑧
③
⑨
④
⑩
⑤
⑪
⑥
FUEL FILTER TURBOCHARGER
JUNCTION BOX (Switch Attached) ECU
SEAWATER PUMP (Inlet) EXPANSION TANK
INTERCOOLER FUEL PUMP
OIL EXTRACTION PUMP OIL FILLER CAP
ENGINE MOUNTING BRACKETS AIR HEATER
AIR FILTER COOLANT FILLER CAP
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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
- 8 -
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INSTALLATION & OPERATION MANUAL
G7 Series
- 9 -
TECHNICAL DATA
Engine type
G300 G300A G350
4-stroke, 4-valve per cylinder
After cooled, direct injection, water cooling
Output PS (kW) 300 (221) 350 (257)
rpm at full load 2,500 2,800
Cylinders I-6
Ignition sequence 1-5-3-6-2-4
Displacement [cm3]6,798
Bore [mm] 107
Stroke [mm] 126
Compression ratio 17.5 : 1
Max. torque [kgm]
@ speed [rpm]
120.3
1,600
Injection system Common rail direct injection (Solenoid injector)
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm]
2.6 2.5
2,500 2,800
Coolant quantity (liter) 25.7
Coolant cap opening pressure (bar) 0.7
Engine oil (liter) 23.5
Engine oil pressure (bar) 2.1(650rpm), 5.3(2500rpm), 5.4(2800rpm)
Exhaust gas pressure (kPa) 10.0 (2500rpm), 10.5 (2800rpm)
Alternator [A] 90
Engine diagnosis yes
Weight (kg) 686
Battery capacity (AH) 24V, 100AH
Idle rpm warmed up (rev/min) 650
Thermostat opening temp. (℃)82 (starting to open), 95 (fully open)
Permissible eng. oil temp (℃)135
Permissible eng. coolant temp (℃)105
Fuel Efficiency(L/h) 69.2 77.6

INSTALLATION & OPERATION MANUAL
G7 Series
-10 -
PERFORMANCE CURVES

INSTALLATION & OPERATION MANUAL
G7 Series
ENGINE IDENTIFICATION
•SERIAL NUMBER ON THE ENGINE BLOCK
Engine identification is affixed to the engine block and the JUNCTION box (See figure).
-11 -
FORMAT : D6GBXXXXXXXX
ENGINE FRONT
•ENGINE NAME PLATE
Engine Family D6GB
Engine Type G300 / G300A
Engine Serial No. XXXXXXXX
Rated Power @ Speed 300 PS @ 2500 rpm
No. Of Cylinder 6
Bore(mm) X Stroke (mm) 107 X 126
Manufacture Date. MM/YYYY
Engine Family D6GB
Engine Type G350
Engine Serial No. XXXXXXXX
Rated Power @ Speed 350 PS @ 2800 rpm
No. Of Cylinder 6
Bore(mm) X Stroke (mm) 107 X 126
Manufacture Date. MM/YYYY

INSTALLATION & OPERATION MANUAL
G7 Series
-12 -
•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.
•Keep the engine horizontal when you install or remove the engine from the engine room
by using correct installation tools or adjusting the length of lifting belts or chains.
•Use strong enough lifting belts or chains to carry the engine weight safely.
ENGINE HANGER

INSTALLATION & OPERATION MANUAL
G7 Series
-13 -
ENGIEN DIMENSIONS
SIDE VIEW
FRONT VIEW
T/M ASSEMBLY BOLT PATTERN
•BELL-HOUSING :SAE 2
•FLYWHEEL :SAE 11-1/2
MODEL : G7
AN ALTERNATOR
DP DRIVE PULLEY
IP IDLER PULLEY
TP TENSIONER PULLEY
WP WATER PUMP PULLEY
AN
DP
IP WP
TP
TOP VIEW
BELT INSTALLATION

INSTALLATION & OPERATION MANUAL
G7 Series
-14 -
CHAPTER 2
ENGINE OPERATION
STARTING ENGINE
WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.
•Before starting the engine, you should
check engine oil, coolant, gearbox oil, fuel
gauge, seawater pump, battery, water
valves and so on.
•When you start the engine, check that the
engine throttle lever ①is in the neutral
position. If not, the engine may not start or
there is possibility of the boat moving
inadvertently. If your boat is equipped with a
neutral safety switch, the engine will only
crank when the engine throttle lever is in the
neutral position. You can also check this on
the EOI.
•After starting the engine, release the key ②
immediately to prevent damage to the starter
motor.
•Avoid maximum rpm and WOT (Wide Open
Throttle) before the cold engine is fully
warmed up.(40℃).
•When cold starting, it may take a few more
seconds to start the engine.
•If the engine does not start in 10 seconds,
Turn off the key and wait After 10 seconds
try again. This method can help avoid starter
motor damage.
STOPPING ENGINE
•The engine should be run for a few minutes
at idle ( in neutral ) before turning it off. This
will avoid boiling and even out the
temperature. This is especially important if
the engine has been operated at high
engine speeds and loads.
•Never switch off the main switches while the
engine is running. This could damage some
parts like alternator.
•The engine room requires a constant supply
of fresh air.
•Be sure that adequate ventilation systems
are installed.

INSTALLATION & OPERATION MANUAL
G7 Series
EMERGENCY STOP
INTAKE AIR HEATER
-15 -
•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.)
•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.
•You can use this switch to avoid unexpected
engine starting during maintenance.
•You can use this switch in any emergency
situation.
•When turning the start switch ON, the coolant
temperature sensor senses the engine coolant
temperature and the control unit (ECU) controls
the preheating time in accordance with the
sensed coolant temperature.
(Work at temperature fell to below zero)
•When the engine is started, the control unit (ECU)
operates the air heater for a certain time. This
preheats the engine and helps to reduce white
smoke at start-up. (Work at temperature fell to
below zero)
•If the indicator lamp blinks regardless of
condition, check the related circuit for a blown
fuse, fused relay etc. since this indicates a
problem in the preheating heater system.
Emergency Stop Switch
Air Heater

INSTALLATION & OPERATION MANUAL
G7 Series
THERMO STAT
EXHAUST MANIFOLD OIL COOLER
CHAPTER 3
COOLING SYSTEM
INTAKE MANIFOLD
Pc
COOLANT
PUMP
HEAT EXCHANGER
INTERCOOLER
TURBOCHARGER
AIRFILTER
SEA WATER
PUMP
SEAWATER
EXPANSION TANK
AIR
Ps
SCHEMATIC DIAGRAM OF ENGINE COOLING
Discharge
WET EXHAUST PIPE
SEAWATER
INTAKE AIR
EXHAUST GAS
COOLANT
-16 -
DRY EXHAUST PIPE
Dry exhaust pipe type
BLOCK → HEAD
Opened
Wet exhaust pipe type
Dry exhaust pipe type
Closed
CABIN HEATER

INSTALLATION & OPERATION MANUAL
G7 Series
-17 -
WATER PICKUP
•Water pickup should be installed in an area
where it won’t pick up air bubbles and will access
clean water during all phases of the engine
operation.
•After start up, you must check for air bubbles by inspecting the waterline. Bubbles will appear
if there is a leakage from the waterline. If bubbles appear, leakage area must be detected and
completely sealed prior to engine operation.
•The seawater pickup inner diameter, as well as all other connecting fittings (hoses, connectors,
water valve etc.) must be at least the size of the inner diameter of the inlet of the seawater
pump. If not, it may inhibit the supply of sufficient water and cause the engine to overheat.
Water strainer ← Water valve ← Water pickup
↓
Seawater pump
↓
Intercooler
↓
Heat exchanger
↓
Exhaust pipe
↓
Discharge Seawater
SEAWATER FLOW –opened circuit

INSTALLATION & OPERATION MANUAL
G7 Series
-18 -
CLEANING STRAINER FILTER
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).
•Strainer must be installed after water inlet valve in
order to allow user to shut off seawater when
cleaning strainer filter.
CAUTION
IF THE SEAWATER STRAINER IS NOT PROPERLY ASSEMBLED, AIR
CAN BE SUCKED INTO THE COOLING CIRCUIT, DISTURBING THE
VACUUM PROCESS. THIS CAN CAUSE THE ENGINE TO OVERHEAT.
•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.
•Check the cap and the gasket for correct
seating and sealing.
•Open the water valve.
•Start the engine and check if there is water
leakage.

INSTALLATION & OPERATION MANUAL
G7 Series
-19 -
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
must be made of steel wire reinforced material.
• The seawater pump impeller must be checked periodically and replaced if necessary.
CAUTION
IF THE WATERPUMP IS NOT PROPERLY ASSEMBLED, AIR CAN BE
SUCKED INTO THE COOLING CIRCUIT, DISTURBING THE VACUUM
PROCESS. THIS CAN CAUSE THE ENGINE TO OVERHEAT.
CAUTION
DO NOT RUN THE ENGINE WITHOUT SEAWATER. THE SEAWATER PUMP
IMPELLER WILL BE DAMAGED. BEFORE STARTING THE ENGINE, BE
SURE TO SUPPLY SEAWATER TO THE PASSAGES.
CAUTION
DO NOT INSTALL ADDITIONAL DEVICES WHICH COULD OBSTRUCT THE
FLOW OF SEAWATER. THIS CAN CAUSE THE ENGINE TO OVERHEAT.