Hyundai Seasall H380 series User manual

INSTALLATION & OPERATION MANUAL
H380 Series

INSTALLATION & OPERATION MANUAL
H380 Series
-1-
TABLE OF CONTENTS
ABOUT THIS MANUAL ………………………………………………………………….....…
CHAPTER 1 ENGINE OVERVIEW ………………………………………………………………
CHAPTER 2 ENGINE OPERATION.……………………………………………………….
CHAPTER 3 COOLING SYSTEM ………………………………………………………….
CHAPTER 4 FUEL SYSTEM ……………………………………………………………….
CHAPTER 5 INTAKE & EXHAUST SYSTEM …………………………………………….
CHAPTER 6 LUBRICATION SYSTEM ……………………………………………………
CHAPTER 7 ELECTRICAL SYSTEM………………………………………………………
CHAPTER 8 INSTRUMENT SYSTEM ……………………………………………………
CHAPTER 9 ANTI CORROSION SYSTEM……………………………………………....
CHAPTER 10 ENGINE STORAGE…………………………………………………………
CHAPTER 11 MAINTENANCE……………………………………………………………...
CHAPTER 12 TROUBLESHOOTING GUIDE………………………………………..……
CHAPTER 13 WARRANTY………………………………………………………………….
2
5
12
15
22
26
29
33
38
50
51
52
55
57

INSTALLATION & OPERATION MANUAL
H380 Series
-2-
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.
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.
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.
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.

INSTALLATION & OPERATION MANUAL
H380 Series
-3-
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
H380 Series
-4-
ENGINE BREAK-IN
!
!WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.
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.
• FREQUENTLY CHECK engine oil level and
add oil if necessary.

INSTALLATION & OPERATION MANUAL
H380 Series
-5-
CHAPTER 1
ENGINE OVERVIEW
ENGINE COMPONENTS
①FUEL FILTER ⑦ENGINE MOUNTING BRACKETS
②SWITCH BOX ⑧OIL FILTER
③SEAWATER PUMP ⑨WATER PUMP
④AIR INTAKE MANIFOLD ⑩EXPANSION TANK
⑤WATER SEPARATOR ⑪C.C.P.C.V.
⑥OIL EXTRACTION PUMP ECU

INSTALLATION & OPERATION MANUAL
H380 Series
①INTERCOOLER ⑧COOLANT PIPE (HEAT EXCHANGER OUTLET)
②DRY EXHAUST PIPE ⑨JUNCTION BOX
③TURBO-CHARGER OUTLET PIPE ⑩ENGINE MOUNTING BRACKET
④LIFTING EYES ⑪HEAT EXCHANGER
⑤AIR FILTER ⑫EXHAUST MANIFOLD
⑥AIR FILTER PIPE ⑬COOLANT PIPE (HEAT EXCHANGER INLET)
⑦ALTERNATOR
-6-

INSTALLATION & OPERATION MANUAL
H380 Series
-7-
TECHNICAL DATA
Engine type
H380
4-stroke, 4-valve
After-cooled, EUI, Turbocharger
Output ps (kW) 380ps (280)
rpm at full load 1800
Cylinders I-6
Ignition sequence 1-5-3-6-2-4
Displacement [cm3]9,960
Bore [mm] 122
Stroke [mm] 142
Compression ratio 16.0 : 1
Max. torque [kgm]
@ speed [rpm]
170
1100
Injection system EUI
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm]
2.5
1800
Coolant quantity (liter) 43
Coolant cap opening pressure (bar) 0.7
Engine oil (liter) 32
Engine oil pressure (bar) 2~3 (1750rpm,) 100 ℃(oil temp.)
Exhaust gas pressure (kPa) Max. 50
Alternator [A] 70A
Engine diagnosis Yes
Weight (kg) 1120
Battery capacity (AH) 24V, 100AH
Idle rpm warmed up (rev/min) 600
Permissible eng. oil temp (℃)135
Permissible eng. coolant temp (℃)105
Propulsion system Shaftdrive

INSTALLATION & OPERATION MANUAL
H380 Series
-8-
•H380
PERFORMANCE CURVES

INSTALLATION & OPERATION MANUAL
H380 Series
ENGINE IDENTIFICATION
•SERIAL NUMBER ON THE ENGINE BLOCK
Engine identification is affixed to the engine block and the JUNCTION box (See figure).
•ENGINE NAME PLATE
FORMAT : D6HAXXXXXX
-9-

INSTALLATION & OPERATION MANUAL
H380 Series
-10-
• To lift the engine, use the three 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.
• Use strong enough lift chains or belts to
carry the engine weight safely.
ENGINE SUSPENSION EYES

INSTALLATION & OPERATION MANUAL
H380 Series
-11-
ENGIEN DIMENSIONS
•H380

INSTALLATION & OPERATION MANUAL
H380 Series
-12-
CHAPTER 2
ENGINE OPERATION
STARTING ENGINE
!
!WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.
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, seacocks
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.
•When cold starting, it may take a few more
seconds to start the engine.
•If the engine does not start in 10 seconds,
release the key and wait 10 seconds. 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.

INSTALLATION & OPERATION MANUAL
H380 Series
EMERGENCY STOP
INTAKE AIR HEATER
Emergency Stop Switch
• 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.
• When the coolant temperature is less than 0°C,
the indicator icon on the LCD tells the driver that
the engine is preheating. The engine is ready to
start when the indicator lamp goes off.
• If the engine is started, the control unit (ECU)
operates the heater for a certain time again and
helps to reduce the white smoke to reduce and
the engine to preheat.
• If the indicator lamp blinks regardless of
condition, check the related circuit for a blown
fuse, melted relay etc. since this indicates a
problem in the preheating heater system.
Air Heater
-13-

INSTALLATION & OPERATION MANUAL
H380 Series
• When using or storing your engine under 0°C,
protect all parts exposed to seawater
(seawater pump, intercooler, heat exchanger,
cooling lines, seawater strainer, valves and
hoses) from freezing.
• The battery capacity decreases as the
temperature drops. We recommend recharging
the battery frequently. Check and clean all
battery cable connections, as oxidized
connections lead to voltage drops and starting
difficulties.
• If water happens to freeze in engine, be sure
to examine the engine for broken parts,
exchange broken parts if necessary and thaw
any frozen water before operating the engine.
WINTER OPERATION AND STORAGE
-14-

INSTALLATION & OPERATION MANUAL
H380 Series
-15-
CHAPTER 3
COOLING SYSTEM
INTAKE MANIFOLD
Pc
COOLANT PUMP
HEAT EXCHANGER
INTERCOOLER
TURBOCHARGER
AIRFILTER
SEA WATER PUMP
THERMOSTAT
HOUSING
HEATER
CONNECTOR
SEAWATER
EXPANSION TANK
AIR
Ps
SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT
EXHAUST MANIFOLD
AIR
EXHAUST PIPE
SEAWATER
INTAKE AIR
EXHAUST AIR
COOLANT

INSTALLATION & OPERATION MANUAL
H380 Series
-16-
Water strainer ←Water valve ←Water pickup
↓
Seawater pump
↓
Intercooler
↓
Heat exchanger
↓
Seawater
SEAWATER FLOW – OPEN COOLING CIRCUIT
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.
!
!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.
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.
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.

INSTALLATION & OPERATION MANUAL
H380 Series
-17-
• 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.
!
!
CLEAN STRAINER FILTER
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
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
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.

INSTALLATION & OPERATION MANUAL
H380 Series
-18-
!
!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 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
IMPELLER DAMAGE MAY OCCUR IF APPROPRIATE TOOLS ARE NOT
USED WHEN REMOVING THE IMPELLER. MAKE SURE TO CHECK O-
RING CONDITION AFTER SEAWATER PUMP REASSEMBLY.
CAUTION
IMPELLER DAMAGE MAY OCCUR IF APPROPRIATE TOOLS ARE NOT
USED WHEN REMOVING THE IMPELLER. MAKE SURE TO CHECK O-
RING CONDITION AFTER SEAWATER PUMP REASSEMBLY.
!
!
CAUTION
DO NOT INSTALL ADDITIONAL DEVICES WHICH COULD OBSTRUCT
THE FLOW OF SEAWATER. THIS CAN CAUSE THE ENGINE TO
OVERHEAT.
CAUTION
DO NOT INSTALL ADDITIONAL DEVICES WHICH COULD OBSTRUCT
THE FLOW OF SEAWATER. THIS CAN CAUSE THE ENGINE TO
OVERHEAT.
!
!
• 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.
• 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.
CHECKING SEAWATER PUMP & IMPELLER

INSTALLATION & OPERATION MANUAL
H380 Series
-19-
ENGINE COOLANT FLOW ( CLOSED COOLING CIRCUIT)
1. Engine Block Coolant Outlet
↓
2. Exhaust manifold
↓ Turbocharger
3. Thermostat housing
↓
4. Heat exchanger
↓
5. coolant pump
• The high-pressure cooling system has a reservoir filled with year-round antifreeze
coolant. The reservoir is filled at the factory.
• The coolant level should be between MAX and MIN marks on the side of the coolant
reservoir when the engine is cool.
ENGINE COOLANT