Hyundai Seasall Q6AC User manual

INSTALLATION & OPERATION MANUAL
Q-engine Series

INSTALLATION & OPERATION MANUAL
Q-engine Series
-1-
TABLE OF CONTENTS
ABOUT THIS MANUAL ………………………………………………………………..…….....………..
SAFETY PRECAUTIONS ………………………………………………………….……..………………
APPROXIMATE STANDARD CONVERSIONS ……………………………………………..…………
CHAPTER 1 ENGINE OVERVIEW ……………………………………………..…...….…….………
ENGINE COMPONENTS ………………………………………..……….……………
TECHNICAL DATA ………………………………………………..…….……….……..
PERFORMANCE CURVES…………………………………………….………..……..
ENGINE IDENTIFICATION……………………………………..……….………….....
ENGINE HANGER…...…………………………………………….……..……...........
ENGINE DIMENSIONS………………………………………….………..….....……..
CHAPTER 2 ENGINE OPERATION ………………………………………………………….………..
STARTING AND STOPPING ENGINE……………………………..…..……….…….
CHAPTER 3 COOLING SYSTEM …………………………………………………………..….……...
SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..…....................
SEAWATER FLOW –OPEN COOLING CIRCUIT…………………...……….….….
WATER PICKUP……………………………………………………..…….…….….…..
WATER STRAINER…………………………………………………..…….…………….
CLEANING STRAINER FILTER……………………………………..……….……………
SEAWATER PUMP………………………………………………………...…..….……
CHECKING SEAWATER PUMP & IMPELLER………………………………..……..
ENGINE COOLANT FLOW……………………………………………….……….…….
ENGINE COOLANT………………………………………………………..……..…….
SUPPLEMENTAL ENGINE COOLANT………………………………….………..….
DRAINING COOLANT……………………………………………………..…….…….
REMOVING AIR BUBBLES IN COOLANT………………………………...….……..
CHAPTER 4 FUEL SYSTEM ………………………………………………………….………………..
FUEL FLOW……………………………………………………………………..………..
FUEL LINE…………………....………………………………………………..…….……
RECOMMENDED FUEL QUALITY ………………....……………………..……...….
DRAINING WATER FROM FUEL FILTER ……………………………………..…..….
CHANGING FUEL FILTER ……………………………..……………….…….….……..
CHAPTER 5 INTAKE & EXHAUST SYSTEM …………………………………………..….………..
CHECK AIR FILTER ……………………………………..…………..……..….……..
CLEANING AIR FILTER ……………………………………..……………….….……
EXHAUST SYSTEM…………………………………………………..……..……..……
CHAPTER 6 LUBRICATION SYSTEM …………….………………………….………….……..……
LUBRICATION COMPONENTS……………………….…………………..……………
ENGINE OIL LEVEL CHECKS…………………….....……………….………………..
RECOMMENDED OIL QUALITY………………………..……………..…...…..........
ENGINE OIL EXTACTION PUMP…………………………….………….....………….
CHECKING OIL FILTER AND BYPASS .………………………………..………………
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INSTALLATION & OPERATION MANUAL
Q-engine Series
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TABLE OF CONTENTS
CHAPTER 7 ELECTRICAL SYSTEM ………………………………………………..………..………
BATTERY CABLE CONNECTIONS ……………………………….........….………..
ACCELERATION SENSOR AND CONTROL LEVER…………….……….…..……
PROCEDURES FOR CONTROL LEVER INSTALLATION…………………..……
BATTERY CHECKS………..………………………………………...………...........
LOAD TEST…………………………………………………………………….………
CHAPTER 8 EOI SYSTEM …………………………………………..…………………………....…
INSTRUMENT(EOI)…………………………………………………………………..
SWITCHES………………………………………………….…………………………
WARNING LAMP…………..……………………………………………………...….
CHAPTER 9 GENSET (Q150GS, Q176GS, Q210GS)……………………………………………
CHAPTER 10 ANTI CORROSION SYSTEM ………………………………………….……...……..
CHAPTER 11 ENGINE STORAGE …………………………………………………..….….……......
WINTER STORAGE…………………………………………………...………….….
LONG TERM STORAGE…………………………………………………………….
.
CHAPTER 12 MAINTENANCE ………………………………………………………..……....……….
THE INITIAL RUNNING CHECK……………...……………..…………..……..…….
MAINTENANCE SCHEDULE ……………………………………………….…….....
MAINTENANCE LOG…………….………………………………………..…….……..
CHAPTER 13 TROUBLESHOOTING GUIDE ……………………………………………….............
CHAPTER 14 WARRANTY ………………………………………………………………….….…......
WARRANTY REGISTRATION CARD ………………………………….…….……..
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INSTALLATION & OPERATION MANUAL
Q-engine Series
-3-
ABOUT THIS MANUAL
This engine installation and operation manual is provided as guidance for the installation of a
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 L500 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.
•Illustrations in this manual are subject to change without notice.

INSTALLATION & OPERATION MANUAL
Q-engine Series
-4-
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. Contact
your Hyundai SeasAll dealer for touch-up
paint.
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 safe 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 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.

INSTALLATION & OPERATION MANUAL
Q-engine 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.
•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
Q-engine Series
-6-
APPROXIMATE CONVERSIONS FROM STANDARD
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
m 3.28 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
N 0.224 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 4 inWc 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
km/h 0.539 knots knots 1.852 km/h
mph 0.869 knots knots 1.1508 mph
km/h 0.62 mph mph 1.61 km/h

INSTALLATION & OPERATION MANUAL
Q-engine Series
-7-
CHAPTER 1
ENGINE OVERVIEW
ENGINE COMPONENTS
①AIR FILTER ENGINE MOUNTING BRACKETS
②INTERCOOLER EXPANSION TANK
③HEAT EXCHANGER EXHAUST MANIFOLD
④STARTER CCV FILTER
⑤ALTERNATOR EXHAUST ELBOW
⑥TURBOCHARGER BELT

INSTALLATION & OPERATION MANUAL
Q-engine Series
-8-
TECHNICAL DATA
Engine type Q280 Q330 Q385 Q405
Engine Duty Rating Heavy Duty (S1) Heavy Duty (S1) Medium Duty (S2) Medium Duty (S2)
Configuration 4-Stroke, Fresh Water Cooling
Output [PS (kW)] 280 (206) 330 (242) 385 (283) 405 (298)
rpm @ full load 2,000 2,000 2,000 2,000
Cylinders In-line 6
Displacement [cc] 11,149
Bore x Stroke [mm] 130 X 140
Compression Ratio 16.0 : 1 16.5 : 1
Injection System Direct Injectors (DI), Bosch Type
Starting System DC 24V Electric Starting System, 5 kW
Cooling System Heat Exchanger Heat Exchanger & Intercooler
Governor RSV Electronic
Cooling Water Capacity [L] 50 55
Aspiration TC TCI TCI
Thermostat Opening Temp. (℃) 71
Engine Oil (L) 40
Flywheel Housing SAE #1
Fuel Consumption [L/h] 51.3 61.8 76.1 78.7
Dry Weight [kg] 1,050 1,070 1,120 1,120

INSTALLATION & OPERATION MANUAL
Q-engine Series
-9-
PERFORMANCE CURVES
0
50
100
150
200
250
-표준 -표준 -표준 -표준 -표준 -표준 -표준
Q405
Q385
Q330
Q280
0
20
40
60
80
100
-표준 -표준 -표준 -표준 -표준 -표준 -표준
Q405
Q385
Q330
Q280
0
100
200
300
400
500
-표준 -표준 -표준 -표준 -표준 -표준 -표준
Q405
Q385
Q330
Q280
Engine Speed(rpm)
Engine Speed(rpm)
Engine Speed(rpm)
Power (ps)
Torque (kgm)
F.C. (L/h)

INSTALLATION & OPERATION MANUAL
Q-engine Series
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•To lift the engine, use the three lifting hanger (see illustration).
•To avoid engine damage, take care that engine lifting 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 Family
D6AC
Engine Type
Q-XXX
Engine Serial No.
XXXXXXX
Rated Power @ Speed
XXX PS @ 2000 rpm
No. Of Cylinder
6
Bore(mm) X Stroke (mm)
130 X 140
Manufacture Date.
MM/YYYY
ENGINE NAME PLATE
ENGINE HANGER

INSTALLATION & OPERATION MANUAL
Q-engine Series
-11 -
ENGINE DIMENSIONS
Side
Front

INSTALLATION & OPERATION MANUAL
Q-engine Series
-12 -
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 etc.
•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.
•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 the coolant and will 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 such as the alternator.
•The engine room requires a constant supply
of fresh air. Be sure that adequate
ventilation systems are installed.

INSTALLATION & OPERATION MANUAL
Q-engine Series
-13-
CHAPTER 3
COOLING SYSTEM
SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT
INTAKE MANIFOLD
Pc
COOLANT
PUMP
HEAT EXCHANGER
INTERCOOLER
TURBOCHARGER
AIRFILTER
SEA WATER
PUMP
SEAWATER
INTAKE AIR
EXHAUST GAS
COOLANT
SEAWATER
EXPANSION
TANK
AIR
Ps
EXHAUST MANIFOLD
AIR
EXHAUST PIPE

INSTALLATION & OPERATION MANUAL
Q-engine Series
-14 -
Water strainer ← Water valve ← Water pickup
↓
Seawater pump
↓
Intercooler
↓
Heat exchanger
↓
Discharge 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.
•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.
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).
•Strainer must be installed after water inlet valve
in order to allow user to shut off seawater when
cleaning strainer filter.

INSTALLATION & OPERATION MANUAL
Q-engine Series
-15 -
•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.
CLEANING STRAINER FILTER

INSTALLATION & OPERATION MANUAL
Q-engine Series
-16 -
SEAWATER PUMP
•The internal diameter of hose connected to
seawater pump inlet should be 60mm
•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.

INSTALLATION & OPERATION MANUAL
Q-engine Series
-17 -
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
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 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

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Q-engine Series
-18 -
ENGINE COOLANT FLOW(CLOSED CIRCUIT)
•Engine coolant must be maintained at the “MIN” level marked on the side of the
expansion tank when the engine is cold.
•As the engine temperature increases, the pressure inside the cooling system increases
to 0.7 bar or more. To maintain proper pressure of the engine cooling system, water
may be ejected from the expansion tank. This is normal. Replenish the coolant if this is
observed.
ENGINE COOLANT
1. Engine block coolant outlet(L)
2. Heat exchanger
Coolant
pump
4. Engine block coolant outlet(S)
5. Exhaust manifold

INSTALLATION & OPERATION MANUAL
Q-engine Series
-19 -
•If the coolant level is below level ‘Low’, add
enough specified coolant to provide protection
against freezing and corrosion. Coolant level
should be between the MAX and MIN. But do
not exceed level ‘MAX’.
•If frequent additions are required, contact an
authorized dealer for a cooling system
inspection.
•Use only soft (demineralized) water in the
coolant mixture.
•The engine has aluminum engine parts and
must be protected by an ethylene-glycol-based
coolant to prevent corrosion and freezing.
•DO NOT USE alcohol or methanol coolant or
mix them with the specified coolant.
•DO NOT USE a solution that contains more
than 60% antifreeze or less than 35% antifreeze,
which would reduce the effectiveness of the
solution. For mixture percentages, refer to the
table.
•In order to drain engine coolant, please use a
spanner to loosen the drain plug ①.
•The drain plug is located crank pully of right side
pipe at below
DRAINING COOLANT
SUPPLEMENTAL ENGINE COOLANT
Ambient
Temperature
Mixture Percentage(volume)
Antifreeze Water
-15℃(5℉) 35 65
-25℃(-13℉) 40 60
-35℃(-31℉) 50 50
-45℃(-49℉) 60 40
REMOVING AIR BUBBLES IN COOLANT
•Start the engine and warm it up at a low
rpm.
•Stop the engine and allow the engine to
cool, then open the cap of the expansion
tank carefully.
*NOTE: Never open the cap when the
engine is hot. It may cause scalding.
•Refill with coolant if needed.
•Reinstall the expansion tank cap
•Check the level of the expansion tank
regularly.
WARNING
NEVER OPEN THE EXPANSION
TANK CAP WHEN THE ENGINE
IS OPERATING OR HOT. IT
COULD RESULT IN SERIOUS
PERSONAL INJURY AND MAY
CAUSE ENGINE DAMAGE.