Hyundai Seasall S250 User manual

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-1-
TABLEOFCONTENTS
PAGENUMBER
ABOUT THISMANUAL ..... .
CHAPTER1 ENGINEOVERVIEW
1. ENGINECOMPONENTS
2. ENGINESUSPENSIONEYES ..
3. ENGINEIDENTIFICATION .
4. SCHEMATICDIAGRAMOF COMMONRAILDIESELENGINE ..
5. TECHNICALDATA ...
6. PERFORMANCECURVE
7. ENGINEDIMENSIONS ...
CHAPTER2 ENGINEMOUNT SYSTEM. ..
1. ENGINEMOUNTINGREQUIREMENTS .
2. MOUNT DIMENSIONS
3. ENGINEMOUNT TOOLFORSTERNDRIVEMODEL ..
CHAPTER3 COOLING&EXHAUSTSYSTEM .
1. SCHEMATICDIAGRAMOF ENGINECOOLING CIRCUIT .. ...
2. THEFLOWOF SEAWATER ..
2.1WATERPICKUP ..
2.2SEAWATERSTRAINER .
2.3SEAWATERPUMP ..
3. THEFLOWOF ENGINECOOLANT .. ...
3.1ENGINECOOLANT ..
3.2REMOVING AIRBUBBLE ...
3.3CABINHEATERCONNECTION
4. EXHAUST SYSTEM .....
CHAPTER4 FUELSYSTEM ..
1. THEFLOWOF FUEL .. .
2. LOWPRESSUREFUELLINE ....
3. ACCELERATIONSENSORANDCONTROLLEVER .
4. RECOMMENDEDFUELQUALITY ....
5. DRAININGWATERFROMFUELFILTER
CHAPTER5 AIRINTAKE SYSTEM ..
1. ENGINEROOMVENTILATION ..
2. AIRFILTERMAINTENANCE ..
CHAPTER6 LUBRICATIONSYSTEM
1. THEFLOWOF ENGINEOIL
2. ENGINEOILLEVELCHECKS .
3. RECOMMENDEDOILQUALITY .....
4. ENGINEOILEXTACTIONPUMP .. .
5.OILFILTERREPLACEMENT ..
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INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
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TABLEOFCONTENTS
PAGENUMBER
CHAPTER7 ELECTRICALSYSTEM .
1. BATTERYCABLECONNECTIONS ... .
2. BATTERYCHECKS .. .
3. FUSE ANDRELAY ... ..
CHAPTER8 INSTRUMENT SYSTEM ... ........
1.INSTRUMENTSCONNECTION ..
2. CUT-OUT FORGAUGE ... .
3. CUT-OUT FOREOI SYSTEM ..
CHAPTER9 EOISYSTEM .. .
1.OVERVIEWOF EOI SYSTEM ..
1.1INFORMATIONLCDITEM ... ..
1.2SWITCHES ...... .
1.3ALARMLAMPS .. ..
2. EOI CONNECTIONS ...... .
3. EOI PINASSIGNMENT .. ...... .
4. NEUTRALSWITCH ANDDUALEOICONNECTION .. .
5. ALARMANDDTC(DIAGNOSISTROUBLECODE) ......
5.1ALARMANDDTC(DIAGNOSISTROUBLECODE) ..
5.2DTC(DIAGNOSISTROUBLECODE) LIST .. ..
CHAPTER10ANTI CORROSIONSYSTEM ...
CHAPTER11 ENGINEOPERATION .. ..
1. ENGINEON/OFF ..
2. EMERGENCYSTOP .. ..
3.WINTEROPERATIONANDSTORAGE ...
CHAPTER12 ENGINESTORAGE ..
CHAPTER13 MAINTENANCE ..
1. MAINCHECKLIST ..
2. MAINTENANCESCHEDULE .. ..
3. MAINTENANCELOG ..
CHAPTER14 TROUBLESHOOTINGGUIDE .....
CHAPTER15 WARRANTY ..
WARRANTYREGISTRATIONCARD .
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INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-3-
ABOUTTHISMANUAL
Thisengine installationand operation manual isprovidedasguidanceforthe installationof
HyundaiSeasAllenginetoaboat, and todescribeengineoperation.Itspurposeistoprovide
technicalinformation toaid in performing an effectiveengineinstallationsoastoachieveboth
maximumperformanceandservicelife.Forinformation on installation, operationandmaintenance
ofthe ZFMarine Transmissionsand SterndriveBravoModels,pleasesee the separatebooklets
included inthe originalpackagingof yourHyundaiSeasAllpurchase.
HyundaiSeasAlliscommitted tomaking clearand accurateinformationavailableforthosewho
maintain,ownand repairthe S250&S220 Seriesengines.HyundaiSeasAllvaluesyourinput
regarding revisionsandadditionalinformation forourmanuals.
!
!WARNING
DEVIATION FROMINSTALLATIONINSTRUCTIONSAND OPERATION
GUIDELINES MAYLEADTOPERSONALINJURYOR DEATHTO
OPERATORSAND NEARBYPERSONNEL.
WARNING
DEVIATION FROMINSTALLATIONINSTRUCTIONSAND OPERATION
GUIDELINES MAYLEADTOPERSONALINJURYOR DEATHTO
OPERATORSAND NEARBYPERSONNEL.
!
!CAUTION
DEVIATION FROMINSTALLATIONINSTRUCTIONSAND OPERATION
GUIDELINES MAYLEADTOIMPROPEROPERATION,DAMAGEOR
DESTRUCTION OFTHEENGINE.
CAUTION
DEVIATION FROMINSTALLATIONINSTRUCTIONSAND OPERATION
GUIDELINES MAYLEADTOIMPROPEROPERATION,DAMAGEOR
DESTRUCTION OFTHEENGINE.
§The manufacturerisnotliableforanydamagesorlossescaused byfaultyinstallation,wrong
handlingofthe equipment and/ordeficientmaintenance.
§The operatorisresponsibleforthe correctandsafeoperation ofthe engine andsafetyofits
occupantsand generalpublic.
§Itisstronglyrecommended thateachoperatorread andunderstand thismanualbefore
installingand operating the engine.
§Thismanualaswellassafetylabelsposted onthe engine usethe following safetyalertsto
drawyourattention tospecialsafetyinstructionsthat shouldbe followed.

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-4-
CHAPTER1
ENGINEOVERVIEW
1.ENGINECOMPONENTS
1.ECU Box
2.Coolant Expansion Tank
3.Engine Oil Cap
4.Engine Oil Filter
5.E-VGT&Cooler
6.AirFilter
7.Engine Oil Gauge
8.AccelerationLeverSensor
9.SeawaterPump
10.Intercooler
11.Heat Exchanger
12.Alternator
1.Turbo Heat Protector
2.Exhaust Elbow
3.Bell Housing (SterndriveModel)
4.Drive Coupler(SterndriveModel)
5.Engine Oil Exchange Button
6.Engine EmergencyStop Button
7.P/STRG Oil ReservoirTank(SterndriveModel)
8.Shift Plate (SterndriveModel)
9.Main Fuel FilterwithWaterDetection Sensor
10.T/MOil CoolerorP/STRGOil Cooler
11.Cabin HeaterConnector
12.BPS &IATS

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-5-
2.ENGINESUSPENSIONEYES
1)Tolift the engine,firstremovethe engine cover.You willfindthreeengineeyes(see
figure).
2)Toavoid engine damage,takecarethatengine liftchainsorbeltsdo nothitortouch
surroundingpartsduringengine lifting.

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-6-
3.ENGINEIDENTIFICATION
§SERIAL NUMBERONTHEENGINEBLOCK
§NAME PLATEONTHEECUBOX
Engine identificationisaffixed tothe engineblock and the ECUbox(see figure).

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-7-
4. SCHEMATICDIAGRAMOF COMMONRAIL DIESEL ENGINE
ECU
Fuelfeed (low)
Fuelfeed (high)
Fuelreturn
Fuel temperature sensor
Boostpressure& air temp.sensor
Glow Plug
Coolant temperature sensor
Camposition sensor
Crankshaft position sensor
EVGT actuator
Railpressure sensor
Water sensor infuel
Feed
pump
Injector
Intercooler
Common rail
High pressure pump
Mainfuel filter
Air filter
VGT
Pump pressure regulator valve
Acc. position sensor
Air temp. sensor
Sensor
Actuator
Rail pressure regulator valve
Fueltank
return feed
return
return
return

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-8-
5.TECHNICAL DATA
Engine type
S250 / 220S S250 / 220P S250J
4-stroke, 4-valve
After-cooled, direct-injection,watercooling
Output ps(kW) 250ps(184)/ 220ps(162)
rpmat full load 3800/3200
Cylinders V-6
Ignition sequence 1-2-3-4-5-6
Displacement [cm3]2959
Bore[mm] 84
Stroke[mm] 89
Compression ratio 17.5: 1
Max. torque [kgm]
@ speed [rpm] 50 48
2500 3500
Injection system Common rail direct injection (Piezoinjector)
Diesel fuel at least CN 51 asperDINEN590
Intakeairpressure(abs. bar)
@ speed [rpm] 2.5 2.5 2.5
3800/3200 3800/3200 3800
Coolant quantity(liter) 11.5
Coolant cap opening pressure(bar) 1.1
Engine oil(liter) 7.2
Engine oil pressure(bar) 2~3at 1750rpm, 100 (oil temp.)
Exhaust gaspressure(kPa) Max. 50
Alternator[A] 150
Engine diagnosis Yes
Weight(kg) 334
Batterycapacity(AH) 12V, 200AHrecommended
Thermostat opening temp.( )82 (starting to open),92 (fullyopen)
Idle rpm(rpm) 680 at engine warming up
Permissible eng. oil temp( )137
Permissible eng. coolant temp( )105
Propulsion system Sterndrive Shaftdrive Waterjet

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-9-
6. PERFORMANCECURVE
§S250S&S250PMODEL
*BSFC:BrakeSpecificFuelConsumption *FC:Fuel Consumption

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-10-
§S250JMODEL
*BSFC:BrakeSpecificFuelConsumption *FC:Fuel Consumption

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-11-
§S220S&S220PMODEL
*BSFC:BrakeSpecificFuelConsumption *FC:Fuel Consumption

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-12-
7.ENGINEDIMENSIONS
§MerCruiserBravo OneXDiesel
§MerCruiserBravoTwo XDiesel
Front view Side view
Front view Side view

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
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§MerCruiserBravoThree XDiesel
§ZF63 A
Front view Side view
Front view Side view

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-14-
§ZF63 C
Front view Side view
Front view Side view
§Waterjetadapter withoutZF45C /ZF 63C

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-15-
CHAPTER2
ENGINEMOUNTSYSTEM
§The mountmust be strong enough tocarrythe loadsapplied bythe weightand powerofthe
engine.It alsomustbe stiff enough thatthe enginedoesnotsag ormovetoo muchwhen
powerisapplied.
§The mountmustposition the engine atthe correctheightand anglesothatthe engine’s
thrustline suitsthe boat.
2.ENGINEMOUNTDIMENSIONS
1. ENGINEMOUNTINGREQUIRMENTS
!
!CAUTION
USE ONLY THEORIGINALHYUNDAISEASALL MOUNTINGSTHATWERE
SUPPLIEDWITHTHEINITIALPURCHASE.
AFTERINSTALLATIONAND ALIGNMENTOFTHEENGINE,MAKESURE
THATNO RESIDUAL TENSION EXISTSINTHEDRIVETRAIN.
CAUTION
USE ONLY THEORIGINALHYUNDAISEASALL MOUNTINGSTHATWERE
SUPPLIEDWITHTHEINITIALPURCHASE.
AFTERINSTALLATIONAND ALIGNMENTOFTHEENGINE,MAKESURE
THATNO RESIDUAL TENSION EXISTSINTHEDRIVETRAIN.

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-16-
3. ENGINEMOUNTTOOLFORSTERNDRIVEMODEL
!
!CAUTION
FOR INFORMATIONONINSTALLATIONOFTHESTERNDRIVE BRAVO
MODELS,PLEASE SEE THESEPARATEBOOKLETSINCLUDEDINTHE
ORIGINALPACKAGINGOFYOUR HYUNDAISEASALLPURCHASE.IFIN
DOUBTABOUTENGINEINSTALLATION,PLEASECONTACTYOUR
NEARESTHYUNDAISEASALL DEALER.
CAUTION
FOR INFORMATIONONINSTALLATIONOFTHESTERNDRIVE BRAVO
MODELS,PLEASE SEE THESEPARATEBOOKLETSINCLUDEDINTHE
ORIGINALPACKAGINGOFYOUR HYUNDAISEASALLPURCHASE.IFIN
DOUBTABOUTENGINEINSTALLATION,PLEASECONTACTYOUR
NEARESTHYUNDAISEASALL DEALER.
Mount hole forS250 andS220model
Mount hole forD170 andD150 model

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-17-
CHAPTER3
COOLING &EXHAUST SYSTEM
1.SCHEMATICDIAGRAMOF ENGINECOOLING CIRCUIT
IN-MANIFOLD
Pc
COOLANT
PUMP
HEATEXCHANGER
INTERCOOLER
OILCOOLER
TURBOCHARGER
AIR FILTER
PsSEA WATER
PUMP
THERMOSTAT
EXHAUSTELBOW
EX-MANIFOLD
EX-MANIFOLD
OIL
SEAWATER
INTAKE AIR
EXHAUSTAIR
COOLANT( THERMOSTATCLOSED &OPENED )
COOLANT(THERMOSTATOPENED)
CABINHEATER
CONNECTOR
SEAWATER
EXPANSION TANK
AIR
E-VGTCOOLER

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
-18-
Waterstrainer ←Watervalve ←Waterpickup
↓
①Seawaterpump
↓
②Intercooler
↓
③Heat exchange ⑤EVGTcooler
↓
④Oil cooler
↓
⑥Exhaust elbow
↓
Seawater
2.THEFLOW OFSEAWATER OPENCOOLING CIRCUIT
EVGT cooler
2.1WATERPICKUP
1)Waterpickupshould beinstalledin anareawhereitwon’tpickupairbubblesand will
access freshwaterduring the durationof engineoperation.
2)Foruseinsterndrivemodels,pleaseseethe section “InstallingSterndriveSeawater
Pickup”ofthe BRAVOMODELSINSTALLATIONMANUAL,includedinthe original
packaging.
3)Forfurthersafety, you can useanadditionaltransomorbottomtype waterpickup.
!
!CAUTION
IFASSEMBLY ISNOTCONDUCTEDPROPERLY,AIRCANBESUCKED
IN,DISTURBING THEVACUUMPROCESS.THISCANCAUSE THE
ENGINETOOVERHEAT.
CAUTION
IFASSEMBLY ISNOTCONDUCTEDPROPERLY,AIRCANBESUCKED
IN,DISTURBING THEVACUUMPROCESS.THISCANCAUSE THE
ENGINETOOVERHEAT.
2.2WATERSTRAINER
1)Strainershouldbe located in an area whereit
willbeeasilyaccessible forperiodicseawater
flowinspection andcleaning.
2)The sizeofstrainermustbe ofsufficientcapacity
topass theseawater(aflowrateover200 liters
perminuteflowrate).
3)Strainermustbe installed afterwaterinletvalve
in ordertoallowusertoshutoff seawaterwhen
cleaning strainerfilter.

INSTALLATION &OPERATION MANUAL
S250 and S220 SeriesEngines
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•Stop the engineand closethe watervalve
•Removethe filtercap
•Removethe filterelement, flushitthoroughlywithclean waterorcompressedair
•Insertthe cleaned filterelementand screwthe filtercap
•Check the cap and the gasketforcorrect seating and sealing
•Open the watervalve
•Start the engine andcheck ifthereiswaterleakage
!
!CAUTION
IFASSEMBLY ISNOTCONDUCTEDPROPERLY,AIRCANBESUCKEDIN,
DISTURBING THEVACUUMPROCESS.THISCANCAUSE THEENGINE
TOOVERHEAT.
CAUTION
IFASSEMBLY ISNOTCONDUCTEDPROPERLY,AIRCANBESUCKEDIN,
DISTURBING THEVACUUMPROCESS.THISCANCAUSE THEENGINE
TOOVERHEAT.
4)Toclean strainerfilter,
2.3SEAWATERPUMP
1)The internaldiameterofhoseconnected toseawaterpumpinlet shouldbe 45~46mm.
2)The cross section ofhosemayshrinkduetoinletpressuredrop.Therefore,the hosefrom
waterpickupinthe boat’shulltoseawaterpumpinletshould beasshortaspossibleand
must be made of steel wirereinforced material.
3)The seawaterpumpimpellermustbechecked periodicallyand replacedif necessary.
4)Tocheck seawaterpumpand impeller:
•Stop the engineand closethe watervalve
•Removethe impellerhousing cover
•Removethe impellerfrominside the seawaterpump
•Check the condition of impellerand bushing