Hyundai Seasall S250S User manual

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-1-
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. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE ……..
5. TECHNICAL DATA ……………………………………………...…………
6. PERFORMANCE CURVES ………………………………………………
7. BELT INSTALLATION & ENGINE DIMESIONS.………………………..
CHAPTER 2 ENGINE MOUNT SYSTEM .………………………………………………..
1. ENGINE MOUNTING REQUIREMENTS ……………………………….
2. MOUNT DIMENSIONS ……………………………………………………
3. ENGINE MOUNT TOOL FOR STERNDRIVE MODEL ………………..
CHAPTER 3 COOLING & EXHAUST SYSTEM ………………………………………….
1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..…...
2. SEAWATER FLOW.……………………………………………………..…
2.1 WATER PICKUP ………………………………………………..
2.2 SEAWATER STRAINER ……………………………………….
2.3 SEAWATER PUMP ………………………………………..……
3. ENGINE COOLANT FLOW…………………………………………..…...
3.1 ENGINE COOLANT …………………………………………..…
3.2 REMOVING AIR BUBBLES.…………………………………...
3.3 CABIN HEATER CONNECTION ………………………………
4. EXHAUST SYSTEM …………………………………………………….....
CHAPTER 4 FUEL SYSTEM ………………………………………………………………..
1. FUEL FLOW.….……..…………………………..………………………….
2. LOW PRESSURE FUEL LINE …………………....………………………
3. ACCELERATION SENSOR AND CONTROL LEVER ………………….
4. RECOMMENDED FUEL QUALITY ………………....……………………
5. DRAINING WATER FROM FUEL FILTER ………………………………
CHAPTER 5 AIR INTAKE SYSTEM ………………………………………………………..
1. ENGINE ROOM VENTILATION …………………………………………..
2. AIR FILTER MAINTENANCE …………………………..…………………
CHAPTER 6 LUBRICATION SYSTEM ……………………………………………………
1. ENGINE OIL FLOW…………..……………………………………………
2. ENGINE OIL LEVEL CHECKS ……………………….…………………
3. RECOMMENDED OIL QUALITY …………………….....………………
4. ENGINE OIL EXTACTION PUMP ………………………..…………….
5. OIL FILTER REPLACEMENT …………………………….…………….
3
4
5
6
7
8
9
10
11
12
13
17
17
18
18
19
19
20
20
20
21
23
23
25
25
26
27
28
28
29
30
30
31
31
32
33
33
34
34
35
35

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-2-
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. CUT-OUT FOR GAUGE ……………………...……………………….….
3. CUT-OUT FOR EOI SYSTEM …………………..………………….……
CHAPTER 9 EOI SYSTEM …………………………………………..………………….….
1. OVERVIEW OF EOI SYSTEM ……………………..……………….……
1.1 INFORMATION LCD ……..……………………...……………….…..
1.2 SWITCHES ………………………………………......………….…….
1.3 ALARM LAMPS ………………………………………..……….……..
2. EOI CONNECTIONS ………………………………………......………….
3. EOI PIN ASSIGNMENT …………..…………………………….......…….
4. NEUTRAL SWITCH AND DUAL EOI CONNECTION …………...…….
5. TRIM WIRING CONNECTION DIAGRAM ……………………….…….
6. G-SCAN……………………………………………………………….……..
7. ALARM AND DTC(DIAGNOSIS TROUBLE CODE) …………….......…
7.1 ALARM AND DTC(DIAGNOSIS TROUBLE CODE) ……….……..
7.2 DTC(DIAGNOSIS TROUBLE CODE) LIST………….……………..
CHAPTER 10 ANTI CORROSION SYSTEM ……………………………………………...
CHAPTER 11 ENGINE OPERATION …………………………………………..…………..
1. ENGINE ON/OFF …………………………………………………..………
2. ENGINE BREAK-IN ………………………………………………………..
3. EMERGENCY STOP …………………..…………………………….…….
CHAPTER 12 ENGINE STORAGE …………………………………………………..…..…
WINTER STORAGE………………………………………….……………..
CHAPTER 13 MAINTENANCE ………………………………………………………...……
1. THE INITIAL RUNNING CHECK…...………………………..……….…..
2. MAINTENANCE SCHEDULE ………………………………………..…..
3. STERNDRIVE & TRANSMISSION MAINTENANCE SCHEDULE ..…
4. MAINTENANCE LOG……………………………………………………..
CHAPTER 14 TROUBLESHOOTING GUIDE ……………………………………….….....
CHAPTER 15 WARRANTY ………………………………………………………….……....
WARRANTY REGISTRATION CARD …………………………….…….…
36
36
37
38
40
40
43
43
43
43
43
45
45
46
47
49
50
51
52
52
55
60
61
61
62
63
64
65
66
67
68
69
69
70
72
77

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-3-
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. For information on installation, operation and maintenance
of the ZF Marine Transmissions and Sterndrive Bravo Models, please see the separate booklets
included in the original packaging of your Hyundai SeasAll purchase.
Hyundai SeasAll is committed to making clear and accurate information available for those who
maintain, own and repair the S250 & S220 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.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-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.
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 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.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-5-
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
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
S250 and S220 Series Engines
-6-
1. ENGINE COMPONENTS
1. ECU Box
2. Coolant Expansion Tank
3. Engine Oil Cap
4. Engine Oil Filter
5. E-VGT & Cooler
6. Air Filter
7. Engine Oil Gauge
8. Acceleration Lever Sensor
9. Seawater Pump
10. Intercooler
11. Heat Exchanger
12. Alternator
1. Turbo Heat Protector
2. Exhaust Elbow
3. Bell Housing (Sterndrive Model)
4. Drive Coupler (Sterndrive Model)
5. Engine Oil Exchange Button
6. Engine Emergency Stop Button
7. P/STRG Oil Reservoir Tank(Sterndrive Model)
8. Shift Plate (Sterndrive Model)
9. Main Fuel Filter with Water Detection Sensor
10. T/M Oil Cooler or P/STRG Oil Cooler
11. Cabin Heater Connector
12. BPS & IATS
CHAPTER 1
ENGINE OVERVIEW

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-7-
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.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-8-
3. ENGINE IDENTIFICATION
SERIAL NUMBER ON THE ENGINE BLOCK
NAME PLATE ON THE ECU BOX
Engine identification is affixed to the engine block and the ECU box (see figure).
Worldwide
Only USA

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
-9-
4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE
ECU
Fuel feed (low)
Fuel feed (high)
Fuel return
Fuel temperature sensor
Boost pressure & air temp. sensor
Glow Plug
Coolant temperature sensor
Cam position sensor
Crankshaft position sensor
EVGT actuator
Rail pressure sensor
Water sensor in fuel Feed
pump
Injector
Intercooler
Common rail
High pressure pump
Main fuel filter
Air filter
VGT
Pump pressure regulator valve
Acc. position sensor
Air temp. sensor
Sensor
Actuator
Rail pressure regulator valve
Fuel tank
return feed
return
return
return