Hyundai Seasall S270S Series User manual

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-1-
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. PREPARING THE ENGINE INSTALLATION ………………………….…….
2. BELLHOUSING FIXING……………………………………………….……
3. ASSEMBLING ENGINE MOUNTS ………….…………………………....
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 AIR CONSUMPTION……………………………………….……..
2. ENGINE ROOM VENTILATION……………………………………….……
3. 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 ……………………………..…………..….
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TABLE OF CONTENTS

INSTALLATION & OPERATION MANUAL
S270 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 …………………..………….…………..…….
4. SEASLINK PRODUCT COMPONENTS…………………………………...
5. INSTALLATION OF SEASALINK DONGLE……………….……………….
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 …………………………………..….…
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INSTALLATION & OPERATION MANUAL
S270 Series Engines
-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. For information on installation, operation and maintenance
of the ZF Marine Transmissions and MerCruiser Bravo Sterndrive 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 S270 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
S270 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. 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 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
S270 Series Engines
-5-
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
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
S270 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 Drain Pump Button
6. Engine Emergency Stop Button
7. Power Steering 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. Boost Pressure Sensor
CHAPTER 1
ENGINE OVERVIEW

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-7-
2. ENGINE HANGER
1) To lift the engine, first remove the engine cover. You will find three engine eyes (see
figure).
2) To avoid damage to the engine or operator, take care that engine lift chains or belts do
not hit or touch surrounding parts during engine lifting.

INSTALLATION & OPERATION MANUAL
S270 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).
Engine Family
Engine Type
Engine Serial No.
Rated Power @Speed
No. Of Cylinder
Bore x Stroke
Manufacture Date
D6EB
S270X
XXXXXXXX
270PS @ 3800rpm
6
84mm x 89mm
MM/YYYY
EPA Engine Family
FHYSN2.94HYS
IMO Engine Family
FHYSN2.94HYS
Max Power
199(kW)
Power Density
67.25 (kW/L)
Displacement / Cyl.
0.49(L/cyl)
Manufacture Date
MM/YYYY
Application
Recreational
Useful Life
1,000 hours or 10 years
Emission Standard
THC+NOx : 5.8 (g/kWh) PM : 0.15 (g/kWh) CO : 5.0 (g/kWh)
EMISSION CONTROL SYSTEM
THIS ENGINE IS EQUIPPED WITH ELECTRONIC DIRECT FUEL INJECTION SYSTEM.
THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL
THIS MARINE ENGINE COMPLIES WITH U.S. EPA REGULATION FOR 2015

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-9-
4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE
ECU
Fuel feed (low pressure)
Fuel feed (High pressure)
Fuel return
Fuel temperature
sensor
Glow
Plug
Cam Position
sensor
Crankshaft
Position sensor
EVGT
actuator
Water sensor
in fuel
Feed pump
Injector Intercooler
High
pressure
pump
Main fuel
filter
Air filter
Pump
pressure
regulator
valve
Acc. Position
sensor
Air Temp.
sensor
Sensor
Actuator
Fuel Tank
Feed
Boost
pressure
sensor
Common rail
Return
Return
Return
VGT
Rail pressure
regulator
valve
Rail pressure
Sensor
Return
Coolant
Temp.
Sensor

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-10 -
5. TECHNICAL DATA
Engine type
S270S S270P S270J
4-stroke, 24-valve
After-cooled, direct-injection, water cooling
Output PS(kW) 270PS (199)
rpm at full load 3800
Cylinders V-6
Ignition sequence 1-2-3-4-5-6
Displacement [cm3] 2959
Bore [mm] 84
Stroke [mm] 89
Compression ratio 17.3±0.5 : 1
Max. torque [kgm]
@ speed [rpm] 57.6 51
2500 3800
Injection system Common rail direct injection (Piezo injector)
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm]
2.78 2.78 2.78
3800 3800 3800
Coolant quantity (liter) 13.15
Coolant cap opening pressure (bar) 1.1
Engine oil (liter) 7.7
Engine oil pressure (bar) 2~3 at 1750rpm, 100 ℃(oil temp.)
Exhaust gas pressure (kPa) Max. 50
Alternator [A] 150
Engine diagnosis Yes
Weight(kg) 327
Battery capacity (AH) 12V, 200AH recommended
Thermostat opening temp. (℃) 82 (starting to open), 95 (fully open)
Idle rpm warmed up (rev/min) 680
Permissible eng. oil temp (℃) 137
Permissible eng. coolant temp (℃) 105
Fuel Consumption (Rated) (l/hr) @ 53.8 @ 3800 rpm
Propulsion system Sterndrive Shaftdrive Waterjet

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-11 -
6. PERFORMANCE CURVE
S270S & S270P MODEL
*F.C : Fuel Consumption
0
50
100
150
200
250
300
350
0
10
20
30
40
50
60
70
1000 1500 2000 2500 3000 3500 4000
Power(ps)
Torque(kgm)
Torque
0
10
20
30
40
50
60
1000 1500 2000 2500 3000 3500 4000
F.C.(L/h)
Engine Speed (rpm)

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-12 -
S270J MODEL
*F.C : Fuel Consumption
0
50
100
150
200
250
300
350
0
10
20
30
40
50
60
70
1000 1500 2000 2500 3000 3500 4000
Power(ps)
Torque(kgm)
0
10
20
30
40
50
60
1000 1500 2000 2500 3000 3500 4000
F.C.(L/h)
Engine Speed(rpm)

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-13 -
7. BELT INSTALLATION & ENGINE DIMENSIONS
Side view
Front view Side view
V-RIBBED BELT INSTALLATION
MODEL : S2-ENG SERIES
AN
ALTERNATOR
DP
DRIVE PULLEY
IP
IDLER PULLEY
PS
POWER STEERING
TP
TENSIONER PULLEY
WP
WATER PUMP PULLEY
Front view
MerCruiser Bravo One X Diesel
MerCruiser Bravo Two X Diesel
(LOW ENG. COVER)
(LOW ENG. COVER)

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-14 -
MerCruiser Bravo Three X Diesel
ZF 63 A
Front view Side view
Front view Side view
(LOW ENG. COVER)
(LOW ENG. COVER)

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-15 -
Front view Side view
Front view Side view
ZF 63 C
Waterjet adapter without ZF 63 C
(LOW ENG. COVER)
(LOW ENG. COVER)

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-16 -
CHAPTER 2
ENGINE MOUNT SYSTEM
1.1 CHECK THE MOUNT HOLE
Mount hole for U125 model
Mount hole for D170 and D150 model
Mount hole for S250 and S270 model
-. It is essential that the engine bed is perfectly flat
before using the engine mount tool.
-. Make sure that the rubber engine mounts are
installed so that no pre-load or side forces occur
when the engine has been installed and aligned
with the stern drive
<Check the position of
the Engine Mounts >
1. PREPARING THE ENGINE INSTALATION
<Engine mount tool>
(X)
(O)
(X)
(O)
Hyundai-SeasAll alignment tool(5 Step)
MerCruiser alignment tool(4 Step)
(O)
(X)
-. Engine installation must be done by a qualified
technician. Hyundai SeasAll engines must be aligned
using the genuine Hyundai SeasAll alignment tool
Otherwise the drive coupler will be damaged.

INSTALLATION & OPERATION MANUAL
S270 Series Engines
1) To prevent twisting the engine mount during
engine alignment, use a spanner on the lower
nut ( ) to keep the bolt from turning while
adjusting the engine height by turning the
middle nut ( ). Adjust the engine height until
the Hyundai SeasAll alignment tool can be
properly inserted.
2) After alignment, place washer ( ) on top of
engine support bracket and tighten lock nut ( )
while keeping the middle nut ( ) from turning
with a spanner.
-. Assemble exhaust pipe after tightening the
mounting bolts between bell housing and
transom plate. Use the following parts:
Mounting Bolt
Washer
Spacer
Fiber Washer
Nut
3. ASSEMBLING ENGINE MOUNTS
2. BELLHOUSING FIXING
-17 -

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-18 -
1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT
IN-MANIFOLD
Pc
COOLANT
PUMP
HEAT EXCHANGER
INTERCOOLER
OIL COOLER
TURBO CHARGER
AIR FILTER
Ps SEA WATER
PUMP
THERMOSTAT
EXHAUST ELBOW
EX-MANIFOLD
EX-MANIFOLD
OIL
SEAWATER
INTAKE AIR
EXHAUST AIR
COOLANT (THERMOSTAT CLOSED)
COOLANT (THERMOSTAT OPENED)
CABIN HEATER
CONNECTOR
SEAWATER
EXPANSION TANK
AIR
E-VGT COOLER
CHAPTER 3
COOLING SYSTEM & EXHAUST SYSTEM

INSTALLATION & OPERATION MANUAL
S270 Series Engines
-19 -
Water strainer ← Water valve ← Water pickup
↓
①Seawater pump
↓
②Intercooler
↓
③Heat exchange ⑤EVGT cooler
↓
④Oil cooler
↓
⑥Exhaust elbow
↓
Seawater
2. SEAWATER FLOW –OPEN COOLING CIRCUIT
EVGT cooler
2.1 WATER PICKUP
1) 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.
2) For sterndrive models, please see the section “Installing Sterndrive Seawater Pickup” of
the Bravo Sterndrive Installation Manual included in the original packaging.
3) For further safety, you must install an additional transom or bottom mounted clamshell-type
water pickup. Water flow from the Bravo sterndrive leg only is not adequate to provide
proper engine cooling.
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.
2.2 WATER STRAINER
1) Strainer should be located in an area where it
will be easily accessible for periodic seawater
flow inspection and cleaning.
2) The size of strainer must be of sufficient capacity
to pass the seawater (a minimum flow rate over
200 liters per minute).
3) Strainer must be installed after water inlet valve
in order to allow user to shut off seawater when
cleaning strainer filter.