Hyundai L500 SERIES User manual

INSTALLATION & OPERATION MANUAL
L500 Series

INSTALLATION & OPERATION MANUAL
L500 Series
-1-
TABLE OF CONTENTS
ABOUT THIS MANUAL ………………………………………………………………..…….....………..
SAFETY PRECAUTIONS ………………………………………………………….……..………………
APPROXIMATE CONVERSIONS FROM STANDARD………………………………………………
CHAPTER 1 ENGINE OVERVIEW ……………………………………………..…...….…….………
ENGINE COMPONENTS ………………………………………..……….……………
TECHNICAL DATA ………………………………………………..…….……………..
PERFORMANCE CURVES…………………………………………….………..……..
ENGINE IDENTIFICATION……………………………………..……….………….....
ENGINE SUSPENSION.…………………………………………….……..……...........
ENGINE DIMENSIONS………………………………………….………..….....……..
CHAPTER 2 ENGINE OPERATION ………………………………………………………….………..
STARTING AND STOPPING ENGINE……………………………..…..…………….
EMERGENCY STOP …………………..………………………………..….…………..
INTAKE AIR HEATER………………………………………………………….………..
CHAPTER 3 COOLING SYSTEM …………………………………………………………..….……...
SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..…....................
SEAWATER FLOW –OPEN COOLING CIRCUIT…………………...……….…….
WATER PICKUP……………………………………………………..…….…….……..
WATER STRAINER…………………………………………………..…….……..…….
CLEANING STRAINER FILTER……………………………………..……….…..………
AUTOMATICDRAIN VALVE..……………………………………………...…..………
SEAWATER PUMP………………………………………………………...…..………
CHECKING SEAWATER PUMP & IMPELLER………………………………..……..
ENGINE COOLANT FLOW……………………………………………….…………….
ENGINE COOLANT………………………………………………………..…….…….
SUPPLEMENTAL ENGINE COOLANT………………………………….……….….
DRAINING COOLANT……………………………………………………..…….…….
REMOVING AIR BUBBLES IN COOLANT………………………………...….……..
CABIN HEATER CONNECTION……………………………………………..…..……
CHAPTER 4 FUEL SYSTEM ………………………………………………………….………………..
EUI SYSTEM…………………………………………………………………..………..
FUEL SUPPLY SYSTEM.….……..…………………………..…………….…….…...
FUEL LINE…………………....………………………………………………..…...……
RECOMMENDED FUEL QUALITY ………………....……………………..……..….
DRAINING WATER FROM FUEL FILTER ………………………………………..….
CHANGING FUEL FILTER ……………………………..……………….…….………..
CHAPTER 5 INTAKE & EXHAUST SYSTEM …………………………………………..….………..
ENGINE ROOM VENTILATION …………………………………………....……......
CHECK AIR FILTER ……………………………………..…………..……..….……..
CLEANING AIR FILTER ……………………………………..……………….….……
EXHAUST SYSTEM…………………………………………………..……..…………
CHAPTER 6 LUBRICATION SYSTEM …………….………………………….………….…………
LUBRICATION COMPONENTS……………………….…………………..…………
ENGINE OIL LEVEL CHECKS…………………….....……………….…….………..
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INSTALLATION & OPERATION MANUAL
L500 Series
-2-
TABLE OF CONTENTS
RECOMMENDED OIL QUALITY………………………..……………..…...…........
ENGINE OIL EXTACTION PUMP…………………………….…………...………….
CHECKING BYPASS AND OIL FILTER………………………………..….…………
CHAPTER 7 ELECTRICAL SYSTEM ………………………………………………..………………
BATTERY CABLE CONNECTIONS ……………………………….........…………..
ACCELERATION SENSOR AND CONTROL LEVER…………….…………..……
PROCEDURES FOR CONTROL LEVER INSTALLATION…………………..……
BATTERY CHECKS………..………………………………………...………...........
LOAD TEST…………………………………………………………………….………
FUSES AND RELAYS……………………………………………………….…………
SYSTEM FUSE BOX………………………………………………………….………..
FUSE BOX………………………………………………………………….……………
FUSES……………………………………………………………………..…...………
RELAYS…………………………………………………………………….………….
CHAPTER 8 EOI SYSTEM …………………………………………..…………………………....…
INSTRUMENT CONNECTIONS……………………………………………….…..…
RPM GAUGE……………………..……………………………………….…………...
USER INTERFACE………………………………………......………..…………...…
EOI FUNCTION…………..……………………………......……………………...….
LCD INFORMATION……………………………………………………………..……
WARNING LAMP…………..……………………………………………………...….
SWITCHES …………………………………………………………………………......
PTO MODE………………………………………………………………………….…
IDLE SETTING MODE…………………………………………………..…..……….
EOI BOX ( INSIDE )…………………………………………………….………….…
CUT OUT FOR EOI SYSTEM…………………………………………………….….
EOI PIN ASSIGNMENT…………………………………………….……………..….
G-SCAN……………………………………………………………….…………....…
G-SCAN CONNECTIONS……………………………………………………….…..
DTC (DIAGNOSIS TROUBLE CODE) AND ALARM LIST……………………..…
CHAPTER 9 ANTI CORROSION SYSTEM ………………………………………….……...……..
CHAPTER 10 ENGINE STORAGE …………………………………………………..….….…….....
WINTER STORAGE…………………………………………………...……….….
.
CHAPTER 11 MAINTENANCE ………………………………………………………..……....……….
THE INITIAL RUNNING CHECK……………...……………..…………..………….
MAINTENANCE SCHEDULE ……………………………………………….…….....
AFTER SALES PART NUMBER..……………………………………….….………..
MAINTENANCE LOG…………….………………………………………..………..
CHAPTER 12 TROUBLESHOOTING GUIDE ………………………………………………............
CHAPTER 13 WARRANTY ………………………………………………………………….……......
WARRANTY REGISTRATION CARD ………………………………….…………..
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INSTALLATION & OPERATION MANUAL
L500 Series
-3-
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 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
L500 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.
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
L500 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. (40℃)
•FREQUENTLY CHECK engine oil level and
add oil if necessary.
•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
L500 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
mm2
0.0016
in2
AREA
in2
645.2
mm2
m2
10.764
ft2
ft2
0.093
m2
VOLUME
cm3
0.061
in³
VOLUME
in³
16.388
cm3
mL
0.06
in3
in3
16
mL
Ldm3
61.023
in³
in³
0.016
Ldm3
Ldm3
0.22
imp.gallon
imp.gallon
4.545
Ldm3
Ldm3
0.264
U.S.gallon
U.S.gallon
3.785
Ldm3
m3
0.76
yd3
yd3
1.3
m3
m3
35.315
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
L500 Series
-7-
CHAPTER 1
ENGINE OVERVIEW
ENGINE COMPONENTS
①FUEL FILTER ENGINE MOUNTING BRACKETS
②JUNCTION BOX OIL FILTER
③SEAWATER PUMP BYPASS OIL FILTER
④ECU WATER PUMP
⑤WATER SEPARATOR EXPANSION TANK
⑥OIL EXTRACTION PUMP C.C.P.C.V.
BELT COVER (OPTION)

INSTALLATION & OPERATION MANUAL
L500 Series
INTERCOOLER COOLANT PIPE (HEAT EXCHANGER OUTLET)
DRY EXHAUST PIPE STARTER MOTOR
TURBO-CHARGER OUTLET PIPE ENGINE MOUNTING BRACKET
LIFTING EYES HEAT EXCHANGER
AIR FILTER EXHAUST MANIFOLD
AIR FILTER CONNECTOR
ALTERNATOR
-8-

INSTALLATION & OPERATION MANUAL
L500 Series
-9-
TECHNICAL DATA
Engine type
L500
4-stroke, 4-valve
After-cooled, Electronic Unit Injector (EUI),
Turbocharger
Output ps (kW) 500PS (368kW)
rpm at full load 1800 rpm
Cylinders I-6
Ignition sequence 1-5-3-6-2-4
Displacement [cm3] 12,736
Bore [mm] 130
Stroke [mm] 160
Compression ratio 16.0 : 1
Max. torque [kgm]
@ speed [rpm] 232
1300
Injection system EUI
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm] 2.7
1800
Coolant quantity (liter) 52
Coolant cap opening pressure (bar) 0.7
Engine oil (liter) 42
Engine oil pressure (bar) 2.7 (600rpm,) 4(1800rpm)
Exhaust gas pressure (kPa) 10
Alternator [A] 80
Engine diagnosis Yes
Weight (kg) 1,310
Battery capacity (AH) 24V, 100AH
Idle rpm warmed up (rev/min) 600 (500~800 rpm idle control is possible but
from 500~600 rpm G-SCAN is required)
Permissible engine oil temp (℃) 135
Permissible engine coolant temp (℃) 105
Fuel Efficiency(L/h) Max 88

INSTALLATION & OPERATION MANUAL
L500 Series
-10 -
PERFORMANCE CURVES

INSTALLATION & OPERATION MANUAL
L500 Series
ENGINE IDENTIFICATION
•SERIAL NUMBER ON THE ENGINE BLOCK
Engine identification is affixed to the engine block . (See figure).
•ENGINE NAME PLATE
FORMAT : D6CEXXXXXX
-11 -

INSTALLATION & OPERATION MANUAL
L500 Series
-12 -
•To lift the engine, use the four lifting eyes
(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 SUSPENSION

INSTALLATION & OPERATION MANUAL
L500 Series
-13 -
ENGINE DIMENSIONS
Top
Side Front

INSTALLATION & OPERATION MANUAL
L500 Series
-14 -
<CRANK PULLEY >
T/M ASSEMBLY BOLT PATTERN
•BELL HOUSING : SAE 1
•FLYWHEEL : SAE 14
BELT INSTALLATION
MODEL : L500
AN ALTERNATOR
DP DRIVE PULLEY
IP IDLER PULLEY
TP TENSIONER PULLEY
WP WATER PUMP PULLEY
PTO PULLEY REFER DRAWING

INSTALLATION & OPERATION MANUAL
L500 Series
-15 -
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
L500 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 engine is started, the control unit (ECU)
operates the air heater for a certain time. This
preheats the engine and helps to reduce white
smoke at start-up.
•If the indicator lamp blinks regardless of
condition, check the related circuit for a blown
fuse, fused relay etc. since this indicates a
problem in the preheating heater system.
Air Heater
-16 -

INSTALLATION & OPERATION MANUAL
L500 Series
-17-
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
HEATER
CONNECTOR
SEAWATER
EXPANSION
TANK
AIR
Ps
EXHAUST MANIFOLD
AIR
EXHAUST PIPE

INSTALLATION & OPERATION MANUAL
L500 Series
-18 -
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.
•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
L500 Series
-19 -
•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