English
Contents
1. 19 SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT 19 SE AWA ER FEO 20 ENGINE COOLANT FLOW 2 23 CHAPTER e Hl E CN uu n e di kn e EUREN 26 SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE 2f SI RS 28 LOW PRESSURE FUEL El TEE 28 ACCELERATION SENSOR AND CONTROL LEVER 29 RECOMMENDED FUEL QUALITY 30 DRAINING WATER FROM FUEL FILTER 30 CHAPTER sa Ip E E RE EE 31 ENGINE ROOM VENTILATION 31 CHECK AIR FIETER iu asie bre adan od ka ava om DG e 32 CLEANING AIR FIL ETE AEREN NI EER 32 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines TABLE OF CONTENTS PAGE NUMBER CHAPTER 7 LUBRICATION SYSTEM 34 ENGINE OIL LEVEL CHECKS 2 34 RECOMMENDED OIL QUALITY 2 6 66 34 ENGINE OIL EXTACTION PUMP 35 OIL FILTER REPLACEMENT 35 CHAPTER 8 ELECTRICAL SYSTEM I a aa aaa lu 36 BATTERY CABLE CONNECTIONS 1 36 BATTERY CHECKS 37 FUSES AND RELAYS 38 CHAPTER 9 INSTRUMENT SYSTEM2. 1 40 INSTRUMENT CONNECTIONS 2 0 40 STANDARD INSTRUMENTS 41 CUT OUT FOR GAUGES 2 02 6 6 6 43 CUT OUT FOR EOI SYSTEM 1 43 CHAPTER 10 EOI SYSTEM AA 1 OVERVIEW OF EOI SYSTEM a a a aaa AA 2 EOI CONNECTIONS 46 3 EOI PIN ASSIGNMENT seem 47 4 NEUTRAL SWITCH AND DUAL EOI 49 5 TRIM WIRING CONNECTION DIAGRAM 50 6 ALARM LIST AND DTC DIAGNOSIS TROUBLE CODES 54 CHAPTER 11 ANTI CORROSION SYSTEM 59 CHAPTER 12 ENGINE STORAGE Ne 60 CHAPTER 13 MAINTENANCE 61 1 PREDELIVERY INSPECTION CHECK LIST 61 2 MAINTENANCE SCHEDULE 2 1 62 3 STERNDRIVE amp TRANSMISSION MAINTENANCE SCHEDULE 63 4 MAINTENANCE LOG 64 CHAPTER 14 TROUBLESHOOTING GUIDE 65 CHAPTER 15 WARRANTY a 67 WARRANTY REGISTRATION CARD 70 2 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines 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
3. 150mm Outer diameter of elbow is 60 5mm Sea waterline X Center of crank axis CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER 33 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular intervals e Be sure the boat is level Start the engine and allow it to reach normal operating temperature Turn the engine off and wait about 5 minutes until the oil has returned to the oil pan Pull the dipstick out wipe it clean and re insert it fully Pull the dipstick out again and check the level The level should be between F and L If it is near or at L add enough oil to bring the level to F Do not fill with engine oil above the F mark RECOMMENDED OIL QUALITY For best performance and maximum protection during all types of operation select only those lubricants which Satisfy the requirement of the API or ACEA classification e Have the proper SAE grade number for the expected ambient temperature range ACEA Above B4 Service oil quality should conform to ACEA or API Above CH 4 Classification 15W 40 15 C above Oil quality 10W 30 20 40 SAE m 5W 30 25 40 OW 30 10 C below 34 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines
4. ENGINE MOUNTING REQUIRMENTS mounts must be strong enough to carry the loads applied by the weight and power of the engine It also must be stiff enough that the engine does not sag or move too much when power is applied mounts must position the engine at the correct height and angle so that the engine s thrust line suits the boat ENGINE MOUNT DIMENSIONS CAUTION USE ONLY THE ORIGINAL HYUNDAI SEASALL ENGINE MOUNTS THAT WERE SUPPLIED WITH THE INITIAL PURCHASE AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE MAKE SURE THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN 15 J HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ENGINE MOUNT TOOL FOR STERNDRIVE MODEL Mount hole for 0125 model Back of Rear Hole e Mount hole for D170 and D150 model Front of front Hole 6 Mount hole for 5250 and 5220 model CAUTION IT IS ESSENTIAL THAT THE ENGINE BED IS PERFECTLY FLAT BEFORE USING ENGINE MOUNT TOOL FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO MODELS PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE 16 27 HYUNDAI SEASALL LI HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines STARTING ENGINE Before starting the engine you should check engine oil coolant gearbox oil fuel
5. FUEL HEATER 0081 251E 38 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines LI HYUNDAI SEASALL RELAYS Q Relays in the ECU Box 1 Oil Extraction Pump Relay 30Amp 2 Main Relay 30Amp wan wan on so x ET 3 Starter Solenoid Relay 30Amp 30A 30A 4 Glow Plug Relay 70Amp Using ohmmeter check that there is continuity between each terminal 85 86 YES Check for continuity between terminals 30 and 87 e Always replace a damaged relay with one of the same rating 39 HYUNDAI SEASALL LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines INSTRUMENT CONNECTIONS Engine Operating Indicator S GE HYUNDAI SEASALL Main EOI Dual EOI Opt Engine Operating Indicator e 6 EE Gauges only available 11289 for dual application 7 HYUNDAI SEASALL Engine to wiring standard 7m option 10m to RPM oauge 85 wiring EDI to coolant temp gauge 52 wiring O EDI to volt gauge 52 wiring 6 EOI to ignition key switch 21 4 wiring Dual wiring option for dual stage For information about the installation and operation of the EOI Engine Operating Indicator system please refer to Chapter 10 40 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines LI HYUNDAI SEASALL STANDARD INSTRUMENTS
6. ENGINE OIL EXTACTION PUMP Allow the engine to warm up at least 5 minutes e Remove the engine oil inlet cap and oil filter e The oil drain hose is connected to the oil extraction pump D route the loose end of the hose into the container being used for the oil change Q e Turn the ignition key on but do NOT start the engine then press and hold the button 3 on the side of the ECU box with the ignition switched on until the engine oil about 6 liters is completely pumped out OIL FILTER REPLACEMENT e Remove the oil filter A with the oil filter wrench Inspect the threads and O ring to apply a light coat engine oil onto the new filter Wipe off the seat Install the new oil filter by hand After the packing seats tighten the oil filter clockwise with the oil filter wrench 2 3 2 5kgf m 24 5 Nm Complete the reassembly and start the Engine Then check for oil leakage Turn off the engine and check the oil level Add oil if necessary WARNING USED OIL MUST BE STORED IN A SAFE PLACE AWAY FROM CHILDREN AND SOURCES OF IGNITION IF YOU HAVE A USED OIL DISPOSAL PROBLEM PLEASE HAVE THE ENGINE CHANGED BY YOUR NEAREST HYUNDAI SEASALL SERVICE DEALER 36 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines BATTERY CABLE CONNECTIONS The size of battery cable should be at least 40mm within a length of 4m it should b
7. HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL U125 SERIES ENGINES Applicable to 1255 U125P 0125 model 1st Edition LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines TABLE OF CONTENTS PAGE NUMBER ABOUT THIS MANUAL uuu ai e ie a n pa n a 3 SAFETY PRECAUTIONS pp 4 mel imi cC 5 CHAPTER T ENGINE EE 6 ENGINE COMPONENTS rr n sonn p n sayo 6 ENGINE SUSPENSION EYES 7 ENGINE IDENTIFICATION scit and u aa pk a pv kk kn s 8 TECHNICAL DATA uuu ok it tdt kt data en ran ray Eo De ki ek n ans diasqa 9 PERFORMANCE CURVES 2 10 ENGINE DIMENSIONS uuu 12 CHAPTER 2 ENGINE MOUNT SYSTEM 15 ENGINE MOUNTING REQUIREMENTS 15 MOUNT DIMENSIONS 15 ENGINE MOUNT TOOL FOR STERNDRIVE MODEL 16 CHAPTER 9 ENGINE OPERATION uu uu i u ate ta tU e 17 STARTING ENGINE u u u kwar sid ab t e ERIVE TESSE 17 STOPPING ENGINE u pak ab Marta m pa pena apresie k r an 17 EMERGENCY STOP 18 WINTER OPERATION AND STORACGE 18 CHAPTER 4 COOLING amp EXHAUST SYSTEM
8. if happens Throttle position n Eng Check symbol CHECK E Coolant high symbol Total and trip hour counter LB RB9s Reset temp gt 110 C kg wi Dimmer control LB 3s or RB 3s Battery voltage Decrease or increase 42 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines BATTERY VOLT METER GAUGE e This gauge will work when the key is in the ON position This gauge indicates real time battery voltage e If battery voltage is not sufficient the engine can not be started For a working engine 12 16V volts is normal If the battery voltage is under 12V you should check battery and alternator At the moment of engine ignition the voltmeter needle may momentarily drop to 8V This is normal CUT OUT FOR GAUGE Gauge 86 mm Coolant Temperature Gauge 2 53 mm e Battery Volt Meter Gauge 53 mm e Ignition Key 27 mm CUT OUT FOR EOI SYSTEM e You can use the installation template enclosed with EOI for a cut out 43 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines The Engine Operating Indicator system gives you a lot of information about the engine s current status You can hear alarm beeps or see information including RPM coolant temperature warning lamps error codes and engine working time If the switch is on warning lamps for batter
9. gauge seawater pump battery seacocks and so on When you start the engine check that the engine throttle lever D is in 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 You can also check this on the EOI 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 When cold starting it may take a few more seconds to start the engine If the engine does not start in 10 seconds release the key and wait 10 seconds After 10 seconds try again This method can help avoid starter motor damage STOPPING ENGINE The should be run for a few minutes at idle in neutral before turning it off This will avoid boiling and 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 like the alternator WARNING 17 DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION EMISSION GAS IS HARMFUL HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines LI HYUNDAI SEASALL EMERG
10. 136 204 05 RPM 6 Coolant Temperature Gauge Battery Voltmeter Gauge Ignition Key switch NOTE Gauge panel show above is not standard but available as an option COOLANT TEMPERATURE GAUGE This gauge will work when the key is in ON position e Avoid max rpm and WOT Wide Open Throttle before a cold engine 15 fully warmed up it can harm the engine e The gauge needle should be in proper range lf the outside temperature is high the gauge needle may sit at a higher range As long as the alarm doesn t sound the engine is normal e f gauge blinks and an EOI alarm sounds check the coolant temperature and level If the coolant is low refill it e H the temperature of the engine coolant is higher than 105 C the engine power will decrease You should check the engine cooling system 41 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines RPM GAUGE 1 When the key is at ignition ON position this gauge will work 2 This gauge indicates real time engine rpm 3 Avoid max rom and WOT Wide Open Throttle before a cold engine is fully warmed up as it can harm the engine Engine revolution Left button LB Right button RB Multifunction LCD display MFD USER INTERFACE In order to move Fuel consumption default Previous page LB Next page RB Preheating symbol Engine coolant temp
11. drain plug is located under the heat exchanger unit 24 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines REMOVING AIR BUBBLES IN COOLANT e Start the engine and warm it up at a low rpm Stop the engine and allow the engine to cool and then open the cap of the expansion tank carefully NOTE Never open the cap when the engine is hot may cause scalding Refill with coolant if needed e Reinstall the expansion tank cap Check the level of the expansion tank regularly CABIN HEATER CONNECTION e In order to use a cabin heater an extra coolant circulation pump is needed e After connecting cabin heater lines engine coolant must be refilled and checked e Please check coolant flow direction as shown in the drawing Outer diameter of connection port is 17 3 mm Outer diameter of line is 019 1 mm WARNING NEVER OPEN THE EXPANSION TANK CAP WHEN THE ENGINE 15 OPERATING OR HOT IT COULD RESULT IN SERIOUS PERSONAL INJURY AND MAY CAUSE ENGINE DAMAGE 25 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines The fuel supply system of this engine is diesel common rail direct injection In order to optimize engine combustion maximum injection pressure is up to 1600 bar Multi injection is possible thanks to the quick response of the solenoid type injector eg
12. 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 U125 Series engines Hyundai SeasAll values your input regarding revisions and additional information for our manuals The manufacturer is not liable for any damages or losses caused by faulty installation wrong handling of the equipment and or deficient maintenance operator is responsible for the correct and safe operation of the engine and safety of its occupants and general public t is strongly recommended that each operator read and understand this manual before installing and operating the engine his 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 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
13. 20 J 1 L d s 15 x NN E e K he 4 i 4 f P9 K d d sen ES Ze BSFC Brake Specific Fuel Consumption Fuel Consumption A1 7 HYUNDAI SEASALL LI HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines ENGINE DIMENSIONS Bobtail Front view L 3 g 4 n P d 1 Lit op Cen E D o ke el 5 H SE do RAA Side view for shaftdrive Side view for sterndrive avi IPS m A I F Wy INI u Side view for waterjet with bearing housing J HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines MerCruiser Bravo One X Diesel Min 264 144 738 Pal RE GELD Front view Side view ZF 25 A LA M OU C i x ae A mamam Front view Side view 43 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ZF 45 A pe I LE ae 9 Ei Jess a Side view Front view Side view HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines
14. 3 64 65 PO341 P0381 P0562 P0563 P0601 P0602 P0604 Internal Control Module Random Access Memory RAM Error P0605 Internal Control Module Read Only Memory ROM Error P0606 ECM PCM Processor P0611 P0617 062 062 0650 Malfunction Indicator Lamp MIL Control Circuit P0670 P0671 P0672 P0673 P0674 P0675 P0676 P0683 P0684 P0685 P0642 P0643 P0652 P0653 P0698 P0699 P1145 Camshaft Position Sensor A Circuit Range Performance Glow Plug Heater Indicator Circuit oystem Voltage Low System Voltage High Internal Control Module Memory Check Sum Error Control Module Programming Error 67 70 71 72 73 74 19 76 77 78 79 Injector Circuit Error Starter Relay Circuit High Injector Bank1 Error Injector Bank2 Error Glow Plug Module Control Circuit Cylinder 1 Glow Plug Circuit Cylinder 2 Glow Plug Circuit Cylinder 3 Glow Plug Circuit Cylinder 4 Glow Plug Circuit Cylinder 5 Glow Plug Circuit 81 82 83 84 85 Cylinder 6 Glow Plug Circuit Glow Control Module Signal Glow Control Module Performance ECM PCM Power Relay Control Circuit Open Sensor Reference Voltage A Circuit Low Sensor Reference Voltage A Circuit High 87 88 Sensor Reference Voltage B Circuit Low Sensor Reference Voltage B Circuit High Sensor Reference Voltage Circuit Low Sensor Reference Voltage Circuit High 91 Overrun Monitoring 56 HYUNDAI SEASALL INSTALLATION 8 OPERAT
15. ACUUM PROCESS THIS CAN CAUSE THE ENGINE TO OVERHEAT 21 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CHECKING SEAWATER PUMP amp IMPELLER Stop the engine and close the water valve Remove the impeller housing cover e 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 of the O ring on the impeller housing cover Open the water valve Start the engine and check if there is water leakage 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 22 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ENGINE COOLANT FLOW THERMOSTAT CLOSED Engine coolant outlet Engine oil cooler Exhaust manifold Engine coolant inlet THERMOSTAT OPENED 6 Engine coolant outlet Engine oil cooler Thermostat opened o
16. ENCY STOP 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 you want to stop the engine Engine Stop Switch WINTER OPERATION AND STORAGE When using or storing your engine under 0 C protect all parts exposed to seawater seawater pump intercooler heat exchanger cooling lines seawater strainer valves and hoses from freezing Sterndrive models should be trimmed down fully to prevent trapping water in the gear case which could then freeze and cause damage The battery capacity decreases as the temperature drops We recommend recharging the battery frequently Check and clean all battery cable connections as oxidized connections lead to voltage drops and starting difficulties e f water happens to freeze in engine be sure to examine the engine for broken parts exchange broken parts if necessary and thaw any frozen water before operating the engine 18 J HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines SCHEMATIC DIAGRAM OF ENGINE CO
17. Failure of any parts caused by lack of cooling water Use of fuels and lubricants that are not suitable for use with or on the product Please refer to Installation and Operation Manual TRANSMISSION AND STERNDRIVE WARRANTIES The ZF Marine Transmissions and CMD Mercury MerCruiser Diesel Sterndrive Bravo Models are covered under separate warranties and serviced by those companies For information on those warranties please see the separate booklets included in the original packaging of your Hyundai SeasAll purchase 69 Z HYUNDAI SEASALL ABSOLUTE MARINE POWER X HYUNDAI SEASALL WARRANTY REGISTRATION CARD Date of Sale Please fill out the following registration card in English BOWNER S INFORMATION Name Company EE ZIP Code Post Code Street P O Box State Province DEALER INFORMATION jew woe ___ Country Telephone ENGINE INFORMATION Number of Engines Single Dual Engine Serial No Gear Drive Serial No BOAT INFORMATION REPOWER LI Ss Au FRP Wood x i Boat Type Hull ID Type of Use Pleasure Commercial Planing SemiDisp Displacement O 2012 HYUNDAI SEASALL Text figures and standards in this guide are based on information current at the time of printing Reprinting reproduction or translation in whole or in part is not permitted without the written approval of HYUNDAI SEASALL All rights according to the appli
18. ION MANUAL LI HYUNDAI SEASALL U125 Series Engines e se remm 99 Pras Minimum Pressure at Enge mm few _ EAR Throttle Pedal Position Sensor Switch D Circuit Low Input Throttle Pedal Position Sensor Switch D Circuit High Input Throttle Pedal Position Sensor Switch Circuit Low Input Throttle Pedal Position Sensor Switch E Circuit High Input 57 Z HYUNDAI SEASALL LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Co Throttle Pedal Position Sensor Switch D E Voltage Correlation Turbocharger Boost Control Position Sensor A Circuit Turbocharger Boost Control Position Sensor A Circuit Range Performance Turbocharger Boost Control Position Sensor A Circuit Low Turbocharger Boost Control Position Sensor A Circuit High Turbocharger Boost Control Position Sensor A Circuit Intermittent 58 Z HYUNDAI SEASALL LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Heat exchanger Sacrificial anodes A sacrificial anode must be replaced when more than 60 of it has been used Check especially frequently when used in saltwater It is recommended to replace the sacrificial anodes at the start of each season CAUTION DON T OPERATE ENGINE WITHOUT ANODES IT IS HARMFUL TO YOUR ENGINE THE SEAWATER VALVE BEFORE THIS MAINTENANCE e MAKE SURE TO CHECK THE ANODE PLUG IN ACCORDANCE WITH TH
19. IS MANUAL DON T LOOSEN COOLANT DRAIN PLUG 59 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines The major consideration in preparing your engine for storage is to protect it from rust corrosion and damage caused by freezing of trapped water The following storage procedures should be followed to prepare your engine for out of season storage or prolonged storage two months or longer and or winter storage CHECK LIST e Visual inspection for leaks and damage Change engine oil and oil filter Replace fuel filter Check air filter element and clean if necessary Check engine coolant level and top up if necessary Check impeller and replace if necessary Check anodes and replace if necessary Clean the engine Flush and drain seawater cooling system Fill fuel tank until full and inspect the fuel system e Remove the battery and store in a cool dry place CAUTION FOR WINTER STORAGE SEAWATER SHOULD BE DRAINED FULLY BY LOOSENING THE HEAT EXCHANGER ANODE REFER TO CHAPTER 10 60 J HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines PREDELIVERY INSPECTION CHECK LIST BEFORE THE WATER TEST ON THE WATER TEST Y N Y N Seawater inlet valve open NE Boat drain plug in place Engine coolant level check before putting boat in water Seawater pump operation Cooling system hose clamps tight
20. LOCK ENGINE NAME PLATE HYUNDAI SEASALL Hyundai seasAll Co Lid Engine Type U125 Engine Family 4 Rated 125ps 4000rpm Engine Weight 220kg Max 4400 of cylinders A Cylinder bore mm 77 2 Piston stroke mm 84 5 A Engine Serial No BU993700 D 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines TECHNICAL DATA U125P U125J Engine type 4 EM 16 valve After cooled direct D water After cooled direct injection water cooling Intake air pressure abs bar 2 5 bar 4000 rpm speed rpm em RN 85 starting to open 95 fully open 9 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines PERFORMANCE CURVE 01255 8 U125P MODEL 150 125 5 2 5 50 0 25 1000 1500 2000 2500 3000 3500 4000 30 320 x eer FT Js ge 4 T __ oe 1000 1500 2000 2500 3000 3500 4000 4500 Engine Speed rpm BSFC Brake Specific Fuel Consumption Fuel Consumption 10 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines U125J MODEL A 7 m 4 lt e To E 1 9 1 Fi peu 1 vi 0 ti 1 4 k B 2
21. NG service tool 2 Connection plug CN2 to dual 7 Connection plug 7 external 3 Connection plug CN3 tachometer 8 Connection plug CN8 key box 4 Connection plug CN4 coolant temp gauge 9 System power fuse 3 amp 5 Connection plug CN5 volt gauge 10 Buzzer WARNING LISTEN FOR A CLICK WHEN FASTENING CONNECTORS THIS SOUND INDICATES THAT THEY ARE SECURELY LOCKED CAUTION DON T CONNECT EXTRA INSTRUMENTS WHICH DRAW MORE THAN 1 AMPERE THE E O I WILL BE OVERLOADED AND DAMAGED 46 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines EOI PIN ASSIGNMENT CN1 MAIN EOI CONNECTOR FROM ENGINE JEDO pq EI pa a s 1 Ignition power 13 RPM signal 2 Main relay power 14 Spare 3 Permanent power 15 Spare 4 Not used 16 Spare 5 Not used 17 Neutral signal 6 Coolant temperature signal 18 K line 7 Not used 19 CAN L 8 Check lamp 20 Charging signal 9 Oil pressure signal 21 CAN 10 Ground 22 Not used 11 Not used 23 Ground 12 Water detection signal 24 Not used CN2 DUAL EOI CONNECTOR a TE SSeS 7 1 Ignition power 13 RPM signal 2 Main relay power 14 Spare 3 Permanent power 15 Spare 4 Not used 16 Spare 5 Not used 17 Neutral signal 6 Not used 18 K line 7 Not used 19 CAN L 8 Check lamp 20 Charg
22. NGINE DAMAGE WHENEVER PERFORMING ANY MAINTENANCE OPERATIONS 62 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines STERNDRIVE amp TRANSMISSION MAINTENANCE SCHEDULE Whichever comes first Maintenance Maintenance intervals 100h Daily tee leg e En _ rn inspect semanie ant anos emp _ oper _ Touch up power package paint and spray with Corrosion Guard Transmission Change sterndrive unit oil Transmission pe Retorque connection of gimbalring to steering shaft o Check steering system and remote control for loose missing or damaged parts Lubricate cables and linkages e Inspect U joints splines and bellows Lubricate U joints splines Check engine alignment Check gimbal bearing and engine coupler Check continuity circuit for loose or damaged connections Check MerCathode unit Filter replacement Transmission 1 The first replacement must be performed after 25 hours of operation 2 The oil must be changed whenever the filter is replaced CAUTION YOU SHOULD EXERCISE THE UTMOST CARE TO PREVENT INJURY TO YOURSELF OR ENGINE DAMAGE WHENEVER PERFORMING ANY MAINTENANCE 63 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engi
23. OF THE ENGINE 3 7 HYUNDAI SEASALL LI HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL U125 Series Engines SAFETY PRECAUTIONS e 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 without the express permission of Hyundai SeasAll This can be dangerous can shorten the life of your engine and can invalidate your warranty engine Original and genuine parts supplied from Hyundai be inspections and maintenance for Hyundai SeasAll does not guarantee any damage caused by the use of imitation parts must used e 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 HOT SURFACES AND FLUIDS e 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 e Refuel only after the engine completely stops Use only the recommended fuel The wrong grade of fuel can cause operating problems can cause the
24. OLING CIRCUIT AIR 0 MAT 1 emm THERMOSTAT COOLANT PUMP IN MANIFOLD EXCHANGER D i t T 1 OIL COOLER EXPANSION TANK E O E deran See J OIL 4 D SEAWATER ww SEAWATER S PUMP gt INTAKE AIR gt EXHAUST AIR COOLANT THERMOSTAT CLOSED 8 OPENED COOLANT THERMOSTAT OPENED 19 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines SEAWATER FLOW OPEN COOLING CIRCUIT Water strainer Water valve Water pickup D Seawater pump Q Intercooler G Transmission oil cooler 4 Heat exchanger 5 Exhaust elbow Sea water 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 e For use in sterndrive models please see the section Installing Sterndrive Seawater Pickup of the BRAVO MODELS INSTALLATION MANUAL included in the original packaging For further safety you can use an additional transom or bottom mounted clamshell type water pickup WATER STRAINER e Strainer should be located an area where it will be easily accessible for periodic seawater flow inspection and cleaning The size of st
25. S NO AIR CIRCULATION EMISSION GAS IS HARMFUL TA 7 HYUNDAI SEASALL LI HYUNDAI SEASALL U125 Series Engines INSTALLATION 8 OPERATION MANUAL ENGINE COMPONENTS ECU Box Engine Oil Cap Engine Oil Filter Seawater Pump Intercooler Q Engine Oil Gauge Co Acceleration Lever Sensor Fuel Filter Alternator Oil Extraction Pump amp Air Filter Engine Oil Exchange Button Engine Emergency Stop Button 6 Injector GA Shift Plate Q Turbo Heat Protector O Belt Drive 10 Coolant Expansion Tank J HYUNDAI SEASALL LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ENGINE SUSPENSION EYES To lift the engine first remove the engine cover You will find two engine eyes see figure e To avoid engine damage take care that engine lift chains or belts do not hit or touch Surrounding parts during engine lifting Use strong enough lift chains or belts to carry the engine weight safely S e ki ror S LE COB e 4 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the ECU box see figure SERIAL NUMBER ON THE ENGINE B
26. SCHEDULE Maintenance Whichever comes first intervals 200h 400 y 2years Check the coolant level and for leaks Replace the seawater pump impeller pe Cooling system Inspect the thermostat Clean the heat exchanger tube bundle pe Check and clean the seawater strainer e Check for leaks gl JL Exhaust system Replace the exhaust rubber bellows pe Check for leaks gl JL Fuel system Replace the fuel filter o o lej __ Replace the secondary fuel filter X Clean the air fiter __ _ Air intake system Clean the inter cooler tube bundle j Check the level and for leaks FOLE Changetheengineoilandfiter 00 the engine oil and filter Check the tight connections Electrical systems contamination Anti corrosion Anti corrosion system the sacrificial anodes the sacrificial the sacrificial anodes d Battery Check the operating vottage Check tightness ofthe bolts nuts and other fasteners Check tightness and for corrosion of hose clamps Steering system Check the oil level and forteaks _ Propulsion system Check the tevel and for teaks 1 e _ 1 If corroded over 60 replace 2 For more detailed maintenance follow manufacturer s specifications Lubrication system CAUTION YOU SHOULD EXERCISE THE UTMOST CARE TO PREVENT INJURY TO YOURSELF OR E
27. SeasAll will pay for all parts and labor needed to repair the damage to the product resulting from a defect in materials or factory workmanship The warranty does not apply to any damage or defect that is the result of abnormal use or carelessness The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date OWNER S OBLIGATIONS It is the owner s obligation to install operate maintain and care for Hyundai SeasAll engines in accordance with the instruction and requirements stated in the Installation and Operation Manual The owner is responsible for providing enough time and cooperation to get the engine repaired by an authorized dealer and to deliver it to a proper facility for repair The owner is responsible for the cost for warranty inspection including landing launching and transport HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Hyundai SeasAll with a reasonable opportunity to repair the engine as well as reasonable access to the product for warranty service Warranty claims shall be made to a Hyundai SeasAll Authorized Repair Facility to service the product Purchaser shall not unless requested by Hyundai SeasAll ship the product or parts of the product directly to Hyundai SeasAll The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty servic
28. T WITH THE IGNITION KEY ON HYUNDAISEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines RECOMMENDED FUEL QUALITY The following fuels should be used for engine operation Standard summer winter diesel fuel according to DIN EN 590 classes A F Diesel fuel according to DIN EN 590 classes 0 4 in arctic climates Summer diesel fuel according to California and U S federal regulations Winter diesel fuel if lubricity is comparable to diesel fuel according to DIN EN 590 Mixture of diesel fuel with 5 Vol RME according to DIN 51606 Later admixing or additional use of additives gasoline or special fuels is not permitted DRAINING WATER FROM FUEL FILTER The fuel filter for a diesel engine plays an important role of separating water from fuel and accumulating the water in its base If water accumulates in the fuel filter a warning light comes on when the ignition switch is at the ON position the water in the fuel filter is over the limit the Water Sensor Lamp on the EOI will light up If this happens you must stop the engine and drain the water in fuel filter yourself or ask the nearest workshop to do this Water and a little fuel will drain at the same time Therefore avoid flames in your workspace If your fuel is not well suited to your engine more frequent drainage will be required To check and drain the water in fuel filter D Loosen the drain plug part D
29. also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchaser s Copy must be given to you immediately after the card has been completely filled out by the selling distributor or dealer This card represents your registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms 67 7 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers who purchase from a dealer authorized by Hyundai SeasAll to distribute the product in the country in which sale occurred and then only after the Hyundai SeasAll specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Routine maintenance outlined in the Installation and Operation Manual must be performed in a timely fashion in order to obtain warranty coverage Hyundai reserves the right to make any warranty coverage contingent upon proof of proper maintenance WHAT HYUNDAI SEASAII WILL DO Hyundai
30. and drain water 100 120cc drainage is proper 2 After water is drained securely tighten the drain plug 3 After starting the engine check to make certain the fuel filter warning light is off CAUTION HYUNDAI SEASALL S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS HIGH PRESSURE PUMP INJECTORS ETC CAN BE ATTRIBUTED TO THE USE OF UNQUALIFIED FUELS IF WATER ACCUMULATED IN THE FUEL FILTER IS NOT DRAINED AT PROPER TIMES DAMAGE TO MAJOR ENGINE PARTS MAY OCCUR WHEN REPLACING THE FUEL FILTER CARTRIDGE USE ONLY GENUINE HYUNDAI SEASALL PARTS 30 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines The intake air system of this engine is optimized by VGT and a highly efficient intercooler system The pressure of the air system is up to about abs 2 5 bar in order to optimize engine combustion Air filter Boost pressure amp air temp sensor Cam Position E Sensor Intercooler VGT Glow m plug Coolant temperature sensor gt rye SS VGT actuator Crankshaft position C ch sensor Vacuum modulator ENGINE ROOM VENTILATION Engines with turbocharged air inlet systems require much more cool fresh air than non turbocharged engines Maximum air consumption is 4GOkg h minimum engine room vent area
31. ater detection sensor High pressure pump Common Injector or return to fuel tank E f F MAL La D Feeding line from fuel tank to fuel filter 2 Feeding line from main fuel filter to high pressure pump 3 Return line to fuel tank engine out X The internal diameter of all fuel lines must be at least 8 mm E HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ACCELERATION SENSOR AND CONTROL LEVER When installing control lever cable to acceleration sensor be sure that the acceleration sensor lever is fully released at the idle position and fully pulled to the full load position The swing distance of the lever between idle and full load position is 65mm The procedures for control lever installation 1 Idle position setting Make sure that the position value indicates 096 in neutral condition 2 Full load position setting Make sure that the position value 96 indicates full load range 90 99 295 at fully forward lever position If not disassemble and adjust the base neutral position of the control lever by moving it to the rear until the condition are met 29 Engine Operating Indicator GD J HYUNDAI SEASALL Engine Operating Indicator GR HYUNDAI SEASALL CAUTION YOU SHOULD PERFORM ABOVE PROCEDURES AFTER CONTROL LEVER INSTALLATION WITH THE ENGINE NOT RUNNING BU
32. cable copyright laws are expressly reserved for HYUNDAI SEASALL Subject to alterations www hyundai seasall com 460 26 Sam Dong Uiwang Si Gyeonggi Do Korea TEL 82 70 8620 8035 FAX 82 70 8244 8555 www hyundai seasall com ABSOLUTE MARINE POWER HYUNDAI SEASALL l 460 26 Sam dong Uiwang si Gyeonggi do 437 815 Korea www hyundali seasall com 82 70 8244 8555 Tel 82 70 8620 8035 seasall_info hyundai seasall com ISSUED November 2012 Copyright 2012 Hyundai SeasAll Co Ltd All rights reserved
33. e at least 50mm if the cable is longer than 4m e Recommended battery capacity is over 150 amperes Connect the battery cable to the starter motor Connect the battery cable to system ground engine block e Battery cables should be clean and tightly connected A A c3 STARTER MOTOR O ENGINE GROUND CAUTION DO NOT TOUCH OR REMOVE ELECTRICAL PART WHEN STARTING OR DURING OPERATION KEEP HAND HAIR AND CLOTHES AWAY FROM THE FLYWHEEL AND OTHER ROTATING PARTS WHILE THE ENGINE IS RUNNING 36 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines BATTERY CHECKS Battery inspection is very important in electronically controlled engines You must check the battery condition regularly LOAD TEST e Perform the following steps to complete the load Voltage Temperature test procedure for maintenance free batteries 20 C 70 F and above Connect the load tester clamps to the terminals and proceed with the test as follows 9 5 16 C 60 F If the battery has been charged remove the surface charge by connecting a 300 ampere 9 4 10 C 50 F load for 15 seconds Connect the voltmeter and apply the specified load 9 1 C 30 F G Read the voltage after the load has been 7 C 20 applied for 15 seconds 8 7 12 C 10 F Disconnect the load 8 5 18 C 0 F Compare the voltage reading with the minimum acceptable vo
34. e is requested in order to obtain coverage 68 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines LIMITATIONS EXPENDABLE PARTS e Filters fuel filter engine oil filter air filter Engine oil and coolant and other fluids such as power steering fluid and hydraulic trim fluid Rubber products seawater pump impeller rubber hoses drive belt Gaskets anodes thermostat WHAT IS NOT COVERED Fuel injector or filter cleaning Drive belt or control adjustments or lubrication checks made in connection with normal services Damage caused by neglect lack of maintenance accidents abnormal operation improper installation or service unapproved modification or freezing temperatures Haul out launch or towing charges removal and or replacement of boat partitions or material for necessary access to the product when such service is due to boat design all related transportation charges and or travel time etc All incidental and or consequential damages storage charges telephone or rental charges of any type inconvenience or loss of time or income are the owner s responsibility Use of other than Hyundai SeasAll genuine replacement parts when making warranty repairs e Participating in or preparing for racing or other competitive activity Water entering the engine via the air inlet filter or exhaust system or submersion Water in the starter motor
35. eded 5 pressure sensor APS 2 power supply circuit BPS power supply circuit ECM P0087 Rail pressure Monitoring Maximum negative deviation of rail pressure exceeded 088 P PRV PRV checkistuck P1171 Minimum rail pressure exceeded P1172 Maximum rail pressure exceeded VH P0238 above upper limit P0237 Voltage below lower limit BPS boost pressure P0069 Mot plausible with atmospheric pressure sensor Sensor T P0653 Supply voltage above upper limit P0652 Supply voltage below lower limit BPS circuit BPS RPS power supply circuit APS 2 power supply circuit 52 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines x Failsatety x Failsatety Alarm DTC Description Possible Cause s doi Cut Note 1 La Buzzer RPM limit P0254 Short circuit to battery of metering unit output O Short circuit to ground of metering unit output l Depending EOI LCD temp Blinking PREV pump pressure regulator valve P PRV circuit P PRV circuit e PRW 0253 Open load of metering unit output of metering unit output P0252 Powerstageerror 000000 error jan Oil pressure low below 0 8 bar Charging Error EM system error Coolant temperature high above 110 C Note 1 RPM Limit Rated rpm 500 Rated rpm 800rpm O
36. 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 HYUNDAISEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines ENGINE BREAK IN 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 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 e 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 operation 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 e FREQUENTLY CHECK engine oil level and add oil if necessary WARNING DO NOT DRIVE IN SPACE WHERE THERE I
37. erial and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 years from the date the product is first sold to a recreational use retail purchaser or when the Product has been operated for 1000 hours whichever occurs first This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a commercial use retail purchaser or when the Product has been operated for 1000 hours whichever occurs first This limited warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty To transfer the warranty to the subsequent owner send or fax a copy of the bill of sale or purchase agreement new owner s information and engine serial number to Hyundai SeasAll s distributor or dealer Upon processing the transfer of warranty Hyundai SeasAll will send registration verification to the new owner of the product by mail WARRANTY REGISTRATION Your selling dealer fills out the Warranty Registration Card and mails it to the distributor responsible for administering the warranty registration for your country Warranty Registration must be made no later than 15 days from the date of sale after purchase from authorized dealer The Warranty Registration Card identifies information on customer and product models and serial numbers date of sale type of use and the selling dealer The distributor or dealer
38. feedback line error VGT actuator adaption error actuator performance error Short circuit battery variable geometry turbocharger actuator circuit Short circuit ground actuator No Load P0234 actuator performance error Air leakage check Intercooler VGT actuator performance error Boost pressure higher than target value P0299 Boost pressure lower than target value P2138 Plausibility With Aps2 Violated 51 acceleration position sensori P2127 Voltage Above Lower Limit P2123 Voltage Above Upper Limit APS1 2 sensor circuit APS sensor ECM engine control module 79 2 J 0643 Supply Voltage Above Upper Limit 0642 Supply Voltage Below Lower Limit P2128 Voltage above upper limit AP S2 acceleration position sensor2 P0653 P0652 CMPS cam position sensor P0340 CMPS circuit P0341 TONES e 5 circuit CKPS Target wheel check CKPS crank position sensor P0335 P0336 Wrong crankshaft signal restart Water in fuel fuel filter drain out water and check the fuel in fuel tank Warning lamp circuit Water detection sensor error Water detection P2264 Water in fuel is detected in fuel P0201 Open load P0261 Short circuit ground P0262 Short circuit battery Injector circuit Injector Defect resistance cylinder Charging dischar
39. ging energy error P0202 load P0264 Short circuit ground X P0265 Short circuit battery Defect resistance cylinder1 Cylinder1 injector P0263 Injector circuit Injector Cylinder2 injector P0266 Charging discharging energy error 25 7 HYUNDAI SEASALL LI INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines DTC Description Pi cut TU e off __ P0268 Short circuit battery Defect resistance Cylinder1 Charging discharging energy error 0204 Open load P0270 Short circuit ground P0271 Short circuit battery Defect resistance cylinder Charging discharging energy error P0205 Open load PO273 Short circuit ground P0274 Short circuit battery Defect resistance cylinder1 Charging discharging energy error Possible Cause s Cylinder3 injector circuit P0269 N d Cylinder4 injector k P0272 aa a 388 dui Note 2 Cylinder5 injector P0275 P0206 Open load P0276 Short circuit ground 0277 Short circuit battery Note 3 circuit Cylinder6 injector Defect resistance cylinder Charging discharging energy error Error path for short circuit of charging switch is detected PO200 injector circuit error P0278 P0611 Injectors Circuit B B Ba B O a Maximum positive deviation of rail pressure exce
40. gnal rail pressure sensor signal eFaulty injector Poor injector O ring Carbon deposit on the injector M Uneven acceleration deceleration Possible Causes eIntermittent faulty fuel line connection rail pressure sensor signal program error or hardware fault Leakage in intake system turbocharger or leakage in vacuum eLeakage in high pressure fuel circuit needle stuck ll Engine stop Possible Causes eRun out of fuel Safety Stop Switch activated Crank signals missing Fuel feed line not connected eFuel pressure regulator valve contaminated stuck jammed Leakage in high pressure fuel circuit regulator contaminated stuck jammed eFuel out of specification eFaulty alternator or voltage regulator Bad fuel quality or water in fuel eFaulty high low pressure fuel pump Clogged low pressure fuel circuit program error or hardware fault B Performance loss Possible Causes Compensation of individual injector not Leakage at the injector adapted Clogged air filter eFuel or intake air temperature too high Dil level too high or too low Engine coolant temperature too high Damaged turbocharger or intake air leakage 66 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines WHAT IS COVERED Hyundai SeasAll warrants its new products to be free of defects in mat
41. his lamp informs you to extract water from fuel filter lf the lamp is on you should stop the engine immediately and drain the water in the fuel filter It is recommended to check and drain the water in the fuel filter at regular periods before the lamp turns on It can be harmful to drive your engine with this lamp on ALTERNATOR LAMP This lamp informs you to recharge your battery If this lamp is turned on you should stop the engine and eliminate electric load as well as check the alternator alternator drive belt and wiring system 45 ENGINE OIL LAMP This lamp informs you of the engine oil pressure low If this lamp is on you should stop the engine and check the oil level with oil gauge If the oil is low refill it If you refill the oil and the lamp still does not turn off you should ask your local service shop for maintenance CHECK ENGINE LAMP This lamp informs you that the engine has a serious problem You can see the DTC on the LCD of the EOI e t may be possible to drive at limited rpm The ECU will control the functions to protect the engine You should immediately have the engine checked at the nearest service shop HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines EOI CONNECTIONS 9 2 23 O 19 8 9 Rear view 1 Connection plug CN1 from engine 6 Connection plug C
42. il switch Oil level Circuit check Alternator Charging circuit check ECTS circuit e ECTS Cooling line check oil kai sens of E C TS engine coolant temp sensor Short circuit to battery of pressure control valve loutput PRV rail pressure Short circuit to ground of pressure control valve regulator valve output Open load of pressure control valve output Note 2 3 would be applied to 5250 220 models 53 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines FULL DTC DIAGNOSIS TROUBLE CODE LIST e see remm s Poss rappen e Pressure s Foose Fue Pressure _ 54 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines DESCRIPTION Turbocharger Boost Sensor A Circuit Low Turbocharger Boost Sensor A Circuit High Injection Pump Fuel Metering Control A Range Performance 36 P0258 Injection Pump Fuel Metering Control A Low Cam Rotor Injector 37 P0254 Injection Pump Fuel Metering Control A High Cam Rotor Injector PS OMMericedw Om ooo Posto Camshaft Poston Sensor 55 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines P code DESCRIPTION 61 62 6
43. ing signal 9 Oil pressure signal 21 CAN H 10 Ground 22 Not used 11 Not used 23 Ground 12 Water detection signal 24 Not used 47 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CN3 TACHOMETER Main relay power RPM signal Ground Illumination Illumination CAN_H CAN_L Not used Or m CN4 COOLANT GAUGE Coolant temperature signal Ignition power Ground Illumination Illumination Not used p Or oN c CN5 VOLT GAUGE 1 Ignition power 2 Ground 3 Illumination 4 Illumination CN6 SERVICE TOOL CAN_H CAN L K line Ground Main relay power Not used S SY n CN7 EXTERNAL Ground Permanent power Ignition power Neutral switch Neutral switch Charging signal RPM signal Dimmer a P a 5 40 1 P O O as Kj N O qo en 48 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CN8 KEY BOX 1 Ignition power 2 Starter power 3 Permanent power NEUTRAL SWITCH AND DUAL EOI CONNECTION 1 Neutral switch wires should be connected at pin 4 and 5 of the external connector of the EOI If there is no neutral switch jumper 4 and 5 with a short jumper wire SYSTEM WITH A NEUTRAL SWITCH SYSTEM WITH NO NEUTRAL SWITCH From neutral switch wiring 2 If there is a dual EOI y
44. is 35cm2 eThe fresh and cooled air must be pumped into the engine in order to perform at normal power and fuel consumption e The temperature at the air inlet should be as low as possible A high temperature of inlet air may reduce engine performance 31 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CHECK AIRFILTER e The original Hyundai SeasAll air cleaner may be cleaned and reused f the air filter is very dirty it can reduce flow of air to the engine This can result in reduced power and fuel efficiency Cleaning the air filter should be carried out periodically according to the procedure below Do not clean the filter element with gasoline or other solvent cleaners CLEANING AIRFILTER e Remove the air filter from engine Put the air filter on a flat surface and shake the dust out Liberally spray K amp N Air Filter Cleaner onto both sides the of filter and allow to soak for 10 minutes to loosen the dirt Wash out the dust with low pressure running water from the inside toward the outside Dry the wet air filter in the shade for 2 3 hour You can reduce drying time by blowing with a CAUTION hair dryer on COLD or by blowing with low WHEN REMOVING THE AIR pressure compressed air FILTER BE CAREFUL THAT DUST OR DIRT DO NOT ENTER CAUTION Do not use high pressure air high THE AIR INTAKE OR DAMAGE MAY RESULT AND DO NOT pres
45. ltage shown in the table below If the voltage is greater than shown in the table the battery is good If the voltage is less than shown in the table replace the battery WARNING BATTERY MUST BE STORED AND WORKED ON IN A SAFE PLACE AWAY FROM CHILDREN AND SOURCES OF IGNITION FLUID IN THE BATTERY IS A CORROSIVE ACID AND MUST BE HANDLED WITH CARE IF SPILLED ON ANY PART OF BODY FLUSH IMMEDIATELY WITH WATER CAUTION DO NOT LOOSEN OR DETACH BATTERY TERMINALS WHILE ENGINE IS RUNNING DOING SO WILL DAMAGE THE CHARGING SYSTEM AND OTHER ELECTRONIC DEVICES 37 Z HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines FUSES An engine s electrical system is protected Standard from electrical overload damage by fuses e f a fuse has blown the element inside the fuse will be melted If the electrical system does not work first check the fuses in ECU box Always replace a blown fuse with one of the same rating Normal Blown e f the replacement fuse blows this indicates an electrical problem Avoid using the system involved and immediately consult an authorized Hyundai SeasAll dealer Fuses in the ECU Box 1 System Power 30Am y p 30A SYSTEM POWER I5A IGNITION POWER 2 Ignition Power 5Amp CES 2494 3 ECM ECU Power 20Amp 4 Main Relay Power 15Amp SECUN EE geg quet 5 Spare 30Amp 6 Fuel Heater Power 30Amp 30A SPARE
46. mE Seawater strainer correctly mounted Clean and tightly closed Engine oil level mE Engine alignment propulsion only alignment propulsion only Power steering fluid level BN Drive belt tension Fuel leaks m All electrical connections tight ae Oil leaks _ EOI warning system operating an Coolant leaks T Water leaks FI Banery fly and securea PAN We Exhaust system nose _ ennen Correct rotation propeller Installed and correct torque Engine coolant and oil drain plug closed Throttle shift and steering system fasteners tightened properly PROPULSION CHECKS Stern drive unit oil level Power trim oil level stern drives Drive unit fasteners torque Exhaust leaks gauges operation emergency stop switch operation RPM within specifications WOT within specifications in forward gear PROPULSION CHECKS Steering operation throughout range mM Power trim operation stern drives Shift operation Drive oil leaks 1 3 AFTER THE WATER TEST Fuel oil coolant water and fluid leaks Power trim cylinders fasteners tight Propeller nut torque and fluid level EE Transmission fluid level Propeller nut torque EE 61 7 HYUNDAI SEASALL LJ INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL H380 Series MAINTENANCE
47. nes MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS 64 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines M Starter motor does not crank the engine Possible Causes Engine stop switch ON position eEngine is not shifted to neutral position Safety Stop Switch activated Wrong neutral switch connection to enonse eStarter motor solenoid or slave solenoid failure or corroded elgnition key switch failure Blown fuse at EOI Wiring or electrical connection fault Defective ECU ll Engine cranks but does not start Possible Causes Weak battery or bad starter motor ncorrect starting procedure eFaulty fuel filter or electric fuel pump Engine starts with difficulty or starts and stalls M Engine idle is rough Possible Causes eFuel return line not connected at injector sl compression pressure rail pressure sensor signal clamp poorly tightened Wiring harness open or poor connection Faulty high pressure fuel pump Bad fuel quality or water in fuel eFaulty injector Clogged fuel filter air filter Carbon deposit on the injector 65 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines M Engine rattling noisy engine Possible Causes Compensation of individual injector not adapted No engine coolant temperature sensor si
48. ou should connect the wiring between 5 external connector of the main EOI and 5 external connector of the dual Main EOI external connector Dual EOI external connector From neutral switch wiring CAUTION FOR USER S SAFETY ENGINE WILL NOT CRANK OR START IF GEAR POSITION LEVER IS NOT IN NEUTRAL OR NOT CONNECTED TO THE EOI EXTERNAL CONNECTION 49 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL U125 Series Engines LI HYUNDAI SEASALL TRIM WIRING CONNECTION DIAGRAM STERNDRIVES ONLY Engine Operating Indicator 22280 REMOTE CONTROL TRAILER SWITCH SIDE TYPE ONLY GAUGE TRIM GAUGE VOLT GEO Q BUZZER DRIVE OIL 50 e TRIM PUMP O TRANSOM PLATE O GEAR LUBE MONITOR 10 BATTERY GAUGE 8 LAMP POWER HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ALARM LIST AND DTC DIAGNOSIS TROUBLE CODE If there is a problem with the engine the display audible or visible alarm and related DTC diagnosis trouble code will give you information about it The DTC display is only for initial assistance and to aid communication with a Hyundai SeasAll dealer if there is an emergency You should contact your nearest Hyundai SeasAll dealer as soon as possible if a system problem arises DTC Description Possible Cause s Note 1 P2263 contraller overheat learning error Overload VGT cooling circuit
49. pening temp 85 6 Exhaust manifold Expansion tank Heat 3 Engine coolant inlet ENGINE COOLANT he high pressure cooling system has a reservoir filled with year round antifreeze coolant The reservoir is filled at the factory e The coolant level should be between MAX and MIN marks on the side of the coolant reservoir when the engine is cool 23 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines e f the coolant level is low add enough specified coolant to provide protection against freezing and corrosion Bring the level to MAX but do not overfill e If frequent additions are required see an authorized dealer for a cooling system inspection Use only soft demineralized water in the coolant mixture e 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 e 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 following table Mixture Percentage Ambient volume Temperature 35 31 F 50 8 Drain plug water Engine coolant drain plug In order to drain engine coolant use a screwdriver to loosen the drain plug CD e The
50. rainer must be of sufficient capacity to pass the seawater a flow rate over 150 liters per minute flow rate e Strainer must be installed after water inlet valve in order to allow user to shut off seawater when cleaning strainer filter 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 20 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines CLEAN STRAINER FILTER 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 e Insert the cleaned filter element and screw on the filter cap e Check the cap and the gasket for correct seating and sealing Open the water valve e Start the engine and check if there is water leakage SEAWATER PUMP e he internal diameter of hose connected to seawater pump inlet should be 32mm he 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 e The seawater pump impeller must be checked periodically and replaced if necessary CAUTION IF ASSEMBLY IS NOT CONDUCTED PROPERLY AIR CAN BE SUCKED IN DISTURBING THE V
51. regulator return valve valve High Pressure _ A eturn Injector Fuel Temperature Se nsor lan m u u a Fuel filter Water in Fuel Sensor S return ia m mo m m Fuel feed low Fuel return Fueltank mew Fuel feed high 26 HYUNDAI SEASALL lt lt lt 2 lt O 2 q lt H o U125 Series Engines HYUNDAI SEASALL SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE Josues mew eum uonisod leooV UJnleJ jany poo www Qum yue lenj Josues 1 uonisod jyeysyuelo Ve EN ili Josues eJnjeJeduue 2 1481000 u JOSU9BS 08095 oJnjeJeduuo jon Joyenjoe SA Jejooou4eju Jojoefu Josueg uonisog ue acil oJnsseJd UBIH Josues dwe Ki oJnsso 19 soog oJnssoeJd D Joy A4 oJnsseJd HYUNDAI SEASALL J f INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines FUEL FLOW Fuel tank Auxiliary fuel filter Fuel filter low pressure Fuel filter with w
52. sure water or hot air to clean and or dry the RUN WITHOUT AIR CLEANER air filter These can damage the performance of THS COULD RESULT IN USE OF NON GENUINE PARTS Apply air cleaner oil over the outside of the COULD DAMAGE THE TURBO CHARGER OR ENGINE filter If too much oil is applied it will reduce performance Reassemble air filter to engine 32 27 HYUNDAI SEASALL INSTALLATION 8 OPERATION MANUAL LI HYUNDAI SEASALL U125 Series Engines EXHAUST SYSTEM Your Hyundai SeasAll engine s exhaust system consists of a coolant cooled exhaust manifold and a seawater cooled exhaust elbow water injected wet exhaust system vessel s exhaust line should not be made too long and should be as straight as possible The maximum back pressure of the exhaust gas should be under 350 mbar Make sure that the shortest height between bottom of the exhaust elbow and the center of the crank axis is 370 mm If the distance between the bottom of the exhaust elbow and the waterline is less than 15cm or if the waterline is above the water injection point there is a risk of flowing back siphoning by engine stopping and outside seawater entering through the transom exhaust hole e order to avoid this risk an air ventilation unit and exhaust riser are needed If in doubt about exhaust system installation please contact your nearest Hyundai SeasAll dealer Exhaust elbow bottom
53. y engine oil and so on will flash When the engine starts normally the lamps all go off If there is a problem the specific lamp will come on You should contact your nearest dealer and have the engine checked as soon as possible OVERVIEW OF EOI SYSTEM Engine Operating Indicator E an HYUNDAI SEASALL 6 Engine Oil pressure Warning Lamp Alternator Charging Warning Lamp Engine Check Lamp O Information LCD 6 Water detection Warning Lamp Buzzer Reset Switch Dimmer Switch Q Function Switch INFORMATION LCD TOTAL FULL RUNNING TIME 00 T ven KWE L CX ET DOHC db LI LI 1 Engine rpm RPM 6 Running Time Hr 2 Engine Coolant 7 Total WOT Running Time Hr 3 Throttle Lever Position 8 Glow Plug Indicator lamp 06 4 Fuel Consumption 9 Neutral Lever Alarm lamp D Neut 5 Battery Voltage V 10 DTC Diagnosis Trouble Code we HYUNDAI SEASALL LI HYUNDAI SEASALL SWITCHES INSTALLATION amp OPERATION MANUAL U125 Series Engines Buzzer Reset Switch This switch is used for turning off the alarm temporarily Dimmer Switch This switch is used for controlling brightness of the other gauges connected to the EOI Function Switch This switch is used for changing the information display on the LCD ALARM LAMPS Alarm may sound when alarm lamps flicker WATER SENSOR LAMP T
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