caution - Hyundai SeasAll
Contents
1. jon 10109 JOSUaS uonisog Josues duet URA 15008 10595 5 0 aunsseid oJunsseJd Jami SED La e Lu ie ow anssold 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 5 TECHNICAL DATA U125S U125P U125J Engine type 4 stroke 16 valve After cooled direct injection water cooling Stroke mm 84 5 17 3 1 Compression ratio Max torque kgm speed rpm 2000 3700 Injection system Common rail direct injection at least CN 51 as per DIN EN 590 O AN C2 O1 or m Diesel fuel Intake deeg bar 2 5 bar 4000 rpm Coolant quantity liter Coolant cap opening pressure bar Engine oil liter Engine oil pressure bar 2 3 at 1800rpm 100 C oil temp Max 45 130 Exhaust gas pressure kPa Alternator A Engine diagnosis Weight kg Battery capacity AH e 220 12V 150AH recommended 42 Thermostat opening temp 85 starting to open 95 fully open Idle rom warmed up rev min 730 135 Permissible eng coolant temp 105 Propulsion system Shaftdrive Permissible eng oil temp Waterjet ZE 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series2. 25 e EE EE return return Injector Fuel Temperature Sensor Water in Fuel Sensor 5 return Fuel feed low Fuel return Fueltank mw Fuel feed high 27 27 HYUNDAI SEASALL ELI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines FUEL FLOW Fuel tank Rack fuel filter Fuel flor low pressure Fuel filter with water detection sensor amp High Common rail l Injector or return to fuel tank LOW PRESSURE FUEL LINE 2 AA Na NANG Feeding line from fuel tank to fuel filter Feeding line from main fuel filter to high pressure pump Return line to fuel tank engine out D 2 The internal diameter of all fuel lines must be at least 8 mm 28 27 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 kK m is fully released at the idle position and fully pulled i 7 aA 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 Engine Operating Indicator 1 Idle position setting Make sure that the position value indicates 0 in neutral condition Sa 0 500 HYUNDAI SEASALL 2 Ful
3. Throttle Pedal Position Sensor Switch Circuit High Input 57 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines e rem 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 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Heat exchanger Sacrificial anodes 1 Sacrificial anode must be replace every 250hr The sacrificial anode check especially frequently when used in saltwater is recommended to replace the sacrificial anode at the start of each season CAUTION e DON T OPERATE ENGINE WITHOUT ANODES IT IS HARMFUL TO YOUR ENGINE e CLOSE THE SEAWATER VALVE BEFORE THIS MAINTENANCE e MAKE SURE TO CHECK THE ANODE PLUG IN ACCORDANCE WITH THIS MANUAL DON T LOOSEN COOLANT DRAIN PLUG 59 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 1 ENGINE ON OFF 1 Before starting the engine you should check engine oil coolant gearbox oil fuel gauge raw water pump battery and so on 2
4. 65 1 THE INITIAL RUNNING CHECK 65 2 MAINTENANCE SCHEDULE 21 1 66 3 STERNDRIVE amp TRANSMISSION MAINTENANCE SCHEDULE 66 4 MAINTENANCE 2 2 67 CHAPTER 14 TROUBLESHOOTING GUIDE 69 CHAPTER 15 WARRANTY 71 WARRANTY REGISTRATION CARD 76 2 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL 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 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 0125 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 The operator is responsible fo
5. S T ven AOI land CC LOL LI S 1 Engine rom RPM 6 Running Time Hr 2 Engine Coolant Temp 7 Total WOT Running Time Hr 3 Throttle Lever Position 8 Glow Plug Indicator lamp 60 4 Fuel Consumption 9 Neutral Lever Alarm lamp Neut 5 Battery Voltage V 10 DTC Diagnosis Trouble Code 43 27 HYUNDAI SEASALL LI HYUNDAI SERSRLL 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 This lamp informs you to extract water from fuel filter If 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 ENGINE OIL LAMP CHECK ENGINE LAMP T
6. 65 P0341 P0381 P0562 P0563 P0601 P0602 P0604 P0605 P0606 P0611 P0617 P062D 062 0650 Malfunction Indicator Lamp MIL Control Circuit P0670 P0671 P0672 P0673 P0674 P0675 P0676 P0683 P0684 P0685 Camshaft Position Sensor A Circuit Range Performance Glow Plug Heater Indicator Circuit System Voltage Low oystem Voltage High Internal Control Module Memory Check Sum Error 67 Control Module Programming Error Internal Control Module Random Access Memory RAM Error Internal Control Module Read Only Memory ROM Error 70 ECM PCM Processor 71 72 73 74 75 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 81 82 83 84 85 Cylinder 5 Glow Plug Circuit Cylinder 6 Glow Plug Circuit Glow Control Module Signal Glow Control Module Performance ECM PCM Power Relay Control Circuit Open P0642 sensor Reference Voltage Circuit Low 87 P0643 Sensor Reference Voltage A Circuit High 88 P0652 Sensor Reference Voltage B Circuit Low P0653 sensor Reference Voltage Circuit High P0698 Sensor Reference Voltage C Circuit Low P0699 Sensor Reference Voltage C Circuit High P1145 91 2 CO Overrun Monitoring 56 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HY
7. HYUNDAI SEASALL U125 Series Engines EOI PIN ASSIGNMENT CN1 MAIN EOI CONNECTOR FROM ENGINE 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 H 10 Ground 22 Not used 11 Not used 23 Ground 12 Water detection signal 24 Not used CN2 DUAL EOI CONNECTOR 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 Charging 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 46 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CN3 TACHOMETER Main relay power RPM signal Ground Illumination Illumination CAN_H L Not used E E CN4 COOLANT TEMP GAUGE Coolant temperature signal Ignition power Ground Illumination Illumination Not used oe 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 GA sk en CN7 EXTERNAL
8. e Dry the wet air filter in the shade for 2 3 hour You can reduce drying time by blowing with a hair dryer on COLD or by blowing with low pressure compressed air CAUTION Do not use high pressure air high pressure water or hot air to clean and or dry the air filter These can damage the performance of the air filter Apply air cleaner oil over the outside of the filter If too much oil is applied it will reduce performance Reassemble air filter to engine CAUTION WHEN REMOVING THE AIR FILTER BE CAREFUL THAT DUST OR DIRT DO NOT ENTER THE AIR INTAKE OR DAMAGE MAY RESULT AND DO NOT RUN WITHOUT AIR CLEANER THIS COULD RESULT IN EXCESSIVE ENGINE WEAR USE OF NON GENUINE PARTS COULD DAMAGE THE TURBO CHARGER OR ENGINE 32 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular intervals 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 perform
9. 27 HYUNDAI SERSRLL INSTALLATION amp OPERATION MANUAL U125 SERIES ENGINES Min 246 114 736 5 4 1 a l el 1 1 d D q 1 25 d K Dh 22 fo gt Sale 9 9 5 L Sr h Ch Me Tr wa _ 1 1 lt lt iar P si mazo AN gel A 5 LT be st 657 6 2 E N P i 1 Applicable to 01255 U125P 1125 model 2nd Edition LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines TABLE OF CONTENTS ABOUT THIS MANUAL SAFETY EE HE ET LE 4 APPROXIMATE CONVERSIONS FROM STANDARD 5 CHAPTER 1 ENGINE OVERVIEW 6 1 ENGINE COMPONENTS 6 2 ENGINE SUSPENSION 7 3 ENGINE IDENTIFICATION 8 4 SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE 10 5 TECHNICAL DATA 1 6 PERFORMANCE CURVE 13 7 BELT LAYOUT 8 ENGINE 14 CHAPTER 2 ENGINE MOUNT SYSTEM 16 1 ENGINE MOUNTING REQUIREMENTS 1 16 2 MOUNT DIMENSIONS 1 16 3 ENGINE MOUNT TOOL FOR STERNDRIVE MODEL 17 CHAPTER 3 COOLING 8 EXHAUST SYSTEM 18 1 SCHEMATIC
10. 6 Engine coolant outlet Engine oil cooler Thermostat opened opening temp 85 Exhaust manifold Expansion tank Heat Engine coolant inlet ENGINE COOLANT The high pressure cooling system has a reservoir filled with year round antifreeze coolant The reservoir is filled at the factory The coolant level should be between MAX and MIN marks on the side of the coolant reservoir when the engine is cool 23 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines e H 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 f frequent additions are required see an authorized dealer for a cooling system inspection Use only soft demineralized water in the coolant mixture 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 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 Ambient Temperature 15 13 F 45 Q Engine coolant drain plug e n order to drain engine coolant use a sc
11. 8 INSTRUMENT SYSTEM 00 2 2 39 1 INSTRUMENTS CONNECTION 39 2 CUT OUT FOR GAUGE 1 1 210 00000 42 CUT OUT FOR EOI SYSTEM 42 CHAPTER 9 EOI SYSTEM tania sevi kk eea eea udis Eia uar dd cens 43 1 OVERVIEW OF EOI SYSTEM 43 1 1 INFORMATION LCD ITEM HIR 43 a A 44 1 3 ALARM LAMPS 44 0 04 44 2 EOI CONNECTIONS AANEREN 45 EOI PIN ASSIGNMENT 46 4 NEUTRAL SWITCH AND DUAL EOI CONNECTION 48 5 TRIM WIRING CONNECTION DIAGRAM 49 Coo ote seen dette ewes an ea KA AN papakan a BAE aaa 50 7 ALARM AND DTC DIAGNOSIS TROUBLE CODE 51 7 1 ALARM AND DTC DIAGNOSIS TROUBLE 51 7 2 DTC DIAGNOSIS TROUBLE CODE LIST 54 CHAPTER 10 ANTI CORROSION SYSTEM 59 CHAPTER 11 ENGINE ORBERATION 60 1 ENGINE ON OFF E 60 2 ENGINE BRAKE 61 3 EMERGENCY kde rt Pc EUR va aca ia c du pa 62 CHAPTER 12 ENGINE STORAGE 63 WINTER 022 1 0 01 64 CHAPTER 13 MAINTENANCE
12. DIAGRAM OF ENGINE COOLING CIRCUIT 18 2 THE FLOW OF SEAWATER 19 2 1 WATER PICKUP 19 2 2 SEAWATER STRAINER 19 2 3 SEAWATER PUMP 20 2 4 SEAWATER DRAIN 22 3 THE FLOW OF ENGINE COOLANT 23 3 1 ENGINE COOLANT 25 3 2 REMOVING AIR BUBBLE eee 25 3 3 CABIN HEATER CONNECTION 26 4 EXHAUST SYSTEM 27 CHAPTER 4 FUEL SYSTEM ener nene og 1 THE FLOW OF FUEL 28 2 LOW PRESSURE FUEL UNE 29 3 ACCELERATION SENSOR AND CONTROL LEVER 30 4 RECOMMENDED FUEL QUALITY 34 5 DRAINING WATER FROM FUEL FILTER 31 CHAPTER 5 AIR INTAKE SYSTEM 34 1 ENGINE ROOM VENTILATION een 32 2 AIR FILTER MAINTENANCE 33 CHAPTER 6 LUBRICATION SYSTEM 33 1 ENGINE OIL LEVEL CHECKS 2 33 2 RECOMMENDED OIL QUALITY 3A 3 ENGINE OIL EXTACTION PUMP 34 4 OIL FILTER REPLACEMENT 35 E 27 HYUNDRI SERSRLL LI HYUNDAI SERSRLL INSTALLATION amp OPERATION MANUAL U125 Series Engines TABLE OF CONTENTS CHAPTER 7 ELECTRICAL SYSTEM 35 1 BATTERY CABLE CONNECTION 35 2 TERY CHECKS Vat a ag a aaa a eg anaa a 36 3 FUSE AND RELAY 220 a gan aan Kaanan ag va bakune aa 37 CHAPTER
13. J HYUNDAI SERSRLL LJ INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 3 ENGINE MOUNT TOOL FOR STERNDRIVE MODEL The genuine alignment tool of Hyundai Seasall Five step ee The alignment tool of MerCruiser Four step 6 Mount hole for U125 model e Mount hole for D170 and D150 model e 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 HYUNDAI SEASALL ENGINES MUST BE USE THE GENUINE ALIGNMENT TOOL OF HYUNDAI SEASALL OTHER THE DRIVE COUPLER WILL BE DAMAGED 17 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CHAPTER 3 COOLING amp EXHAUST SYSTEM 1 SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT AIR Ir H CABIN HEATER CONNECTOR E A Fe THERMOSTAT i COOLANT x 3 PUMP X P1 4 1 J 0 m 3 SEAWATER _ eme gt SEAWATER PUMP p_ INTAKE AIR EXHAUST AIR COOLANT THERMOSTAT CLOSED 4 OPENED saka kak m gt COOLANT THERMOSTAT OPENED ES 27 HYUNDRI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Ser
14. Main EOI Dual Opt Engine Operating Indicator e e ER ia Gauges only available TRES application 7 HYUNDAI SEASALL Engine to EOI wiring standard 7m option 10m EOI to RPM gauge 85 wiring EOI to coolant temp gauge 52 wiring EO to volt gauge 52 wiring EOI to ignition key switch 21 4 wiring O Dual EOI wiring option for dual stage For information about the installation and operation of the Engine Operating Indicator system please refer to Chapter 10 39 27 HYUNDRI SERSRLL ELI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines STANDARD INSTRUMENTS HYUNDAI SEASALL 136 204 5 RPM Gauge 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 the position Avoid max rom and WOT Wide Open Throttle before a cold engine is fully warmed up as it can harm the engine The gauge needle should be in proper range If 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 If the gauge blinks and an EOI alarm sounds check the coolant temperature and level If the coolant 15 low refill it e H the temperature of the engine coolant is higher than 105 the en
15. 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 21 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 2 4 SEA WATER DRAIN e Remove anode then please let the sea water drain e Removing and Inspection procedure 1 Remove the anode plugs on the heat exchanger A and the intercooler B 2 Squeeze the hose C connecting the heat exchanger to the intercooler several time to ensure that seawater does not remain in the hose and bundle A Anode plug water 3 While anodes are removed inspect for usability INTERCOOLER See Chapter 11 Anti Corrosion System 4 Replace anode plugs before running engine 22 27 HYUNDAI SEASALL ELI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 3 ENGINE COOLANT FLOW THERMOSTAT CLOSED 6 Engine coolant outlet Engine oil cooler Exhaust manifold Engine coolant inlet THERMOSTAT OPENED
16. When you start the engine check that the engine throttle leverCD is at neutral position If not the engine may not start or there is possibility of shooting off Especially if your boat is equipped with a neutral safety lever when the engine throttle lever is not at neutral position you can t crank You can also check this on the EOI 3 After starting the engine release the key immediately to prevent damage to the start motor 5 Avoid max rom and WOT Wide Open Throttle before the cold engine is fully warmed up 6 At a cold start it takes a few or more seconds to start the engine 7 If the engine does not start in 10 seconds release the key After 10 seconds try again This method can help avoid start motor damage WARNING DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION EMISSION GAS IS HARMFUL 60 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 2 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 1 DO NOT operate engine at idle rom for extended periods of time during the first 10 hours 2 DO NOT operate at any one constant speed for extended periods of time 3 DO NOT exceed 75 of full throttle during the first 10 hours except during the engine initial Break In Procedure After the next 10 hours
17. 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 RPM Gauge 86 mm Coolant Temperature Gauge 53 mm 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 42 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines The Engine Operating Indicator EOI 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 battery 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 Oil pressure Warning Lamp e Alternator Charging Warning Lamp e Engine Check Lamp O Information LCD Water detection Warning Lamp Buzzer Reset Switch 63 Dimmer Switch Function Switch HYUNDAI SEASALL INFORMATION LCD TOTAL FULL RUNNING TIME 00 rmm ven UNES
18. 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 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 SERSRLL LI INSTALLATION amp OPERATION MANUAL U125 Series Engines HYUNDAI SEASALL 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 a filter Boost pressure amp air temp sensor Cam Position Se
19. occasional operating at full throttle 5 minutes at a time maximum is permissible 4 AVOID full throttle accelerations from neutral position 5 DO NOT operate at all full throttle until engine reaches normal operating temperature 6 FREQUENTLY CHECK engine oil level and add oil if necessary STOPPING THE ENGINE The engine should be run for a few minute at idle in neutral before turning it off This will avoid boiling the cooling system and even out the temperature This is especially important if the engine has been operated at high engine speeds and or with heavy loads Shutting down the engine in this fashion will extend the life of your engine WARNING DO NOT OPERATE IN SPACES WHERE THERE IS NO AIR CIRCULATION EXHAUST GAS IS HARMFUL 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 3 EMERGENCY STOP e 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 62 27 HY
20. ASALL A 37 Cheoldobangmulgwan ro Uiwang si Gyeonggi do 437 815 Korea www hyundai SeaSall com Fax 82 0 70 8244 8555 Tel 82 0 70 8620 8035 seasall info hyundai seasall com ISSUED Feb 2014 Copyright 2014 Hyundai SeasAll Co Ltd All rights reserved
21. Charging discharging energy error P0206 Open load P0276 Short circuit ground P0277 Short circuit battery Defect resistance cylinder1 Charging discharging energy error Error path for short circuit of charging s witch is detected Maximum positive deviation of rail press ure exceeded P0269 P0272 P0275 P0278 P061 1 P0087 Maximum negative deviation of rail pres sure exceeded P1171 Minimum rail pressure exceeded P1172 Maximum rail pressure exceeded P0238 Voltage above upper limit P0088 P0237 Voltage below lower limit P0069 Not plausible with atmospheric pressure sensor P0653 Supply voltage above upper limit P0652 Supply voltage below lower limit B2 0125 Series Engines Expectation Cause s Injector circuit Injector Injector circuit Injector Injector circuit Injector Injector circuit Injector Charging system battery alternator check Injectors circuit e PRS circuit e PRS e APS 2 power supply circuit e BPS power supply circuit e ECM Fuel filter RPS check e P PRV PRV check stuck BPS circuit e RPS power supply circuit e APS 2 power supply circuit 27 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Failsafey Failsafety Description Expectation Cause s P0254 Short circuit to battery of metering unit output PPRV Short circuit
22. Engines 6 PERFORMANCE CURVE 01255 amp U125P MODEL HB F 15 75 mi Well LLL 5 25 0 0 1000 1500 2000 2500 3000 23500 4000 4500 Torque kgm Power ps F C L h x LAC 2 ere ar gl LEET CTT e 1000 1500 2000 2500 3000 3500 4000 4500 Engine Speed rpm BSFC Brake Specific Fuel Consumption FC Fuel Consumption 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 125 MODEL Power ps 8 200 BSFC Brake Specific Fuel Consumption FC Fuel Consumption 12 27 HYUNDRI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 7 BELT LAYOUT amp ENGINE DIMENSIONS POLCA MODEL 0125 WITH SP MODEL U125 WITHOUT SP ALTERNATOR LAN AN ALTERNATOR DP DRIVE PULLEY DP DRIVE PULLEY IP IDLERPULLEY IDLER PULLEY WP WATER PUMP PULLEY WP WATER PUMP PULLEY SP SEA WATER PUMP Bobtail Y Lal CE Fon n n a T Se a5 E Em LO J RE He e RH IFS WA WT SS 1 ee Se a E SE ES r A Li i eh 1A SH 1 lan Side view for shaftdrive Side vie
23. Fuel oil coolant water and fluid leaks Transmission fluid level mE Steering operation throughout range Power trim operation stern drives Forward Neutral Reverse gear operation 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 2 MAINTENANCE SCHEDULE O Check Clean lt gt Check Replace if necessary Replace Which ever comes first Every Every 250 Every 500 Every 1 000 1 500 Hours Hours Hours 1 years 2 years 4 years Hours 5 years Coolant level and leakage1 Sea water strainer ol Exhaust system leakage le Fuel system leakage ol Engine oil level and leakage Battery voltage Steering system oil level and leakage ol Transmission oil level and leakage Gl Fuel filter and water separator e Engine oil and oil filter e Sacrificial anode 1 Connection and contamination in electric Pf oe system Loose of the bolts and nuts 1059 Loose and the damaged hose clamps i Exhaust bellows 10 Sea water pump impeller of e __ __ 2 Drive belt Heat Exchanger included tube bundle Intercooler included tube bundle Turbocharger Replace the coolant every 2 years For more detailed transmission follow the transmission manufacturer s manual NOTE These procedures are considered normal maintenan
24. GINE SUSPENSION 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 Ep T ml 4 Ej IV of Ca 9 Em a ha 7 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 3 ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the ECU box see figure SERIAL NUMBER ON THE ENGINE BLOCK ENGINE NAME PLATE HYUNDAI SEASALL Hyundai SeasAll Co Engine Type 25 Engine Family D4FB Rated Power 125ps 4000rpm Engine Weight 220kg Max RPM 4400 of cylinders 4 Cylinder bore mm 77 2 Piston stroke mm 84 5 Engine Serial No BU993700 ki 27 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL U125 Series Engines HYUNDAI SERSRLL 4 SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE Josues jang mem uonisod unjal jang E yug Jon i 105095 5 5 det Josues amp 009 5 S ei 19N nd moi E jon ul JOSUAS Josues 5A
25. Ground Permanent power Ignition power Neutral switch Neutral switch Charging signal RPM signal Dimmer kad nuu mE 19 Ho St por E de 47 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL 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 you should connect the wiring between 5 external connector of the main and 5 external connector of the dual EOI 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 48 27 HYUNDAI SEASALL ELI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines TRIM WIRING CONNECTION DIAGRAM STERNDRIVES ONLY Ee TRIM dian mm 59 LIMITE 10 12 14 m T1773 CE TRIM SV 7 VOLT D N m HED NDER D CE Ten a za
26. INJURY TO YOURSELF WHENEVER PERFORMING ANY MAINTENANCE 67 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS 68 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Starter motor does not crank the engine Possible Causes eEngine stop switch ON position Engine is not shifted to neutral position Safety Stop Switch activated Wrong neutral switch connection to EOI Weak battery or battery connections are loose 4 en ai corroded Starter motor solenoid or slave solenoid failure Ignition key switch failure Blown fuse at Wiring or electrical connection fault Defective ECU Engine cranks but does not start Possible Causes Weak battery or bad starter motor Incorrect starting procedure Faulty fuel filter or electric fuel pump Engine starts with difficulty or starts and stalls Possible Causes Low fuel pressure in fuel rail in high pressure fuel circuit rail pressure sensor signal Oil level too high or too low program error or hardware fault Engine idle is rough Possible Causes Fuel return line not connected at injector Low compression pressure rail pressure sensor signal clamp poorly tightened Wiring harness open or poor co
27. Turbocharger Boost Sensor A Circuit High Fuel Pump Secondary Circuit High Turbocharger Over boost Condition P0252 Injection Pump Fuel Metering Control A Range Performance P0253 P0254 P0261 P0262 P0263 P0264 P0265 P0266 P0267 P0268 P0269 P0270 P0271 P0272 P0273 P0274 P0275 P0276 P0277 P0278 P0299 P0300 P0335 P0336 P0340 Injection Pump Fuel Metering Control A Low Cam Rotor Injector Injection Pump Fuel Metering Control A High Cam Rotor Injector Cylinder 1 Injector Circuit Low Cylinder 1 Injector Circuit High Cylinder 1 Contribution Balance Cylinder 2 Injector Circuit Low Cylinder 2 Injector Circuit High Cylinder 2 Contribution Balance Cylinder 3 Injector Circuit Low Cylinder 3 Injector Circuit High Cylinder 3 Contribution Balance Cylinder 4 Injector Circuit Low Cylinder 4 Injector Circuit High Cylinder 4 Contribution Balance Cylinder 5 Injector Circuit Low Cylinder 5 Injector Circuit High Cylinder 5 Contribution Balance Cylinder 6 Injector Circuit Low Cylinder 6 Injector Circuit High Cylinder 6 Contribution Balance Turbocharger Under boost Random Multiple Cylinder Misfire Detected Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range Performance 61 Camshaft Position Sensor A Circuit Malfunction 55 27 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Q P code DESCRIPTION 62 63 64
28. UNDAI SEASALL LI INSTALLATION amp 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 CAUTION FOR WINTER STORAGE SEAWATER SHOULD BE DRAINED FULLY BY LOOSENING THE HEAT EXCHANGER ANODE REFER TO CHAPTER 10 63 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines WINTER STORAGE Protect your engine from freezing and corrosion damage by following the procedures indicated below LUBRICATION SYSTEM COOLING SYSTEM Start the engine and allow it to reach normal IF the seawater system is not filled with an operating temperature antifreeze solution as per the instructions above completely drain the seawater system by removing the heat exchanger and intercooler Turn off the engine Drain the engine oil using the oil extraction pump If the oil extraction pump is not installed drain oil by removing the anodes oil pan drain plug Remove the sea water pump impeller and store Change the oil and oil filter and refill the in a dark place out of sunlight engine with new oil according to technical Check all connections with inlet hose
29. UNDAI SEASALL U125 Series Engines P code DESCRIPTION P1171 P1172 P1173 P1185 P1186 P1187 P1188 P12BF P1302 P1307 P1308 P1309 P1325 P1636 P1652 P1653 P1655 P1670 P1671 Injector IQA Checksum Error P1679 EMS Data Fail Data frame CS Message error P1694 P1695 P1697 HI SCAN message Error P2009 Variable Swirl Actuator Control Circuit Low Bank 1 P2010 Variable Swirl Actuator Control Circuit High Bank 1 P2015 P2016 P2017 P2122 P2123 P2127 P2128 Minimum Rail Pressure Exceeded Maximum Rail Pressure Exceeded Set Value of PCV not in Plausibility Range Maximum Pressure Exceeded Minimum Pressure at Engine Speed Too Low Regulator Valve Stick Leakage ECU torque monitoring Not plausible signal ECU torque monitoring ADC error Acceleration Sensor Range Performance Acceleration Sensor Circuit Low Input Acceleration Sensor Circuit High Input Glow Relay Malfunction Voltage Regulator for Injector Ignition Key No Signal After Run Check Error Tachometer Output Fault Invalid Injector IQA C2I EMS Message Error EMS Memory Error Variable Swirl Actuator Position Sensor Switch Circuit Range Performance Variable Swirl Actuator Position Sensor Switch Circuit Low Variable Swirl Actuator Position Sensor Switch Circuit High Throttle Pedal Position Sensor Switch D Circuit Low Input Throttle Pedal Position Sensor Switch D Circuit High Input Throttle Pedal Position Sensor Switch E Circuit Low Input
30. ance and maximum protection during all types of operation select only those lubricants which Satisfy the requirement of the API or ACEA classification Have the proper SAE grade number for the expected ambient temperature range ACEA Above B4 Service oil quality should conform to ACEA or API API Above CH A Classification T 15W 40 15 above Il quality 10W 30 20 40C SAE 5W 30 25C 40C OW 30 10 below 33 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ENGINE OIL EXTACTION PUMP Allow the engine to warm up at least 5 minutes Remove the engine oil inlet cap and oil filter e The oil drain hose is connected to the oil extraction pump CD route the loose end of the hose into the container being used for the oil change 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 5 7 liters is completely pumped out OIL FILTER REPLACEMENT 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 Th
31. ble 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 modifications or freezing temperatures Haul out crane launching or towing charges removal and or replacement of boat partitions or material for necessary access to the product 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 loss of time or income the 5 responsibility Use of other than Hyundai SeasAll genuine replacement parts when making warranty repairs 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 Failure of any parts caused by lack of cooling water Damage caused by blockage of the cooling system by foreign matter Use of fuels and lubricants that are not suitable for use with or on the product as specified in the Installation and Operation Manual Normal wear and tear Storage damage partially painting scratch Cost resulting from ineffective or repeated repairs improper repairs due to misdiagnosis Owner s personal cost indirect loss resulting from maintenance TRANSMISSION AND STERNDRIVE WARRANTIES Transmissions and drive systems ZF Mari
32. ce CAUTION YOU SHOULD EXERCISE THE UTMOST CARE TO PREVENT ENGINE DAMAGE OR INJURY TO YOURSELF WHENEVER PERFORMING ANY MAINTENANCE 66 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 3 STERNDRIVE amp TRANSMISSION MAINTENANCE SCHEDULE Maintenance Whichever comes first Maintenance intervals l 100h Daily Item Check sterndrive unit oil level Transmission Trim pump oil level Steering fluid level Check water pickups for debris or marine growth Check water strainer and clean 0 Inspect sterndrive unit anodes and replace if 50 eroded Lubricate propeller shaft and the retorque nut Touch up power package paint and spray with Corrosion Guard Transmission Change sterndrive unit oil Transmission e Retorque connection of gimbalring to steering shaft e Check steering system and remote control for loose missing or damaged parts Hubemecesamimags e Inspect U joints splines and bellows Lubricate U joints splines e 9 Check gimbal bearing and engine coupler e Check continuity circuit for loose or damaged connetions e Check Mercathode unit e Filter replacement ZF Transmission 1 The first replacement must be preformed 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 ENGINE DAMAGE OR
33. ce 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 amp OPERATION MANUAL U125 Series Engines 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 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines APPROXIMATE CONVERSIONS FROM STANDARD mm 009 inch LENGTH cm 04 inch LENGTH inch 254 m m am mw o m ow
34. dealer or by the Distributor responsible for the territory It is Hyundai SeasAll s Distributor s responsibility to communicate all warranty issues to the factory in a timely manner so that they can be quickly resolved 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 The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS COVERED Hyundai SeasAll warrants its products to be free of defects in material and workmanship during the warranty period LIMITATIONS EXPENDABLE PARTS Not included are the following expendable parts Filters fuel filter engine oil filter air filter Lubricants engine oil coolant power steering oil Rubber products seawater pump impeller rubber hoses belts engine coupler rubber isolation mounts bellows Gaskets anodes 74 27 HYUNDRI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines WHAT IS NOT COVERED Fuel injector or filter cleaning Belt ca
35. e Circulate into the seawater system by running the engine 64 27 HYUNDAI SEASALL LI HYUNDAI SERSRLL INSTALLATION amp OPERATION MANUAL U125 Series Engines 1 THE INITIAL RUNNING CHECK BEFORE THE WATER TEST seawater inlet valve open Engine coolant level Cooling system hose clamps tight Engine oil level ON THE WATER TEST Boat drain plug in place Check before putting boat in water Seawater pump operation Seawater strainer correctly mounted Clean and tightly closed Power steering fluid level Engine alignment propulsion only Drive belt tension Fuel leaks Oil leaks All electrical connections tight EOI warning system operating Coolant leaks Battery fully charged and secured Water leaks All fuel connection tight Exhaust leaks Exhaust system hose clamps tight EOI and gauges operation Pitty ttt __ LL ie Engine mount tight Engine emergency stop switch operation E Idle RPM within specifications Engine alignment Correct rotation propeller Installed and torque Engine coolant and oil drain plug closed OIL _ ETT TTT econ in forward gear PROPULSION CHECKS Stemarveuntotieet Power rim ot evel genge _ Deieren _ Power tim cyinders fasteners ig _ Throttle shift and steering system fasteners tightened properly AFTER THE WATER TEST
36. e Warranty year hour year Hour 5006 Standby Power 1 000 4 3 000 WARRANTY STARTING DATE Warranty Begins 1 When engine is delivered to the first retail purchaser 2 When the engine 15 first leased or rented 3 When the engine is operated for greater than 10 hours whichever occurs first 4 When the products reaches the first day of the 7 month after the product has been shipped from Hyundai SeasAll the warranty date will be started automatically If you submit the Pre Delivery Inspection Card and Warranty Registration Card the starting date can be changed to the date on your documents WARRANTY REGISTRATION Warranty Registration Card must be submitted to Hyundai SeasAll within 30 days of the Warranty Starting Date The Warranty Registration Card identifies information on customer and product models and serial numbers date of sale type of use and the selling dealer etc If the Warranty Registration Card and Pre Delivery Inspection Card are not approved or not submitted to Hyundai SeasAll within 30 days from Warranty Starting Date Hyundai SeasAll reserves the right to decline warranty reimbursement TRANSFER OF WARRANTY COVERAGE BETWEEN OWNERS 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 the revised Warranty Registration Card and Pre Delivery Inspection Card should be sub
37. em e The 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 e f 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 n order to avoid this risk air ventilation unit and exhaust riser are needed If in doubt about exhaust system installation please contact your nearest Hyundai dealer Exhaust elbow bottom 150mm Outer diameter of elbow is 60 5mm Sea waterline 3 0mm Center of crank axis CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION PLEASE CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER 26 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL 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 Pressure Pump Common rail e pressure E Limit regulator return valve valve I High 1
38. en 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 OIL CHANGED BY YOUR NEAREST HYUNDAI SEASALL SERVICE DEALER 34 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CHAPTER 7 ELECTRICAL SYSTEM BATTERY CABLE CONNECTIONS The size of battery cable should be at least 40mm within a length of 4m e And it should be 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 e Connect the battery cable to system ground engine block Battery cables should be clean and tightly connected e c Po STARTER MOTOR 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 35 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL 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
39. gine power will decrease You should check the engine cooling system 40 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 1 3 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 When press the LB RB button the below information change the next information progressively e f there is a problem in the engine the multifunction LDC display MFD show the related symbol and alram In order to move Previous page LB Next page RB If happens Eng Check symbol CHECK Coolant high symbol temp gt 110 C RPI Low Battery voltage symbol Glow plug symbol Fuel consumption default Total and trip hour counter LB RB 3s Reset LB 3s or RB 35 Decrease or increase 41 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines BATTERY VOLT METER GAUGE e This gauge will work when the key is in the position This gauge indicates real time battery voltage e f battery voltage is not sufficient the engine can not be started For
40. he 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 2 3 SEAWATER PUMP e The internal diameter of hose connected to seawater pump inlet should be 32mm The 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 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 VACUUM PROCESS THIS CAN CAUSE THE ENGINE TO OVERHEAT 20 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CHECKING SEA WATER PUMP amp IMPELLER e Stop the engine and close the water valve e Remove the impeller housing cover e Remove the impeller from inside the seawater pump e Check the condition of impeller and bushing e Apply soapy water to impeller when assembling and reassemble towards rotation direction e Replace of the O ring on the impeller housing cover e Open the water valve e
41. his 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 This lamp informs you that the engine has a serious problem You can see the DTC on the LCD of the EOI It may be possible to drive at limited rom The ECU will control the functions to protect the engine You should immediately have the engine checked at the nearest service shop 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines EOI CONNECTIONS gt 2 23 19 62 JO Rear view 10 6 3 1 Connection plug CN1 from engine 6 Connection plug CN6 service tool 2 Connection plug to dual EOI 7 Connection plug CN7 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 45 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL
42. ies Engines 2 SEAWATER FLOW OPEN COOLING CIRCUIT Water strainer Water valve Water pickup 1 Seawater pump 2 Intercooler 3 Transmission oil cooler 4 Heat exchanger 5 Exhaust elbow Sea water 2 1 WATER PICKUP Water pickup should be installed in an area where it wont pick up air bubbles and will access clean water during all phases of the engine operation For use in sterndrive models please see the section Installing Sterndrive Seawater Pickup of the BRAVO MODELS INSTALLATION MANUAL included in the original packaging further safety you can use an additional transom or bottom mounted clamshell type water pickup 2 2 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 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 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CLEAN STRAINER FILTER Stop the engine and close t
43. ine Block Casting Crankshaft Forging Connecting Rods Camshaft Forging Transmission Cover Housing Flywheel Housing Intake Manifold Fresh Water Pump Housing and Oil Pan Cylinder Liner or Cylinder Bore scratches are not included in extended major part warranty coverage Commercial Applications Engine Rating Includes Base Engine Warranty uu at es ER maa st soo 3 3 Warranty period is limited by Years or Hours whichever occurs first Major Components Engine Block Casting Crankshaft Forging Connecting Rods Camshaft Forging Transmission Cover Housing Flywheel Housing Intake Manifold Fresh Water Pump Housing and Oil Pan Cylinder Liner or Cylinder Bore scratches are not included in extended major part warranty coverage Hyundai SeasAll Rating Categories For Marine Auxiliary Engine Ratings in accordance with SO 8528 Standby Power 1 Operating less than 500 hours per year with average 90 load of the declared Standby Power 2 No overload capability is available for this rating Prime Power 1 Average power operation is not exceed 70 of the declared Prime Power 2 A10 overload is permissible for 1 hour per 12 hours of operation 3 Maximum prime power shall not exceed 500 hours per year 72 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Marin Auxiliary Engine Extended Major Components Base Engine Engine Rating Included Base Engin
44. l System Pressure Too High Fuel Pressure Regulator 1 Performance Fuel Pressure Regulator 1 Control Circuit Low Fuel Pressure Regulator 1 Control Circuit High Intake Air Temperature Sensor 2 Circuit Low Intake Air Temperature Sensor 2 Circuit High Atmospheric Pressure Sensor Voltage Lower Limit Atmospheric Pressure Sensor Voltage Upper Limit 14 15 16 17 Intake Air Temperature 1 Circuit Low Input Intake Air Temperature Sensor1 Circuit High Input Engine Coolant Temperature Circuit Range Performance Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature Circuit High Input Fuel Temp Sensor A Circuit Low Input 20 21 22 23 24 25 26 27 28 29 30 31 Fuel Temp Sensor A Circuit High Input Fuel Rail Pressure Sensor Circuit Low input Fuel Rail Pressure Sensor Circuit High Input Fuel Rail Pressure Sensor Circuit Intermittent Injector Circuit Error Cylinder 1 Injector Open Load Cylinder 2 Injector Open Load Cylinder 3 Injector Open Load Cylinder 4 Injector Open Load Cylinder 5 Injector Open Load Cylinder 6 Injector Open Load Fuel Pump Secondary Circuit Low 54 27 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Q P code DESCRIPTION 32 33 34 35 36 37 38 39 40 4 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 P0232 P0234 P0237 Turbocharger Boost Sensor A Circuit Low P0238
45. l load position setting Make sure that the position value 96 indicates gud load 90 99 2 at fully forward lever ia ale position not disassemble and adjust the base neutral position of the control lever by moving it HEER Bn to the rear until the condition are met HYUNDAI SEASALL CAUTION YOU SHOULD PERFORM ABOVE PROCEDURES AFTER CONTROL LEVER INSTALLATION WITH THE ENGINE NOT RUNNING BUT WITH THE IGNITION KEY ON 29 27 HYUNDAI SERSRLL 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 If the water in the fuel filter is over the
46. mitted to Hyundai SeasAll s distributor or dealer Upon processing the transfer of warranty Hyundai SeasAll will verify the warranty registration of the new owner WHAT HYUNDAI SEASALL WILL DO Hyundai 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 78 27 HYUNDRI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines OWNER S OBLIGATIONS It is the owner s obligation to install operate maintain and for Hyundai SeasAll engines in accordance with the instructions 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 hauling out launching and transportation BUSINESS PARTNER S OBLIGATIONS is Hyundai SeasAll s Distributor and or Dealer s responsibility to support the retail customer with prompt diagnosis and repair whether or not the engine was sold by the servicing
47. ne Mercury etc are covered under separate warranties provided 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 75 27 HYUNDAI SERSRLL NEW THINKING NEW POSSIBILITIES HYUNDAI SEASALL Date of sale This card is essential for registration of the customer s warranty Please fill out the following registration card in English 5 INFORMATION Name or Company BAN E Mail Address DEALER INFORMATION ENGINE INFORMATION Number of Engines Single Dual E Engine Model eam Engine Serai _ Transom TT engine Mode ____ _ Engine Transom pen _ BOAT INFORMATION REPOWER H Manufacturer stee L1 O O 2 1 LA Bote Pleasure Commercial L Planinno L Dien L Displacement Dealer s Instructions Dealers must complete this card to register the warranty Please return the copy to your national Importer Distributor immediately Unregistered engines are subject to warranty rejection REMARKS SIGNATURE 37 Cheoldobangmulgwan ro Uiwang Si Gyeonggi Do Korea TEL 82 70 8620 8035 FAX 82 70 8244 8555 NEW THINKING NEW POSSIBILITIES LJ HYUNDAI SE
48. nnection Faulty high pressure fuel pump Bad fuel quality or water in fuel Faulty injector Clogged fuel filter air filter eCarbon deposit on the injector 69 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Engine rattling noisy engine Possible Causes Compensation of individual injector not adapted engine coolant temperature sensor signal rail pressure sensor signal Faulty injector injector O ring deposit on the injector Uneven acceleration deceleration Possible Causes Intermittent faulty fuel line connection rail pressure sensor signal program error or hardware fault Leakage in intake system eo turbocharger or leakage in vacuum in high pressure fuel circuit Injector needle stuck Engine stop Possible Causes Run out of fuel Safety Stop Switch activated Crank signals missing Fuel feed line not connected Fuel pressure regulator valve contaminated stuck jammed Leakage in high pressure fuel circuit regulator contaminated stuck jammed Fuel out of specification Faulty alternator or voltage regulator Bad fuel quality or water in fuel Faulty high low pressure fuel pump Clogged low pressure fuel circuit program error or hardware fault Performance loss Possible Causes Compensa
49. ns m em 00 m 16388 m m Lam 61023 VOLUME Lam 022 imp galion VOLUME pee FORCE 4 448 TEMP C 5 9x F 32 FORCE TEMP 0 004 inWc 249 098 TORQUE win 135 TORQUE WEIGHT E kJ kWh 043 BTU Ib BTU Ib ES kJ kWh vu Ss emer Ss FUEL 3 RN FUEL e CONSUMP gikWh 0 0016 CONSUMP g kWh FLOW RATE FLOW GAS EXE GAS mm FLOW RATE FLOW RATE LIQUID pve LIQUID m CRES Ws Ws 03048 K R EE E ER SE mph ose knots mts 1186 we wn om mm wm 5 27 HYUNDAI SERSRLL r N LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CHAPTER 1 ENGINE OVERVIEW 1 ENGINE COMPONENTS ECU Box Engine Oil Gauge Engine Oil Cap Acceleration Lever Sensor Engine Oil Filter Fuel Filter Seawater Pump VGT Intercooler Alternator Injector Oil Extraction Pump Shift Plate Air Filter Turbo Heat Protector Q Engine Oil Exchange Button Belt Drive Engine Emergency Stop Button 49 Coolant Expansion Tank gt 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 2 EN
50. nsor Glow plug Coolant temperature sensor Crankshaft position LIH 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 460kg h minimum engine room vent area is 35cm2 The fresh and cooled air must be pumped into the engine in order to perform at normal power and fuel consumption he temperature at the air inlet should be as low as possible high temperature of inlet air may reduce engine performance SCH 27 HYUNDAI SEASALL ELI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines AIR FILTER MAINTENANCE The original Hyundai SeasAll air cleaner be cleaned and reused f the air filter is very dirty it can increase airflow resistance and reduce flow of air to the engine This can result in reduced power and fuel efficiency Cleaning the air filter should be carry out periodically according to the procedure below Do not clean the filter element with gasoline or other solvent cleaners Remove the air filter from engine Putthe air filter on a flat surface and shake 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 running water of low pressure from the inside toward the outside
51. procedure for maintenance free batteries 20 C 70 F and Connect the load tester clamps to the terminals Pu and proceed with the test as follows If the battery has been charged remove the surface charge by connecting a 300 ampere load for 15 seconds Connect the voltmeter and apply the Read the voltage after the load has been se emm applied for 15 seconds 4 Disconnect the load Compare the voltage reading with the minimum acceptable voltage 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 36 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines FUSES AND RELAY FUSE Standard e An engine s electrical system is protected from electrical overload damage by fuses e 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
52. r 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 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 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 E 27 HYUNDRI SERSRLL LI HYUNDAI SERSRLL SAFETY PRECAUTIONS e Read and understand this operators 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 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 used for inspections and maintenance Hyundai seasAll does not guarantee any damage caused by the use of imitation parts Engine inspection and maintenan
53. rewdriver to loosen the drain plug drain plug is located under the heat exchanger unit 24 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines REMOVING AIR BUBBLES IN COOLANT Start the engine and warm it up at a low rpm e 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 It may cause scalding e Refill with coolant if needed e Reinstall the expansion tank cap e Check the level of the expansion tank regularly CABIN HEATER CONNECTION In order to use a cabin heater an extra coolant circulation pump 15 needed After connecting cabin heater lines engine coolant must be refilled and checked Please check coolant flow direction as shown in the drawing Outer diameter of connection port is 217 3 mm om From Outer diameter of is 19 1 mm WARNING NEVER OPEN THE EXPANSION TANK CAP WHEN THE ENGINE IS OPERATING OR HOT IT COULD RESULT IN SERIOUS PERSONAL INJURY AND MAY CAUSE ENGINE DAMAGE 25 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines EXHAUST SYSTEM e Your Hyundai SeasAll engine s exhaust system consists of a coolant cooled exhaust manifold and a seawater cooled exhaust elbow water injected wet exhaust syst
54. s maintenance specifications Tighten Or replace the connection if necessary Replace or Check the cooling system 500 hours and every two years Heat exchanger amp Inter cooler Check the oil level on the dipstick and if necessary add more oil to reach the correct oil level FUEL SYSTEM INTAKE SYSTEM Check for fuel leaks where the line from the Remove the air filter from engine fuel tank connects to the engine Tighten or replace the connection if necessary Clean the air filter Intake part should be kept hermetically sealed Close the fuel valve Clean the water separating fuel filter Replace the filter element After replacing the filter element open the fuel ELECTRICAL SYSTEM valve to fill the entire fuel circulation line Disconnect the battery cable to system Fill the fuel tank with fresh fuel to avoid EE condensation in the fuel tank Disconnect the battery cable Close the fuel valve Clean the battery cable and terminals Coat the terminal connection with a battery COOLING SYSTEM terminal anti corrosion agent Close the water valve Whenever the battery will be stored for an Connect a freshwater source to the seawater extended period of time be sure the cells are inlet Run the engine at idle to flush all full of battery is fully charged seawater out of the system Fill the cooling system seawater side with a 30 50 solution of anti freez
55. stribute the product in the country in which the 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 SeasAll reserves the right to make any warranty coverage contingent upon proof of proper maintenance This warranty may be rendered invalid at Hyundai SeasAll s discretion based upon 1 Modifications not authorized by Hyundai SeasAll 2 Handling errors mproperly performed Pre Delivery Inspection Unsuitable fuels coolant or lubricants Using the engine outside of the specified duty cycle rating Overloading Improperly performed repairs Improper maintenance interval s No submitted Pre Delivery Inspection Card and Warranty Registration Card ONO C1 Gu 71 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines DURATION OF WARRANTY Leisure Applications Extended Major Components Base Engine Engine Rating Includes Base Engine Warranty Operating less than 1 500 hours per year and Full Power operation lt 10 of total use period Warranty period is limited by Years or Hours whichever occurs first Major Components Eng
56. tion of individual injector not Leakage at the injector adapted Clogged air filter Fuel or intake air temperature too high Oil level too high or too low coolant temperature too high 70 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines HYUNDAI SEASALL RATING CATEGORIES FOR MARINE ENGINE S5 Pleasure Duty Full power operation restricted to within 10 of total use period Cruising speed RPM at engine RPM lt 90 of rated speed RPM Operating less than 400 hours per year 54 Special Pleasure Duty Special Light Duty Commercial Full power operation restricted to within 10 of total use period Cruising speed RPM at engine RPM lt 90 of rated speed RPM Operating less than 1 000 hours per year 53 Light Duty Commercial Full power operation restricted to within 2096 of total use period Cruising speed RPM at engine RPM lt 90 of rated speed RPM Operating less than 1 500 hours per year S2 Medium Duty Commercial Full power operation restricted to within 3096 of total use period Cruising speed RPM at engine RPM lt 90 of rated speed RPM Operating less than 3 000 hours per year 51 Heavy Duty Commercial Uninterrupted and unlimited use at full power APPLICATION OF WARRANTY COVERAGE Warranty coverage is available only to retail customers who purchase from a dealer authorized by Hyundai SeasAll to di
57. to ground of metering a pump pressure P PRV circuit unit output regulator valve P0253 P PRV Open load of metering unit output P0092 Short circuit to battery of pressure control valve output PRV Short circuit to ground of pressure rail pressure daha control valve output PRV circuit regulator valve Open load of pressure control valve output oil pressure Oil pressure low below 0 8 bar Oil switch Oil level Circuit check sensor Charging Error Charging system error Alternator Charging circuit check E C TS ECTS circuit engine coolant temp sensor Coolant temperature high above Depending EOI LCD temp Blinking Cooling line check Note 1 RPM Limit Rated rpm 500rpm Rated rpm 800rpm Note 2 3 would be applied to 5250 220 models 53 27 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines Q FULL DTC DIAGNOSIS TROUBLE CODE LIST P code DESCRIPTION P0016 P0047 P0048 P0069 P0087 P0088 P0089 P0091 P0092 P0097 P0098 P0107 P0108 P0112 P0113 P0116 P0117 P0118 P0182 P0183 P0192 P0193 P0194 P0200 P0201 P0202 P0203 P0204 P0205 P0206 P0231 Crankshaft Position Camshaft Position Correlation Turbocharger Boost Control Solenoid Circuit Low Turbocharger Boost Control Solenoid Circuit High Manifold Absolute Pressure Barometric Pressure Correlation Fuel Rail System Pressure Too Low Fuel Rai
58. undai 5 dealer as soon as possible if a system problem arises VGT Variable Geometry turbocharger APS1 acceleration position sensor1 APS2 acceleration position sensor2 CMPS cam position sensor CKPS crank position sensor Water detection in fuel Cylinder1 injector Cylinder2 injector DTC Expectation Cause s Fail safety Description Note 1 RPM limit 1250 rpm fixed Note 2 3 P2263 EVGT controller overheat learning error Feedback line error PWM failure Short circuit battery Short circuit ground Boost pressure higher than target value Boost pressure lower than target value Overload VGT cooling circuit VGT actuator adaption error Note 2 3 n VGT actuator performance error P2563 P0048 VGT actuator circuit VGT actuator VGT actuator performance error Air leakage check Intercooler VGT actuator performance error HH P0047 P0234 9 0299 2138 Plausibility With Aps2 Violated Voltage Above Lower Limit Voltage Above Upper Limit P2127 P2123 P0643 APS1 2 sensor circuit APS sensor ECM engine control module Supply Voltage Above Upper Limit P0642 Supply Voltage Below Lower Limit P2128 Voltage above upper limit P0653 P0652 Supply voltage below lower limit No camshaft signal Wrong camshaft signal No crankshaft signal engine running poao CMPS circuit P0341 GMRS Supply
59. voltage above upper limit P0335 CKPS circuit CKPS P0336 e Target wheel check Wrong crankshaft signal restart e Water in fuel fuel filter drain out water and check the fuel in fuel tank e Warning lamp circuit e Water detection sensor error P2264 Water in fuel is detected Open load Short circuit ground Short circuit battery Defect resistance cylinder1 Charging discharging energy error Open load Short circuit ground Short circuit battery Defect resistance cylinder1 P0201 P0261 e Injector circuit P0262 Injector P0263 P0202 P0264 Injector circuit Injector P0265 P0266 Charging discharging energy error 27 HYUNDAI SERSRLL LI HYUNDAI SERSRLL Cylinder3 injector Cylinder4 injector Note 2 Cylinder5 injector Note 3 Cylinder6 injector Injector Bank Error Injectors Circuit RPS rail pressure sensor Rail pressure Monitoring BPS boost pressure sensor INSTALLATION amp OPERATION MANUAL Failsafety Failsafety Description Note 1 RPM limit P0203 Open load P0267 Short circuit ground P0268 Short circuit battery Defect resistance cylinder1 Charging discharging energy error P0204 Open load P0270 Short circuit ground P0271 Short circuit battery Defect resistance cylinder1 Charging discharging energy error P0205 Open load P0273 Short circuit ground P0274 Short circuit battery Defect resistance cylinder1
60. w for waterjet with bearing housing se 27 HYUNDRI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines MerCruiser Bravo One X Diesel Min 264 114 ik 7m il zx LET i Front view Side view ZF 25 P z et se 1 oo ey m 4 Eu dz HJ gi d 1 ih c ui eet i SH FELIS AERE ir Front view Side view 44 27 HYUNDAI SERSRLL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines ZF 45 A Front view Side view Front view Side view 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines 1 ENGINE MOUNTING REQUIRMENTS e The 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 2 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 710
61. with one of the same rating Normal Blown f the replacement fuse blows this indicates an electrical problem Avoid using the system involved and immediately consult authorized Hyundai SeasAll dealer Fuses in the ECU Box System Power y p 30A SYSTEM POWER 15A IGNITION POWER 2 Ignition Power 5Amp AAS 3 ECM ECU Power 20Amp 4 Main Relay Power 15Amp nel 5 Spare 6 Fuel Heater Power 30A SPARE FUEL HEATER 0181 81 amp 818 37 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines RELAYS Relays in the ECU Box 1 Oil Extraction Pump Relay 30Amp 2 Main Relay 30Amp 3 Starter Solenoid Relay 30Amp 4 Glow Relay 70Amp Using an ohmmeter check that there is continuity between each terminal 85 86 YES Apply 12V to terminal 85 and ground to terminal 86 Check for continuity between terminals 30 and 87 Always replace a damaged relay with one of the same rating 38 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines CHAPTER 8 INSTRUMENT SYSTEM INSTRUMENT CONNECTIONS Fi 1406 TITIN de A a W Engine Operating Indicator zgzopm 7 HYUNDAI SEASALL
62. zong 6 CONTROL 6 TRIM TRAILER SWITCH SIDE TYPE ONLY TRANSOM PLATE GAUGE TRIM GEAR LUBE MONITOR GAUGE VOLT BATTERY GAUGE amp LAMP POWER BUZZER DRIVE OIL 49 27 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL U125 Series Engines G SCAN G scan is diagnosis tool have function the DTC analysis fault code searching data analysis and ECU upgrade on Users Secu NF 2006 2 0 1 Fault Code Searching Data Analysis ECU Upgrade Ee 2 Flight Recording 1 G SCAN CONNECTIONS G scan can be connected to the CN6 connector of EOI as well as G scan connector in the ECU box For information about the CN6 of EOI please refer to Chapter 9 When connected to G scan you can not confirm the information of the engine through the EOI Connection plug CN6 service tool 50 27 HYUNDAI SEASALL INSTALLATION amp 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 Hy
Download Pdf Manuals
Related Search