INSTALLATION & OPERATION MANUAL

H380 Series

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 INSTALLATION & OPERATION MANUAL
H380 Series

TABLE OF CONTENTS

ABOUT THIS MANUAL …………………………………………………….…………..…….....……….. 3

SAFETY PRECAUTIONS ……………………………………………….………………..……………… 4
APPROXIMATE CONVERSIONS FROM STANDARD……………………………………………… 6

CHAPTER 1 ENGINE OVERVIEW ………………………………………..………...….…….……… 7

ENGINE COMPONENTS ……………………………………..………….…………… 7
TECHNICAL DATA ……………………………………………..……….…………….. 9
PERFORMANCE CURVES……………………………………..…….………..…….. 10
ENGIEN IDENTIFICATION……………………………………..……….…………..... 11
ENGIEN SUSPENSION …..……………………………………………..……........... 12
ENGIEN DIMENSIONS…………………………………………….……..….....…….. 13

CHAPTER 2 ENGINE OPERATION …………………………………………………..…….……….. 15

STARTING AND STOPPING ENGINE……………………………..…….…………. 15
EMERGENCY STOP …………………..…………………………………..………….. 16
INTAKE AIR HEATER…………………………………………………….….……….. 16

CHAPTER 3 COOLING SYSTEM ……………………………………………………….…….……... 17

SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..………............. 17
SEAWATER FLOW – OPEN COOLING CIRCUIT…………………..……….……. 18
WATER PICKUP……………………………………………………….…..…….…….. 18
WATER STRAINER………………………………………………….……...……..……. 18
CLEANING STRAINER FILTER………………………………….………….…..……… 19
AUTOMATIC DRAIN VALVE……………………………………………………………...20
SEAWATER PUMP………………………………………………………..…..………. 21
CHECKING SEAWATER PUMP & IMPELLER…………………..……..……..…….. 22
ENGINE COOLANT FLOW……………………………………………………………. 23
ENGINE COOLANT………………………………………………….…….…….……. 23
SUPPLEMENTAL ENGINE COOLANT……………………………….………….…. 24
DRAINING COOLANT……………………………………………………..…….……. 24
REMOVING AIR BUBBLES IN COOLANT……………………………..….….…….. 25
CABIN HEATER CONNECTION……………………………………….………..…… 25

CHAPTER 4 FUEL SYSTEM …………………………………………………………..….………….. 26

EUI SYSTEM………………………………………………………….……….……….. 26
FUEL SUPPLY SYSTEM.….……..…………………………..……….………….…... 27
FUEL LINE…………………....…………………………………………………...…… 27
RECOMMENDED FUEL QUALITY ………………....……………….…….……..…. 28
DRAINING WATER FROM FUEL FILTER ………………………….…….……..…. 28
CHANGING FUEL FILTER CARTRIDGE …………………….……..…….……….. 29

CHAPTER 5 INTAKE & EXHAUST SYSTEM ……………….………………………….….……….. 30

ENGINE ROOM VENTILATION ………………………………………..…..……...... 30
CHECK AIR FILTER …………………..……………………..…………..….….…….. 31
CLEANING AIR FILTER ……………………………………..……………….….…… 31
EXHAUST SYSTEM………………………………………………………...….……… 32

CHAPTER 6 LUBRICATION SYSTEM …………………………………….……………….………… 33

LUBRICATION COMPONENTS……………………….……………….….………… 33
ENGINE OIL LEVEL CHECKS…………………….....……………….……………… 34

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 INSTALLATION & OPERATION MANUAL
H380 Series

TABLE OF CONTENTS

RECOMMENDED OIL QUALITY……………………………………….…………….. 34

ENGINE OIL EXTACTION PUMP…………………………….………..…..…………. 35
CHECKING BYPASS AND OIL FILTER…………………………………….………… 35
REPLACING FULL FLOW OIL FILTER………………………………..…………….. 36

CHAPTER 7 ELECTRICAL SYSTEM ………………………………………………………………… 37

BATTERY CABLE CONNECTIONS …………………………….......……..……….. 37
ELECTRICAL STARTING…………………………………………………..…………. 37
ACCELERATION SENSOR AND CONTROL LEVER…………….………………… 38
PROCEDURES FOR CONTROL LEVER INSTALLATION………………………… 38
BATTERY CHECKS………..………………………………………...……….….......... 39
LOAD TEST……………………………………………………………………………… 40
FUSES AND RELAYS…………………………………………………..……………… 40
SYSTEM FUSE BOX……………………………………………………….…...……… 40
FUSE BOX………………………………………………………………………………. 40
FUSES……………………………………………………………………………………. 40
RELAY……………………………………………………………………………………. 41

CHAPTER 8 EOI SYSTEM …………………………………………..……………………………...… 42

INSTRUMENT CONNECTIONS……………………………………………………… 42
RPM GAUGE……………………..………………………………………..….……….. 43
USER INTERFACE………………………………………......…………….………..… 43
EOI FUNCTION…………..……………………………......………………..……...…. 44
LCD INFORMATION…………………………………………………………………… 44
WARNING LAMP…………..………………………………………………………..…. 45
SWITCHES …………………………………………………………………..……........ 46
PTO MODE……………………………………………………………………………… 46
IDLE SETTING MODE……………………………………………………...…………. 46
EOI BOX ( INSIDE )………………………………………………………….……….… 47
CUT OUT FOR EOI SYSTEM…………………………………………………………. 47
EOI PIN ASSIGNMENT……………………………………………………………..…. 49
G-SCAN……………………………………………………………….……..………..… 50
G-SCAN CONNECTIONS………………………………………………….………….. 50
DTC (DIAGNOSIS TROUBLE CODE) AND ALARM LIST…………..…………..… 51

CHAPTER 9 ANTI CORROSION SYSTEM ……………………………………………….…..…….. 55

CHAPTER 10 ENGINE STORAGE ……………………………………………………..…..………...... 56

WINTER STORAGE …..…………..……………………......…………..…………... 57

CHAPTER 11 MAINTENANCE ……………………………………………………………..…..………. 58

THE INITIAL RUNNING CHECK……………………....……………..………..………….58
MAINTENANCE SCHEDULE ………………………………………..……...……..... 59
AFTER SALES PART NUMBER..………………………………………..….……….. 60
MAINTENANCE LOG………………………………………………………....……….. 61

CHAPTER 12 TROUBLESHOOTING GUIDE …………………………………………………........... 62

CHAPTER 13 WARRANTY ……………………………………………………………….……..…...... 64

WARRANTY REGISTRATION CARD ……………………………………………….. 69

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 INSTALLATION & OPERATION MANUAL
H380 Series

ABOUT THIS MANUAL

This engine installation and operation manual is provided as guidance for the installation of
Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide
technical information to aid in performing an effective engine installation so as to achieve both
maximum performance and service life.

Hyundai SeasAll is committed to making clear and accurate information available for those who
maintain, own and repair the H380 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 for the correct and safe operation of the engine and safety of its
occupants and general public.
• It is strongly recommended that each operator read and understand this manual before
installing and operating the engine.
• This manual as well as safety labels posted on the engine use the following safety alerts to
draw your attention to special safety instructions that should be followed.
• This manual able to changed without notice

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.

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 INSTALLATION & OPERATION MANUAL
H380 Series

SAFETY PRECAUTIONS

• Read and understand this operator’s manual HOT SURFACES AND FLUIDS
as well as other information supplied by
Hyundai SeasAll for safer use of these • There is always a risk of burns when working
products. Be sure to check your engine with a hot engine. Be aware of hot parts like
regularly. the turbocharger system, the exhaust system,
hot coolant hoses, etc. Wait until the engine
• Do not use the engine for a purpose other is fully cool to do inspection and maintenance.
than what is intended by Hyundai SeasAll.
REFUELING
Do not modify the performance of the
supplied engine without the express
• Refuel only after the engine completely stops.
permission of Hyundai SeasAll. This can be
dangerous, can shorten the life of your
• Use only the recommended fuel. The wrong
engine and can invalidate your warranty.
grade of fuel can cause operating problems,
can cause the engine to stop and can cause
• Original and genuine parts supplied from
engine damage.
Hyundai SeasAll must be used for
inspections and maintenance. Hyundai • Pay special attention to safe practices when
SeasAll does not guarantee any damage refueling.
caused by the use of imitation parts.
PAINT DAMAGE
• Engine inspection and maintenance should
be carried out by properly trained and factory • Damage of the engine or parts paint during
approved service engineers. maintenance and inspection can cause
corrosion. Any damage must be repainted
• The engine should be inspected if the after inspection and maintenance.
electronic engine control unit shuts down the
engine. WELDING ON ENGINE

• If you don’t use the studs for PTO pulley, • Welding directly on the engine block can
remove them for safety. cause damage to the engine control systems.
The ECU and related electronic devices must
be disconnected and removed if unavoidable
welding is needed.

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 INSTALLATION & OPERATION MANUAL
H380 Series

ENGINE BREAK-IN

INITIAL BREAK-IN PROCEDURE USING AND ASSEMBLING GENUINE PARTS

• The first 20 hours of operation is the engine • Installation must be done and repairs must be
break-in period. During this period, it is performed using the special tools and
important that the engine is operated as procedures specified by Hyundai SeasAll.
outlined below.
• The limited warranty does not apply to any
• DO NOT operate engine at idle rpm for damage to our products caused by the
extended periods of time during the first 10 installation or use of parts and accessories
hours. which are not manufactured or sold by us.

• DO NOT operate at any one constant speed • Check for compliance with torque tightening
for extended periods of time. requirements. (Contact your Hyundai SeasAll
dealer or refer to the manual)
• DO NOT exceed 75% of full throttle during the
first 10 hours except during the engine initial • Any gaskets, O-rings, seals or other sealing
Break-In Procedure. During the next 10 hours, parts should be replaced with new parts during
occasional operating at full throttle (5 minutes repairs.
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.

• FREQUENTLY CHECK engine oil level and

add oil if necessary.

WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.

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 INSTALLATION & OPERATION MANUAL
H380 Series

APPROXIMATE CONVERSIONS FROM STANDARD

MULTIPLY MULTIPLY
SYMBOL SYMBOL SYMBOL SYMBOL
BY BY
mm 0.039 inch inch 25.4 mm

LENGTH cm 0.4 inch LENGTH inch 2.54 cm

m 3.28 ft ft 0.3048 m

mm2 0.0016 in2 in2 645.2 mm2

AREA AREA
m2 10.764 ft2 ft2 0.093 m2

cm3 0.061 in³ in³ 16.388 cm3

mL 0.06 in3 in3 16 mL

Ldm3 61.023 in³ in³ 0.016 Ldm3

VOLUME Ldm3 0.22 imp.gallon VOLUME imp.gallon 4.545 Ldm3

Ldm3 0.264 U.S.gallon U.S.gallon 3.785 Ldm3

m3 0.76 yd3 yd3 1.3 m3

m3 35.315 ft³ ft³ 0.028 m3

kgf 2.204 lbf lbf 0.453 kgf

FORCE FORCE
N 0.224 lbf lbf 4.448 N

TEMP. o
F=9/5x℃+32 TEMP. C=5/9x(℉-32)
o

Bar 14.5 psi psi 0.068 Bar

MPa 145 psi psi 0.0068 MPa

Pa 0.102 mmWc mmWc 9.807 Pa

PRESSURE PRESSURE
Pa 0.004 inWc inWc 249.098 Pa

KPa 4 inWc inWc 0.249 KPa

mWg 39.37 inWc inWc 0.025 mWg

TORQUE Nm 0.738 lbf ft TORQUE lbf ft 1.356 Nm

kg 2.205 lb lb 0.454 kg
WEIGHT WEIGHT
kg 35.273 oz oz 0.028 kg

kJ/kWh 0.43 BTU/lb BTU/lb 2.326 kJ/kWh

WORK MJ/kg 430 BTU/lb WORK BTU/lb 0.0023 MJ/kg

kJ/kg 0.24 Kcal/kg Kcal/kg 4.184 kJ/kg

ENERGY kJ/kg 0.697 BTU/hph ENERGY BTU/hph 1.435 kJ/kg

FUEL g/kWh 0.736 g/hph FUEL g/hph 1.36 g/kWh

CONSUMP. g/kWh 0.0016 lb/hph CONSUMP. lb/hph 616.78 g/kWh
FLOW RATE FLOW RATE
m3/h 0.588 ft³/min ft³/min 1.699 m3/h
(GAS) (GAS)
FLOW RATE FLOW RATE
m3/h 4.403 US gal/min US gal/min 0.2271 m3/h
(LIQUID) (LIQUID)
m/s 3.281 ft/s ft/s 0.3048 m/s

kph 0.539 knots knots 1.852 kph

SPEED SPEED
mph 0.869 knots knots 1.1508 mph

kph 0.62 mph mph 1.61 kph

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 INSTALLATION & OPERATION MANUAL
H380 Series

CHAPTER 1
ENGINE OVERVIEW

ENGINE COMPONENTS

① FUEL FILTER ⑦ ENGINE MOUNTING BRACKETS

② SWITCH BOX ⑧ OIL FILTER

③ SEAWATER PUMP ⑨ WATER PUMP

④ AIR INTAKE MANIFOLD ⑩ EXPANSION TANK

⑤ WATER SEPARATOR ⑪ C.C.P.C.V.

⑥ OIL EXTRACTION PUMP ECU

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H380 Series

① INTERCOOLER ⑧ COOLANT PIPE (HEAT EXCHANGER OUTLET)

② DRY EXHAUST PIPE ⑨ JUNCTION BOX

③ TURBO-CHARGER OUTLET PIPE ⑩ ENGINE MOUNTING BRACKET

④ LIFTING EYES ⑪ HEAT EXCHANGER

⑤ AIR FILTER ⑫ EXHAUST MANIFOLD

⑥ AIR FILTER CONNECTOR ⑬ COOLANT PIPE (HEAT EXCHANGER INLET)

⑦ ALTERNATOR

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 INSTALLATION & OPERATION MANUAL
H380 Series

TECHNICAL DATA

H380
Engine type 4-stroke, 4-valve
After-cooled, EUI, Turbocharger
Output ps (kW) 380ps (280)
rpm at full load 1800
Cylinders I-6
Ignition sequence 1-5-3-6-2-4
Displacement [cm3] 9,960
Bore [mm] 122
Stroke [mm] 142
Compression ratio 16.0 : 1

Max. torque [kgm] 170

@ speed [rpm] 1100
Injection system EUI
Diesel fuel at least CN 51 as per DIN EN 590

Intake air pressure (abs. bar) 2.5

@ speed [rpm] 1800
Coolant quantity (liter) 43
Coolant cap opening pressure (bar) 0.7
Engine oil (liter) 32
Engine oil pressure (bar) 2~3 (1750rpm,) 100 ℃(oil temp.)
Exhaust gas pressure (kPa) Max. 50
Alternator [A] 70A
Engine diagnosis Yes
Weight (kg) 1,120
Battery capacity (AH) 24V, 100AH
Idle rpm warmed up (rev/min) 600
Permissible eng. oil temp (℃) 135
Permissible eng. coolant temp (℃) 105
Fuel Efficiency(L/h) MAX. 69.8

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 INSTALLATION & OPERATION MANUAL
H380 Series

PERFORMANCE CURVES

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 INSTALLATION & OPERATION MANUAL
H380 Series

ENGINE IDENTIFICATION

Engine identification is affixed to the engine block and the JUNCTION box (See figure).

• SERIAL NUMBER ON THE ENGINE BLOCK

FORMAT : D6HAXXXXXX

• ENGINE NAME PLATE

Engine Family D6HA

Engine Type H380
Engine Serial No. XXXXXXX
Rated Power @ Speed 380 PS @ 1800 rpm
No. Of Cylinder 6
Bore(mm) X Stroke (mm) 122 X 142
Manufacture Date. MM/YYYY
Type Approval No.
EPA/CCNR

EPA Engine Family FHYSN12.7HYS IMO Engine Family FHYSN12.7HYS

Max Power 280 (kW) Power Density (kW/L)
Displacement / Cylinder 1.66 (L/cyl) Date of Manufacture MM/YYYY
Application Commercial Useful Life hours or years
Emission Standard THC+NOx : (g/kWh) PM : (g/kWh) CO : (g/kWh)
EMISSION CONTROL SYSTEM
THIS ENGINE IS EQUIPPED WITH ELECTRONIC DIRECT FUEL INJECTION SYSTEM. THIS
ENGINE IS CERTIFIED TO OPERATE ON DIESEL
THIS MARINE ENGINE COMPLIES WITH U.S. EPA REGULATION FOR 2015 EPA

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 INSTALLATION & OPERATION MANUAL
H380 Series

ENGINE SUSPENSION

• To lift the engine, use the three engine eyes

(see figure).

• 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.

• Keep the engine horizontal when you install

or remove the engine from the engine room
by using correct installation tools or adjusting
the length of lifting belts or chains.

• Use strong enough lifting belts or chains to

carry the engine weight safely.

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 INSTALLATION & OPERATION MANUAL
H380 Series

ENGIEN DIMENSIONS

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 INSTALLATION & OPERATION MANUAL
H380 Series

PTO PULLEY REFER DRAWING

<CRANK PULLEY >

T/M ASSEMBLY BOLT PATTERN

• BELL-HOUSING : SAE1
• FLYWHEEL : SAE14

BELT INSTALLATION

MODEL : H380
AN ALTERNATOR
DP DRIVE PULLEY
IP IDLER PULLEY
TP TENSIONER PULLEY
WP WATER PUMP PULLEY

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 INSTALLATION & OPERATION MANUAL
H380 Series

CHAPTER 2
ENGINE OPERATION

STARTING ENGINE

• Before starting the engine, you should • The engine room requires a constant supply
check engine oil, coolant, gearbox oil, fuel of fresh air. Be sure that adequate
gauge, seawater pump, battery, water ventilation systems are installed.
valves and so on.

• When you start the engine, check that the STOPPING ENGINE
engine throttle lever ① is in the neutral
• The engine should be run for a few minutes
position. If not, the engine may not start or
at idle ( in neutral ) before turning it off. This
there is possibility of the boat moving
will avoid boiling and even out the
inadvertently. If your boat is equipped with a
temperature. This is especially important if
neutral safety switch, the engine will only
the engine has been operated at high
crank when the engine throttle lever is in the engine speeds and loads.
neutral position. You can also check this on
the EOI. • Never switch off the main switches while
the engine is running. This could damage
• After starting the engine, release the key ② some parts like alternator.
immediately to prevent damage to the
starter motor.

• Avoid maximum rpm and WOT ( Wide

Open Throttle) before the cold engine is fully
warmed up.(40℃).

• When cold starting, it may take a few more

seconds to start the engine.

• If the engine does not start in 10 seconds,

Turn off the key and wait After 10 seconds
try again. This method can help avoid starter
motor damage.

WARNING
DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION.
EMISSION GAS IS HARMFUL.

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 INSTALLATION & OPERATION MANUAL
H380 Series

EMERGENCY 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. Emergency Stop Switch

• You can use this switch in any emergency

situation.

INTAKE AIR HEATER

• When turning the start switch ON, the coolant

temperature sensor senses the engine coolant
temperature and the control unit (ECU) controls
the preheating time in accordance with the
sensed coolant temperature.
(Work at temperature fell to below zero)

• When the engine is started, the control unit (ECU)

operates the air heater for a certain time. This
preheats the engine and helps to reduce white
smoke at start-up. (Work at temperature fell to
below zero) Air Heater

• If the indicator lamp blinks regardless of

condition, check the related circuit for a blown
fuse, fused relay etc. since this indicates a
problem in the preheating heater system.

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 INSTALLATION & OPERATION MANUAL
H380 Series

CHAPTER 3
COOLING SYSTEM

SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT

AIR

EXHAUST MANIFOLD
AIRFILTER COOLANT PUMP
Pc
HEATER
CONNECTOR
TURBOCHARGER

INTAKE MANIFOLD THERMOSTAT

EXHAUST PIPE HOUSING
EXPANSION TANK

AIR

HEAT EXCHANGER

INTERCOOLER

SEAWATER
INTAKE AIR
Ps SEA WATER PUMP
EXHAUST AIR

COOLANT

SEAWATER

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 INSTALLATION & OPERATION MANUAL
H380 Series

SEAWATER FLOW – OPEN COOLING CIRCUIT

Water strainer ← Water valve ← Water pickup

↓
Seawater pump
↓
Intercooler
↓
Heat exchanger
↓
Seawater

WATER PICKUP

• Water pickup should be installed in an area

where it won’t pick up air bubbles and will access
clean water during all phases of the engine
operation.

• The seawater pickup inner diameter, as well as all

other connecting fittings (hoses, connectors, water
valve etc.) must be at least the size of the inner
diameter of the inlet of the seawater pump. If not,
it may inhibit the supply of sufficient water and
cause the engine to overheat

WATER STRAINER

• Strainer should be located in an area where it will

be easily accessible for periodic seawater flow
inspection and cleaning.

• The size of strainer must be of sufficient capacity

to pass the seawater (a flow rate over 400 liters
per minute flow rate).

• 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.

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 INSTALLATION & OPERATION MANUAL
H380 Series

CLEANING 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.

• 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.

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 INSTALLATION & OPERATION MANUAL
H380 Series

AUTOMATIC DRAIN VALVE

• The Automatic Drain Valve allows condensed

water in the intercooler to drain when the
engine is a idle or is stopped.

CHECKING AUTOMATIC DRAIN VALVE

• Stop the engine and remove the Automatic

Drain Valve from the intercooler. Condensate water Emission from intercooler.

• Removing procedure:

• Remove the Snap Ring ①

• Remove the Plunger ②

• Remove the Spring ③

• Clean the inside of the Automatic Drain

Valve with a cloth or by brushing

• Installation is in the reverse order of removal. Snap-Ring Plunger Spring

• Put the Automatic Drain Valve on a flat surface.

Make sure that Snap Ring ① and plunger ②
are in contact.

• If there is more than a 2mm gap between the

Snap Ring ①, and the Plunger ② replace the
spring.

Normal Replace a part

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H380 Series

SEAWATER PUMP

• The internal diameter of hose connected to

seawater pump inlet should be 50.8mm(2 inch).

• 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 THE WATERPUMP IS NOT PROPERLY ASSEMBLED, AIR CAN BE
SUCKED INTO THE COOLING CIRCUIT, DISTURBING THE VACUUM
PROCESS. THIS CAN CAUSE THE ENGINE TO OVERHEAT.

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
DO NOT INSTALL ADDITIONAL DEVICES WHICH COULD OBSTRUCT THE
FLOW OF SEAWATER. THIS CAN CAUSE THE ENGINE TO OVERHEAT.

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 INSTALLATION & OPERATION MANUAL
H380 Series

CHECKING SEAWATER PUMP & IMPELLER

• Stop the engine and close the water valve.

• Remove the impeller housing cover.

• 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.

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 INSTALLATION & OPERATION MANUAL
H380 Series

ENGINE COOLANT FLOW ( OPENED COOLING CIRCUIT)

1. Engine Block Coolant Outlet

↓
2. Exhaust manifold
↓ Turbocharger
3. Thermostat housing
↓
4. Heat exchanger
↓
5. coolant pump

ENGINE COOLANT

• The coolant level should be between MAX and MIN marks on the side of the coolant
reservoir when the engine is cool.

• As the engine temperature increases, the pressure inside the cooling system increases
to 0.7 bar or more. To maintain proper pressure of the engine cooling system, water
may be ejected from the expansion tank. This is normal. Replenish the coolant if this is
observed.

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SUPPLEMENTAL ENGINE COOLANT

• If the coolant level is below level ‘Low’, add

Mixture Percentage(volume)
enough specified coolant to provide protection Ambient
Temperature
against freezing and corrosion. Coolant level Antifreeze Water
should be between the MAX and MIN. But do
-15℃ (5℉) 35 65
not excess level ‘MAX’.
-25℃ (-13℉) 40 60
• If frequent additions are required, contact an
authorized dealer for a cooling system -35℃ (-31℉) 50 50
inspection. -45℃ (-49℉) 60 40

• Use only soft (demineralized) water in the

coolant mixture.

• 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.

• 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
table.

Heat Exchanger
DRAINING COOLANT

• In order to drain engine coolant, please use a

screwdriver to loosen the drain plug ①.

• The drain plug is located under the heat

exchanger unit.

+
Drain Plug

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REMOVING AIR BUBBLES IN COOLANT

• 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. It may cause scalding.

• Refill with coolant if needed.

• Reinstall the expansion tank cap

• Check the level of the expansion tank regularly. Coolant flow direction:

CABIN HEATER CONNECTION

• In order to use a cabin heater, an extra coolant

circulation pump is needed.

• After connecting cabin heater lines, engine

coolant must be refilled and checked.

• Please check coolant flow direction, as shown in

the drawing.

• If a cabin heater is installed, the volume of the

cooling circuit will be increased. It may be
necessary to add an additional expansion tank to
avoid losing cooling water as the expansion tank
on the engine may not have sufficient capacity.
To heater
• Contact your Hyundai SeasAll dealer if you have ※HOSE IN DIAMETER Φ17
any concerns. From heater

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.

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CHAPTER 4
FUEL SYSTEM

The unit injector consists of a pumping element (A),

a controlling component (B), and a nozzle (C) as
shown in the illustration. The pumping element (A)
generates the fuel pressure as the force from the
cam drives the plunger via the rocker arm. The
controlling component (B) controls the operation of
the spill valve and needle control valve by driving
the solenoid according to the commands from ECU.
Finally the nozzle element (C) injects the
pressurized fuel into the cylinder.

EUI SYSTEM

VGT
EUI EXTERNAL
CONNECTOR
VGT SPEED

AIR PRESS. &

COOLANT
TEMPERATURE
TEMPERATURE
FUEL CAM
TEMPERATURE POSI-
TION

ECU

AIR HEATER ACCELERATION

CRANK
RELAY LEVER
POSITION

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FUEL SUPPLY SYSTEM

• The fuel system consists of an electronic control

unit (ECU), unit injectors, a fuel pump, fuel lines, a
fuel filter, an overflow valve, a fuel tank etc.

• Fuel from the fuel filter is supplied into the fuel

gallery in the cylinder head. After fuel is injected
by six unit injectors it passes through the overflow
valve installed at the exit of the fuel gallery. Fuel
returned from the cylinder head goes back into the
fuel tank.

• Accordingly, the fuel system continues to supply

the proper amount of fuel required by the engine
as determined by the control unit (ECU).

• The fuel supplied from the fuel pump to the

engine is injected by the injector, the remaining
fuel returns to the fuel tank.

FUEL LINE

※ The inner diameter of the fuel hoses

① From fuel tank to separator
should be at least Ø 10
② From separator to fuel pump
③ From fuel pump to fuel filter
④ From fuel filter to fuel gallery
⑤ From fuel gallery to fuel tank ( return )

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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

• Other admixing or additional use of additives or special fuels is not permitted

DRAINING WATER FROM FUEL FILTER

• The water separator for a diesel engine plays the

important role of separating water from fuel and
accumulating the water in its base.

• 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:

1) Loosen the drain plug (part ①) and drain water.

2) After water is drained, securely tighten the drain

plug.

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.

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CHANGING FUEL FILTER CARTRIDGE

When replacing a fuel filter element

A

• Clean around the fuel filter.

• Loosen air vent bolt ‘A’ on fuel filter and

relieve the pressure in the fuel line.

• Replace the filter element.

(Replacement of the filter cartridge)

1) Check if there is any gasket on the cartridge when
replacing it.
2) Apply oil to gasket and tighten it sufficiently by hand.
3) Tightening torque regulation :
43.1±2Nm (4.4±0.2 kgf.m, 31.8±1.4 lb.ft) Priming Pump Fuel Filter

• Pump until fuel drains from air vent, using

priming pump.( Pumping time can be reduced
by filling a new cartridge with fuel before
mounting)

• Air bleeding of cylinder head side is not

necessary when replacing a filter and
generally it is possible to start the engine
using the normal cranking procedure.

• Tighten the air vent bolt ‘A’.

• Start the engine and check if there is fuel

leakage.

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CHAPTER 5
INTAKE & EXHAUST SYSTEM

The intake air system of this engine is optimized by EVGT and a highly efficient intercooler
system. The pressure of the air system is up to about abs. 2.7 bar in order to optimize engine
combustion.

Air
filter
Boost Pressure &
ATS#1

Cam position
sensor
Intercooler

VGT

EVGT actuator

Coolant
temperature
sensor
Crankshaft position
sensor

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ENGINE AIR CONSUMPTION

-. Engine need to proper intake air for combustion this requires a minimum internal area of air
supply ducting the area can be calculated by using the formula <TABLE1>
Number of Length of pipe (Meters)
A = cross section of area in cm2 pipe bends
(90°) 1 2 3 4 5

1 1 1.04 1.09 1.13 1.20

A = 1.9 X Engine power(KW) 2 1.39 1.41 1.43 1.45 1.49

 A= 1.9 X 280(KW) = 532cm2 = Ø260.4 3 - 1.70 1.72 1.74 1.78

-. Minimum intake area is Ø219.5, when use longer ducts or more bends are used the area is
corrected by multiplying by coefficient from<Table1> We recommend position of air pipe
that distance 25~35cm from around air filter. Air inlet must never be installed in the
transom stern. In this area is mixed with water and exhaust gases

ex) Length of pipe : 3M , number of pipe bands : 2

 Ø260.4 X 1.43 = Ø372.4
※ Minimum Banding R = 2 X O.D of pipe(90° cases)

ENGINE ROOM VENTILATION

-. Engine room need to proper ventilation for optimum ship operation this requires a minimum
internal area of air ventilation the area can be calculated by using the formula.

A = 1.65 X Engine power(KW)

 A= 1.65 X 280(KW) = 462cm2 = Ø242.6

-. Minimum ventilation area is Ø204.5, when use longer ducts or more bends are used the
area is corrected by multiplying by coefficient from<Table1> The supply for air at intake
and exhaust pipe should be the same size. The Distance between air inlets and air outlets
should be as long as possible. If the distance too short, results in a bad ventilation effect.
The suction fan is to be installed in the exhaust air duct so that ventilate the engine room
more effectively and keep low temperature in engine room

Extraction fan capacity(Air Flow m3/min) =0.07 X Engine power(KW)

Extraction fan capacity = 0.07 X 280(KW) = 19.6m3/min
※ General pressure drop of Engine room = 0.1~0.5kPa

ex) Length of pipe : 3M , number of pipe bands : 2

 Ø242.6 X 1.43 = Ø347

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CHECK AIR FILTER

• The original Hyundai SeasAll air cleaner may be

cleaned and reused.

• If 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.

CLEANING AIR FILTER

• Remove the air filter from engine.

• Put the air filter on a flat surface and shake

dust out.

• Liberally spray K&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.

• 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
pressure water or hot air to clean and/or dry the
RUN WITHOUT AIR CLEANER.
air filter. These can damage the performance of THIS COULD RESULT IN
the air filter. EXCESSIVE ENGINE WEAR.
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.

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EXHAUST SYSTEM

• DO NOT extend or bend the pipe in exhaust

line excessively.

• The exhaust gas pressure should not exceed

145 ± 10 mmHg @1800rpm for the best
performance of the engine. Be sure that rain
does not fall into the exhaust pipe.

• The exhaust pipe can be rotated 90° according

to the installation requirements. Tighten the
exhausted pipe to the reinforced bracket to
prevent damage from vibration.

Exhaust Pipe

CAUTION
IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION, PLEASE
CONTACT YOUR NEAREST HYUNDAI SEASALL DEALER.

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CHAPTER 6
LUBRICATION SYSTEM

LUBRICATION COMPONENTS

① Cylinder block Gasket

② Oil bypass filter assembly Oil pan

③ Oil pump assembly ⑨ Plate

④ Oil filter ⑩ Oil cooler

⑤ Front cover Element.

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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,

F
until the oil has returned to the oil pan.

• Pull the dipstick out, wipe it clean, and re- L

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.

• Have proper SAE grade number for expected ambient temperature range.

Description Specifications Limit

ACEA Above B4
Service oil quality should conform to ACEA or API
CI – 4 or classification.
API
higher

Oil quality 15W-40 -15°C above

10W-30 -20°C ~ 40°C
SAE
5W-30 -25°C ~ 40°C
0W-30 10°C below

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ENGINE OIL EXTACTION PUMP

• Allow the engine to warm up at least 5 minutes

then turn off engine.

• Remove the engine oil filler cap and oil filter.

• The oil drain hose is connected to the oil

extraction pump ①. Route the loose end of the
hose into the container being used for the oil
change ②.

• Turn the ignition key on (but do NOT start the

engine) then press and hold the button ③ until
the engine oil completely pumped out.

• When you stop pushing the button, the pump

will turn off.

CHECKING BYPASS OIL FILTER

• Close the oil flow from the lubricant system by

stopping the engine or using the valve.

• Loosen the rotor cover nut and remove the rotor

cover from the rotor body.

• Using the spatula remove the accumulated

Rotor cover nut
sediments in the rotor cover. Wash the
components of the rotor using proper detergent.
All components of rotor (including two nozzles in
rotor body) are washed thoroughly, make sure
that there are not fragments’ scrap and other
contaminants before installation.

• Check the O-ring of the rotor assembly for

damage. If needed, replace it with a new one.

• Install a new gasket to the rotor cover.

Reassemble the rotor assembly.

• Replace the rotor and make sure that the rotor

rotates smoothly.

• Replace the filter cover and tighten the cover nut Rotor cover
to the specified torque. <Cover nut tightening
torque : 12.7~16.7 N.m(1.3~1.7 kgf.m, 9.4~12.3
lb-ft) >
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REPLACING FULL FLOW OIL FILTER

• Remove the drain plug(A) at the lower part of oil

filter and drain the engine oil.

• Remove the cap of oil filter upper part and

remove the oil filter.
WARNING
• Install new oil filter. Be sure to replace the USED OIL MUST BE STORED IN A
SAFE PLACE AWAY FROM
gasket with a new one.
CHILDREN AND SOURCES OF
IGNITION. IF YOU HAVE A USED OIL
• Run the engine and check for the oil leaks. DISPOSAL PROBLEM, PLEASE
HAVE THE ENGINE OIL CHANGED
BY YOUR NEAREST HYUNDAI
• Turn off the engine and check the oil level. Add SEASALL SERVICE DEALER.
oil if necessary.

① Cylinder block ⑧ Oil bypass assembly

② Oil filter Oil cooler

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CHAPTER 7
ELECTRICAL SYSTEM

BATTERY CABLE CONNECTIONS

1) The diameter of battery cable should be at least 40mm2 within a length of 4m.
2) And it should be at least 50mm2 if the cable is longer than 4m.
3) Recommended battery capacity is over 100 amperes.
4) Connect the battery (+) cable to the start motor.
5) Connect the battery (-) cable to system ground (engine block).
6) Battery cables should be clean and tightly connected.

(+) Cable ( For Starter moter)

(-) Cable (For Engine Ground )

ELECTRICAL STARTING

1) Where main internal combustion engine are arranged for electrical starting, at least sets
of batteries are to be fitted.
2) The arrangement is to be such that batteries cannot be connected in parallel.

CAUTION
DO NOT TOUCH OR REMOVE ELECTRICAL PARTS WHEN STARTING OR
DURING OPERATION.
KEEP HAND, HAIR, AND CLOTHES AWAY FROM THE FLYWHEEL AND
OTHER ROTATING PARTS WHILE THE ENGINE IS RUNNING.

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ACCELERATION SENSOR AND CONTROL LEVER

• When installing control lever cable to acceleration

40 mm
sensor, be sure that the acceleration sensor lever
is fully released to the idle position and fully pulled
to the full-load position. The swing distance of lever
between idle and full-load position is 40mm.

PROCEDURES FOR CONTROL LEVER INSTALLATION

• Idle position setting

Make sure that the position value (%) indicates 0% in

neutral position

• Full load position setting

Make sure that the position value(%) should

indicates full load range(100%) at full forward lever
position. If not, disassemble and adjust the base
neutral position of the control lever by moving it to
the rear until the conditions are met.

15
• You can see the value(%) of lever position on the 10 RPMx100 20

LCD display of rpm gauge as well as EOI. 5 25

0 30

CAUTION
YOU SHOULD PERFORM ABOVE PROCEDURES AFTER CONTROL
LEVER INSTALLATATION WITH THE ENGINE NOT RUNNING BUT
WITH THE IGNITION KEY ON.

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BATTERY CHECKS

Battery inspection is very important in electronically controlled engines: You must check the
battery condition regularly.

LOAD TEST

• Perform the following steps to complete the load

test procedure for maintenance-free batteries. Voltage Temperature

• Connect the load tester clamps to the terminals 18.5 V 20°C (70°F) and above
and proceed with the test as follows:
18.4 V 16°C (60°F)
① If the battery has been charged, remove the
surface charge by connecting a 300 ampere 18.3 V 10°C (50°F)
load for 15 seconds.
18.1V 4°C (40°F)
② Connect the voltmeter and apply the
specified load. 17.9 V -1°C (30°F)

③ Read the voltage after the load has been 17.8 V -7°C (20°F)
applied for 15 seconds.
17.7 V -12°C (10°F)
④ Disconnect the load.
17.5 V -18°C (0°F)
⑤ 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.

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FUSE AND RELAYS

SYSTEM FUSE BOX (IN JUNCTION BOX)

• Alternator_40Amp

• Alternator_40Amp

FUSE BOX(IN JUNCTION BOX)

• Ignition power : 5 Amp

• VGT power : 15 Amp

• Main power : 20 Amp

• Air heater auxiliary : 5 Amp

• Starter auxiliary : 5 Amp

• Fuel heater : 20 Amp

FUSES

• An engine’s electrical system is protected

from electrical overload damage by fuses.

• If a fuse has blown, the element inside the

fuse will be melted. If the electrical system
does not work, first check the fuses in
junction box. Always replace a blown fuse
with one of the same rating.

• If the replacement fuse blows, this indicates

an electrical problem. Avoid using the system
involved and immediately consult an
authorized Hyundai SeasAll dealer.

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RELAY

• Oil pump_20Amp

• Air heater_20Amp

• Starter sol_20Amp

• Main_20Amp

• Fuel heater_20Amp

• VGT power_20Amp

• Using an ohmmeter, check that there is Terminal Continuity

continuity between each terminal.
30 - 87 NO
85 - 86 YES

• Check for continuity between the terminals 30 and 87.

• Always replace the damaged relay with one of the

same rating.

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CHAPTER 8
EOI SYSTEM
The Engine Operating Indicator (EOI) system gives you a lot of information about the engine’s
current operation. You can hear alarm beeps and 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, etc. flash. When the engine starts normally, all the lamps turn off. If
there is a problem, the specific lamp will come on. In this case, contact your Hyundai SeasAll
dealer and have the engine checked as soon as possible.

INSTRUMENT CONNECTIONS

Main_12 connector
Op_11 connector

Gearbox oil pressure

Tank level

Speed sw (option)
Neutral sw_1(female)

Neutral sw_2(male)
APS connector

Instrument connection cable (10m)

※ If there is no neutral switch, you must connect the neutral switch-1 and
neutral switch-2 of the instrument connection cable.
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RPM GAUGE

1) When the ignition key is in the ON position, this gauge will work.
2) This gauge indicates real-time engine rpm.
3) Avoid maximum rpm and Wide Open Throttle (WOT) before a cold engine is fully
warmed up as it can harm the engine.

Engine speed

Left Button (LB) Right Button (RB)

Multifunction LCD display

USER INTERFACE

1) Press the LB/RB button to cycle through the display as shown below

2) If there is a problem with the engine, the multifunction LDC display shows the related
symbol and alarm.

In order to move :
Previous page : LB , Next page : RB
<if happens>

Engine Check symbol and Oil pressure

Buzzer out 1) Sensor (10 ~ 180 ohm) + wiring optional
Gear oil pressure
2) In case of no connection, no display

Oil symbol and Buzzer out Fuel tank

(pressure < 0.5bar)
Dimmer control LB 3s or RB 3s
Decrease or increase
Coolant high temp. symbol
and Buzzer out Fuel consumption
(temp. > 110℃)
Percent load
Low battery and Buzzer Engine coolant temp.
out
Throttle position

Battery voltage

Boost pressure

Total and trip hour counter LB+RB 3s

Reset

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EOI FUNCTION

1) RPM gauge 7) Coolant high temperature warning lamp

2) Key switch 8) LCD information

3) G scan terminal port 9) Function switch

4) Check engine lamp 10) PTO/IDLE Change switch

5) Charging warning lamp 11) PTO/IDLE RPM Up/Down switch

6) Oil pressure warning lamp

LCD information

1) Total engine full throttle time (Hr) 5) Battery voltage (V)

2) Throttle position (%) 6) Engine RPM (rpm)

3) Diagnosis Trouble Code (DTC) 7) Engine oil temp (℃) (Option)

4) Engine coolant temp (℃)

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WARNING LAMPS

Alarm will sound when alarm lamps flicker.

CHECK ENGINE OIL PRESSURE WARNING

• This lamp informs you that the engine has • This lamp informs you if the engine oil
a serious problem. pressure is low.
• You can see the DTC on the LCD of the If this lamp is on, you should stop the
EOI . engine and check the oil level with the
• The ECU may limit the engine oil gauge (dip stick). If the oil is low,
performance to protect the engine in some refill it. If you refill the oil and the lamp
cases. You should check the engine at the still does not turn off, you should ask
nearest Hyundai SeasAll dealer your Hyundai SeasAll dealer for
immediately. maintenance.

CHARGING WARNING COOLANT TEMPERATURE

• This lamp informs you that charging circuit WARNING

has a problem (such as with the alternator). • This lamp informs you that the engine
• If this lamp is turned on, you should stop coolant is abnormally high (110℃ +).
the engine and eliminate electric load, as • If the lamp is on, you should stop the
well as check the alternator, drive belt engine immediately and check with the
system and wiring system. nearest Hyundai SeasAll dealer
immediately.
• It can be harmful to drive your engine
with this lamp on.

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SWITCHES

1) Function switch - use to change the information display on the LCD.

2) PTO/IDLE change switch – use to enable PTO/IDLE RPM adjustment function
3) UP/DOWN switch – use to raise or lower PTO/IDLE RPM.

PTO MODE

1) Used to adjust the fixed RPM of PTO.

2) When PTO switch is ON, engine speed will be upgraded 700RPM (initial RPM) .
3) You can adjust the RPM using the UP / DOWN switch.
4) When PTO switch is OFF, engine speed will be returned to the value set for IDLE RPM.
5) Adjustable RPM area : 700 RPM ~ 1900 RPM

IDLE SETTING MODE

1) Used to adjust the IDLE RPM.

2) Operate IDLE switch on Quiescent state.
3) When the switch moved to the UP or DOWN position, RPM value increases or decreases
by increments of 25 RPM.
4) When IDLE switch is OFF, IDLE RPM value will be returned to the initial RPM value.
5) Adjustable RPM area : 600RPM ~ 800RPM.

If you need to change the IDLE RPM value in the range of 600 RPM to 500 RPM, the
value can be changed using the G-SCAN. Contact your Hyundai-SeasAll dealer.

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EOI BOX ( INSIDE )

① Connection Plug – CN1 (Engine Main Connector)

② Connection Plug – CN2 (Inspect Terminal)
③ Connection Plug – CN3 (Key Switch)
④ Connection Plug – CN4 (RPM Gauge-Main)
⑤ Connection Plug – CN5 (RPM Gauge-Aux)
⑥ Connection Plug – CN6 (G-SCAN Connect Terminal)
⑦ System power fuse(3A)
⑧ Buzzer

CUT-OUT FOR EOI SYSTEM

You can use an installation template enclosed with the EOI for a cut-out.

WARNING
LISTEN FOR A CLICK WHEN LOCKING CONNECTORS. THIS SOUND
INDICATES THAT THEY ARE SECURELY LOCKED.

CAUTION
DO NOT CONNECT EXTRA INSTRUMENTS WHICH DRAW OVER
1 AMPERE. THE E.O.I WILL BE DAMAGED BY OVERLOAD.

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EOI PIN ASSIGNMENT

CN1 (ENGINE MAIN CONNECTOR)

13
24

1
12

1. GROUND 13. NEUTRAL SWITCH 2

2. IDLE SWITCH 14. CAN 1-L
3. PTO LAMP 15. GEARBOX OIL PRESSURE
4. OIL PRESSURE SENDER 16. START SWITCH
5. OIL PRESSURE SWITCH 17. CHARGE WARNING LAMP
6. CLUTCH SWITCH 18. PTO SWITCH
7. CAN 1-H 19. PTO RES/DEC
8. BATTERY + 20. CHECK LAMP
21. PTO SEC/INC
9. CAN 2-H
22. TANK LEVEL
10. CAN 2-L
23. HIGH COOLANT TEMP LAMP
11. NEUTRAL SWITCH 1
24. NOT USED
12. KEY SWITCH

CN2 (INSPECTION TERMINAL)

13
24

1
12

1. GROUND 13. NEUTRAL SWITCH2

2. IDLE SWITCH 14. CAN 1-L
3. PTO LAMP 15. GEARBOX OIL PRESSURE
4. OIL PRESSURE SENDER 16. START SWITCH
5. OIL PRESSURE SWITCH 17. CHARGE WARNING LAMP
6. CLUTCH SWITCH 18. PTO SWITCH
7. CAN 1-H 19. PTO RES/DEC
8. BATTERY + 20. CHECK LAMP
21. PTO SEC/INC
9. CAN 2-H
22. TANK LEVEL
10. CAN 2-L
23. HIGH COOLANT TEMP LAMP
11. NEUTRAL SWITCH1
24. NOT USED
12. KEY SWITCH

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CN3 (KEY SWITCH)

3 1
1. KEY SWITCH
2. START SWITCH
3. BATTERY +

CN4 (RPM Gauge-Main)

1. BATTERY +
2. NOT USED
3. GROUND 1 4

4. KEY SWITCH
5. DIMMER
6. CAN 1-H
7. CAN 1-L 5 8
8. NOT USED

CN5 (RPM Gauge-Aux)

1. NOT USED
1 4
2. BUZZER
3. OIL PRESSURE SENDER
4. NOT USED
5. GEARBOX OIL PRESSURE
5 8
6. NOT USED
7. NOT USED
8. TANK LEVEL

CN7 (Diagnosis)

1. CAN 2-H 1 3
2. CAN 2-L
3. NOT USED
4. GROUND
5. BATTERY + 4 6
6. NOT USED

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G-SCAN

G-scan is a diagnostic tool which can perform the functions of DTC analysis, fault code
searching, data analysis and ECU upgrading.

G-SCAN CONNECTIONS

The G-scan can be connected to the diagnostic connector of the EOI (1), as well as to
the G-scan connector in the junction box (2).

IN THE JUNCTION BOX

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DTC(DIAGNOSIS TROUBLE CODE) AND ALARM LIST

If there is a problem in the engine, the EOI 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.

WARNING
NO. ITEM DTC DISRIPTION P-CODE FAIL SAFE & DEFAULT VALUE BUZZER
LAMP

1 Sensor Reference Voltage "A" Circuit Low P0642 ○ ○

2 Sensor Reference Voltage "A" Circuit High P0643 ○ ○

▪ RPM 700 Fixed
Accelerator lever
▪ Sensor Default Value : 0V, 0%
3 Throttle/Pedal Position Sensor "A" Minimum Stop PerformanceP2109 ○ ○

4 Throttle Actuator Control System - Forced Limited RPM P2110 ○ ○

5 Intake Air Heater "A" Circuit Low P0541

6 Intake Air Heater "A" Circuit High P0542

Air Heater Bad cold-start
7 Intake Air Heater "A" Circuit Open P0543

8 Intake Air Heater System Performance P2609

9 Alternator Charging System Voltage High P2504 Fixed to Engine Idle RPM ○ ○

10 Barometric Pressure Circuit Low Input P2228

Ambient air Pressure Sensor Default Value : 100kpa
11 Barometric Pressure Circuit High Input P2229

12 Manifold Absolute Pressure Circuit Low Input P0107 ○ ○

Boost Pressure ▪ Engine Power Limitation

13 Manifold Absolute Pressure Circuit High Input P0108 ○ ○
(Manifold Absolute Pressure) ▪ Sensor Default Value : 150kpa

14 Manifold Absolute Pressure Plausible Fault P1106 ○ ○

15 Camshaft Position Correlation Fault P0016 ○ ○

16 Crankshaft Position Position Correlation Fault P0017 ○ ○

▪ Engine Power Limitation
CAM & CRANK SENSOR
▪ Injection Timing Fixed to BTDC 6
17 Crankshaft Position Sensor "A" Circuit P0335 ○ ○

18 Camshaft Position Sensor "A" Circuit P0340 ○ ○

19 Internal Control Module Memory Check Sum Error P0601 ○ ○

20 ECU Safety Circuit integrity checks Error P060A ○ ○

ECU Engine Running Impossible
21 Fuel Injector Group "A" Supply Voltage Circuit Low P2147 ○ ○

22 Fuel Injector Group "A" Supply Voltage Circuit High P2148 ○ ○

23 Engine Coolant Temperature Circuit Low Input P0117 ▪ Sensor Default Value ○ ○
- Key on & Starting : -10℃
24 Engine Coolant Temperature Engine Coolant Temperature Circuit High Input P0118 - Driving : 100℃ ○ ○

25 Engine Coolant Over Temperature Condition P0217 Engine Power Limitation over 110℃ ○ ○

26 Low Pressure Fuel System Sensor Circuit Low P2541 ○ ○

Fuel Pressure Sensor Default Value : 350Kpa
27 Low Pressure Fuel System Sensor Circuit High P2542 ○ ○

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28 Fuel Pressure Level 1 Derate P1087

29 Fuel Pump Fuel Pressure Level 2 Derate P1088 ○ ○

Engine Power Limitation
30 Fuel Pressure Level 3 Dreate P1089 ○ ○

31 Fuel Temperature Sensor "A" Circuit Low Input P0182

Fuel Temperature Sensor Default Value : 40℃
32 Fuel Temperature Sensor "A" Circuit High Input P0183

34 Engine Check lamp circuit Low P1653 Lamp no working

Engine check lamp &
Engine over-heated lamp
35 High Coolant Temperature Lamp P1656 Lamp no working

36 Injector Needle "1" High side circuit Low - Cylinder 1 P1201 ○ ○

37 Injector Needle "1" High side circuit High - Cylinder 1 P1202 ○ ○

No Injection
38 Injector Needle "1" Low side circuit Low - Cylinder 1 P1203 ○ ○

39 Injector Needle "1" Low side circuit High - Cylinder 1 P1204 ○ ○

40 Injector Needle "2" High side circuit Low - Cylinder 5 P1205 ○ ○

41 Injector Needle "2" High side circuit High - Cylinder 5 P1206 ○ ○

No Injection
42 Injector Needle "2" Low side circuit Low - Cylinder 5 P1207 ○ ○

43 Injector Needle "2" Low side circuit High - Cylinder 5 P1208 ○ ○

44 Injector Needle "3" High side circuit Low - Cylinder 3 P1209 ○ ○

45 Injector Needle "3" High side circuit High - Cylinder 3 P1210 ○ ○

No Injection
46 Injector Needle "3" Low side circuit Low - Cylinder 3 P1211 ○ ○

47 Injector Needle "3" Low side circuit High - Cylinder 3 P1212 ○ ○

48 Injector Needle "4" High side circuit Low - Cylinder 6 P1213 ○ ○

49 Injector Needle "4" High side circuit High - Cylinder 6 P1214 ○ ○

Injector No Injection
50 Injector Needle "4" Low side circuit Low - Cylinder 6 P1215 ○ ○

51 Injector Needle "4" Low side circuit High - Cylinder 6 P1216 ○ ○

52 Injector Needle "5" High side circuit Low - Cylinder 2 P1217 ○ ○

53 Injector Needle "5" High side circuit High - Cylinder 2 P1218 ○ ○

No Injection
54 Injector Needle "5" Low side circuit Low - Cylinder 2 P1219 ○ ○

55 Injector Needle "5" Low side circuit High - Cylinder 2 P1220 ○ ○

56 Injector Needle "6" High side circuit Low - Cylinder 4 P1221 ○ ○

57 Injector Needle "6" High side circuit High - Cylinder 4 P1222 ○ ○

No Injection
58 Injector Needle "6" Low side circuit Low - Cylinder 4 P1223 ○ ○

59 Injector Needle "6" Low side circuit High - Cylinder 4 P1224 ○ ○

60 Injector Needle "1,3,5" High side circuit Low - Cylinder 1,2,3 P1225 ○ ○

61 Injector Needle "1,3,5" High side circuit High - Cylinder 1,2,3 P1226 ○ ○
No Injection
62 Injector Needle "2,4,6" High side circuit Low - Cylinder 4,5,6 P1227 ○ ○

63 Injector Needle "2,4,6" High side circuit High - Cylinder 4,5,6 P1228 ○ ○

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64 Injector Spill "1" High side circuit Low - Cylinder 1 P1229 ○ ○

65 Injector Spill "1" High side circuit High - Cylinder 1 P1230 ○ ○

No Injection
66 Injector Spill "1" Low side circuit Low - Cylinder 1 P1231 ○ ○

67 Injector Spill "1" Low side circuit High - Cylinder 1 P1232 ○ ○

68 Injector Spill "2" High side circuit Low - Cylinder 5 P1233 ○ ○

69 Injector Spill "2" High side circuit High - Cylinder 5 P1234 ○ ○

No Injection
70 Injector Spill "2" Low side circuit Low - Cylinder 5 P1235 ○ ○

71 Injector Spill "2" Low side circuit High - Cylinder 5 P1236 ○ ○

72 Injector Spill "3" High side circuit Low - Cylinder 3 P1237 ○ ○

73 Injector Spill "3" High side circuit High - Cylinder 3 P1238 ○ ○

No Injection
74 Injector Spill "3" Low side circuit Low - Cylinder 3 P1239 ○ ○

75 Injector Spill "3" Low side circuit High - Cylinder 3 P1240 ○ ○

76 Injector Spill "4" High side circuit Low - Cylinder 6 P1241 ○ ○

77 Injector Spill "4" High side circuit High - Cylinder 6 P1242 ○ ○

Injector No Injection
78 Injector Spill "4" Low side circuit Low - Cylinder 6 P1243 ○ ○

79 Injector Spill "4" Low side circuit High - Cylinder 6 P1244 ○ ○

80 Injector Spill "5" High side circuit Low - Cylinder 2 P1245 ○ ○

81 Injector Spill "5" High side circuit High - Cylinder 2 P1246 ○ ○

No Injection
82 Injector Spill "5" Low side circuit Low - Cylinder 2 P1247 ○ ○

83 Injector Spill "5" Low side circuit High - Cylinder 2 P1248 ○ ○

84 Injector Spill "6" High side circuit Low - Cylinder 4 P1249 ○ ○

85 Injector Spill "6" High side circuit High - Cylinder 4 P1250 ○ ○

No Injection
86 Injector Spill "6" Low side circuit Low - Cylinder 4 P1251 ○ ○

87 Injector Spill "6" Low side circuit High - Cylinder 4 P1252 ○ ○

88 Injector Spill "1,3,5" High side circuit Low - Cylinder 1,2,3 P1253 ○ ○

89 Injector Spill "1,3,5" High side circuit High - Cylinder 1,2,3 P1254 ○ ○
No Injection
90 Injector Spill "2,4,6" High side circuit Low - Cylinder 4,5,6 P1255 ○ ○

91 Injector Spill "2,4,6" High side circuit High - Cylinder 4,5,6 P1256 ○ ○

92 Intake Air Temperature Sensor 1 Circuit Low Input P0112 ▪ Sensor Default Value
Intake Temperature - Key on & Starting : -10℃
93 Intake Air Temperature Sensor 1 Circuit High Input P0113 - Driving : 50℃

94 System Voltage Low P0562 ○ ○

Sensor Default Value : 28V
95 System Voltage High P0563 ○ ○
System Voltage
96 Sensor Reference Voltage "B" Circuit Low P0652 ○ ○
Sensor Default Value : 0V
97 Sensor Reference Voltage "B" Circuit High P0653 ○ ○

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98 Turbocharger Turbine Overspeed P0049 Engine Power Limitation ○ ○

99 TURBO CHARGER SPEED Turbocharger speed sensor circuit Low P2580 ○ ○

Sensor Default Value : 100000RPM
100 Turbocharger speed sensor circuit high P2581 ○ ○

101 VGT initialize Error P1045 ○ ○

102 VGT PWM Drive Error P3270 ○ ○

103 VGT Position control Error P3284 ○ ○

104 VGT Power supply Error P3285 ○ ○

▪ VGT Vane Full Open
VGT
▪ Engine Power Limitation
105 VGT Wiping Function Error P3286 ○ ○

106 VGT Position sensor Error P3287 ○ ○

107 VGT Temperature sensor Error P3288 ○ ○

108 VGT Electronic Module Error P3289 ○ ○

109 Stater Relay Circuit P0615 ○ ○

110 STARTER MOTOR Starter Relay Circuit Low P0616 ○ ○

111 Starter Relay Circuit High P0617 ○ ○

109 ENGINE OIL PRESSURE Engine Oil Pressure Low - ○ ○

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CHAPTER 9
ANTI CORROSION SYSTEM

ANODE
INTERCOOLER HEAT EXCHANGER

1) ANODE for corrosion protection. Must be replaced every 250 hours.

2) When used in salt or brackish water, regular inspection is required. It is strongly
recommended to replace the sacrificial anode at the start of each season.

CAUTION
• DON’T OPERATE ENGINE WITHOUT ANODES. IT IS HARMFUL TO
YOUR ENGINE.
• CLOSE THE SEAWATER VALVE BEFORE REMOVING ANODES.
• MAKE SURE TO CHECK THE ANODE PLUG IN ACCORDANCE WITH
THIS MANUAL.
• DON’T LOOSEN COOLANT DRAIN PLUG.

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CHAPTER 10
ENGINE STORAGE

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
• 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
• 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 9.

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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
-. Turn off the engine. Drain the engine oil using
removing the heat exchanger and intercooler
the oil extraction pump. If the oil extraction
anodes.
pump is not installed, drain oil by removing the
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 hoses.
maintenance specifications. Tighten or replace the connection if necessary.

-. Check the oil level on the dipstick and if -. Check the cooling system (heat exchanger,
necessary add more oil to reach the correct oil intercooler, thermostat, hoses, clamps, etc.)
level. every 500 hours or every two years, whichever
comes first. Replace any worn components.
• FUEL SYSTEM
-. Check for fuel leaks where the line from the • INTAKE SYSTEM
fuel tank connects to the engine. Tighten or -. Remove the air filter from engine.
replace the connection if necessary. -. Clean the air filter.
-. Close the fuel valve. Clean the water -. Intake part should be kept hermetically sealed.
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
ground
condensation in the fuel tank.
-. Disconnect the battery (+) cable.
-. Close the fuel valve.
-. Clean the battery cable and terminals.
• COOLING SYSTEM -. Coat the terminal connection with a battery
-. Close the water valve. terminal anti-corrosion agent.
-. Connect a freshwater source to the seawater -. Whenever the battery will be stored for an
inlet. Run the engine at idle to flush all extended period of time, be sure the cells are
seawater out of the system. full of battery is fully charged.
-.Fill the cooling system (seawater side) with a
30~50% solution of anti-freeze. Circulate
into the seawater system by running the engine.

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CHAPTER 11
MAINTENANCE

THE INITIAL RUNNING CHECK

BEFORE THE WATER TEST ON THE WATER TEST

Y N Y N
Seawater inlet valve open Seawater pump operating properly
Engine coolant level Seawater strainer correctly mounted ,
Cooling system hose clamps tight Clean and tightly closed

Engine oil level Engine alignment (propulsion only)

Power steering fluid level Fuel leaks

Drive belt tension Oil leaks

All electrical connections tight Coolant leaks

EOI warning system operation Water leaks

Battery fully charged and secured Exhaust leaks and color

All fuel connections tight EOI and gauges operating properly

Exhaust system hose clamps tight Engine emergency stop switch

operating properly
Engine mounts tight
Idle RPM, within specifications
Engine alignment
WOT RPM, within specifications
Correct propeller rotation
(in forward gear)
(Installed and torqued)
Engine coolant and oil drain plug
closed
Throttle, shift and steering system
fasteners tightened properly
Boat drain plug in place
(Check before putting boat in water)

PROPULSION CHECKS AFTER THE WATER TEST

Steering operation throughout full Fuel, oil, coolant, water and fluid – no
range leaks
Forward - Neutral - Reverse gear Oil and fluid levels
proper operation Propeller nut torque
Drive line components properly
torqued
Propeller nut torque
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MAINTENANCE SCHEDULE
○ : Check/Clean, ◇ : Check (Replace if Necessary), ● : Replace

Minimun 1 y
Daily 250h 600h 1000h /Necessary

Check coolant level and check for leaks 1) ○

Clean Seawater strainer ○

Check for Exhaust system leaks ○

Check for Fuel system leaks ○

Check the engine oil level and check for
leaks ○

Check the battery operating voltage ○

Check the oil level and check the steering
system for leaks ○
Check transmission lubrication level and the
propulsion system2) for leaks ○

Engine oil and filter3) ● ◇

Check the sacrificial anodes1) Anti
corrosion
system ● ◇
Check hose clamps for tightness and
corrosion ◇ ◇
Check the electrical system for tight
connections ◇ ◇
Check tightness of the bolts, nuts and other
fasteners ◇ ● ◇

Fuel filter and water separator ◇ ● ◇

Air filter ◇ ● ◇

Drive belt ◇ ◇

Heat exchanger tube bundle ◇ ◇

Inter-cooler tube bundle ◇ ◇

Checking Inter-cooler automatic drain valve ◇ ◇

Replace the seawater pump impeller ◇ ● ◇

Turbocharger ◇ ◇

1) Replace the coolant every two years.

2) For detailed propulsion system information, refer to the manufacturer’s manual.
3) Replace the engine oil after the first 100 hours of operation.

CAUTION
YOU SHOULD EXERCISE THE UTMOST CARE TO PREVENT INJURY
TO YOURSELF OR ENGINE DAMAGE WHENEVER PERFORMING
ANY MAINTENANCE OPERATIONS.

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A/S PART NUMBER

P/N DESCRIPTION QTY Remarks

26325-82700 OIL FILTER ELEMENT SERVICE KIT 1

31945-82000 FILTER CATRIDGE-FUEL 1

31945-7L002 ELEMENT-WATER SEPARATOR 1

00500-4H170 AIR FILTER 1

00400-4H160 SEAWATER PUMP ASSEMBLY 1

00400-4H290 IMPELLER KIT 1

00400-4H298 MINOR KIT-SEAWATER PUMP 1

00400-4H299 MAJOR KIT-SEAWATER PUMP 1

00100-4H102 ANODE 2

ENGINE OIL
00300-1A004 8
(GENUINE ORIGINAL EQUIPMENT CI-4 , 4L )

00900-4H180 V-RIBBED BELT 1

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MAINTENANCE LOG

DATE MAINTENANCE PERFORMED ENGINE HOURS

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CHAPTER 12
TROUBLESHOOTING GUIDE

■ Starter motor does not crank the engine

Possible Causes
•Engine stop switch is not in the “ON” position
•Engine is not shifted to neutral position
(Switch is pressed)
•Weak battery or battery connections are loose
•Starter motor solenoid or slave solenoid failure
or corroded

•Ignition key switch failure •Defective EOI fuse (3A)

•Wiring or electrical connection fault •Defective ECU

■ Engine cranks but does not start

Possible Causes
•Weak battery or bad starter motor •Low fuel pressure
•No fuel •Low compression pressure
•ECU not functioning •Crank position sensor not functioning
•Incorrect starting procedure •Fuel is not reaching the engine
•Faulty fuel filter or electric fuel pump •Bad fuel quality or water in fuel
•Faulty fuse •Faulty injector

■ Engine starts with difficulty or starts and stalls

Possible Causes
•Low fuel pressure in fuel rail •Faulty alternator or voltage regulator
•Leakage in high pressure fuel circuit •No engine coolant temperature sensor signal
•Faulty fuse •Low battery voltage
•No rail pressure sensor signal •Low compression pressure
•Oil level too high or too low •Clogged fuel filter
•ECU program error or hardware fault

■ Engine idle is rough

Possible Causes
•No rail pressure sensor signal •Low compression pressure
•Wiring harness open or poor connection •Faulty high pressure fuel pump
•Bad fuel quality or water in fuel •Faulty injector
•Clogged fuel filter / air filter •Carbon deposit on the injector

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■ Engine rattling, noisy engine

Possible Causes
•Incorrect compensation of individual injectors •No engine coolant temperature sensor signal
•Low compression pressure •Clogged injector return line
•No rail pressure sensor signal •Faulty injector
•Poor injector O-ring •Carbon deposit on the injector

■ Uneven acceleration / deceleration

Possible Causes
•Intermittent faulty fuel line connection •Oil suction
•No rail pressure sensor signal •ECU program error or hardware fault
•Damaged turbocharger or leakage in vacuum
•Leakage in intake system
line
•Clogged fuel filter •Low compression pressure
•Leakage in high pressure fuel circuit •Injector needle stuck

■ Engine stops

Possible Causes
•Out of fuel •Crank signals missing
•Fuel pressure regulator valve contaminated,
•Fuel feed line not connected
stuck, jammed
•Rail pressure regulator valve contaminated,
•Leakage in high pressure fuel circuit
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 •ECU program error or hardware fault

■ Performance loss

Possible Causes
•Incorrect compensation of individual injectors •Leakage at the injector
•Clogged air filter •Fuel or intake air temperature too high
•Oil level too high or too low •Engine coolant temperature too high
•Damaged turbocharger or intake air leakage •Low compression pressure
•Clogged fuel filter •Poor valve clearance

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CHAPTER 13
WARRANTY

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 < 90% of rated speed (RPM)
- Operating less than 400 hours per year

S4 : Special Pleasure Duty / Special Light Duty Commercial

- Full power operation restricted to within 10% of total use period
- Cruising speed (RPM) at engine RPM < 90% of rated speed (RPM)
- Operating less than 1,000 hours per year

S3 : Light Duty Commercial

- Full power operation restricted to within 20% of total use period
- Cruising speed (RPM) at engine RPM < 90% of rated speed (RPM)
- Operating less than 1,500 hours per year

S2 : Medium Duty Commercial

- Full power operation restricted to within 30% of total use period
- Cruising speed (RPM) at engine RPM < 90% of rated speed (RPM)
- Operating less than 3,000 hours per year

S1 : 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 distribute 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
3) Improperly performed Pre-Delivery Inspection
4) Unsuitable fuels, coolant or lubricants
5) Using the engine outside of the specified duty cycle rating
6) Overloading
7) Improperly performed repairs
8) Improper maintenance interval(s)
9) No submitted Pre-Delivery Inspection Card and Warranty Registration Card

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 INSTALLATION & OPERATION MANUAL
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DURATION OF WARRANTY
Leisure Applications
Extended Major Components
Base Engine
Engine Rating (Includes Base Engine Warranty)
year hour year hour
S250/D170/U125 S5 2 1,000 4 2,000
**H380/L500 S5 2 - 4 5,000

** Operating less than 1,500 hours per year and Full Power operation < 10% of total use period

• 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.

Commercial Applications
Extended Major Components
Base Engine
Engine Rating (Includes Base Engine Warranty)
year hour year hour
S250/D170/U125 S4 1 1,000 3 2,000
S220/D150 S3 1 1,500 3 6,500
H380/L500 S1 1 5,000 3 10,000

• 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 ISO 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) A 10% overload is permissible for 1 hour per 12 hours of operation.
3) Maximum prime power shall not exceed 500 hours per year.

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 INSTALLATION & OPERATION MANUAL
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Marin Auxiliary Engine

Extended Major Components
Base Engine
Engine Rating (Included Base Engine Warranty)
year hour year Hour
L500G Standby Power 2 1,000 4 3,000
H350G/L460G Prime Power 1 - 3 10,000

WARRANTY STARTING DATE

Warranty Begins:
1) When engine is delivered to the first retail purchaser
2) When the engine is first leased or rented
3) 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
submitted 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.

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 INSTALLATION & OPERATION MANUAL
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OWNER’S OBLIGATIONS

It is the owner’s obligation to install, operate, maintain and care 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

It 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 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 SeasAll. 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.

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 INSTALLATION & OPERATION MANUAL
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WHAT IS NOT COVERED

• Fuel injector or filter cleaning

• Belt, cable 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 or loss of time or income) are the owner’s 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 Marine, 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.

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 WARRANTY REGISTRATION CARD

Date of sale
This card is essential for registration of the customer’s warranty. Month Day Year
Please fill out the following registration card in English.

If Warranty Transfer , Check box

■OWNER’S INFORMATION

Name or Company E-Mail Address

Country State / Province / City

Operating Location

■ DEALER INFORMATION

Dealer / Installer Distributor Name

City E-Mail Address

■ ENGINE INFORMATION

Number of Engines Single Dual

Engine Model Gear Model

Engine Serial No. Gear/Drive Serial No.

Transom Serial No.

Engine Model Gear Model

Engine Serial No. Gear/Drive Serial No.

Transom Serial No.

■ BOAT INFORMATION REPOWER

Manufacturer Material Steel Alu. FRP Wood.
Model LOA ft Beam ft
Boat Type Hull ID
Type of Use Pleasure Commercial Planning Semi Disp. 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 : ___________________________

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 INSTALLATION & OPERATION MANUAL
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