Hyundai SeasAll L700 Engines Installation & Operation Manual

INSTALLATION & OPERATION MANUAL L13 Series

INSTALLATION & OPERATION MANUAL L13 Series -1- ABOUT THIS MANUAL …………………………………….…………………………..…….....……….. SAFETY PRECAUTIONS ………………………………………………………….……..……………… APPROXIMATE STANDARD CONVERSIONS …………..…………………………………………… CHAPTER 1 ENGINE OVERVIEW ……………………………………………..…...….…….……… ENGINE COMPONENTS ………………………………………..……….…………… TECHNICAL DATA ………………………………………………..…….…………….. PERFORMANCE CURVES…………………………………………….………..…….. ENGINE IDENTIFICATION……………………………………..……….…………..... ENGINE HANGER….…………………………………………….……..…….............. ENGINE DIMENSIONS………………………………………….………..….....…….. CHAPTER 2 ENGINE OPERATION ………………………………………………………….………... STARTING AND STOPPING ENGINE……………………………..…..……………. EMERGENCY STOP …………………..………………………………..….………….. INTAKE AIR HEATER………………………………………………………….……….. CHAPTER 3 COOLING SYSTEM ………………………….………………………………..….……... SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..….................... SEAWATER FLOW – OPENED COOLING CIRCUIT….………………...…….….. WATER PICKUP……………………………………………………..…….…….…….. WATER STRAINER…………………………………………………..…….……..……. CLEANING STRAINER FILTER…………………………..…………..……….…...… AUTOMATIC DRAIN VALVE..……………………………………………...…..……… SEAWATER PUMP………………………………………………………...…..….…… CHECKING SEAWATER PUMP & IMPELLER………………………………..…….. ENGINE COOLANT FLOW – CLOSED COOLING CIRCUIT …..…….…………. ENGINE COOLANT………………………………………………………..…….……. SUPPLEMENTAL ENGINE COOLANT………………………………….……….…. DRAINING COOLANT……………………………………………………..…….……. REMOVING AIR BUBBLES IN COOLANT………………………………...….…….. CABIN HEATER CONNECTION……………………………………………..…..…… CHAPTER 4 FUEL SYSTEM ………………………………………………………….……………….. EUI SYSTEM…………………………………………………………………..….…….. FUEL SUPPLY SYSTEM.….……..…………………………..…………….……..…... FUEL LINE…………………....………………………………………………..…...…… RECOMMENDED FUEL QUALITY ………………....……………………..……..…. DRAINING WATER FROM FUEL FILTER ………………………………………..…. CHANGING FUEL FILTER ……………………………..……………….…….……….. CHAPTER 5 INTAKE & EXHAUST SYSTEM …………………………………………..….……….. ENGINE AIR CONSUMPTION & ROOM VENTILATION …………..………….... CHECK AIR FILTER ……………………………………..…………..……..….…….. CLEANING AIR FILTER ……………………………………..……………….……… EXHAUST SYSTEM…………………………………………………..……..………… CHAPTER 6 LUBRICATION SYSTEM …………….………………………….………….…….…… LUBRICATION COMPONENTS……………………….…………………..………… ENGINE OIL LEVEL CHECKS…………………….....……………….…….……….. 3 4 6 7 7 9 10 11 12 13 15 15 16 16 17 17 18 18 18 19 20 21 22 23 23 24 24 25 25 26 26 27 27 28 28 29 30 31 32 32 33 34 34 35 TABLE OF CONTENTS

INSTALLATION & OPERATION MANUAL L13 Series -2- RECOMMENDED OIL QUALITY………………………..……………..…...……........ ENGINE OIL EXTACTION PUMP…………………………….…………...……..……. CHECKING OIL FILTER……………………………………………....….………....… CHAPTER 7 ELECTRICAL SYSTEM ………………………………………………..…………..…… BATTERY CABLE CONNECTIONS ……………………………….........………….. ACCELERATION SENSOR AND CONTROL LEVER…………….………………… PROCEDURES FOR CONTROL LEVER INSTALLATION………………………… BATTERY CHECKS………..………………………………………...………............. LOAD TEST…………………………………………………………………….….…… FUSES AND RELAYS……………………………………………………….………… SYSTEM FUSE BOX………………………………………………………….……….. FUSE BOX………………………………………………………………….…………… FUSES……………………………………………………………………..…...….…… RELAYS…………………………………………………………………….………..…. CHAPTER 8 EOI SYSTEM …………………………………………..………………………….......… INSTRUMENT CONNECTIONS……………………………………………….…..… RPM GAUGE……………………..……………………………………….………..…... USER INTERFACE………………………………………......………..…………....… EOI FUNCTION…………..……………………………......………………………...…. LCD INFORMATION…………………………………………………………………… WARNING LAMP…………..………………………………………………………..…. SWITCHES ……………………………………………………………………….…...... PTO MODE…………………………………………………………………………...… IDLE SETTING MODE…………………………………………………..…..……..…. EOI BOX ( INSIDE )…………………………………………………….……….…..… CUT OUT FOR EOI SYSTEM……………………………………………………..…. EOI PIN ASSIGNMENT…………………………………………….……………...…. SEASLINK PRODUCT COMPONENTS………………………………………...…... INSTALLATION OF SEASLINK DONGLE…………………………………………… G-SCAN……………………………………………………………….……………....… G-SCAN CONNECTIONS………………………………………………………....….. DTC (DIAGNOSIS TROUBLE CODE) AND ALARM LIST……………………..… CHAPTER 9 ANTI CORROSION SYSTEM ………………………………………….……...…….... CHAPTER 10 ENGINE STORAGE …………………………………………………..….….………...... WINTER STORAGE…………………………………………………...………………. LONG TERM STORAGE……………………………………………………………… CHAPTER 11 MAINTENANCE ………………………………………………………..……....….……. THE INITIAL RUNNING CHECK……………...……………..…………..……..……. MAINTENANCE SCHEDULE ……………………………………………….…..…..... A/S PART NUMBER..……………………………………….….…………….…...….. MAINTENANCE LOG…………….………………………………………..……...….. CHAPTER 12 TROUBLESHOOTING GUIDE ……………………………………………….............. CHAPTER 13 WARRANTY ………………………………………………………………….……........ WARRANTY REGISTRATION CARD ………………………………….………….. 35 36 36 37 37 38 38 39 39 40 40 40 40 41 42 42 43 43 44 44 45 46 46 46 47 47 48 50 51 52 52 53 57 58 59 60 61 61 62 63 64 65 67 72 TABLE OF CONTENTS

INSTALLATION & OPERATION MANUAL L13 Series -3- ABOUT THIS MANUAL This engine installation and operation manual is provided as guidance for the installation of Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide technical information to aid in performing an effective engine installation so as to achieve both maximum performance and service life. Hyundai SeasAll is committed to making clear and accurate information available for those who maintain, own and repair the L500 Series engines. Hyundai SeasAll values your input regarding revisions and additional information for our manuals. WARNING DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION GUIDELINES MAY LEAD TO PERSONAL INJURY OR DEATH TO OPERATORS AND NEARBY PERSONNEL. CAUTION DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION GUIDELINES MAY LEAD TO IMPROPER OPERATION, DAMAGE OR DESTRUCTION OF THE ENGINE. • The manufacturer is not liable for any damages or losses caused by faulty installation, wrong handling of the equipment and/or deficient maintenance. • The operator is responsible for the correct and safe operation of the engine and safety of its occupants and general public. • It is strongly recommended that each operator read and understand this manual before installing and operating the engine. • This manual as well as safety labels posted on the engine use the following safety alerts to draw your attention to special safety instructions that should be followed. • Illustrations in this manual are subject to change without notice.

INSTALLATION & OPERATION MANUAL L13 Series -4- SAFETY PRECAUTIONS HOT SURFACES AND FLUIDS • There is always a risk of burns when working with a hot engine. Be aware of hot parts like the turbocharger system, the exhaust system, hot coolant hoses, etc. Wait until the engine is fully cool to do inspection and maintenance. REFUELING • Refuel only after the engine completely stops. • Use only the recommended fuel. The wrong grade of fuel can cause operating problems, can cause the engine to stop and can cause engine damage. • Pay special attention to safe practices when refueling. PAINT DAMAGE • Damage of the engine or parts paint during maintenance and inspection can cause corrosion. Any damage must be repainted after inspection and maintenance. WELDING ON ENGINE • Welding directly on the engine block can cause damage to the engine control systems. The ECU and related electronic devices must be disconnected and removed if unavoidable welding is needed. . • Read and understand this operator’s manual as well as other information supplied by Hyundai SeasAll for safe use of these products. Be sure to check your engine regularly. • Do not use the engine for a purpose other than what is intended by Hyundai SeasAll. Do not modify the performance of the supp-lied engine without the express permission of Hyundai SeasAll. This can be dangerous, can shorten the life of your engine and in-validate your warranty. • Original and genuine parts supplied from Hyundai SeasAll must be used for inspections and maintenance. Hyundai SeasAll does not guarantee any damage caused by the use of imitation parts. • Engine inspection and maintenance should be carried out by properly trained and factory approved service engineers. • The engine should be inspected if the electronic engine control unit shuts down the engine.

INSTALLATION & OPERATION MANUAL L13 Series -5- ENGINE BREAK-IN WARNING DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION. EMISSION GAS IS HARMFUL. INITIAL BREAK-IN PROCEDURE • The first 20 hours of operation is the engine break-in period. During this period, it is important that the engine is operated as outlined below. • DO NOT operate engine at idle rpm for extended periods of time during the first 10 hours. • DO NOT operate at any one constant speed for extended periods of time. • DO NOT exceed 75% of full throttle during the first 10 hours except during the engine initial Break-In Procedure. During the next 10 hours, occasional operating at full throttle (5 minutes at a time maximum) is permissible. • AVOID full throttle accelerations from neutral position. • DO NOT operate at all full throttle until engine reaches normal operating temperature. (40℃) • FREQUENTLY CHECK engine oil level and add oil if necessary. USING AND ASSEMBLING GENUINE PARTS • Installation must be done and repairs must be performed using the special tools and procedures specified by Hyundai SeasAll. • The limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. • Check for compliance with torque tightening requirements. (Contact your Hyundai SeasAll dealer or refer to the manual) • Any gaskets, O-rings, seals or other sealing parts should be replaced with new parts during repairs.

INSTALLATION & OPERATION MANUAL L13 Series -6- APPROXIMATE CONVERSIONS FROM STANDARD SYMBOL MULTIPLY BY SYMBOL SYMBOL MULTIPLY BY SYMBOL LENGTH mm 0.039 inch LENGTH inch 25.4 mm cm 0.4 inch inch 2.54 cm m 3.28 ft ft 0.3048 m AREA mm 2 0.0016 in 2 AREA in 2 645.2 mm 2 m 2 10.764 ft 2 ft 2 0.093 m 2 VOLUME cm 3 0.061 in³ VOLUME in³ 16.388 cm 3 mL 0.06 in 3 in 3 16 mL Ldm 3 61.023 in³ in³ 0.016 Ldm 3 Ldm 3 0.22 imp.gallon imp.gallon 4.545 Ldm 3 Ldm 3 0.264 U.S.gallon U.S.gallon 3.785 Ldm 3 m 3 0.76 yd 3 yd 3 1.3 m 3 m 3 35.315 ft³ ft³ 0.028 m 3 FORCE kgf 2.204 lbf FORCE lbf 0.453 kgf N 0.224 lbf lbf 4.448 N TEMP. o F=9/5x℃+32 TEMP. o C=5/9x(℉-32) PRESSURE Bar 14.5 psi PRESSURE psi 0.068 Bar MPa 145 psi psi 0.0068 MPa Pa 0.102 mmWc mmWc 9.807 Pa Pa 0.004 inWc inWc 249.098 Pa KPa 4 inWc inWc 0.249 KPa mWg 39.37 inWc inWc 0.025 mWg TORQUE Nm 0.738 lbf ft TORQUE lbf ft 1.356 Nm WEIGHT kg 2.205 lb WEIGHT lb 0.454 kg kg 35.273 oz oz 0.028 kg WORK kJ/kWh 0.43 BTU/lb WORK BTU/lb 2.326 kJ/kWh MJ/kg 430 BTU/lb BTU/lb 0.0023 MJ/kg kJ/kg 0.24 Kcal/kg Kcal/kg 4.184 kJ/kg ENERGY kJ/kg 0.697 BTU/hph ENERGY BTU/hph 1.435 kJ/kg FUEL CONSUMP. g/kWh 0.736 g/hph FUEL CONSUMP. g/hph 1.36 g/kWh g/kWh 0.0016 lb/hph lb/hph 616.78 g/kWh FLOW RATE (GAS) m 3 /h 0.588 ft³/min FLOW RATE (GAS) ft³/min 1.699 m 3 /h FLOW RATE (LIQUID) m 3 /h 4.403 US gal/min FLOW RATE (LIQUID) US gal/min 0.2271 m 3 /h SPEED m/s 3.281 ft/s SPEED ft/s 0.3048 m/s kph 0.539 knots knots 1.852 kph mph 0.869 knots knots 1.1508 mph kph 0.62 mph mph 1.61 kph

INSTALLATION & OPERATION MANUAL L13 Series -7- CHAPTER 1 ENGINE OVERVIEW ENGINE COMPONENTS ① FUEL FILTER ENGINE MOUNTING BRACKETS ② JUNCTION BOX OIL FILTER ③ SEAWATER PUMP ④ ECU WATER PUMP ⑤ WATER SEPARATOR EXPANSION TANK ⑥ OIL EXTRACTION PUMP CCV FILTER THERMOSTAT BELT COVER (OPTION)

INSTALLATION & OPERATION MANUAL L13 Series INTERCOOLER COOLANT PIPE (HEAT EXCHANGER OUTLET) DRY EXHAUST PIPE STARTER MOTOR TURBO-CHARGER OUTLET PIPE ENGINE MOUNTING BRACKET LIFTING EYES HEAT EXCHANGER AIR FILTER EXHAUST MANIFOLD AIR FILTER CONNECTOR ALTERNATOR -8-

INSTALLATION & OPERATION MANUAL L13 Series -9- TECHNICAL DATA Engine type L500 L600 L700 L13G 4-stroke, 4-valve After-cooled, Electronic Unit Injector (EUI), Turbocharger Output ps (kW) 500PS (368kW) 600PS (441kW) 700PS (515kW) 460PS (338kW) 500PS (368kW) 415PS (305kW) 450PS (331kW) rpm at full load 1,800 rpm 2,000 rpm 2,300rpm 1,500rpm 1,800rpm 1,500rpm 1,800rpm Cylinders I-6 Ignition sequence 1-5-3-6-2-4 Displacement [cm 3 ] 12,736 Bore [mm] 130 Stroke [mm] 160 Compression ratio 16.0 : 1 Max. torque [kg.m] @ speed [rpm] 232 245 - 1,200 1,200 - Injection system EUI Diesel fuel at least CN 51 as per DIN EN 590 Intake air pressure (abs. bar) @ speed [rpm] 2.7 1,800 Coolant quantity (liter) 52 Coolant cap opening pressure (bar) 0.7 Engine oil (liter) 42 Engine oil pressure (bar) 2.7 (600rpm), 4(1,800rpm), 4(2,000rpm) [100℃(oil temp.)] Exhaust gas pressure (kPa) 10 Alternator [A] 90 Engine diagnosis Yes Weight (kg) 1,310 1,320 1,310 Battery capacity (AH) 24V, 100AH Thermostat opening temp. (℃) 71 (starting to open), 83 (fully open) Idle rpm warmed up (rev/min) 600 (500~800 rpm idle control is possible) (But from 500~600 rpm G-SCAN is required) Permissible engine oil temp (℃) 135 Permissible engine coolant temp (℃) 105 Fuel Efficiency(L/h) 89.2 116.4 143.4 76.6 89.2 68.9 80.3

Hyundai SeasAll L700 Engines Installation & Operation Manual

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