Hyundai Seasall D170s User manual
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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TABLE OF CONTENTS
PAGE NUMBER
ABOUT THIS MANUAL ………………………………………………………………….....….
SAFETY PRECAUTIONS ……………………………………………………………………...
CHAPTER 1 ENGINE OVERVIEW ………………………………………………………………
1. ENGINE COMPONENTS ………………………………………………………
2. ENGINE SUSPENSION EYES ………………………………………………..
3. ENGINE IDENTIFICATION …………………………………………………….
4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE ……..
5. TECHNICAL DATA ……………………………………………...…………
6. PERFORMANCE CURVES..………………………………………………
7. ENGINE DIMENSIONS ………………………………………………...…
CHAPTER 2 ENGINE MOUNT SYSTEM .………………………………………………..
1. ENGINE MOUNTING REQUIREMENTS ……………………………….
2. MOUNT DIMENSIONS ……………………………………………………
3. ENGINE MOUNT TOOL FOR STERNDRIVE MODEL ………………..
CHAPTER 3 COOLING & EXHAUST SYSTEM ………………………………………….
1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..…...
2. SEAWATER FLOW ……………………………………………………..…
2.1 WATER PICKUP ………………………………………………..
2.2 SEAWATER STRAINER ……………………………………….
2.3 SEAWATER PUMP ………………………………………..……
3. ENGINE COOLANT FLOW …………………………………………..…...
3.1 ENGINE COOLANT …………………………………………..…
3.2 REMOVING AIR BUBBLE ……………………………………...
3.3 CABIN HEATER CONNECTION ………………………………
4. EXHAUST SYSTEM …………………………………………………….....
CHAPTER 4 FUEL SYSTEM ………………………………………………………………..
1. FUEL FLOW ……………………………………..………………………….
2. LOW PRESSURE FUEL LINE …………………....………………………
3. ACCELERATION SENSOR AND CONTROL LEVER ………………….
4. RECOMMENDED FUEL QUALITY ………………....……………………
5. DRAINING WATER FROM FUEL FILTER ………………………………
CHAPTER 5 AIR INTAKE SYSTEM ………………………………………………………..
1. ENGINE ROOM VENTILATION …………………………………………..
2. AIR FILTER MAINTENANCE …………………………..…………………
CHAPTER 6 LUBRICATION SYSTEM ……………………………………………………
1. ENGINE OIL LEVEL CHECKS ……………………….…………………
2. RECOMMENDED OIL QUALITY …………………….....………………
3. ENGINE OIL EXTACTION PUMP ………………………..…………….
4. OIL FILTER REPLACEMENT …………………………….…………….
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INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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TABLE OF CONTENTS
PAGE NUMBER
CHAPTER 7 ELECTRICAL SYSTEM …………………………………………………….
1. BATTERY CABLE CONNECTIONS ……………………………...…….
2. BATTERY CHECKS ………………………………………………..…….
3. FUSE AND RELAY …………………………………………………...…..
CHAPTER 8 INSTRUMENT SYSTEM ……………………...………………………........
1. INSTRUMENT CONNECTIONS .…………..……………………………
2. CUT-OUT FOR GAUGE ……………………...………………………….
3. CUT-OUT FOR EOI SYSTEM …………………..………………………
CHAPTER 9 EOI SYSTEM …………………………………………..…………………….
1. OVERVIEW OF EOI SYSTEM ……………………..……………………
1.1 INFORMATION LCD ……..……………………...…………………..
1.2 SWITCHES ………………………………………......……………….
1.3 ALARM LAMPS ………………………………………..……………..
2. EOI CONNECTIONS ………………………………………......………….
3. EOI PIN ASSIGNMENT …………..……………………………......…….
4. NEUTRAL SWITCH AND DUAL EOI CONNECTION …………..…….
5. TRIM WIRING CONNECTION DIAGRAM …………………………….
6. ALARM AND DTC(DIAGNOSIS TROUBLE CODE) ……………......…
6.1 ALARM AND DTC(DIAGNOSIS TROUBLE CODE) ……………..
6.2 DTC(DIAGNOSIS TROUBLE CODE) LIST……….. ……………..
CHAPTER 10 ANTI CORROSION SYSTEM ……………………………………………...
CHAPTER 11 ENGINE OPRATION …………………………………………..…………..
1. ENGINE ON/OFF …………………………………………………..………
2. ENGINE BREAK-IN ………………………………………………………..
3. STOPPING THE ENGINE …………………………………………………
4. EMERGENCY STOP …………………..…………………………….…….
5. WINTER OPERATION AND STORAGE ……………………….………..
CHAPTER 12 ENGINE STORAGE …………………………………………………..………
CHAPTER 13 MAINTENANCE ………………………………………………………..……
1. PREDELIVERY INSPECTION LIST……………………………………..
2. MAINTENANCE SCHEDULE ………………………………………..…..
3. STERNDRIVE & TRANSMISSION MAINTENANCE SCHEDULE ….
4. MAINTENANCE LOG………………………………………………………
CHAPTER 14 TROUBLESHOOTING GUIDE ………………………………………….....
CHAPTER 15 WARRANTY ………………………………………………………………….
WARRANTY REGISTRATION CARD ………………………………….…
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INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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ABOUT THIS MANUAL
This engine installation and operation manual is provided as guidance for the installation of
Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide
technical information to aid in performing an effective engine installation so as to achieve both
maximum performance and service life. For information on installation, operation and maintenance
of the ZF Marine Transmissions and Sterndrive Bravo Models, please see the separate booklets
included in the original packaging of your Hyundai SeasAll purchase.
Hyundai SeasAll is committed to making clear and accurate information available for those who
own, maintain and repair the D170 & D150 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.
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.
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.
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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SAFETY PRECAUTIONS
Read and understand this operator’s manual
as well as other information supplied by
Hyundai SeasAll for safer use of these
products. Be sure to check your engine
regularly.
• Do not use the engine for a purpose other
than what is intended by Hyundai SeasAll. Do
not modify the performance of the supplied
engine without the express permission of
Hyundai SeasAll. This can be dangerous, can
shorten the life of your engine and can
invalidate your warranty.
• Original and genuine parts supplied from
Hyundai SeasAll must be used for
inspections and maintenance. Hyundai
SeasAll does not guarantee any damage
caused by the use of imitation parts.
• Engine inspection and maintenance should
be carried out by properly trained and factory
approved service engineers.
• The engine should be inspected if the
electronic engine control unit shuts down the
engine or puts it into the “limp home” mode.
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.
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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CHAPTER 1
ENGINE OVERVIEW
1. ENGINE COMPONENTS
1. ECU Box
2. Coolant Expansion Tank
3. Engine Oil Cap
4. Engine Oil Filter
5. P/S Oil Cooler
6. Fuel Pump
7. Engine Oil Gauge
8. Acceleration Lever Sensor
9. Seawater Pump
10. Intercooler
11. Heat Exchanger
12. Alternator
1. VGT
2. Exhaust Elbow
3. Bell Housing
4. Air Filter
5. Engine Oil Extraction Pump
Button
6. Engine Emergency Stop Button
7. VGT Controller
8. Shift Plate
9. Oil Extraction Pump
10. Injector
11. PRV
12. BPS & IATS
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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2. ENGINE SUSPENSION EYES
1) To lift the engine, first remove the engine cover. You will find two engine eyes (see
figure)
2) To avoid engine damage, take care that engine lift chains or belts do not hit or
touch surrounding parts during engine lifting.
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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3. ENGINE IDENTIFICATION
SERIAL NUMBER ON THE ENGINE BLOCK
NAME PLATE ON THE ECU BOX
Engine identification is affixed to the engine block and the ECU box (see figure).
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
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4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE
Fuel
temperature
sensor
Rail
pressure
regulator
valve
Glow
plug
Coolant
temperature
sensor
Cam Position
Sensor
Crankshaft
position
sensor Vacuum
modulator
VGT actuator
Rail pressure sensor
Water sensor
in fuel
Fuel feed (low)
Fuel feed (high)
Fuel return
Feed
pump
Injector
Intercooler
Common rail
High
pressure
pump
Main
fuel
filter
Air
filter
VGT
ECU
Pump
pressure
regulator
valve
Accel position
sensor
Sensor
Actuator
Boost pressure & air
temp sensor
Air temp.
sensor
Fuel tank
return
return
return
return
INSTALLATION & OPERATION MANUAL
D170 and D150 Series Engines
-9-
5. TECHNICAL DATA
Engine type
D170 / 150S D170 / 150P D170J
4-stroke, 4-valve
After-cooled, direct-injection, water cooled
Output ps (kW) 170ps (125) / 150ps (110)
rpm at full load 3800/3200
Cylinders I-4
Ignition sequence 1-3-4-2
Displacement [cm3] 2188
Bore [mm] 87
Stroke [mm] 92
Compression ratio 17.3 : 1
Max. torque [kgm]
@ speed [rpm] 36 34
2000 3500
Injection system Common rail direct injection
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm] 2.5 2.5 2.5
3800/3200 3800/3200 3800
Coolant quantity (liter) 6.5
Coolant cap opening pressure (bar) 1.1
Engine oil (liter) 6
Engine oil pressure (bar) 2~3 at 1800rpm, 100 ℃(oil temp.)
Exhaust gas pressure (kPa) Max. 45
Alternator [A] 120
Engine diagnosis Yes
Weight (kg) 261
Battery capacity (AH) 12V, at least 150AH recommended
Thermostat opening temp. (℃) 85 (starting to open), 95 (fully open)
Idle rpm warmed up (rev/min) 790
Permissible engine oil temp (℃) 135
Permissible engine coolant temp (℃) 104
Propulsion system Sterndrive Shaftdrive Waterjet
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