Hyundai HDFN35T Operation And Maintenance Manual
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Hyundai HDFN35T Operation And Maintenance Manual

Hyundai HDFN35T Operation And Maintenance Manual

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OPERATION AND MAINTENANCE
MANUAL FOR A LIFEBOAT
WITH ENGINE
FREE FALL LIFEBOAT
(HDFN 25&35 T/F)
Note
For operation and maintenance of the launching appliance the end user
should be guided by the instructions provided by the manufacturers of these
equipments in their respective manuals.
Revision 1 / 2011.08.31
HYUNDAI LIFEBOATS Co., Ltd.
772, Deajung-Ri, Onsan-Eup, Ulju-Gun, Ulsan, Korea 689-892
Tel: +82 52 240 3500 / Fax: +82 52 237 4855 / Web Site: www.hdboat.com
1

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Summary of Contents for Hyundai HDFN35T

  • Page 1 Revision 1 / 2011.08.31 HYUNDAI LIFEBOATS Co., Ltd. 772, Deajung-Ri, Onsan-Eup, Ulju-Gun, Ulsan, Korea 689-892 Tel: +82 52 240 3500 / Fax: +82 52 237 4855 / Web Site: www.hdboat.com...
  • Page 2 OPERATION AND MAINTENANCE MANUAL FOR A LIFEBOAT SYSTEM TABLE OF CONTENTS 1. General 1.1 Technical specification 2. Method of checking proper closure of release hooks. 3. Launching operation 3.1 Free fall launching operation 3.2 Launching by the davit 4. Recovery operation (Max 3 Persons Onboard) 5.
  • Page 3 Complement 2,887.5 kg (35P) 2,062.5 kg (25P) weight Fully Laden weight 7,701.5 kg 8,001.5 kg 6,647.5 kg 6,947.5 kg MAX. Drop Height 25.7 M Dimensions 7.950x3.070x1.550 (m) 1.1.2 Engine Manufacture Hyundai lifeboats Co., ltd. Type HB29D1 Towing Power 320 kg...
  • Page 4 Fig. 1.1 Lifeboat davit arrangement...
  • Page 5 Fig. 1.2.1 Free Fall Lifeboat General Arrangement for NON-Tanker Type...
  • Page 6 Fig. 1.2.2 Free Fall Lifeboat General Arrangement for Tanker Type...
  • Page 7 2. Method of checking proper closure of release hooks 2.1. Safe use and operation of lifeboats during drills, inspection and maintenance is de- pendent on knowing that the release gear is properly reset. Never enter lifeboat without ensuring complete closure of release hooks. Incomplete resetting of the release hooks can cause the lifeboat to drop resulting in death.
  • Page 8 Ensuring release hook closure. The release hook needs to be checked firstly when passenger enters the lifeboat in case that it is supported by the fall and reset properly as follows: Operation Guide Schematic Diagram Check that the hook is in the closed position.
  • Page 9 Operation Guide Schematic Diagram Check that the safety pin a’ssy-handle is inserted in the connect-handle. <Activity on the ship> Check that connect-handle is in upper position. <Activity on the ship>...
  • Page 10 3. Launching operation 3.1 Free fall launching operation Operation Guide Schematic Diagram Remove the safety pin1 and turn- buckles. <Activity on the ship> Note. SAFETY PIN 1. Electric cable is disconnected au- tomatically during free-fall launch- Open the boarding hatch and em- bark.
  • Page 11 Operation Guide Schematic Diagram Fasten the seat belts. <Activity in the lifeboat> Remove the safety pin 2 and operate (step on) the release handle for free-fall launching. <Activity on the lifeboat> After free-fall launching, helmsman move to steering seat and start en- STEERING FREE−FALL gine.
  • Page 12 3.2 Launching by the davit Operation Guide Schematic Diagram anchored rope & securing chains remove from upper deck. Please see if whether or not the sling rope connected. For jib launching, sling rope shall be securely con- nected to the boat. The master link connected to boat shall be taken out by boarding per- son inside the boat.
  • Page 13 The electric cable which has been connected to boat for recharging shall be disconnected by person who prepares freefall-launching. Roll down the winch using control lever. At that time, you can see the boat move along the ramp & get out of jumping stopper.
  • Page 14 4. Recovery operation (Max 3 persons onboard) Operation Guide Schematic Diagram Please be ready to recover the boat, the boarding person in the boat , connect sling ropes to both sides of boat for fall recovery. You should connect sling ropes to floating block.
  • Page 15 The boarding person for boat re- covery will do connect the safety pin inside the boat, and then get out of the boat. Lock the hatch securely. provided wire rope for floating block shall be connected to anchoring eye. Please turn the power off using R.P.B.
  • Page 16 5. Release gear system 5.1 General This section describes the details of the release gear system. Read this section carefully for safe operation. This release gear system consists of external hook and internal release handle near the after sheet. 5.2 Structure and part names The structure and parts names of the external hook and internal release handle are shown in Figures 5.2.1 and 5.2.2.
  • Page 17 5.3 Releasing Firstly, pull out the snap-pin (item 41), safety-pin (item 11), snap-pin (item 42) and safe- ty-pin (item 20) in the order named. (see figure 5.3.1 ) and then push the handle (item 19) down by using hands or feet. Fig.
  • Page 18 5.4 Resetting After the resetting of hook, the posture of hook is returned at the close position. And insert safety pin a’ssy hook and snap-pin on the ship. (see figure 5.4.1) Fig. 5.4.1 Reset principle of the hook unit on the ship And board in the lifeboat, Raise the connect handle and insert safety pin a’ssy cam and snap-pin in the lifeboat.
  • Page 19 5.5 Emergency release and recovery 5.5.1 Emergency release In case of the emergency situation, turn the emergency nut (item 16) counterclockwise by using the hexagon ratchet (item 48) after pull out the snap-pin (item 41), safety-pin (item 11), snap-pin (item 42) and safety-pin (item 20) in the order named as above. (See figure 5.4.1) 5.5.2 Recovery Pull the master link in the hook (item 4) and then, raise the handle (item 19) after inserting...
  • Page 20 Note: All users are requested to include a clear statement in their manual that any inspec- tion, servicing and repairs should be completed in accordance with the system for inspec- tion and servicing developed by Hyundai lifeboats Co., Ltd. Personnel undertaking inspections, maintenance and adjustment of lifeboats, launching appliances and associated equipment are to be fully trained and familiar with these duties.
  • Page 21 Table 6.2.1.1 - Inspection procedure and maintenance plan for boat Mainten- ance Items Method Inspection procedure Plan Inspect for deformation or oth- er defects. Inspect for peeling Outside hull Visual or any damage of re- tro-reflective material. Inspect for deformation or oth- Outside canopy Visual er defects.
  • Page 22 Maintenance Plan Items Method Inspection procedure High pressure Visual Inspect for any damage. Air support pipe system Regulator Visual Inspect for any damage. (only tank- er version) Inspect for corrosion or any Air cylinder Visual damage. Note: 2 When waterborne. * W : Weekly, M : Monthly, Y : Annual Table 6.2.1.2 - Inspection procedure and maintenance plan for engine Mainten-...
  • Page 23 Table 6.2.1.3 - Inspection procedure and maintenance plan for electric parts Mainten- ance Items Method Inspection procedure Plan Visual Check lead wire. Measure voltage of battery. Battery Measure When voltage is low, charge battery. Inside lamp Operation Check light on. Canopy lamp Operation Check light on.
  • Page 24 Maintenance plan Items Two buoyant rescue quoits A manual pump One set of fishing tackle Portable fire-extinguishing equipment A radar reflector Thermal protective aids Compartments for storage Seat belts Instructions of immediate action Water resistant instructions * W : Weekly, M : Monthly, Y : Annual 6.2.2 On board maintenance procedures 6.2.2.1 General As a result of inspection, any defective parts should be repaired in accordance with fol-...
  • Page 25 6.2.2.3 Engine 6.2.2.3.1 Oil coating and filling When any rust exists, remove rust and coat with machine oil. Rotating parts should be filled with lubricating oil. 6.2.2.3.2 Operating test An operational test of the engine should be carried out on board the ship and in the afloat condition after launching at an appropriate opportunity to check the running condition.
  • Page 26 6.2.2.4 Electric parts 6.2.2.4.1 Battery Fill up battery with electrolyte if level is below the designated position. Tighten up electric terminal if it is loose. 6.2.2.5 Release gear Procedure of apply grease - Check the amount of grease on the grease nipple - Apply grease if necessary.
  • Page 27 Table 6.3.1.1 - Inspection procedure and maintenance plan for davit Maintenance plan Items Method Inspection procedure Weekly Monthly Check corrosion, deformation Frame Visual and depression. Check corrosion, deformation Visual and depression. Moving out from stowed posi- Operation Davit arms tion. Turning out from stowed posi- Operation tion.
  • Page 28 Table 6.3.1.3 - Inspection procedure and maintenance plan for electric parts Maintenance plan Items Method Inspection procedure Weekly Monthly Visual Check wiring. Electric motor Operation Check normal operation. Visual Check wiring. Limit switch Operation Check normal operation. Lubricate Lubricate/grease. Push-button switch box Check wiring and other de- Visual fects.
  • Page 29 6.3.2.3 Boat winch 6.3.2.3.1 Prior to commencement of the maintenance work for the winch, the boat should be secured to prevent movement. 6.3.2.3.2 Oil should be checked and changed if discoloured. In case that oil level is low, oil should be added until the its surface comes to the designated level in the oil gauge. 6.3.2.3.3 Surfaces of each gear inside the gear box should be checked.
  • Page 30 7. Simulation launching system Operation Guide Schematic Diagram Disconnect the davit hook from suspension eye and connect it to the ring for the sliding rope. Note. Weight load should not act on the sliding rope.(only for safety) <Activity on the ship> Unravel the turn buckle until the holding pin comes loose for weight load not to act on it.
  • Page 31 APPENDIX A MARINE DIESEL ENGINE (TYPE HB29D1, HB36D1)
  • Page 32 MARINE DIESEL ENGINE (HB29D1, HB36D1) OWNER`S MANUAL HLB CO., LTD (DWG NO. E0901-00002) UPDATE : 2 January, 2013...
  • Page 33 INDEX 1. General arrangement plan --- 2 page 2. Operation the engine --- 5 page 3. Maintenace --- 10 page 4. Technical data --- 27 page 5. Engine part list--- 31 page 6. Transmission manual --- 61 page...
  • Page 34 1. GENERAL ARRANGEMENT PLAN 1) NAMES OF PARTS (1) Intake manifold (2) Speed control lever (3) Engine stop lever (4) Fuel injection pump (5) Fuel feed pump (6) Water pump (7) Oil filter (8) Exhaust manifold (9) Alternator (10) Starter motor (11) Oil level dipstick (12) Oil pressure switch (13) Oil pan...
  • Page 35 2) DIMENSIONS...
  • Page 36 2) DIMENSIONS ENGINE TYPE HB29D1, HB36D1 MARINE GEAR TYPE HBG200 L (mm) W (mm) H (mm) X1 (mm) X2 (mm) X3 (mm) X4 (mm) 251.3 M1 (mm) M2 (mm) 331.9...
  • Page 37 2. OPERATING THE ENGINE Operating manual This Owner’s Manual is intended to help you get the maximum return on your investment and to ensure your safety. We recommend that you thoroughly read and understand this Owner’s Manual before handling, storing, installing, operating or servicing the engine.
  • Page 38 STARTING ENGINE (TURN KEY TYPE) Electric start with remote control and instrument panel 1. Set the No.1 battery switch to the “ON” position. 2. Put the marine gear into “neutral position” by means of gear separation button. 3. Set the fuel cock to the “ON” or “OPEN” position. 4.
  • Page 39 STARTING ENGINE (BUTTON TYPE-SMART KEY) 1. Put the marine gear into “neutral position” by means of gear separation button. 2. Press 1 time the "START" button on engine operation panel (Automatically all lamps are light on for 1 second) 3. Automatically fuel solenoid valve is operated and operate pre-heating system for 9 seconds and then starter motor rotate the engine.
  • Page 40 ALARM SYSTEM INSTRUMENT PANEL ALARM POINT GLOW LAMP GLOW SWITCH ON OIL LAMP BELOW 0.5 kg/cm CHARGE LAMP ALTERNATOR CONDITION CHECK WATER LAMP ABOVE 110℃ Automatically engine stop when the oil lamp or water lamp light is on. MANEUVERING TYPE (A) 1.
  • Page 41 TYPE (B) 1. At first, put the throttle control lever into the idle position(a). The marine gear engaged to “Ahead” or “Astern” when the gear control lever is put into the “Ahead” or “Astern” position. When the throttle control lever is moved in direction of “Ahead” or “Astern” the engine R.P.M is increased.
  • Page 42 3. MAINTENANCE BLEEDING THE FUEL SYSTEM Bleeding air from the fuel system may be required 1. After the fuel filter has been removed or any fuel lines have been disconnected 2. If the fuel tank has been allowed to run dry 3.
  • Page 43 5. For the best results, it is recommended that the oil level be kept at the upper mark. 6. Use SAE 15W-40 oil or equivalent. 7. Always drain the oil completely when changing. Never mix different oils or engine damage may result. Changing engine oil 1.
  • Page 44 Fan belt deflection : 7~9mm Low belt tension can result in engine overheating and insufficient battery charging. A belt that is too tight may cause bearing failures and belt life may be shortened. BELT TENSION ADJUSTMENT 1. Loosen both bolts that attach the alternator. 2.
  • Page 45 COOLING SYSTEM. Cooling water pump : impeller type. Cooling water : fresh water Cooling system capacity (with keel cooler) HB29D1 ------ 5.5 ℓ HB36D1 ------ 5.5 ℓ TEMP. COOLING WATER----- 75~100°C An anti-freeze concentration of 40% should be used as an all year round coolant. This concentration will give low temperature protection down to -25℃.
  • Page 46 ELECTRIC SYSTEM ELECTRIC SYSTEM The engine is equipped with a 12 volt electrical system consisting of a starter motor and an alternator, the max charging current of which is 50 Amp. BATTERY The level of the electrolyte in the battery should be checked every 14 days or every 25 operating hours. The battery must never be isolated from the alternator, when the engine is running.
  • Page 47 CONNECTOR CONFIGURATION. Connector View and Numbering Order Connector view Illustration in the Shop Actual Illustration Remarks Manual Male Male It is not the shape of the connector housing, but the connector pin that distinguishes between male and female connector. For individual detailed numbering refer to the Connector Configuration.
  • Page 48 STARTING SYSTEM (TURN KEY TYPE)
  • Page 49 ALTERNATOR SYSTEM (TURN KEY TYPE)
  • Page 50 GLOW SYSTEM (TURN KEY TYPE)
  • Page 51 OIL WARNING SYSTEM (TURN KEY TYPE)
  • Page 52 WATER TEMP. WARNING SYSTEM (TURN KEY TYPE)
  • Page 53 ENGINE STOP SYSTEM (TURN KEY TYPE)
  • Page 54 ENGINE CIRCUIT DIAGRAM (BUTTON TYPE – SMART KEY) ※ NOTE When check of engine circuit diagram, use the multimeter – Do not use the checkclamp...
  • Page 55 REPLACEABLE PARTS LIST Q’TY REF.NO PART.NO DESCRIPTION REMARKS HB29D1 HB36D1 E5640-72531 BELT 08900-M1040 FILTER – FUEL E6201-32443 FILTER – OIL T2368-69951 RELAY – GLOW Only turn key 95101-M1040 RELAY – STARTER / FUEL CUT type PERIODIC CHECKS WEEKLY MONTHLY YEARLY 5-YEARLY REMARKS CHECKS:...
  • Page 56 TROUBLESHOOTING PROBLEM: ENGINE WILL NOT START OR IS DIFFICULT TO START Possible Cause Corrective Action Engine doesn’t crank • Change oil level by whether (temperature). Or crank slowly. • Check battery and cables • Ensure that there is fuel in the tank. •...
  • Page 57 PROBLEM: LOW ENGINE POWER OUTPUT Possible Cause Corrective Action Clogged or faulty fuel • Check and clean injection nozzles, being careful not to damage the orifice. injector • Replace injection nozzle(s) if not working properly after cleaning. • Check valves for leakage – grind valves to correct. Low compression •...
  • Page 58 THE ENGINE MUST BE STOPPED IMMEDIATELY IF: Possible Cause Corrective Action Engine speed suddenly • Check the fuel system and injection timing. changes Unusual sound occurs • Check all moving parts Exhaust smoke or dark • Check for loose or damaged parts emissions appear Bearing overheated •...
  • Page 59 4. TECHNICAL DATA ENGINE SYSTEM HB29D1 HB36D1 TYPE Vertical, water-cooled 4cycle diesel engine Working principle 4 stroke Number of Cylinder Cylinder Cylinder volume 1393 1647 Bore and Stroke ¢ X mm 80 X 92.4 87 X 92.4 Combustion Chamber Spherical type Compression ratio 22:1 output...
  • Page 60 LUBRICATING SYSTEM HB29D1 / HB36D1 Type of lubrication oil Gear pump Lubrication oil pressure : Kg/㎠ warm engine, minimum Lubrication oil viscosity SAE 15W-40 Lubrication oil content ℓ MARINE GEAR (HBG200) Lubrication oil viscosity GRADE Lubrication oil temperature ℃ Lubrication oil content liter COOLING WATER SYSTEM HB29D1 / HB36D1...
  • Page 61 TORQUES HB29D1 / HB36D1 Cylinder head bolts Kgf.m 10.5 ~ 11 Connecting rod bolts Kgf.m 4.5 ~ 5.0 Flywheel / counterweights Kgf.m 10 ~ 11 Gearbox Kgf.m 3 ~ 3.5 Flexible coupling between Kgf.m 9 ~ 9.5 Head cover Kgf.m 0.9 ~ 1.2 Glow plug Kgf.m...
  • Page 62 LUBRICATION OIL CHART FOR HB29D1, HB36D1 OIL COMPANY OIL TYPE ENGINE OIL BP OIL Vanellus C6 Multi grade ◎ www.bp.com CHEVRON TEXACO / FAMM Ursa Marine 15W-40 ◎ www.fammllc.com CALTEX Delo 400 Multigrade ◎ www.caltexoils.com TOTAL / FINA / ELF www.lubmarine.com DIAOLA W (15W 40) ◎...
  • Page 63 ENGINE PART LIST (TYPE HB29D1, HB36D1)
  • Page 64 TABLE OF CONTENTS E 0 1 0 C Y L I N D E R B L O C K … … … … … … … … … … … … … … … … … … E 0 2 0 O I L P A N …...
  • Page 65 E010 CYLINDER BLOCK Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5803-A1013 CYLINDER BLOCK ASS’Y E5640-A0013 CYLINDER BLOCK ASS’Y E5803-01113 CYLINDER BLOCK E5640-01113 CYLINDER BLOCK E5900-96031 PLUG E5900-96021 PLUG 06311-75018 PLUG 06311-75045 PLUG 15221-0338-3 CAP, SEALING 15221-0339-2 CAP, SEALING 05012-00408 PIN, STRAIGHT 05012-00609 PIN, STRAIGHT 05012-00612...
  • Page 66 E010 CYLINDER BLOCK Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 15021-3366-1 GASKET E6301-33812 PIN, PIPE E6200-35013 OIL PUMP ASS’Y E5500-35154 GASKET, OIL PUMP 01023-50650 BOLT WITH WASHER 19202-3566-1 GEAR, OIL PUMP DRIVING 05712-00410 E6300-35681 NUT, FLANGE E5500-39013 SWITCH, OIL E6300-35692 GUIDE, OIL GAUGE 21604-M1010 BRACKET-LH...
  • Page 67 E020 OIL PAN Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5608-01613 OIL PAN E500-01623 GASKET, OIL PAN E6314-02033 FLANGE BOLT WITH PIN E6313-32111 FILTER 1, OIL 01654-50820 FLANGE BOLT WITH PIN 04811-00160 O RING E6313-36414 OIL GAUGE 06331-35016 PLUG 04717-01600 WASHER, SEAL...
  • Page 68 E030 CYLINDER HEAD Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5803-A0301 CYLINDER HEAD ASS’Y E5603-A0301 CYLINDER HEAD ASS’Y E5803-03112 CYLINDER HEAD E5603-03112 CYLINDER HEAD 15221-0337-3 SEALING CAP 15221-0349-3 SEALING CAP 5900-96021 PLUG E6850-13581 GUIDE, INLET VALVE E6850-13561 GUIDE, EXHAUST VALVE E6301-03148 PLUG, HOT 01513-50822...
  • Page 69 E040 GEAR CASE Q'TY REMARKS REF.NO. PART NO. DESCRIPTION HB29D1 HB36D1 E5608-A0011 GEARCASE ASSEMBLY E5627-04116 GEARCASE ORDER BY 1 E5800-96031 PLUG 04811-00150 O RING 04811-00220 O RING 04811-00360 O RING 05012-00612 STRAIGHT PIN E5627-32313 OIL FILTER SUPPORT E5800-96031 PLUG 04811-00180 O RING E5627-32323 OIL FILTER SUPPORT GASKET...
  • Page 70 E040 GEAR CASE Q'TY REMARKS REF.NO. PART NO. DESCRIPTION HB29D1 HB36D1 E5627-04132 GASKET, GEARCASE 01123-50802 BOLT 01123-50835 BOLT WITH WASHER 01123-50860 BOLT WITH WASHER 01123-50870 BOLT WITH WASHER 01123-50875 BOLT WITH WASHER 01123-50885 BOLT WITH WASHER 15521-7332-1 WATER RETURN FLANGE E5500-73332 WATER RETURN FLANGE GASKET 01023-50620...
  • Page 71 E050 MAIN BEARING CASE GROUP Q’TY REMARKS REF.NO. PART.NO. DESCRIPTION HB29D1 HB36D1 E6300-A0033 MAIN BEARING CASE ASS’Y E6300-04542 BOLT 1, BEARING CASE E6300-04362 GASKET E6300-04813 COVER BEARING E6300-04822 GASKET, BEARING COVER 01654-50830 BOLT, FLANGE E5500-04464 SEAL, OIL E6300-A0043 MAIN BEARING CASE ASS’Y 1 E6300-A0053 MAIN BEARING CASE ASS’Y 2 04014-50100...
  • Page 72 E060 VALVE, ROCKER ARM Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E6301-13111 VALVE, INLET E6301-13121 VALVE, EXHAUST 15221-1324-2 SPRING, VALVE E5500-13332 RETAINER, VALVE SPRING E6403-13361 COLLET, VALVE SPRING E6301-13151 SEAL, VALVE STEM E5800-14001 ROCKER ARM SHAFT ASS’Y E5800-14261 ROCKER ARM SHAFT ORDER BY 7 E6301-14331 CAP, SEALING...
  • Page 73 E070 CYLINDER HEAD COVER Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5608-14502 CYLINDER HEAD COVER ASS’Y E5608-14511 CYLINDER HEAD COVER E6510-14671 O RING 07712-01607 STEEL BALL E5608-14531 COVER-VALVE E5608-05551 CONNECTOR, AIR BREATHER 03024-50510 SCREW E5850-14561 OIL PROTECTOR E5850-14521 GASKET, CYLINDER HEAD COVER E5608-05512 AIR BREATHER 09318-88180...
  • Page 74 E080 CAMSHAFT Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5500-15553 TAPPET E6300-15113 ROD, PUSH E5603-A0031 CAMSHAFT ASS’Y E5603-16151 CAMSHAFT ORDER BY 3 06350-00607 PLUG 15521-1651-1 GEAR, CAMSHAFT 05712-00720 E5500-16272 STOPPER, CAMSHAFT 01123-50818 BOLT E6300-24012 IDLE GEAR ASS’Y E6300-24212 GEAR, IDLE ORDER BY 10 E6300-24281 BUSH, IDLE GEAR...
  • Page 75 E090 PISTON, CRANKSHAFT Q’TY REMARKS REF.NO. PART.NO. DESCRIPTION HB29D1 HB36D1 E5803-21011 PISTON ASS’Y E6301-21017 PISTON ASS’Y E5803-21111 PISTON E6301-21114 PISTON E6300-21313 PIN, PISTON E6720-21312 PIN, PISTON E5800-21052 PISTON RING ASS’Y E6301-21053 PISTON RING ASS’Y E5800-21152 RING 1 PISTON E6301-21152 RING 1 PISTON E5800-21162 RING 2 PISTON E6300-21162...
  • Page 76 E090 PISTON, CRANKSHAFT Q’TY REMARKS REF.NO PART.NO DESCRIPTION HB29D1 HB36D1 E6300-21353 BUSHING E5800-22141 BOLT, CONNECTING ROD E6300-22312 BEARING, CONNECTING ROD E5800-A0100 CRANK SHAFT ASS’Y E5800-23115 CRANK SHAFT ORDER BY 14 06350-00708 PLUG 08121-06002 BEARING, BALL E6200-23472 CRANKSHAFT METAL 1 E6200-23482 CRANKSHAFT METAL 2 15521-2353-1 SIDE METAL 1...
  • Page 77 E100 FLYWHEEL Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E5806-25011 FLYWHEEL ASS’Y E5806-25111 FLYWHEEL ORDER BY 1 15221-6382-4 GEAR, RING ORDER BY 1 E5500-25164 BOLT, FLYWHEEL E5608-04611 HOUSING, FLYWHEEL 15521-0479-2 GASKET 15521-0468-2 COVER, TIMING MARK 01123-50816 BOLT 01674-51032 BOLT, FLANGE 01133-51240 BOLT E6530-63012...
  • Page 78 E100 FLYWHEEL Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 01517-51028 STUD 02176-50100 04512-50100 WASHER, SPRING 06331-35016 PLUG 43504-M1010 COUPLING, TRANSMISSION BOLT ORDER BY 20 43504-M1020 COVER, MISSION HOUSING 11403-08253 BOLT 21604-M1030 BRKT-REAR 01133-51230 BOLT...
  • Page 79 E110 NOZZLE, HOLDER Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E6300-53005 NOZZLE HOLDER ASS’Y E6300-53651 SEAL, HEAT E6300-53621 GASKET E5610-53714 PIPE 1, INJECTION E5610-53723 PIPE 2, INJECTION E5610-53734 PIPE 3, INJECTION 15121-5385-2 CLAMP 1, PIPE T4815-67371 CLAMP 2, PIPE 03024-50520 SCREW E6301-65512 PLUG, GLOW...
  • Page 80 E120 FUEL, CAMSHAFT Q’TY REMARKS REF.NO PART.NO DESCRIPTION HB29D1 HB36D1 E5610-16022 CAMSHAFT, FUEL ASS’Y E5610-16171 CAMSHAFT, FUEL 08240-00001 BEARING, BALL 08153-06205 BEARING, BALL 05712-00525 E6300-51052 GOVERNOR SLEEVE ASS’Y E6300-51153 GEAR, INJECTION PUMP Order by 5 07715-00403 BALL E6300-55453 SLEEVE GOVERNOR 07715-03205 BALL 15221-5569-2...
  • Page 81 E120 FUEL, CAMSHAFT Q’TY REMARKS REF.NO. PART.NO. DESCRIPTION HB29D1 HB36D1 01513-50822 STUD E5500-52122 SHIM 1(T0.3) INJECTION PUMP E5500-52112 SHIM 2(T0.15) INJECTION PUMP E5800-52111 SHIM 3(T0.1) INJECTION PUMP E5800-51015 INJECTION PUMP ASS’Y 04512-50080 WASHER, SPRING 02156-50080 01123-50822 BOLT E6500-42412 JOINT, FUEL PIPE E5629-24401 EYE BOLT 01513-50618...
  • Page 82 E130 SPEED CONTROL PLATE Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E6301-54122 ADJUSTING BOLT E6305-92021 E6305-96652 GASKET E6305-54221 NUT, GAP E6305-54281 RING SNAP E6305-54421 E6858-57151 LEVER, SPEED CONTROL E5850-57112 SPEED CONTROL PLATE E5850-57212 GASKET, SPEED CONTROL E5850-57921 SPRING 05411-00420 PIN, SRPING 15471-5798-1 OIL SEAL 01754-50620...
  • Page 83 E140 ENGINE STOP LEVER Q'TY REF.NO. PART NO. DESCRIPTION REMARKS. HB29D1 HB36D1 E5850-54093 IDLE APPARATUS ASSEMBLY 04724-00140 PACKING E5850-54282 BUSH E5850-54272 SHAFT E5850-54261 SPRING E5850-54291 IDLE ADJUSTMENT BODY 04811-00060 O RING 15521-5426-1 SPRING E5850-54252 IDLE ADJUSTING BOLT E5850-92011 E5205-54271 E5500-51662 GASKET E5608-57481 OIL FILLER COVER...
  • Page 84 E140 ENGINE STOP LEVER Q'TY REF.NO. PART NO. DESCRIPTION REMARKS. HB29D1 HB36D1 E5850-57212 SPEED CONTROL PLATE GASKET E5850-57712 STOP LEVER 2 ASSEMBLY E5850-57921 SPRING E5850-57112 SPEED CONTROL PLATE 15471-5798-1 OIL SEAL 02761-50060 FLANGE NUT 01754-50620 BOLT, FLANGE E5850-57731 ENGINE STOP LEVER 1 05411-00420 SPRING PIN 01513-50614...
  • Page 85 E150 GOVERNOR Q'TY REMARKS REF.NO. PART NO. DESCRIPTION HB36D1 HB29D1 E5850-56021 GOVERNOR LEVER ASSEMBLY E5627-56051 FORK LEVER ASSEMBLY E5627-56121 FORK LEVER 1 15021-5616-4 FORK LEVER PIN 1 E6200-54172 E6300-54231 SPRING 15601-5443-1 SET SCREW 15221-5615-1 FORK LEVER SHAFT E6300-56131 FORK LEVER 2 15021-5624-3 LEVER SHAFT BOLT 04512-50060...
  • Page 86 E160 WATER PUMP Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E6308-73031 WATER PUMP ASS’Y E5627-73471 BODY, WATER PUMP E5800-73551 BEARING WATER PUMP E5800-73513 IMPELLER E5800-73052 MECHANICAL SEAL ASS’Y E5800-73522 FLANGE E5616-74252 PULLEY, FAN E5627-73432 GASKET, WATER PUMP 01123-50828 BOLT 01023-50618 BOLT 01518-50822 STUD...
  • Page 87 E170 WATER PIPE Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 E6304-72911 FLANGE THEMO WATER E5500-72911 GASKET WATER FLANGE 01123-50822 BOLT 01513-50822 STUD 01123-50870 BOLT 02763-50080 E5500-73342 PIPE, WATER RETURN 15521-7334-1 PIPE 09318-88180 BAND, PIPE E5800-73011 THERMOSTAT ASS’Y E5500-73272 GASKET THERMOSTAT COVER H6308-73270 COVER-THERMOSTAT 01123-50835...
  • Page 88 E180 ALTERNATOR Q’TY REMARKS REF.NO. PART NO. DESCRIPTION HB29D1 HB36D1 E7230-64012 DYNAMO E5800-64102 COLLAR 01173-51005 BOLT 04013-50100 PLAIN WASHER 04512-50100 SPRING WASHER 02176-50100 E5800-64423 DYNAMO STAY 04015-50080 PLAIN WASHER 01123-50832 BOLT WITH WASHER 01754-50612 FLANGE BOLT 05712-00720 E5620-74285 FAN DRIVE PULLEY E5640-72531 FAN BELT 04012-50050...
  • Page 89 E190 MANIFOLD Q’TY REF.NO. PART.NO. DESCRIPTION HB29D HB36D1 REMARKS E5800-11821 GASKET INTAKE MANIFOLD E5800-11766 MANIFOLD, INTAKE 01123-50822 BOLT 01513-50822 STUD E5800-12352 GASKET, EXHAUST MANIFOLD 28504-M1022 WATER COOLDED EXHAUST MANIFOLD 02751-50080 NUT, FLANGE U3215-75471 GASKET 28504-M1031 FLANGE, EXHAUST MANIFOLD 01123-50825 BOLT 28101-M1010 AIR CLEANER 14000-05700...
  • Page 90 E200 COOLANT RESERVE TANK Q’TY REMARKS REF.NO. PART.NO. DESCRIPTION HB29D1 HB36D1 H6308-73270 COVER-THERMOSTAT 14000-02500 CLAMP E6500-72941 HOSE, COOLANT FITTING 28511-M1040 NIPPLE 28504-M1022 WATER COOLDED EXHAUST MANIFOLD 25115-M2010 NECK-RADIATOR 25111-M1010 83025-0040 HOSE, EXIT 25110-M1010 COOLER, KEEL 99306-2000 CAP-SEALING...
  • Page 91 E210 INSTRUMENT PANEL Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 94114-M1011 INSTRUMENT PANEL 95101-M1020 LAMP, WARNING 95101-M1030 BUZZER TURN KEY TYPE 95101-M1050 CIRCUIT BREAKER T2540-41133 KEY ASS’Y T2560-41151 94114-M1020 SMART START KEY SMART KEY TYPE E220 RELAY BOX Q’TY REF.NO. PART.NO.
  • Page 92 E230 WIRING Q’TY REF.NO. PART.NO. DESCRIPTION REMARKS HB29D1 HB36D1 91104-M1010 WIRING, ASS’Y TURN KEY TYPE E9110-50000 WIRING ASS’Y –ENG SUB SMART KEY TYPE E9120-21001 WIRING ASS’Y –ENG CONTR E240 SWITCH, ISOLATOR Q’TY REF.NO PART.NO DESCRIPTION REMARKS HB29D1 HB36D1 37201-M1010 Isolator 95101-M1070 Switch, battery choice...
  • Page 93 TRANSMISSION MANUAL (TYPE HBG200)
  • Page 94 INTRODUCTION The present manual is part of the product’s scope of supply and reading and understanding are essential. This manual contains guidelines and recommendations to let the owner use and safely operate the marine transmission. This manual should always accompany the transmission and should be carefully stored in a safe and easily accessible.
  • Page 95 DIMENSION SPECIFICATION Ratios (forward/backward) 2.54:1 / 2.43:1 Fluid grade ATF oil Weight (kgf) 11.2 Oil capacity (L)
  • Page 96 MAINTENANCE Frequent and systematic inspection will assure to your transmission many years of trouble-free service. Oil level checks Weekly check oil level, using oil gauge. With engine in OFF position, weekly check against oil leaks from the output flange. Correct oil level : index mark on dipstick. Always use the same oil grade when refill the oil.
  • Page 97 IDELTIFICATION A name plate is fixed on each transmission housing : information printed on are essential for warranty and spare part ordering :...
  • Page 98 TROUBLESHOOTING SYMPTOM CAUSE REMEDY High oil temperature - Improper oil level (high or low) - Check and fill or drain with proper oil to the correct level. Excessive noise - Bearing failure - Overhaul marine transmission - Improper alignment - Check alignment of engine and transmission and transmission output flange to propeller shaft.
  • Page 99 TRANSMISSION PART LIST REF.NO. PART NO. DESCRIPTION Q'TY REMARKS. E4250-31004 COVER-CASE E4240-31004 CASE E4190-31003 COVER-OIL SEAL INPUT E4210-31002 COVER-OUTPUT E4510-31000 GASKET-COVER BEARING E4460-31002 WASHER-FLAT HEADED BOLT E4290-31002 GAUGE-TM OIL E0216-03000 SEAL WASHER E0210-03000 SEAL WASHER E4310-31050 NUT ROCKING E4162-32000 FLANGE E1100-12510 DRAIN PLUG E4280-31002...
  • Page 100 REF.NO. PART NO. DESCRIPTION Q'TY REMARKS. E4450-31003 BRKT-CONTROL E4360-31003 LEVER-CONTROL AB146 PIVOT ST9565 CLAMP 1321-02016 SPLIT PINS 1339-03015 SPRING PIN 1021-05010 SLOTTED HEAD SCREWS 1021-06020 SLOTTED HEAD SCREWS 1012-05001 NYLON NUT 1042-08018 HEXAGON BOLTS WITH FLANGE 1042-08030 HEXAGON BOLTS WITH FLANGE 1042-06025 HEXAGON BOLTS WITH FLANGE 1003-08020...
  • Page 101 REF.NO. PART NO. DESCRIPTION Q'TY REMARKS. E4180-32000 SHAFT-IDLE E4370-31000 NEEDLE ROLLER BEARING E4380-31000 NEEDLE ROLLER BEARING E4150-32000 GEAR-IDLE E4220-31003 SPACE(IDLE SHAFT) 2805-14000 O - RING E4320-31000 TAPER ROLLER BEARING E4380-31000 SPACE-GEAR E4370-31002 SLEEVE BEARING-GEAR E4112-32000 GEAR FORWARD E4390-31000 NEEDLE ROLLER BEARING E4140-32000 CONE CLUTCH E4171-32000...
  • Page 102 To order spare parts for the engine and transmission, please contact HLB CO., LTD Korea / Head Office #772, Daejung-Ri, Onsan-Eup, Ulju-Gun, Ulsan, Korea Tel: +82 52 240 3530~2 Fax: +82 52 237 4854 www.hdboat.com www.hlbnetworks.com E-mail: service@hdboat.com Singapore / Branch Office 10, HoechiangRoad, #14-02 Keppel Tower, Singapore 089315 Tel: +65 6493 6923~4 Fax: +65 6493 6925...

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