MARINE DIESEL ENGINE TYPE HB29D1, HB36D1 ManuaL UNDAI HYUNDAI UFEBOATSCO,, (TD.‘OWNER'S MANUAL NAMES OF PARTS =-=-~~ OL WARNING SYSTEM -~ : (WATER TEMP. WARNING SYSTEM ENGINE STOP SYSTEM ~~~ REPLACEABLE PARTS LIST ~ PERIODIC CHECKS ‘TROUBLESHOOTING ‘TECHNICAL DATA ~~~ LUBRICATION OIL CHART FOR HBZ901, HE36Dt ~ PART'S MANUAL DIO CYLINDER BLOCK ~~~ 20 OIL PAN. ss E030 CYLINDER HEAD E040 GEAR CASE E050 MAIN BEARING CASE GROUP E060 VALVE, ROCKER ARM = £190 SPEED CONTROL PLATE ‘Et40 ENGINE STOP LEVER E150 GOVERNOR «=~ 160 WATER PUMP ~~~ E17 WATER PIPE E160 ALTERNATOR E199 MANIFOLD £200 COOLANT RESERVE TANK E210 INSTRUMENT PANEL ~~ RELAY BOX ~~ F238 WIRING ~~ “ 24a SWITCH, ISOLATOR ~~ = ‘TRANSMISSION MANUAL BRELORIESSSRERSEIEREREES arheseceBIER UREL LT NAMES OF PARTS (1) Intake manifold (2) Speed control lever (3) Engine stop lever (4) Fuel injection pump (5) Fuol feed pump (6) Water pump (7) Dit fitter (8) Exhaust manifold a {9) Alternator {10} Startr motor {11 Oi lovel dipstick (12| Oil pressure switch 13] Oil pan (14) Marine gear (161 Coupling flange (17) Engine mounting bracket (18) Controt lover marine gear (19| Marine gear control cable bracket (20) Coolant outlet plug (21) Coolant tank cap (23) Air cleaner {25| Coolant water temperature switch (26) Stop solenoid valve (27) Bet @ @DIMENSIONS:r=} BS 5 =] 2 a all a a Es = OPERATING THE ENGINE Before start Operating manual This Owner’s Manual is intended to help you get the maximum return on your investment snd 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, Should your engine require parts or service, please contact HYUNDAI IFEBOATS CO. ITD. We will need the folowing information in order to assist vou. 1. Engine make, model number and serial number. 2. Names and code numbers of parts to be order 3 Make and made number of the machine in which engi is installed. Preparation before first start 1. Check that ol levels between the marks onthe dipstick, placed atthe sido of the engino 2 Check the lubricating oll of reverse and reduction gear 2. We always racommend checking of ol level before start. 4 Fillthe fuel tank. Use only diesel fue. -Aftor the engine has been taken into use Always check the engine and make sure its ready for safe operation before installing the engine, be ‘sure that the equipments on firm, level Ground. Oo not run the engine on gradients. Never use starting {iuid or gasoline in the air intake. Engine damage will result and an explosion may occur. Bofore start 1. The oil level ofthe engine should be checked every 14 days or every 26 hours of running. 2. The oil level ofthe reduction gear should be checked every 14 days or every 25 hours of runing. 3, Check the quantity of fuel in the tank, STARTING ENGINE Electric start with remote control and instrument panel 1. Setthe No.1 battery ewitch tothe “ON” position. 2. Putthe merine gear into betwean “neutral position” and “max position” by means of gear separation button, 3. Setthe fuel cocktothe “ON” or “OPEN” position. 4 The engine stop lever must be in te “START” postion. 5. Tum the starter switch to the “ON” positon. 6. Verify thatthe oi pressure and charge lights are on. 7. In cold weather (for cold encine starts), turn the starter switch counterclockwise to the “PREHEAT” positon for 8te 19 seconds, (D0 not operate glow plugs continuously for more than 180 seconds). second son 52 ‘WAlfor each plug) { 8. Tum the key to the “START” position to engage the starter motor. Relesse the key immodiataly as the engine starts8 Norify that the oil prossure and charge lights are now off. If immediately and check the fellowing. A. Correctoil level. B. Verity that the engine contains clean oil ofthe propor viscosity. ©. Check for fauity wiring. D. Verity that the battery is charged sufficiently. 10.Run at a moderate speed until the engine reaches a normal operating temperature before doing work. ither light is on, stop the engine NOTE! Do not turn the starter switch to "START" while the engine is running. {ithe engine does not startin 10 seconds, wait 3 seconds and repeat the Starting sequence, ‘Never run the starter motor continuously for more than 20 seconds, | ‘Always warm up the engine before working. Using a cold engine will shorten its life. When the temperature would fall down below -15°C(5°F), you have to separate the battery from the ‘engine and keep it in indacr. Use the battery next engine starting. MANEUVERING TYPE(A) 1. With the control lever in neutral position the engine is idling, ‘ené the marine gesr is in neutral, When the lever is moved forward in range 1, the marine gear is engaged to “Anead” first by means of working clutch-forward, and then in range 2 tho engine RP.Misincreased. When the lever is moved irom the neutral positon to range 3, the marine Gear is engaged to “Astern” first by means of working clutch-backward, And then in range 4 the engine R.P.M is increased. NOTE: D0 NOT STOP CONTROL LEVER IN CLUTCH RANGE (0-1 or 0-3) 2. Only engage “Ahead” or “Astem” when the engine is idling. 43.To accelerate engine without engaging gear operate gear release button § and move cortrol handle in either direction, ‘TVPE(B) 1. At first, put the throttle contral laver into the idle posttion(a) ‘The marine geer engaged to “Ahead” or “Aster” when the ‘geer control lever is put into the “Ahead” or “Astern” position When the throu control fever is moved in direction of “Ahead or “Astem” the engine R.P.M is increased. /~ High speed High speed MoTE:00 NOT sro» GEAR CONTROL LEVER CLUTCH ies RANGEIN-F or N-R) cate ier 2. When the throttle lever is idle position(a), only the gear { TE) control lever is engaged “Ahead” or “Aster 3. Put the gear contra lever into “Ahead” or “Aster” as soon as possible7) | Ss I a Fo 5 oa Fa 2 2 F im ‘STOPPING THE ENGINE 1, Move the engine control lever into the neutral postion. 2. Tur the starter switch to “OFF” and ramove the key. 3. Tum the all of battery switch to “OFF” ie “agin wil be topped hen tis td shut or ‘Hf engine do not be stopped in spite of doing the preceding 1-3, move the engine IMPORTANT stop lever (2) to the “STOP” position(D).MAINTENANCE BLEEDING THE FUEL SYSTEM * The cir vont on the fuel injection pump must always be closed during on ‘The engine may not runif left open, Bleeding sir from the fuel system may be requi 1. After the fuel fier has been removed or ary fuel lines have been disconnected. 2. lf the fuol tank hes boon allowed to run éry. 3. After long-term storage. PROCEDURE 1. Ensure thet there is fue inthe tark. 1. To eliminate air from the fuel fiter, turn the air bleed vent on top of the fuel filter to the [AIR] position. Crank the engine 29 seconds uni the sir inthe fiker is pushed out by the fuel and then stop the ‘engine 30 seconds, 4 to 5 times. Do not crank the engine for more than 20 seconds at one time. Turn the air bleod vent back tothe [ON] position and start engine. Ifthe engine will not start, proceed to step’. 2.70 bleed air from the injection pump, turn the air vent knob on the fuel injection pump counterclockwise to open. Crank the engine for § seconds, 3 to 4 times. BE ALERT- the engine may stort during cranking 4, When the engine starts or when turning it elockwse. 5. If the engine still does not start, loosen the fuel line connection at the injection nozzle. Crank the engine for seconds and retighten connection Ifthe engine still wil not star, repeet this procedure for the remaining injection nozzles in sequence. 6. Clean up eny fe! spils immediatly Start the engine and check fr leaks. is expelled from the injection pump. close the air vent knob by ‘THE FUEL FILTER CHANGE & BLEEDING Plug ends of open fuel lites during service to prevent dit end ether contaminants from entering and damaging te fuel system. Change te filter as fllowings 1. Replece the fuel fier certidge every 400 hours. 2. Tuim the fuel fiter counterclockwise by hand 3. Screw the new fiter on clockwise. Install and hand-tighten only Bleed sr rom the fuel system. Check for leaks. 4. Loosen an air plug 2. Check fuel leakage of air plus. 3. Operate manu! pump up ané down. Bloed air fom the fuel system, 4, Stertthe engine after screw air plug.JONVNGINIVIN ENGINE OIL & OIL FILTER NOTE : Stop the engine when you change engine cl, fuel oil cartridge or check engine oil level. Checking and adding engine 1. Always check ol level before starting 2 Wait at east 5 minutes after shutdown to get an accurete oil level reading, 3. Wipe the dipstick cloan, ingot all the way in and remove to get the correct ol level reeding, 4.11 the oll leval is below the lower mark on the dipstick, add oil through the fil port on top of tha engine. 8 Forthe best result, it's recommended thatthe oll level be kept atthe upper mark. 6 Engine oil quantity :5.8 4 7. Use SAE 18VV-40 oil or equivalent. & Always drain the oil complately whan changing. No\ result mix different oils or engine damage may ‘Changing engine oi! 1. Change the ol attr tho fist £0 hours of operation 2, flemove the dren plug from the oi pan or using ol drain pump and allow al ofthe alto drain Draining the ol wll be easier when the engine is slightly war. 4. Reinstall the plug and fil wth the correct amount of ol through the fil port ontop othe engin. Ensure that the ol level on tha éipstickis atthe upper mark. 4. Change the ol after every 100 hours of operation thereafter. Replacing the oi fier 1. Replace oil iter with at least every ?timas oil change. 2 Remove the iter using a fter wrench. 3. Apply a thin layer of clesn oil to the gasket on the new ‘ier. 4 Screw the new fiter on. Hand tighten only. 4. Ensuring that il levels correct and run the engine, 6 Check forloaks. Rechact that the fiter is hand-tight. 7. Clean up and properly dispose of any spilled cit. Wipe any spilled oil rom the engine. FAN BELT BELT TENSION AND WEAR ‘The correct tension can be determined by applying a 22 tb. load at mid-span. The resulting belt Ueflection should be 0.28 to 0.35 inches. Inspect the belt regularly for cracks, tears or bitleness. NOTE: Love bel tension can esti engine overheating and insufiiont battery charging. Abt that is too tight may cause bearing failures and bette may be shertened. BELT TENSION ADJUSTMENT 1. Loosen both bolts that attach the alternator. 2 Mave the alternator to adjust belttension. 4. Retighten the bolts after adjustment.COOLING SYSTEM Cooling water pump : impeller type. Aflow:max 9217 £ fin, Pump mounting bott torque : 3.3 ~3.7 Kot -m(S2.4 = 38.3N-m) Cooling water: frash water Cooling system capacity (with keel covter) HB2901---—---63 # 83501 ‘TEMP. COOLING WATER 75-100°C An arti-reeze concentration of 40% should be used as an all year round coolant. This concentration will gve low temperature protection down to -25°C, In addition to, «40% concentration will protect the cooling system from corrosion [NOTE : Anti-ireeze contains some poisonous substances which are toxic if taken internally, and can be absorbed in toxic amounts under prolonged skin contact. H clothing is splashed with anti- ‘reeze, it should be washed before being worn again. If anti-freeze is swallowed accidentally, {ind medical advice immediately. KEL COOLERJONVNGINIVIN ELECTRIC SYSTEM ELECTRIC SYSTEM The enging is equipped with a 12 volt electrical system consisting of a start motor and an alternator, ‘the max charging current of which is 50 Amp. lectical wising diagram forthe engine with control and instrument panels is shown on pages 6 t0 11. BATTERY ‘The level ofthe electrolyte in the battery should be checked every 14 days or every 25 operating hours. ‘The battery must never be isolated from the aiternator, wien the engine is running. LONG-TERM STORAGE (BATTERY) 1. Before long-term engine storage remove the battery. Add electrolyte, fully charge the battery, and readjust the electrolyte lave, if necessary. Store the battery in 8 dry, dark place. Do not store onthe ground or a concrete surface. 2. Batteries wil discharge even when notin use. During tong periods of inactivity, recharge regularly to meintain readiness and bettery life. WARNING! Iris not allowed to connect additional equipment to the wiring system of the engine. Possiole addtional equipment has to be connected directly to the terminals ofthe battery,CONNECTOR CONFIGURATION Connector View and Numbering Order Connector view: ‘Mustration inthe Shop Manual Romarles ie toe Itisnotthe shape ofthe connactor housing, butthe connector pin that distinguishes z botwoon male and female connector. G For individual detailed numbering refer to the Connecter Configuration. Female Connectors pin: in order from upper right to lower left. Mole Connector's pins are numbered in order from upper if to lower right.UTEP A) EL byALTERNATOR SYSTEM 29 lalste))GLOW SYSTEM RRR eR @: BV PLS ana lau i} (an sa ala RES a)OIL WARNING SYSTEM (ara ar] TNSTRURENT PANE, (aN S7W 3) (asArA] (BATTERY Al) 5 cory ™ ne