ME Manual Appendix

附件目录
ContentsforAppendix
1 空冷器 Charge Air Cooler
2 盘车机 Turning Gear
3 盘车机控制箱 Turning Gear Control System
4 辅助风机 Auxiliary Blowers
5 辅助风机控制箱 Auxiliary Blowers Control System
6 HPS 泵控制箱 Instruction Book for HPS Starter Box
Exhaust valve and valve seat grinding

7 排气阀研磨机
machine
8 液压顶撑 Top bracing
9 油含水 Waterin oil sensor
10 轴承磨损监测系统 Bearing Wear Monitoring System
11 油雾探测器 Oil Mist Detector
12 气缸油加热柜 Heating Tank for Cylinder Oil
13 排气阀翻转台 Worktable for exhaust valve
14 喷油器试验台 Fuel valve test pump unit
15 轴向振动监测仪 Axial Vibration Monitor
Form Version：V1 Page1 / 1

16 扭振减振器 Torsional Vibration Damper
17 增压器 Turbocharger
Form Version：V1 Page1 / 1

Kelvion Heat Exchangers (China) Co., Ltd
凯络文换热器(中国)有限公司
凯络文增压空冷器是一种管片式热交换器。其
凯络文
凯络文
直接向德国凯络文公司购买，或向凯络文换热器（芜
湖）有限公司购买，也可以在我们世界各地的维修中
心购买。
The Kelvion charge air cooler is a finned tube heat exchanger. The
hot air flows through the fins on the outside of the tubes and the
cooling fluid flows through the tubes. The heat exchanger surface of
the cooler consists of elliptcal core tubes with rectangular
threaded-on fins or round core tubes with either wound-on fins or
continuous flat plate fins. The bond between fin and tube is
achieved either by mechanical means or by soldering.

Kelvion
Kelvion
Germany or Kelvion Industrial Heat Exchangers Systems(China)Co.,Ltd
or from our service centres world wide.
OPERATION INSTRUCTION
FOR MODEL
CP13（46ME-B/ME-C）/CP23（50ME-B/ME-C）
/CP23P（50ME-B/ME-C&45ME-C）
TURNING GEAR
Qiyao Power Systems CO,.LTD

TEL:0086 21 65687121 FAX:0086 21 65685300
0
CONTENTS
1 Application............................................. 2
2 Principal Technical Parameters ......................... 2
3 Construction............................................ 3
4 Installation............................................ 4
5 Operation............................................... 5
6 Maintenance and Pionts for Attention ................... 6
7 Common Breakdown and Slovent ........................... 7
8 Operation of Manual Release Screw for Brake .......... 10
9 Part List for Order ................................... 10
10 Wiring Drawing for E-motor ........................... 14
1
1 Application
This tuning gear is used for cranking the crankshafts of large low
speed diesel engines type 45/46/50 ME-B/ME-C.
2 Principal Technical Parameters

2.1.1 Electric motor（CP13）
Type M2QA132S6A V1
Rated power 3.0kw（3.45 kw）
Rated speed 940r/min（1145 r/min）
Power source 3×AC380v/50Hz（3×AC440v/60Hz）
Brake voltage DC99/400W
Brake moment of force ≥65 Nm
Heating voltage AC220V
Protection class IP55
Insulation class F
2.1.2 Speed reducer（CP13）
Rated output torque 10600Nm
Max output torque 13200 Nm
Total speed ratio 934:1
Output speed 1. 01 r/min（1.23 r/min）
2.2.1 Electric motor（CP23/CP23P）
Type M2QA132M6A V1
Rated power 4.0kw（4.6 kw）
2
Rated speed 945r/min（1150 r/min）
Power source 3×AC380v/50Hz（3×AC440v/60Hz）
Brake voltage DC99/400w
Brake moment of force ≥65 Nm
Heating voltage AC220V
Protection class IP55
Insulation class F
2.2.2 Speed reducer（CP23/CP23P）
Rated output torque 18500Nm
Max output torque 23000 Nm
Total speed ratio 934:1
Output speed 1. 01 r/min（1.23 r/min）
3 Construction (See Page 15)

This turning gear is composed of, electric motor, speed reducer ,
stirring-bar interlocking mechanism, movable gear. The electric motor
drives the speed reducer. On the output shaft is mounted a movable gear.
The engagement and disengagement of gear with crankshaft gear are
performed by the disengagement and engagement mechanism. The
housings of the electric motor and the speed reducer are base-connected.
There are five holes on the speed reducer base for fixing the turning gear.
The two-position three-way valve is communicated with the starting air
pipe and the switch is connected with the control circuit of center control
3
room. When the string-bar is on the outside position, the position switch
is on and the two-position three-way valve is under such a condition that
the starting air is cut off. So the diesel engine can’t be started up. But the
circuit is energized and the indicated light in the center control room is on.
You can start the turning gear. When the string-bar is on the inside
position, the indicated light in the center control room is off. Therefore,
this turning gear plays a part in interlocking mechanism.
Fill the speed reducer with L-CKD320 industrial gear oil(or
equivalent industrial gear oil with dynamic viscosity of 300-320 cst at
40 ℃ ,flash point not lower than 220 ℃ ,cloud point not lower than
0℃,carbon residue not higher than 1.7% before adding additive and
mechanical impurity not higher than 0.02%). The quantity of gear oil
filled should be within sight through oil level dipstick glass. That is to say,
the oil level can’t be lower than the visible level range through the oil
level dipstick glass. It also can’t be higher than the visible level range
through the oil level dipstick glass. If so, drain the oil through the drain
port at the lower part of the speed reducer till the oil level requirement is
met. When the oil level is lower than the specified lower limit, add oil
promptly to the visible level range through the oil level dipstick glass.
4 Installation (See Page 11)

Lift and mount the turning gear onto the side plate of the diesel
engine (with the gear at the inner side position and without the
4
stirring-bar interlocking mechanism) and let the five holes in the base of
speed reducer correspond with those in the side plate of the engine. By
adjusting the left and right positions of the turning gear and the thickness
of the distance tube (i.e. gasket) under speed reducer, the turning gear
axis can be parallel with the crankshaft axis and the engagement
clearance between the gear and crankshaft gear within the requirements
and even contact of their gear surface can also be ensured. Then, tighten
the nuts of the four bolts for fixing turning gear with a tightening moment
of 500 Nm. After tightening, recheck the flank clearance of the gears. If it
is abnormal, readjust it till meets the requirement.
After fixing the turning gear, mount the stirring-bar. Then connect it
with power supply and air line according to the special instruction for the
motor respectively. After this, check the switch circuit of the turning gear,
the position switch, the two-position three-way valve and starting pipe for
correct connection. Finally, conduct a test-run on the turning gear to see
whether all are normal, such as vibration, noise, temperature rising of
lubricating oil for the speed reducer as well as odor. Put it into application
after all are proved normal.

Temperature Rising of Lubricating Oil ≤45℃
Noise of Reducer locating in Position C(See page 24) ≤90dB
Vibration speed of speed reducer ≤6.3 mm/s
5 Operation (See Page 15)

When the crankshaft is not turning, the gear moves to the outer side
5
and the stirring-bar is on the left position. Before turning the crankshaft,
move the gear to the inner side by the stirring-bar interlocking
mechanism and have the gears engaged correctly. After these, start the
electric motor to crank up the crankshaft.
WARNING:
When the gear moves to the inter side, it should not contact
the housing of the speed reducer. The normal distance between
them should be larger than 2mm.
The engaging surfaces of the gears should be slightly coated
with grease.
The running and stopping of the turning gear are controlled
by the control press button. For the operation method, please refer
to the instruction for the electric motor.
6 Maintenance and Points for Attention

6.1 Before lifting the turning gear, remove the stirring-bar interlocking
mechanism. Then dismantle the gear.
6.2 During lifting and installing, the electric motor is not allowed to be
collided.
6.3 The turning gear can be dismantled for check only when it is under
static condition, and the crankshaft gear and the gear are under
6
disengaged condition. It is not allowed to dismantle it for check
during operation.
6.4 Before removing the electric motor, disconnect the power supply
first. Then drain off the lubricating oil in the speed reducer.
6.5 There must be often remained some grease between the gear and the
output shaft of the speed reducer.
6.6 For lifting purpose, a special lifting ring should be used. But do not
carry out lifting operation at such positions of electric motor, gear
and handle.
6.7 Put a protecting shield on the electric motor to prevent it from water,
oil and other liquid erosion.
6.8 Renew the lubricating oil for the first time after 80 operating hours,
then renew it after every 500 operating hours.
7 Common Breakdown and Solvent

Common
Item Analysis Solvent
Breakdown
Connect the power

Power source wiring
E-motor is source according to the
1 maybe not right or
not running. requirement of wiring
loose.
drawing (See page 28).
7
Connect the power
Brake maybe not in source according to the
action. requirement of wiring
drawing (See page 28).
The control box maybe Remove the problem of
damaged. the control box.
Common
Breakdown
Replace the damaged

Bearing maybe
bearings with spare
damaged.
parts.
Replace the damaged

Brake maybe damaged.
High bearings with new one.
temperature Connect the power

2
for house of Brake maybe not in source according to the
E-motor. action. requirements of wiring
drawing (See Page 28).
Open the speed reducer

The speed reducer
and replace the broken
maybe damaged.
parts with new ones.
8
Open the chain driving
The
mechanism. Replace the
movable
Chain maybe damaged.
damaged chain with new
gear is not
ones.
3 turning
while the Open the speed reducer

The speed reducer
E-motor and replace the broken
maybe damaged.
runs. parts with new ones.
Common
Breakdown
Bearing of E-motor Replace the damaged
maybe damaged. bearing with spare parts.
Abnormal The speed reducer Open the speed reducer

4
noisy. maybe damaged or and check. Replace the
bearings maybe wear wear out parts with new
out. ones.
9
8 Operation of Manual Release Screw for Brake
There is manual release screw for brake just locating at the position of
motor-fan cover. This is a special screw. In normal condition, the screw is
loose. Twist the screw clockwise, the brake can be released and the
E-motor can run freely by hand.
9 Parts list for order
10
Sketch map for the Turning gear
11
SERIES
DRAWING NO PART NAME QTY MATERIAL
NO
1 CP23-10-00 Cover parts 1 Q235A
2 GB/T819.2-1997 M5×12 Bolt 8 8.8
3 CP23-02-01-02 Shaft 1 304
4 GB/T894.1-1986 18 Snap ring 2 65Mn
5 CP23-02-01-01 Move knob 2 45
6 GB/T70.1-2000 M6×40 Bolt 2 8.8
7 GB/T859-1987 6 Spring washer 18 65Mn
8 Three way valve 1
9 GB/T70.1-2000 M8×16 Bolt 8 8.8
11 GB/T288-1994 22217CC/W33 Bearing 1 G
12 CP23-09-01 Front end-cover 1 ZG270-500
13 GB/T120.2-2000 16×32-B Pin 3 30
14 GB/T 5783-2000 M12×40 Screw 4 8.8
16 GB/T97.1-1985 12 Washer 4 200HV
17 CP23-02-02-01-00 Support parts 1 Q235A
18 JB/T 7271.4-1994 BM16×63 Handle cover 1 PLASTIC
19 CP23-02-01-04-00 Stirring-bar parts 1 Q235A
20 GB/T70.1-2000 M5×16 Bolt 2 8.8
22 Position switch 1
23 CP23-02-01-06-00 Bolt set 1
24 GB/T117-2000 5×20 Pin 2 35
25 CP23-02-01-03 Stirring-bar support 1 QT500-7
26 GB/T70.1-2000 M8×25 Bolt 8 8.8
27 CP23-02-01-04-04 Knob 2 ZCuSn10Pb1
28 GB/T 894.1-1986 12 Snap ring 2 65Mn
29 CP23-05-03 Screw M18×1.5 3 Q235A
30 CP23-05-04 Gasket 3 T2
31 GB/T301-1995 51207 Bearing 1 E
32 CP23-08-05 Underside cover 1 20
33 CP23-08-11 Ring 1 45
34 GB/T276-1994 6308 Bearing 1 E
35 GB/T893.1-1986 90 Snap ring 1 65Mn
36 CP23-08-02 Worm 1 35CrMoA
37 GB/T 818-2000 M8×20 Bolt 4 8.8
38 CP23-05-05 Cover 1 Q235A
39 CP23-05-06 Looking window 1 glass
40 GB/T297-1994 33210 Bearing 1 G
41 CP23-08-04 Top cover 1 20
12
42 SN70-TC05007008 Seal 50×70×8 1 RUBBER
43 GB/T819.2-1997 M8×25 Bolt 6 8.8
44 CP23-05-01 Central support 1 ZG270-500
45 Motor 1
46 CP23-05-02 MIDDLE SUPPORT 1 ZG270-500
47 CP23-08-01 Worm wheel 1 ZCuAl10Fe3
48 GB/T292-1994 7020C Bearing 1 G
49 CP23-04-01 Back cover 1 Q235A
50 GB/T893.1-1986 78 Snap ring 1 65Mn
51 CP23-08-09 Ring 1 F4
52 CP23-03-01 Solar gear 1 35CrMoA
53 CP23-03-07 Ring 1 F4
54 CP23-03-03 Center shaft 3 40Cr
55 CP23-03-02 Planet frame cover 1 40Cr
56 GB/T288-1994 21307CC Bearing 3 G
57 CP23-03-04 Planet gear 3 35CrMoA
58 CP23-03-06 Ring gear 1 40Cr
59 CP23-06 Ring 1 ZG270-500
60 CP23-03-05 Planet frame 1 35CrMoA
61 GB/T70.1-2000 M10×35 Bolt 22 8.8
63 GB/T70.1-2000 M6×16 Bolt 16 8.8
64 CP23-09-02 Gear cover 1 Q235A
65 SN70-TC07510010 Seal 75×100×10 1 RUBBER
66 CP23-03-08 Key 2 40Cr
67 CP23-07 Gear 1 QT500-7
13
10 Wiring Drawing for E-motor
Wiring Drawing for E-motor Type M2QA132S6A V1 and M2QA132M6A V1
14
Sketch map for the fixing of the Turning gear
15
Instruction Book For
Turning Gear Starter Box
Engine No.: CSB009+ SERIES
Engine type: 6G45ME-C9.5
Motor rated power: 4.8kw

Motor rated current: --
Power supply: 440V;60HZ
Color for enclosure: Munsell 7.5BG7/2
1
◆ 概述 ◆Introduction
The switch box can be operated to

本开关箱可以实现低速主机盘车机的起
start/stop and forward/reverse of the
动、停车、正倒车运转控制以及远距离正
车运转和倒车运转控制。 turning gear and remote operation for all
the low speed main engines.
◆Operation on the switch box

◆ 通过控制箱本体操作
The mode selector switch S1 is
当选择开关 S1 置于 LOCAL，可在控制 positioned in LOCAL and press S2 then
箱本体上控制盘车机马达。按下按钮 S2； the motor will run ahead, press S3, the
盘车机正转，按下 S3，盘车机马达反转。 motor will run astern.
◆Operation on the remote operation

◆ 通过遥控按钮盒操作
box
当选择开关 S1 置于 REMOTE，可在盘车 positioned in REMOTE and press S02
机遥控按钮盒控制盘车机。按下按钮 S02 then the motor will run ahead, press
盘车机马达正转，按下按钮 S03 盘车机 S03, the motor will run astern.
反转。
◆ Space heater
◆ 空间加热
The switch box is equipped with the

本开关箱备有电机空间加热线圈电源接 heating for the electric motor space. It
口，如果需要，可以实现盘车机电机空间
can carry out heating to the electric
加热功能。
motor space if need.
2
船用辅助鼓风机使用说明书
适用于分体式离心辅助鼓风机
Operation Instruction of Marine Auxiliary Blower

For split-body and centrifugal type
上海齐耀系统工程有限公司
QIYAO POWER SYSTEMS CO., LTD
1 概述
分体式船用辅助鼓风机，是一种电机直接带动叶轮的离心式风
机，用于 MDT、WIN GD、MHI 等各型船用柴油机的辅助进气。
2 结构
分体式船用辅助鼓风机按客户订货要求供货，主要结构有以下三
种（图 1）：
图 1.a(单出口带蜗壳)
图 1.b（三出口）图 1.c（不带蜗壳供货）
1—电机 2—气封 3—叶轮
4—壳体 5—进气锥弧管 6—排气孔
分体式船用辅助鼓风机的叶轮由轮毂直接安装在电机轴上，通过
平键联接，叶轮与进口集流管采用套口方式连接。密封采用进口具有
热弹性的 PS 气封。风机结构紧凑、密封优良，维修时无须拆开机壳
与柴油机的连接便可取出叶轮，维修方便。
产品制造、检验和试验均按照国家有关风机标准。性能符合要求，
工作可靠，运行平稳。
3 主要技术指标
1
3.1 性能参数与性能曲线：辅助鼓风机的性能是指订货图中选择的满
足主机需求的静压-流量要求，各型辅助鼓风机运行特性符合所需的
静压-流量(性能运行特性曲线举例示意如图 2)，具体型号设计完全可
满足客户订货图中对性能的要求。
静压P(Pa)
6500
6000
5500
5000 A
4500
4000
3500
3000
2500
B
2000
1500
1000
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6
流量m3/s
图 2（性能特性曲线举例）
3.2 安装尺寸（图 3）
辅助鼓风机的安装尺寸是指风机安装到主机相关管道的接口尺
寸，主要是进口锥管安装和风机出口法兰或壳体连接板二个安装面。
具体型号根据客户订货图要求设计，完全符合安装要求。
图 3.a（单出口带壳体）
图 3.b（三出口）图 3.c（不带蜗壳供货）
2
4 使用、维护
4.1 安装、起吊风机时应使用设计的专用起吊孔，注意安全操作。
4.2 注意区分顺时针和逆时针的风机叶轮以及电机的接线，风机叶轮
旋转应与方向指示牌及壳体出风口一致。
4.3 使用中应注意：
4.3.1 监察风机的振动情况是否正常(v≤6.3mm/s)，振动过大影响风机
寿命和性能，否则需修复叶轮平衡或更换新叶轮。
4.3.2 监察电机、电压、电流参数等是否正常，超过要求应停机检查，
进行必要的维护维修。
4.3.3 运行中检查各处是否有漏气、异响，如需要应检查和更换相关
密封件。
4.4 使用随机提供工具备件箱中的专用叶轮拆卸工具小心拆卸叶轮，
经修理的叶轮应进行动平衡校正或更换新的叶轮，以保证风机工
作平稳。
4.5 如需更换电机轴上的密封圈，注意按其说明，安装时涂适当润滑
油脂，安装方向正确，不可碰坏损伤。
5 工具备件清单
每套风机都会随机附带有一份相应的工具备件清单。
3
1 Application
The split-body type marine auxiliary blower is used for most models of
MDT、WIN GD、MHI diesel engine and so on.
2 Main construction
There are three types supplied by us according to the demands of clients
(see Fig. 1)
Fig. 1.a (type of single outlet with shell)
Fig. 1.b (type of three outlets) Fig. 1.c (type of without shell)
1——electric motor 2——PS-seal
3——impeller 4——auxiliary blower shell
5——air passing in tube 6——leaking out hole
These auxiliary blowers are composed of air passing in tube 5, blower shell
4, impeller 3, PS-seal 2, electric motor 1 and so on. The impeller is connected
with the shaft of electric motor through key directly, using PS-seal for sealing.
The characteristic of such construction is being high revolving speed, more
small external size and good command for sealing.
When maintain and check the auxiliary blower, it needn’t dismount it from
the diesel engine. It’s quite convenient to take out the impeller with the electric
motor together while maintaining and checking. They are according to certain
Blower Industry Standard of China when designing, manufacturing and doing
experiments. It has more advantages such as convenience for maintaining and
checking, reliable running and so on.
1
3 Main technical parameter
3.1. Function curve (see Fig. 2 for example)
The function of the blowers is designed according with the drawings
afforded by clients. The running character1curve is according with the
demands of main engine.
静压P(Pa)
6500
6000
5500
5000 A
4500
4000
3500
3000
2500 B
2000
1500
1000
1 2 3 4 5 6
流量m3/s
Fig. 2(function curve for example)

3.2 Installation dimensions (see Fig. 3)
The installation dimensions of the blower are also according with these
drawings afforded by clients. They include the dimensions on the connecting
face of the inlet tube and the blower shell or the connecting plate to shell.
Fig. 3.a(type of single outlet with shell)
Fig. 3.b （type of three outlets） Fig. 3.( type of without shell)
2
4 Operation and maintenance
4.1. When lifting the auxiliary blower, please use the lifting hole being
specially designed.
4.2. When supplying the power source, please be attention that the
revolving direction should be the same as the direction plate.
4.3. Cautions:
4.3.1. Whether it is normal or not of vibration(v≤6.3mm/s). The old
impeller may be repaired or changed by a new one if the vibration is over
the demands.
4.3.2. Whether it is normal or not of motors’ rated voltage and current.
Otherwise it needs to be checked carefully.
4.3.3. Whether air leaking or not by checking the connect face and
leaking out hole. Otherwise some parts such as PS -seal need to be
changed.
4.4. Please dismount the impeller by special tools in spare parts box,
carefully mounting and dismounting PS-seal.
4.5. When change the PS-seal, please put some grease on it and don’t do
any damage to the sealing lip. To be sure that the installation direction of
seal is correct.
5. List of tools and spare parts
There are always some tools and spare parts in the spare box with
the equipment according to the list paper.
3
QIYAO POWER SYSTEMS Co., LTD
地址：上海市共青路 357 弄 1 号邮政编码：200090
ADD:No.1 Lane 357 Gongqing Road，Shanghai，China（2009）
电话（Tel）：021-65687121 传真（Fax）：021-65680330
Aux. Blower Starter Box
Engine No.: CSB009 + SERIES
Motor rated power: 22kW

Motor rated current: -
Color for enclosure: Munsell 7.5 BG 7/2
1
◆概述 ◆Introduction
The instruction book applied to the aux.

本说明书适用于 MAN B&W ME-C/ME-B
blower starter boxes for MAN B&W
TⅢ 型辅助鼓风机开关箱。开关箱可实现
ME-C/ ME-B T3 type engines. The
辅助鼓风机的起动、停止、运行控制。工
作原理按照 MAN B&W 相关资料要求。 starter box is used to start / stop and
running of the aux. blowers. The design
principles are in according with MAN
B&W relevant information.
◆通过开关箱操作 ◆Operation on the switch box

当辅助风机开关箱上的选择开关 S1 在
positioned in LOCAL and press S2, the
LOCAL 位置时，并且按动 S2,辅助鼓风
auxiliary blower will start directly.
机将立即起动。
当辅助风机开关箱上的选择开关 S1 在 The mode selector switch S1 is
OFF 位置时，辅助鼓风机将立即停止。 positioned in LOCAL, the auxiliary
blower will stop directly.
◆Operation on the ACU

◆通过 ACU 上操作

当辅助鼓风机开关箱上的选择开关 S1 positioned in REMOTE, the start /stop
在 REMOTE 位置时，辅助鼓风机的启动、
of the auxiliary blower is controlled by
停止由 ACU 控制。
the ACU.
2
HPS Starter Box
Engine No.: CSB009 + Series
Motor rated power: 12.8KW

Motor rated current: --
Color for enclosure: Munsell 7.5BG7/2
1
◆概述 ◆Introduction
本说明书适用于 MAN B&W ME-C/ME-B The instruction book applied to the

TⅢ型 HPS 泵开关箱。开关箱可实现 HPS starter boxes for MAN B&W
HPS 泵的起动、停止、运行控制。工作 ME-C/ ME-B TⅢ engines. The starter
原理按照 MAN B&W 相关资料要求。 box is used to start / stop and running
of the HPS Pump. The design
principles are in according with MAN
B&W relevant information.
◆Operation on the switch box

◆通过开关箱操作
当液压油泵开关箱上的选择开关 S1 在 positioned in LOCAL and press S2,
LOCAL 位置时，并且按动 S2，HPS 泵 the HPS pump will start directly.
将立即起动。 The mode selector switch S1 is
当 HPS 泵开关箱上的选择开关 S1 在 positioned in LOCAL, the HPS pump
OFF 位置时，HPS 泵将立即停止。 will stop direct.
◆通过 ACU 上操作 ◆Operation on the ACU

当 HPS 泵开关箱上的选择开关 S1 在
REMOTE 位置时，HPS 泵的启动、停止 positioned in REMOTE, the start /stop
由 ACU 控制。 of the HPS is controlled by the ACU.
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排气阀和阀座电动磨削机使用说明书
Operation Instruction for DM Series Exhaust Valve and

Valve Seat Grinding Machine
目录
1 概述 ................................................................................................................... 3
1.1 产品信息 ..................................................................................................................................................... 3
1.2 制造商信息 ................................................................................................................................................. 3
1.3 安全事项 ..................................................................................................................................................... 3
２产品介绍 ...................................................................................................... 4
2.1 产品技术参数 ............................................................................................................................................. 4
2.2 结构简介 ..................................................................................................................................................... 5
2.3 设备特点 ..................................................................................................................................................... 6
2.4 适用范围 ..................................................................................................................................................... 6
3 磨削机的安装 .................................................................................................. 6
3.1 安装地点的选择 ......................................................................................................................................... 6
3.2 电源连接 ..................................................................................................................................................... 7
4 磨削前的准备 .................................................................................................. 8
4.1 电控系统的检查 ......................................................................................................................................... 8
4.2 更换砂轮 ..................................................................................................................................................... 9
4.3 砂轮的修整 ................................................................................................................................................. 9
4.4 砂轮组件的平衡 ......................................................................................................................................... 9
4.5 砂轮罩壳的调整 ....................................................................................................................................... 10
4.6 磨削角度的调整 ....................................................................................................................................... 10
5 排气阀的磨削 ................................................................................................ 12
5.1 排气阀对中夹紧 ....................................................................................................................................... 12
5.2 磨头位置调整 ........................................................................................................................................... 12
5.3 磨削操作 ................................................................................................................................................... 12
6 排气阀座的磨削 ............................................................................................. 13
6.1 排气阀座对中夹紧 ................................................................................................................................... 13
6.2 磨头位置调整 ........................................................................................................................................... 14
6.3 磨削操作 ................................................................................................................................................... 14
7 磨削机的维护保养 ........................................................................................ 15
8 故障处理 ......................................................................................................... 15
9 随机工具及安装件 ........................................................................................ 15
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contents
１GENERAL DESCRIPTION .......................................................................... 16

1.1 EQUIPMENT INFORMATION .......................................................................................................................... 16
1.2 MANUFACTURER INFORMATION .................................................................................................................. 17
1.3 SAFETY INFORMATION ................................................................................................................................ 17
２EQUIPMENT DESCRIPTION ...................................................................... 18

2.1TECHNICAL INFORMATION ........................................................................................................................... 18
2.2 EQUIPMENT STRUCTURE ............................................................................................................................. 18
2.3 FEATURES ................................................................................................................................................... 19
2.4 APPLICATION............................................................................................................................................... 19
3 INSTALLATION ............................................................................................. 20
3.1 LOCATION OF THE EQUIPMENT .................................................................................................................... 20
3.2 ELECTRIC POWER CONNECTION .................................................................................................................. 21
4 GRINDING PREPARATIONS ....................................................................... 22

4.1 INSPECTIONS OF THE ELECTRIC CONTROL SYSTEM: ..................................................................................... 22
4.2REPLACING OF GRINDING WHEEL ................................................................................................................. 22
4.3 DRESSING OF GRINDING WHEEL .................................................................................................................. 23
4.4 BALANCING OF GRINDING WHEEL ............................................................................................................... 23
4.5 ADJUSTING OF GRINDING WHEEL COVER ..................................................................................................... 24
4.6ADJUSTING OF GRINDING ANGLE.................................................................................................................. 24
5 VALVE GRINDING........................................................................................ 25
5.1 CENTERING OF THE VALVE SPINDLE............................................................................................................. 25
5.2 GRINDING HEAD POSITION .......................................................................................................................... 26
5.3 GRINDING OPERATION ................................................................................................................................. 26
6 VALVE SEAT GRINDING ............................................................................. 27

6.1 CENTERING OF THE VALVE SEAT .................................................................................................................. 27
6.2 GRINDING HEAD POSITION .......................................................................................................................... 27
6.3 GRINDING OPERATION ................................................................................................................................. 27
7 MAINTENANCE ............................................................................................ 28
8 TROUBLE SHOOTING ................................................................................. 29
9 APPENDIX TOOLS AND INSTALLING PARTS ......................................... 29
附录 APPENDIX ............................................................................................... 30
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1 概述
1.1 产品信息
DM 系列排气阀和阀座磨削机是以电力为动力源的磨削加工设备，适用于各型柴油机排气阀与
阀座密封面的修复磨削。该磨削机结构简单可靠，磨削精度高，操作快捷方便，体积小巧。
本说明书适用于 DM 系列排气阀/排气阀座磨削机的使用及维护保养，文中的图表仅用于本文
的说明，保留对设备和技术资料进行更新和改进的权力。
1.2 制造商信息
设计制造：上海齐耀系统工程有限公司
地址：中国上海市共青路 357 弄 1 号邮编：200090
电话：+86-21-65687121
传真：+86-21-65680330
1.3 安全事项
1.3.1 使用及维护保养人员应在使用或维护前仔细阅读和学习本手册，并遵守相关安全
规定。
1.3.2 安全措施与注意事项
运输：
运输及装卸时应注意安全。
必须使用安全合格的吊装工具与设备，吊装螺钉确保无损坏及安装紧固。
吊装时不允有人员许站在设备下。
使用：
检查砂轮型号正确且无损伤、裂纹等缺陷，检查裂纹的正确方法是：砂轮装好后，用一非金属
棒轻击砂轮每个面,无裂纹的砂轮应会发出清脆声音,否则会听到不正常的音调。
防止砂轮破损，砂轮应存放在常温干燥环境中，应保护不受潮及被液体、灰尘及杂物的污染，
否则会损伤砂轮并导致不平衡。
每次磨削前检查各部件的连接应牢固，而且运转正常方可进行磨削操作。特别是砂轮安装螺钉
必须紧固。
操作中如必要应使用防护镜、呼吸罩、耳塞等防护用品。
操作中应防止碰到高速旋转的磨削砂轮，与所有旋转件都应保持距离。
操作时不要穿着宽松衣饰（如领带，纱巾等），长发须注意防护以免卷入。
磨削中注意防止磨屑烫伤，并注意周围无易燃品，以防被磨削火花引燃。
其它注意事项：
不要用水清洁设备。
设备闲置或维修时应停掉设备和关闭电源。
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操作中如遇意外情况，按下操作面板上的紧急停止键。
使用保险丝保护设备中各类电器。
1.3.3 安全说明及标识
安全说明包含在说明书各章节中，操作者应严格遵守，以免造成对人员、财物、环境等的损害。
安全标识包含如下几类：
危险!
可能造成严重人身伤害
乃至死亡的伤害。
警告!
可能造成财物或环境
损害。
注意!
要求正确使用设备，
否则可能有轻微伤害或
损失。
２产品介绍
2.1 产品技术参数：
2.1.1 磨削精度：
径向跳动 ≤0.02mm
表面光洁度 Ra0.5μm
角度精度 ±1′
2.1.2 设备参数：
转盘转速约 10 r/min
磨削砂轮尺寸 Φ150×13×Φ32
磨削砂轮转速 ≥4000r/min
电源总功率需求 1.1kW
电源要求 3 相 380V/50Hz 或 440V/60Hz
磨削用时 10～20 分钟/磨削面
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2.2 结构简介
磨削机由六个部分构成：机座部件，主机体部件，传动部件，磨座部件，磨头部件和电控箱，
如图 1 所示。
1. 机座部件 2. 主机体部件 3. 传动部件

4. 磨座部件 5. 磨头部件 6. 电控箱
图1 DM 型电动磨削机结构示意图
2.2.1 机座部件
磨削机的支架，其底面安装防震垫以防止磨削机的震动。
2.2.2 主机体部件
主机体部件包含气阀稳定支架，主轴组件，机架组件，转盘，大带轮，气阀及阀座的对中夹紧
装置等，主要用于对中夹紧排气阀和阀座，并通过传动部件带动工件旋转。
2.2.3 传动部件
包括驱动马达、齿轮箱及小带轮，是把驱动马达的转速减速后通过皮带传动到主机体部件上带
动工件旋转，满足工件所需的转动速度。
2.2.4 磨座部件
磨座部件主要包括连接座，上、下导轨及角度调节装置等，主要用于对磨削砂轮的操作，是磨
削时保证砂轮进给的装置，并可以对磨削角度进行精确调节。
2.2.5 磨头部件
主要包括磨削马达、同步带轮组件及砂轮组件，通过磨削马达座与磨座部件上滑板相联接。
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2.2.6 电控箱
磨削机动作的控制系统，整体置于磨座部件的连接座内，电控箱面板如图 2 所示（内部线路图
分别见附录 1）。
图 2 电控箱面板图
（DM-3 型-用于除 DM35A 外其他机型）
2.3 设备特点：
本磨削机为电动式，结构简单可靠，自动对中，防震，精度高，磨削排气阀座时无需拆除气阀
稳定支架，操作简便快捷。
2.4 适用范围：
本设备主要用于二冲程船用低速柴油机排气阀与阀座配合面磨损时的修复磨削（具体型号参考
附录 5）。
3 磨削机的安装
3.1 安装地点的选择
应考虑选取最经济有效的合适地点安装此设备。
该处应避免有强烈震动。
该处应方便吊装并有足够的操作空间。
参考磨削机认可的安装图纸要求，安装在
船内合适的地方（附录 5）。
为了防止磨削机的震动，把备件箱中的橡胶减
震垫放置在框架和机座中间，用螺栓 4×M20 固定。

图 3 磨削机的安装
3.2 电源连接：
电源为 3 相 380V/50Hz 或 440V/60Hz 功率总需求为 1.1KW。

目前有效型号控制箱为 DM-3。
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DM-3 型控制箱适用于除 DM35A 磨削机外其他型号电动磨削机。
具体电路图见说明书后附录。
所有型号磨削机设备带有相同的插座及插头（图 4），用户根据电源与设备距离选择
电源线长度进行连接(用户自备)，安装完成后开启电源，检查电控箱面板上各开关控制
正常。
图 4 插座及插头
危险!
注意用电安全，在安装、维修时必须断开电源。
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4 磨削前的准备
4.1 电控系统的检查：磨削操作前应检查电控系统的连接及面板上的各开关。
4.1.1 检查面板上各开关处于关闭状态。
4.1.2 打开电源，指示灯亮。
4.1.3 开启驱动马达开关，带动转盘旋转，检查转向为逆时针。
4.1.4 开启磨削马达开关，带动砂轮旋转，检查转向正确，开向磨气阀转向逆时针，开向磨阀座
时转向为顺时针。
4.1.5 按下急停键，设备应停转。
4.1.6 关上驱动马达及磨削马达开关，让急停键复位后关掉总电源。
4.2 更换砂轮（图 5）
磨削机上已装有一经过了平衡校正的砂轮组件。当需换上备用砂轮时，按如下步骤操作：
4.2.1 拆除磨削马达轴上的压紧螺栓。
4.2.2 使用备件箱中的拆卸螺钉取出砂轮组件。
4.2.3 用备件箱中二件砂轮拆卸扳手拆除盖板并取出旧砂轮，注意盖板是左旋螺纹。
4.2.4 同样用二件砂轮扳手装上新砂轮，应保证夹紧。注意新砂轮装入前应检查，不允许有裂纹
和破损。注意更换的新砂轮需按 4.3 修整，然后按 4.4 进行平衡后才能装机使用。
危险!
砂轮及砂轮组件在安装
时必须确保紧固。
图 5 砂轮组件
4.3 砂轮的修整(图 6)
新砂轮或旧砂轮外边缘有缺损或脏物污染时，应在平衡前修整对中，步骤如下：
4.3.1 砂轮装入砂轮组件后，先取出平衡块，用内六角螺钉安装紧固在磨削马达轴上。
4.3.2 从备件箱取出砂轮修整器装在上滑座的支架上，调好修整器的金刚石刀的切削点，
并紧固。每次切削量不大于 0.1mm(相当于金刚石刀往前转 1/8 转)。
4.3.3 开启磨削马达，前后缓慢移动砂轮进行修整，应多次修整至砂轮对中。
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警告!
注意修整中的砂尘!
修整时切勿碰到旋转的砂轮!
图6 砂轮的修整
4.4 砂轮组件的平衡 (图 7)
砂轮修整对中后，应对砂轮组件进行平衡校正。步骤如下：
4.4.1 从工具备件箱中取出砂轮平衡器，从砂轮组件上取出一平衡块，把砂轮组件装入
砂轮平衡器轴上。
4.4.2 让砂轮自由转动，其静止位置即为重心向下的位置，划上记号。
4.4.3 参考记号，在合适位置放上平衡块。
4.4.4 调整各平衡块位置，自由转动砂轮，到砂轮可停在任何位置，说明平衡了。
4.4.5 如不校正平衡会导致震动而磨削效果不佳，如砂轮上不干净或残缺时，会导致同
样的问题，因此应当经常校正砂轮平衡。
注意!
震动及磨削不良也可
能是因为砂轮积尘、太
脏或砂轮不平衡!
因此应经常检查砂轮，
定期进行平衡校正。
图 7 砂轮平衡
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4.5 砂轮罩壳的调整
砂轮罩壳缺口位置根据要磨削的零件来改变。磨削排气阀杆时，罩壳缺口朝上，磨削排气阀座
时，罩壳缺口朝下，调好后要把罩壳上的紧定螺钉支紧。
4.6 磨削角度的调整
磨削机磨削角的原始设计角度为 30°，刻度盘在角度调节螺钉上固定时，其“0”位应对准角
度指示箭头(如图 9 所示)。磨削排气阀座时角度为 30°，则不须再调，如根据阀杆和阀座图纸需要
调整角度时，调整是通过一个安装在上滑座的角度调整螺钉 M16×1.5 实现的，首先松开两侧的两
个紧固螺栓 M12，顺时针转动角度调节螺钉 M16×1.5，把上滑座抬高到所需角度(因机型而异)，刻
度盘上每格为 1′，转动一圈即为 30′。角度调好后，扳紧并紧螺母 M16×1.5，并将两侧的两个
紧固螺栓 M12 用手旋紧(图 8、图 10)。
图 8 角度调节装置
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图 9 磨阀座时角度调节螺钉与刻度盘的位置(因机型而异)
图 10 磨气阀时角度调节螺钉与刻度盘的位置示意(因机型而异)
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5 排气阀的磨削
5.1 排气阀对中夹紧
5.1.1 根据柴油机制造商说明书中的要求对排气阀进行检查，如垂直度，同轴度要求等，
先行校正。
5.1.2 检查排气阀与对中夹紧相关的圆柱面、磨削面、检测面，应清洁且无毁损。
5.1.3 将排气阀缓慢放入对中组件中，用拨杆顺时针转动夹紧对中组件，使气阀夹紧对
中。
5.1.4 用手拧紧气阀稳定支架调节螺栓轻轻顶住阀杆，使阀杆磨削时不致晃动。
5.1.5 用百分表在阀杆外径无损面测量径向跳动应≤0.02，可通过轻微调节气阀稳定支架
调节螺栓达到，如图 11 所示。
图 11 排气阀的对中夹紧
5.2 磨头位置调整
按 4.5 说明调整砂轮罩壳缺口向上，以便用砂轮上边缘磨削排气阀。同时按 4.6 说明，调节和
查看角度刻度盘，抬高上滑座到所需角度(因机型而异)。
5.3 磨削操作：分为粗磨和精磨二步，以达到所需的光洁度与精度。
5.3.1 粗磨
1) 转动手柄，移动上、下滑板，使磨削砂轮尽量靠近待
磨削面，即将接触时停止进给。使用径向进给手轮使砂轮
进给到轻微接触待磨削面。(图 12)
图 12
2)使用磨削行程手轮使砂轮后退，先离开磨削面。
3)顺时针转动径向进给手轮 3～6 个分度，每分度对应进给磨削深度为 0.01mm。每次磨削深度

0.03～0.06mm，初期取较大值，后期取较小值(图 13)。
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警告!
磨削操作中注意砂尘!
操作中切勿碰到旋转的砂轮!
图 13
4) 打开电源，开启驱动马达带动工件旋转，转盘为顺时针旋转，转速在 10r/min 左右。
5)开启磨削马达带动砂轮旋转，注意在控制箱面板上开关指向标识为“磨气阀”一侧（DM-2
型控制箱无须选择），砂轮应为逆时针旋转。
6)缓慢使用磨削行程手轮使上滑板前后进给，工件每转一圈，行程手轮大约进给 1/8 转。
7)可反复几次磨削，直至磨削表面光洁平整。
5.3.2 精磨
精磨前清除砂轮外圆表面及磨削面磨屑等垃圾，径向进给磨削深度大约 0.01mm，其余操作同
粗磨，直至磨削面光洁度达到要求为止，完成后清理磨削面，并关闭马达，切断电源。
6 排气阀座的磨削
6.1 排气阀座对中夹紧
6.1.1 检查阀座的支承面，对中夹紧面及检测面不得有破损，并清洁。
6.1.2 检查并清洁磨削机转盘上的各个定位销，其对应编号应与转盘上的编号一致。
6.1.3 各定位销的切口平面位置靠内，小心放入阀座，以定位销上平面支承阀座。
6.1.4 用拨杆转动偏心定位销，使各定位销上的标记线与转盘上的刻线对齐。
6.1.5 用百分表在阀座外径无损面测量径向跳动应≤0.02，检查阀座是否对中，可参照刻
线用拨杆左右均匀调节偏心定位销，使阀座对中夹紧，如图 14。
图 14 排气阀座的对中夹紧
13
6.2 磨头位置调整
按 4.5 说明调整砂轮罩壳缺口向下,以便用砂轮下边缘磨削排气阀座。同时按 4.6 说明，调节和
查看角度刻度盘，根据图纸角度要求调整角度。
6.3 磨削操作：分为粗磨和精磨二步，以达到所需的光洁度与精度。
6.3.1 粗磨
1) 转动手柄，移动上、下滑板，使磨削砂轮尽量靠近待磨削面，即将接触时停止进给。使用径
向进给手轮使砂轮进给到轻微接触待磨削面。(图 15)。
2)使用磨削行程手轮使砂轮后退，先离开磨削面。
3)逆时针转动径向进给手轮 3～6 个分度，每分度对应进给磨削深度为 0.01mm。每次磨削深度

0.03～0.06mm，初期取较大值，后期取较小值(图 16)。进给量调好后，导轨上的斜块调节螺钉应紧
固。
图 15 图 16
4) 接通电源，开启驱动马达带动工件旋转，转盘为顺时针旋转，转速在 10r/min 左右。
5)开启磨削马达带动砂轮旋转，注意在控制箱面板上开关指向标识为“磨阀座”一侧，砂轮应
为顺时针旋转。
6)缓慢使用磨削行程手轮使上滑板前后进给，工件每转一圈，行程手轮大约进给 1/8 转。
7)可反复几次磨削，直至磨削表面光洁平整。
6.3.2 精磨
精磨前清除砂轮外圆表面及磨削面磨屑等垃圾，径向进给磨削深度大约 0.01mm，其余操作同
粗磨，直至磨削面光洁度达到要求为止，完成后清理磨削面，并关闭马达，切断电源。
警告!
磨削操作中注意砂尘!
操作中切勿碰到旋转的砂轮!
14
7 磨削机的维护保养
为确保良好的磨削效果及操作安全，应定期进行如下检查保养：
7.1 检查砂轮表面应清洁、无破损及其平衡性。
7.2 检查电控箱上所有开关应动作正常、灵活、可靠。
7.3 每年二次向传动部件的齿轮箱内添加润滑脂。
7.4 检查并保持上、下导轨的良好润滑状态及尽可能小的配合间隙。
7.5 磨削机每次使用后都必须关闭总电源，清洁设备并涂上一层防锈油膜，用防水塑料
布扎紧罩住设备以防灰尘和潮湿，确保设备安全及状态良好。
8 故障处理
故障描述原因处理措施
砂轮没修整查看砂轮情况，精磨前应清洁或
修整砂轮
砂轮不平衡当马达空转感到震动较大时，须
平衡校正砂轮
减小进刀量，按精磨要求进行精
磨削面不平整终磨时进刀量太大磨
上、下导轨松弛调整斜块调节螺钉到合适间隙
气阀稳定支架调节螺栓设置不当重新设置
磨削面跳动过大对中夹紧不正确检查对中夹紧机构无松动，重新

打表对中夹紧
磨削角度不对角度调校错误重新校准零位，并确认角度调整
操作正确
电机停转电控系统错误检查急停按键、保险丝等电路系
统
9 随机工具及安装件(详见随机备件箱内清单)
磨削机工具备件箱中带有以下工具：
9.1 砂轮平衡器：用于对磨削砂轮组件进行平衡校正。
9.2 挠棒：又称拨杆，用于扳动阀座定位销及扳动排气阀对中组件和夹紧螺栓。
9.3 砂轮扳手：用于把砂轮装到砂轮组件中，或从砂轮组件中拆换砂轮时使用。
9.4 砂轮修整器：将该工具装到上滑座修整支架中，用于修整砂轮。
9.5 内六角扳手：用于设备维修维护时的拆装工作。
9.6 砂轮拆卸工具：用于砂轮维修维护时，方便从磨削机上拆卸下砂轮组件。
9.7 减震垫块：安装设备时装于设备底脚下，用于防震。
15
１GENERAL DESCRIPTION
1.1 Equipment information

Type DM grinding machine is a kind of grinding equipment whose power is the electric power. It is
an effective tool purposed for reconditioning the sealing surface of some types engine valves and valve
seats. The grinder presented here is simple, credible, precise and convenient.
This manual is intended primarily for the operator of the valve and valve seat grinding machine of the
type DM. The charts and drawings are used in this manual and may be changed in the future.
1.2 Manufacturer information

Address：No.1 lane 357 Gongqing road , shanghai, china. Postcode: 200090
Telephone：+86-21-65687121 Fax：+86-21-65680330
1.3 Safety information
1.3.1 This manual must be carefully studied before using the equipment. It will help you to
use the equipment to its full capacity and to avoid costly mistakes. All safety
instructions must be complied with. Failure to do so can result in serious injury or
damage to equipment and the environment.
1.3.2 Safety precautions
Transportation：
Ensure that the equipment is transported safely.
Make sure the lifting eyebolts are undamaged and adequately fastened.
Do not carry loads above people.
Operation:
Make sure the correct type of grinding wheel is used. Make sure the grinding wheel is not cracked by
performing the ring test: use a non-metallic implement, gently tap the wheel at each side while holding the
wheel in the center. An undamaged wheel will omit a clear tone. If cracked, there will be a dead tone.
When idle, or stored, all grinding wheels should be protected from the effects of moisture, humidity
and fluids, as these may be absorbed and cause the grinding wheel to become unbalanced.
Make sure the screw on the grinding wheel is fixed tightly before every operation.
Use safety goggles, breathing filter and hearing protection when the grinding machine is in operation
and while dressing the grinding wheel, if necessary.
Keep away from the rotating grinding wheel and other rotating parts.
Do not wear loose fitting clothing i.e. sleeves, ties or hair styles which may become entangled in the
machine.
Use proper protection against glowing grinding particles whilst grinding and keep inflammable
material at safe distance at all times.
16
Other warnings:
Do not clear the machine with water.
Always turn off the power switch when the operation is completed, or if the electric power supply is
interrupted when grinding. Beware of the wrong starting in the machine during maintenance.
Push down the “emergency button” while emergency appears.
Use fuses to protect these components.
1.3.3 Safety instructions

Safety instructions with important information concerning risks associated with particular operations,
or recommendations in respect of suitable actions or measures, are include in the text.
Three different levels of safety instructions, as shown below, are used:
Danger! Warning! Caution!

Risk of serious or fatal injury to Risk of injury to personnel Use the equipment correctly.
personnel. Safety instructions in and/or damage of property . Safety instructions in this
this group indicate when there is Safety instructions in this group indicate when there is a
a risk of serious injury or injury group indicate when there is a risk of injury or damage if the
that could cause death as a risk of injury or damage to instruction is not obeyed.
consequence of misuse. property or the environment.
２EQUIPMENT DESCRIPTION
2.1Technical information
2.1.1 Grinding accuracy：
Eccentricity ≤0.02mm
Surface roughness Ra0.5μm
Angle accuracy ±1′
2.1.2 Equipment data：
Grinding object speed about 10 r/min
Grinding wheel size Φ150×13×Φ32
Grinding wheel speed ≥4000r/min
Required power 1.1kW
Electric voltage AC 3 phases 380V/50Hz or 440V/60Hz
Normal grinding time 10～20 minutes/sealing surface
17
2.2 Equipment structure
The machine includes six parts, they are: framework assembly, main body, driving assembly,
grinding seat, grinding head and electric control system, see figure 1.
1. Framework assembly 2. Main body 3. Driving assembly

4. Grinding seat 5. Grinding head 6. Electric control system
Figure 1
2.2.1Framework assembly is the support part of the grinding machine, there are four damping
pads at the feet of the framework assembly to prevent the shake while grinding.
2.2.2Main body
Main body includes stabilising support subassembly, main shaft subassembly, frame subassembly,
turntable, belt wheel , centring subassembly. They can drive the valve spindle and valve seat to rotate, as
well as centre the valve spindle and valve seat.
2.2.3 Driving assembly includes motor, gear box and belt wheel. They drives the main body
to rotate by driving motor.
2.2.4Grinding seat
rinding seat includes connecting seat, top slider, lower slider and angle adjuster etc. They can control
the position of the grinding head and regulate the angle accurately.
18
2.2.5 Grinding head
Grinding head includes wheel subassembly, gear belt subassembly and grinding motor, connecting
with top slider of the grinding seat by the seat of the motor.
2.2.6 Electric control system
z The machine is controlled by the panel of the electric controlling box. (see figure 2 and
APPENDIX 1 )
Figure 2（DM-3 control box）
2.3 Features：
The grinding machine is driven by electric power and easy to operate. It is of robust construction and
designed as a professional tool for grinding valve spindles and valve seats. Automatic centering and
insensibility to vibrations assures a high quality grinding result.
2.4 Application：
The grinding machine is available for use on two-stroke crosshead engine exhaust valves and valves
seats.
3 INSTALLATION
3.1 Location of the equipment

Carefully consider where to locate the grinding machine in the most effective and economical use.
Avoid any area with excessive vibrations.
Ensure availability of lifting facilities and necessary headroom clearance.
mount the machine on a suitable foundation according to the mounting drawing by us（appendix5）
Mount the grinding machine on the damping pads supplied in the spare box to prevent the vibrations
by 4 bolts of M20 (figure 3).
19
Figure 3
3.2 Electric power connection (see figure 4)

3 phases 380V/50Hz or 440V/60Hz Required total power :1.1KW
Model DM-3 control box is be applicable for other models except of DM35A grinder.
The detail electric diagrams are at the end of this book.（See appendix）.
This machine equipped with plug and plug seat（Figure 4）. Customer connects the cable by the distance
between the machine and the power. After installation, check the rotation of the grinding wheel and the
turntable.
Figure 4
CAUTION!
Be caution of unexpected start while connecting the cables.
20
4 GRINDING PREPARATIONS
4.1 inspections of the Electric control system:

Before and during each grinding operation the following must be checked:
4.1.1 Check the panel of the controlling box.
4.1.2 Turn on the power switch. The dedicator on the panel should be on.
4.1.3 Turn on the switch of the driving motor, check the correct direction of the turntable.
4.1.4 Turn on the switch of the grinding motor, check the correct direction of the grinding
wheel.
4.1.5 After pushing down the “emergency button”, the equipment stops.
4.1.6 Turn off the switches of the driving motor and the grinding motor. Reset the
“emergency button”. Turn off the power.
4.2 Replacing of grinding wheel (figure 5)

The machine is equipped with one pre-balanced grinding wheel mounted on the grinding motor when
delivered, plus spare grinding wheels according to following:
4.2.1 Remove screw at the outer end of grinding motor shaft.
4.2.2 Remove the complete assembly of grinding wheel and grinding wheel hub by pulling it
from the grinding motor shaft by the screw tool in the spare and tool box.
4.2.3 Split the grinding wheel hub into two halves using pin spanners from the spare and tool
box. The grinding wheel hub is left hand threaded.
4.2.4 Fix the new grinding wheel and tighten the hub using the two pin spanners. Make sure
that it is fixed tightly and check the new grinding wheel before replacing, no crack and
damage is allowed.
Attention：the new wheel must be dressed and

balanced before use.
Danger!
The wheel and the
wheel subassembly
must be fixed tightly.
Figure 5
21
4.3 Dressing of grinding wheel (figure 6)
A new grinding wheel should be dressed until concentric before balancing.
4.3.1 Remove the balancing weights, fix the wheel subassembly on the shaft of the grinding
motor.
4.3.2 Get the dresser out of the spare box and set the dressing bracket. Adjust the diamond
cutting point and tighten the lock nut. Each cut should be 0.1mm in maximum (1/8 turn
of the screw).
4.3.3let the grinding motor run. Dress the wheel until concentric by slowly moving the
grinding wheel back and forth over the diamond cutting point.
Figure 6
Warning!
Be care of the dust while dressing!
Be care of the high speed wheel!
4.4 Balancing of grinding wheel (figure 7)

When replacing the grinding wheel, or whenever need arise, always balance the grinding wheel.
4.4.1 Get the wheel balancer out of the spare box. Remove the balancing weights firstly, and
mount the grinding wheel on the shaft of the balancer.
4.4.2 Let the wheel swing back and forth until it stays with its heaviest point downward.
Then mark this point with a marking pen.
4.4.3 Mount the weights symmetrically according to the mark.
4.4.4 Adjust weights symmetrically up or downward until the wheel stay put when placed in
any angular position. The grinding wheel is now balanced.
4.4.5 Vibrations and poor cutting performance could be caused either by a grinding wheel
clogged with dirt and residue, or by an unbalanced grinding wheel. Truing and
balancing should therefore be done regularly.
22
Emery wheel balancer
Emery wheel fixture
Figure 7
Caution!
Vibrations and bad grinding result may be these reasons
such as dust, dirty or unbalanced wheel!
Check the wheel subassembly regularly!
4.5 Adjusting of grinding wheel cover
The gap location of the grinding wheel cover is adjusted according to the valve or valve seat. While
grinding the valve, the gap is upward. On the other hand, while grinding the valve seat , the gap is
downward.
4.6 Adjusting of grinding angle

The basic angle setting of the grinding head is 30°, this angle can be used to grind the valve seat
normally(according to the engine manufacture′s recommendation). You can check the angle meter, the
angle arrow should indicates the position of “0”(figure9). You can change the angle according to engine
manufacture′s recommendation by a adjusting screw M16×1.5 if grinding valve. Firstly, loose the two
bolts M12 on both sides of the slide seat. Turn the screw M16×1.5 clockwise, the slide seat is raised to
the required angle(according to the engine manufacture′s recommendation). Each division on the angle
meter corresponds 1′angle change, there are 30′per round. Then screw the nut M16×1.5 and the two
bolts M12 tightly by hand(figure 8、figure 10).
23
Figure 8
Figure 9
24
Figure 10
5 VALVE GRINDING
5.1 Centering of the valve spindle
5.1.1 Before commencing work, check the valve spindle according to the instruction from the
engine manufacturer, such as coaxial degree, cylindrical degree ect. .
5.1.2 Check the valve spindle such as related grinding surface, inspecting surface.
5.1.3 Lower the valve stem slowly into the hole in the machine. Make the centering
subassembly to center the valve by using a regulating bar in the spare box.
5.1.4 Adjust the stabilizing bolts evenly against the valve stem and tighten slightly and
equally by hand, preventing the valve from vibration while grinding.
5.1.5 Check the dial gauge on the surface of valve spindle, insure the spindle center’s
deviation is less than 0.02 by adjusting the stabilizing bolts slightly. (See figure 11)
Figure 11
25
5.2 Grinding head position
Adjust the gap of the wheel cap upward according to item 4.5. And turn the grinding head to the angle
position required in the instruction from the engine manufacturer according to the item 4.6.
5.3 Grinding operation:

The grinding process is performed in two steps: coarse grinding to remove material, and fine grinding
to provide the required surface finish.
5.3.1 Coarse grinding
1) Adjust the grinding wheel to position as close as possible to the
valve surface. Use the feeding wheel to guide the grinding wheel
toward the surface.(figure 12)

figure12
2) Upon contact, stop the feed and retract the grinding wheel with the hand wheel.
3) A division responds cutting depth of 0.01mm, Feed upwards 3～6 divisions, about 0.03～0.06mm..
The cutting depth in prophase is more than in anaphase (figure13). Check the clearance between the slide
guide and the slider block after feeding.
figure13
4) Open the electrical power, start the driving motor on the controlling panel, and the turntable
should turn clockwise at the speed of about 10 rpm.
5) Start the grinding motor, the switch directs the “valve” on the panel of the controlling box, the
direction of the revolution should be anticlockwise.
6) Feed slowly with the hand wheel in the grinding route subassembly, approximately 1/8 turn per
round of the valve.
7) Grinding can be done several times until the surface is smooth.
5.3.2 Fine grinding
Clear the wheel before fine grinding. Feed upwards about depth 0.01mm, grind the valve surface
finely until the required surface finish. After grinding, clean the valve and shut off the power.
Warning!
Caution the dust during operation!
Do not touch the high speed wheel!
26
6 VALVE SEAT GRINDING
6.1 Centering of the valve seat
6.1.1 Before commencing work, check the valve seat according to the instruction from the
engine manufacturer, such as related grinding surface, inspecting surface.
6.1.2 Check these orientation pins on the turntable, be sure the serial number is accordant.
6.1.3 The gap on every pin is toward to the axis of the main body assembly. Put the valve
seat onto the top of these pins.
6.1.4 Turn around the pins with a Regulating bar in the spare box, make the marks both on
the pins and turntable accordant with each other.
6.1.5 Check the dial gauge on the surface of valve seat, insure the seat center’s deviation is
less than 0.03 by adjusting these pins slightly.( See figure 14)
Figure 14
6.2 Grinding head position
Adjust the gap of the wheel cap downward according to item 4.5. And turn the grinding head to the
angle position required in the instruction from the engine manufacturer according to the item 4.6. The
angle dial should be at the position “0”.
6.3 Grinding operation:

The grinding process is performed in two steps: coarse grinding to remove material, and fine grinding
to provide the required surface finish.
6.3.1 Coarse grinding
1) Adjust the grinding wheel to position as close as possible to the
seat surface. Use the feeding wheel to guide the grinding wheel
toward the surface.(figure 15)

figure15
2) Upon contact, stop the feed and retract the grinding wheel with the hand wheel.
3) A division responds cutting depth of 0.01mm, Feed upwards 3～6 divisions, about 0.03～0.06mm..
27
The cutting depth in prophase is more than in anaphase (figure16). Check the clearance between the slide
guide and the slider block after feeding.
figure16
4) Open the electrical power, start the driving motor and the turntable should turn clockwise at the
speed of about 10 rpm.
5) Start the grinding motor, the switch directs the “valve seat” on the panel of the controlling box,
the direction of the revolution should be clockwise.
6) Feed slowly with the hand wheel in the grinding route subassembly, approximately 1/8turn per
round of the valve.
7) Grinding can be done several times until the surface is smooth.
6.3.2 Fine grinding
Clear the wheel before fine grinding. Feed upwards about depth 0.01mm, grind the valve surface
finely until the required surface finish. After grinding, clean the valve seat and shut off the power.
Warning!
Caution the dust during operation!
Do not touch the high speed wheel!
7 MAINTENANCE
Check the following regularly in order to ensure a good grinding result and a safe operation:
7.1Check no dirty, no crack and the balance of the wheel subassembly.

7.2Check the electrical controlling panel of the box.
7.3 Add the grease into the gear box 2 times per year.
7.4 Lubricate the slide guide regularly. Check and adjust the clearance between the
guide and the slider block correctly before each grinding operation.
7.5 Keep the grinding machine clean and protected with a thin layer of oil after each
grinding operation. And protect the machine from the dust and water by water-proof
plastic cloth.
28
8 TROUBLE SHOOTING
Fault or problems Cause Action
not Dress grinding wheel when

1.Grinding wheel clogged and especially
dressed before the final cut.
2.Grinding wheel not Balance grinding wheel.
balanced
Uneven “wavy”surface 3.too much feeding Fine grinding must be done.
4.slack in the top slide Reset the slider block screw.
guide
5.Stabilising screws not Set these screws carefully.
set
Check the centering
the surface not center Centering is not correct
subassembly.
Incorrect angle difference The adjustment of angle is Check the adjustment of
between valve spindle and seat not correct. angle.
Error in the electrical Check the electric control
Motor stop control system system.
9 Appendix tools and installing parts (see the list in the spare box)
There are following appendixes in the spare box along with the machine.
9.1 Wheel balancer：used for balancing the wheel subassembly.
9.2 Regulating bar：used for turning the orientation pins or the centering subassembly for
valve
9.3 Pin spanner：used for installing or removing the wheel .
9.4 Diamond wheel dresser： used for dressing the wheel .
9.5 Hexagon wrench keys：used for installing or resmantling the machine.
9.6 Tool for didmantling grinding wheel：1 pieces，used for taking-down the grinding wheel
from grinder.
9.7 Damping pad：installed for preventing the vibration on the foots of the machine .
29
附录 1 APPENDIX 1：DM-3 电控箱电路图 Electric diagram of DM-3 control box
30
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
独立液压顶推支撑装置
Hydraulic top bracing – Stand alone type
认可资料
For Approval drawing
顶撑型号 Type： HCHT26(40)
数量 Qty: 2 套 sets/船 ship
主机厂 Engine maker: QMD
机型 Engine type: 6G45ME-C9.5(CSB009)
第 1 页 / 共 38 页
目录
INDEX
1、简介 Introduction ............................................................................................................ 3
2、安全 Safety .................................................................................................................... 4
3、技术参数 Technical description ...................................................................................... 5
4、系统组成 System parts ................................................................................................... 6
4.1 液压顶推支撑单元 Hydraulic top bracing unit .................................................. 6
4.2 运输用起吊工具 Lifting tools for transport. ....................................................... 6
4.3 正确定位安装法兰的安装工具 Fitting tool for correct positioning of mounting
flanges. .................................................................................................................. 7
4.4 电气控制箱 Electric control box. ...................................................................... 7
4.5 液压手摇泵 Hydraulic hand pump.................................................................... 7
4.6 其他工具及备品 Other spare parts & tools ....................................................... 7
5、工作原理 Working principle ........................................................................................... 8
6、控制系统 Control system............................................................................................... 9
7、操作 Operation ............................................................................................................. 11
8、安装 Installation ............................................................................................................ 12
8.1 准备 Preparation ........................................................................................... 12
8.2 安装法兰的安装 Installation of mounting flanges ........................................... 13
8.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders .................... 16
8.4 液压控制单元包括蓄能器的安装 Installation of hydraulic unit including oil
accumulator ......................................................................................................... 17
8.5 电气控制系统的安装 Installation of electric control system ............................ 18
8.6 液压顶推支撑的充油、补油及调整 Filling, refilling and adjustment of top bracing
............................................................................................................................ 18
9、服务和维护 service and maintenance .......................................................................... 20
9.1 备件 spare parts ............................................................................................ 20
9.2 服务检查 service inspection .......................................................................... 20
9.3 油压的控制 control of oil pressure ................................................................. 20
9.4 调节绿色位置带 Adjusting green position band ............................................. 21
9.5 推力杆不重合度 Distance rod alignment ........................................................ 21
9.6 更换密封件 Replacing sealing rings............................................................... 22
9.7 更换蓄能器 Replacing oil accumulator........................................................... 23
10、故障分析 Trouble shooting ........................................................................................ 25
11、图纸 Drawings ............................................................................................................ 26
第 2 页 / 共 38 页
1、简介 Introduction
独立式主机液压顶支撑装置（以下简称液压顶推支撑）是安装在主机和船体结构之间(参
照液压顶推支撑布置图 HCHT26(40)-01)，用来防止船体与主机之间产生共振，从而降低主
机振动所产生的影响一种减振装置。液压顶支撑使主机和船体之间由于主机热膨胀以及船舶
不同装载所产生的变形是柔性的。
Hydraulic top bracing stand-alone type of M/E（shortened form：Hydraulic top bracing）
are installed between the engine and the hull (refer to the arrangement diagram ：
HCHT26(40 )-01 ), to detune the natural frequencies of the engine and thus lower the
impact of the vibrations. The hydraulic top bracing units are flexible to thermal expansion
of the engine and various loading conditions of the vessel.
标准安装方式是安装在主机的右侧；如果更方便的话，也可以安装在主机左侧，一般只
需安装在一侧即可。
The standard installation is on the starboard side of the engine, but port side
installation can alternatively be used if this is more convenient. Installation is only
necessary on one side.
其标准的配置有 2 套、4 套或者 6 套等不同方案，具体数量取决于主机的缸数和缸径。

液压顶支撑的液压缸直径设计为 200mm，一般情况下，主机缸径不大于 600mm 时，液压
顶推支撑利用低压类型，压力设置 26bar，主机缸径大于 600mm 时，液压顶推支撑利用高
压类型，压力设置 40bar。
The standard installation features two or four or six top bracing units, depending on
engine size and cylinder number. generally, the top bracing units are designed with a
cylinder diameter of 200 mm and deliverer in a low-pressure version (26bar) for engines
with bore≤600mm, and a high-pressure version (40bar) for engines with bore＞600mm.
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2、安全 Safety
液压顶推支撑的设计原理是通过液体产生压力来提供较大的机械力。工作过程处于高压
和较大机械作用的环境，一旦失去控制，就会对操作者和设备造成伤害和损失。因此，为了
安全起见，在使用设备之前必须彻底的了解设备是如何操作和控制的。
Hydraulic equipment is designed to accomplish work using liquid pressure to produce
a greater mechanical force. The operator is subject to hazards from high-pressure liquids
and large mechanical forces. Either of these forces, when out of control, have the
potential to cause enormous damage and great bodily injury. All safety devices should be
controlled and the operator should have a thorough knowledge of how the equipment
operates before the equipment is used
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3、技术参数 Technical description
液压缸直径 Cylinder diameter：200mm

安装长度 Build-in length：475mm
重量 Weight：~132kg
预紧力 Nominal force (7bar)：22kN（7bar）
最大支撑力 Max. force (26bar)：82 kN（26bar）
最大支撑力 Max. force (40bar)：127 kN（40bar）
液压油牌号 Oil type：VG32 or VG46
润滑脂 Lubricating grease：二硫化钼 Molykote (MoS2)
电制 Power：24V DC
液压顶推支撑外形尺寸参照图:HCHT26(40)-02
Outline dimensions please refer to diagram of hydraulic top bracing：HCHT26(40)-02
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4、系统组成 System parts
液压顶推支撑系统主要由以下几部分组成：
The parts of the hydraulic top bracing system, shown on the following pages, are:
4.1 液压顶推支撑单元 Hydraulic top bracing unit

根据主机型号的不同，液压顶推支撑系统有 2 套、4 套或 6 套顶推单元组成等不同配置
（参照液压顶推支撑系统原理图 HCHT26(40)-03）。每套单元主要由一只液压蓄能器、一
套液压控制单元、一组液压缸和一套安装法兰组成。
Two, four or six sets of hydraulic top bracing units (refer to hydraulic top bracing
system principle diagram：HCHT26(40)-03), depending on the engine type, each
consisting of: an oil accumulator, a hydraulic control unit , a cylinder unit , a set of
mounting flanges.
4.2 运输用起吊工具 Lifting tools for transport.
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4.3 正确定位安装法兰的安装工具 Fitting tool for correct positioning of
mounting flanges.
4.4 电气控制箱 Electric control box.
4.5 液压手摇泵 Hydraulic hand pump
4.6 其他工具及备品 Other spare parts & tools
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5、工作原理 Working principle
每套液压顶推支撑系统单元主要由一套液压缸单元和安装在液压缸本体上带有液压蓄
能器的液压控制单元组成。
Each top bracing unit consists of a single acting hydraulic cylinder and a hydraulic
control unit including an oil accumulator mounted directly on the cylinder house.
当主机运行时，顶推单元建立起压力，来降低主机的振动强度。当主机停车时，压力释
放至初始压力 7bar。
When the engine is running, the unit builds up a pressure on the engine in proportion
to the vibration lever. When the engine is at standstill, the pressure is released to the
nominal pressure, 7 bar.
当船体与主机之间距离变大时，液压缸液压当船体与主机之间距离变小时，液压缸油压
油压下降，液压油从蓄能器流向液压缸。力上升，单向阀阻止液压油进入蓄能器，如
When the distance between hull an engine 果压力达到最大设定值，此时安全阀打开，
increase, oil flows into the cylinder under 将油引至蓄能器，将主机震动控制在允许范
pressure from the oil accumulator. 围内。
When the distance between hull an engine
decreases, a non-return valve prevents
the oil form flowing back to the
accumulator and the pressure on the
engine rises, of the pressure reaches the
preset maximum value, the relief valve
allows the oil to flow back to the
accumulator, maintaining the force on the
engine and hull structure below the
specified level.
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6、控制系统 Control system
当液压活塞处于正冲程，即主机与船体之间距离变大时，液压油从蓄能器通过单向阀流
向液压缸，当液压活塞处于负冲程，由于有单向阀作用，液压油缸内油压升高，阀块上的安
全阀将会打开，一般情况下，当主机缸径不大于 600mm 时，安全阀在 26bar 压力时打开，
当主机缸径大于 600mm 时，安全阀在 40bar 压力时打开，将油引至液压蓄能器，使得活
塞可以继续运动。在安全阀的低压侧，阀块上有一个 25bar 打开的安全阀。
During positive stroke of the hydraulic piston-when the distance between hull side
and engine side increases oil flows from the accumulator through the non-return valve to
the cylinder. On negative stroke, the piston provides a rising pressure in the cylinder due
to the non-return valve. A relief valve in the valve block opens at 26 bar, for engines with
bore≤600mm,or 40bar, for engines with bore >600mmand leads the oil back to the
accumulator, and thereby allows the piston to move in negative direction. On the
low-pressure side, a safety relief in the valve block opens at 25 bar.
正常工作期间，蓄能器为液压缸提供 7bar 的液压油，这也是系统最小的工作载荷，在

实际过程中，当主机开始振动时，液压油油压会迅速增加。
During normal service the accumulator supplies oil at a pressure of 7 bar to the
cylinder, and consequently this will be the minimum workload of the system. In practice,
the oil pressure will increase rapidly when engine starts to vibrate.
通过电磁换向阀，可以释放液压缸内的压力。电磁阀打开时，液压缸与蓄能器直接相连，
此时液压缸单元不能建立压力。一般来说，当主机运行时，电磁阀断开；主机停止时，电磁
阀导通。
By means of a solenoid valve in a parallel pipe branch the pressure of the system can
be released. When the valve is open, the workspace is directly connected to the
accumulator and the top bracing cannot build up the pressure. Practically, the valve is
open when the engine is at standstill and closed when the engine is running.
液压顶推支撑系统单元原理图如下：
The hydraulic top bracing system unit working principle is as followed；
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7、操作 Operation
液压顶推支撑是自动运行的。但在测试和运行情况，也可以选择手动控制模式。运行模
式可以通过电气控制箱上选择开关进行选择，共有如下三种模式：
The hydraulic top bracing system is operated automatically. For test or service
purposes, manual control is also possible. The operation mode is selected at the control
panel, the three possible operation modes are:
1）自动：液压顶推支撑是通过“备车”和“完车”的车钟信号来自动控制的，这也是常规模式。
根据主机状态，液压顶推支撑将处于“运行”或“停止”，控制灯可以显示实际的运行情况。
AUTO: The top bracing system is controlled automatically by the engine telegraph order
“stand by” and “finish with engine”. This is the normal operation mode Depending on the
engine status; the top bracing will be “INSERVICE” or “OUT OF SERVICE”. The control
lamps indicate the actual state.
2）运行：液压顶推支撑系统处于运行状态且一直建有压力。此模式下电磁阀处于关闭状态，
当主机运行，系统建立压力。此模式仅仅用于调试或信号失灵的情况下。
IN SERVICE：The top bracing system is permanently active and pressurized. The
solenoid valve closes the pertaining pip branch and the top bracing cylinders builds up a
pressure when the engine is running. This mode should only be used in testing or by
failure in the control signal.
3）停止：液压顶推支撑处于停止状态，电磁阀导通，此时系统压力释放，大约维持在 7bar，
为了安全考虑，此模式仅仅运用于液压顶推支撑需要维修的时候。
OUT OF SERVICE ：The top bracing system is not active. The solenoid valves are open
and the system pressure is released to approximately 7 bar. Due to safety precaution, this
mode should always be used when servicing the top bracing
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8、安装 Installation
液压顶推支撑正常工作的前提就是液压缸单元安装点的刚性要满足要求，如果不符合，
结构就必须给予加强。液压顶推支撑正确的正确安装包括：确定安装长度，以及两平行法兰
的平行度，其安装标准如下：
The top bracing will only work correctly if the supporting hull structure is sufficiently
rigid. When this is not the case, the structure should be sufficiently reinforced. It is
important that the top bracing be installed with correct build-in length and with parallel
flanges without misalignment.
顶撑的安装长度及两侧法兰的平行度，对顶撑的正常工作非常重要。要求：
安装长度公差：475+1/+3mm(参照 8.1.3)，
安装平行度：≤1°(参照 8.1.3)；
It is important that the top bracing be installed with correct build-in length and with
parallel flanges without misalignment. The parameters for the installation are:
Installation tolerance：493+1/+3mm(refer to 8.1.3)；
Installation parallelism ≤1°(refer to 8.1.3)。
运行不重合度
Service misalignment
建议在主机工作一段时间后，在主机处于热态情况下对安装长度进行调整。
We recommend a re-adjustment of the top bracing cylinders shortly after installation,
at normal loading condition of the vessel and with warm engine.
8.1 准备 Preparation
8.1.1 检查所有零部件是否齐全和完好。
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Check that parts are present and in good condition.
8.1.2 检查液压顶推支撑安装点及其对应的船体侧结构或支撑在水平线上，并确保结构具有
液压缸单元安装所必须的刚性和强度。
Check at all top bracing positions that the hull side supporting structure is in line with a
cross girder or supported otherwise to insure necessary strength and rigidity of the
installation.
8.1.3 检查主机侧安装点的平面是否垂直于连接线，并检查安装点与船体侧结构之间的距离。
Check that the face of the engine fix point is cut perpendicular to the connection line.
Control the distance between the fix points.
8.2 安装法兰的安装 Installation of mounting flanges

8.2.1 将安装法兰用 8 个 M20×30 的螺栓紧固在安装工具上。
将安装工装调整到安装长度。
Fasten the mounting flanges on the fitting tool, using the 8×M20×30 bolts. The tool is
made with the correct build-in length.
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8.2.2 在液压顶推支撑上方布置 0.5 吨的手拉葫芦，将安装工装提升到安装位置。

Rig a 0.5t chain block above the top bracing position. Rig the tool in the chain block and
elevate it to the correct height with the large mounting flange facing the hull side.
8.2.3 测量主机安装点与船体结构之间的距离和法兰不平行度。
Measure the gap and inclination between the hull fix point and the large mounting flange.
See the sketch below.
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8.2.3.1 如果安装长度不够，可通过对船体结构进行修整使之达到安装长度要求。
If the build-in length is too short for the tool to fit, extend the length by cutting or grinding
the hull fix point-alternatively the engine fix point.
8.2.3.2 如果两侧法兰的不平行度大于 1°，则需要对船体侧结构进行修整。如修整后安装长

度变得太长，可使用垫片来调整。我们推荐，主机侧的垫片应放在液压缸单元和安装法兰之
间，并将垫片点焊在安装法兰上，如需要可以更换 4 个更长的螺栓。
If the inclination is greater than 1°, make a new perpendicular cut to the supporting
bracket. If the build-in length becomes too long, make a steel shim to compensate for the
gap. We recommend placing the shim on the engine side between the top bracing and the
mounting flange and tack weld the shim to the mounting flange, it is necessary to install
longer bolts in all 4 holes.
8.2.3.3 如果间隙超过 4mm, 更换一个新的船体安装点，或者可按照 8.2.3.2 选用垫片来弥

补间隙。
If the gap exceeds 4 mm, replace the hull fix point with a new one. Alternatively make a
steel shim to compensate for the gap and follow the description in 8.2.3.2.
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8.2.4 安装长度和平行度符合要求
Build-in length correct, parallelism correct
8.2.4.1 将焊接法兰点焊在主机安装点处，同时确保与支架的角度在水平和垂直方向上 90°。

Tack weld the flange to the engine fix point, while making sure that the angle to the
support bracket is 90° in both horizontal and vertical direction.
8.2.4.2 将焊接法兰点焊在船体安装点处。
Tack welds the flange to the hull fix point.
8.2.4.3 移除安装工具，完成焊接工作，为了减小变形，焊接时，应尽可能远离热源。
Remove the fitting tool and complete the welding job in order to minimize deformations. It
is recommended to apply as little heat as possible.
8.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders

8.3.1 将手拉葫芦安装到起吊工具的吊环上。注意：不要用液压缸单元的推力杆起吊，除非
需要拆除液压顶推支撑单元，不要拆除起吊工具，否则单元会散架。
Rig the chain block to the lifting eye of the transport bracket. Note: Do not lift the top
bracing cylinder in the distance rod. Do not remove the transport brackets (the unit will fall
apart), unless it is necessary to dismantle the top-bracing unit.
8.3.2 把液压缸单元调到正确的位置，并用 4 个 M20×70 的螺栓将其安装在船体安装点处，

在水平方向上调整液压缸，以便将螺栓处于槽孔的中心位置，拧紧螺栓，安装顶推支撑于船
体侧。
Elevate the top bracing cylinder to the correct position and mount it on the hull fix point
with 4×M20×70 bolts. Adjust the cylinder in the horizontal direction so that the mounting
bolts are in the middle of the slotted holes. Tighten the bolts.
8.3.3 在主机侧安装点用 4 个 M20×50 的螺栓安装液压缸单元，但不要紧固。

Mount the top bracing cylinder on the engine fix point with the with 4×M20×50 bolts, but
do tighten them.
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8.3.4 拆除靠近主机侧起吊工具上的螺栓，确保零件不散架。
Remove the bolt nearest to the engine fix point, making sure that the parts do not fall
apart.
8.3.5 为确保推力杆在水平和垂直方向成一条线，拧紧主机侧安装点的螺栓时可能需要松开
船体侧部分的螺栓做最后修正，最后拧紧所有八颗紧固螺栓（扭矩：200Nm）。
Tighten the bolts at the engine fix point making sure the distance rod is aligned in both
horizontal and vertical direction. It might be necessary to loosen the bolts at the hull part
for a final correction. Finally tighten all eight installation bolts (200Nm).
8.3.6 拆除起吊工具
Remove the transport brackets.
8.4 液压控制单元包括蓄能器的安装 Installation of hydraulic unit including oil
accumulator
8.4.1 确保液压控制单元的安装底座和安装表面都是干净并清洁的，液压控制单元和蓄能器
是整体起吊。
Ensure that the mounting base of the hydraulic unit and the mounting surface of the
hydraulic unit are clean and in good condition. The hydraulic unit and the oil accumulator
are delivered as one unit.
8.4.2 在液压控制单元底部的沉孔里安装 O 形圈。

Install the O-ring in the counter bore at the bottom of the hydraulic unit.
8.4.3 在液压缸安装基座安装液压控制单元，用 2 个 M12×50 的螺栓安装并拧紧（扭矩：

50Nm）。
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Mount the hydraulic unit on the mounting base of the cylinder unit, Mount with 2×M12×50
and tighten the bolts（50Nm）
8.5 电气控制系统的安装 Installation of electric control system

8.5.1 电气控制系统应按照电气系统图和所提供的电气原理图进行接线和安装（电气原理图
参照 HCHT26-05、电气接线图参照 HCHT26(40)-05、HCHT26(40)-05-01）。
The electric control system should be installed an wired in accordance with the cabling
overview and the electric principle diagrams and electric connection diagram in the
supplying drawings (refer to the diagram HCHT26(40)-05、HCHT26(40)-05-01).
8.6 液压顶推支撑的充油、补油及调整 Filling, refilling and adjustment of top
bracing
8.6.1 确保电气接线正确，且压力传感器及电磁阀已经连接到电气控制箱，且通电。
Check the electric line, make sure that it is correct, and the pressure transmitter and the
solenoid valve is connected to the electric control box，and power on.
8.6.2 将控制开关置于“停止”位置，此时电磁换向阀导通，工作压力释放至最小工作载荷。
Set the control switch ‘OUT OF SERVICE’. The solenoid valve is now open and the
hydraulic pressure is released to the minimum workload.
8.6.3 利用充气工具检查蓄能器内氮气压力，如果氮气压力低于 4bar，需对蓄能器进行补充

氮气，如果蓄能器内氮气压力正常（正常范围 3.8~4bar），则利用手摇泵对液压缸充油。
Check the pressure by nitrogen in the accumulator, if the pressure is less than 4 bar, the
oil accumulator must be re-charged, if the pressure is normal(3.8~4bar), pump oil into the
top bracing system using the hydraulic hand pump.
8.6.3.1 将空气排放软管与液压控制单元高处的测压接头相连，且将手摇泵软管与液压缸低
处的快速接头相连。
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Connect the air bleeding hose to the highest mounted minimizes coupling and the hose
from the hydraulic hand pump unit to the lowest mounted minimizes coupling.
8.6.3.2 打开空气排放软管上的阀，以便可以排出液压缸单元内的空气。
Open the valve on the air bleeding hose and bleed the top bracing system.
8.6.3.3 取下锁紧片，调节锁紧螺母，或利用手摇泵向液压缸单元内充油，直到推力杆上的
绿色位置带与缸体的边缘持平。
Unlock the locking patch, adjust the nut or pump oil into the top bracing system using the
hydraulic hand pump, that the green position band on the pressure rod is leveled with the
edge of the cylinder house.
8.6.3.4 紧固锁紧片。
Lock the locking patch.
8.6.3.5 确保排放软管上的球阀已打开，利用手摇泵向液压顶推支撑系统充油，
Make sure the ball valve on the bleeding hose is open. Filling the top bracing system
using the hydraulic hand pump.
8.6.3.6 持续充油，直到液压顶推支撑系统里所有的空气通过排放软管排出，当所有的空气
排出后，拆下排放软管并关闭阀。
Continue filling oil until all air has escaped from top bracing system through the bleeding
hose. When all air has escaped, disconnect the bleeding hose and close the valve.
8.6.3.7 持续缓慢地向液压顶推支撑充油直到压力表显示为 7bar。

Continue filling oil slowly in to the top bracing until the pressure gauge reads 7bar.
8.6.3.8 拆开软管并检查推力杆上绿色位置带与缸体边缘持平。
Disconnect the hose and check that the green position band on the pressure rod is
leveled with the edge of the cylinder house.
8.6.3.9 安装并锁紧位于液压控制单元上测压接头盖子。
Mount and tighten the lid on the minimizes coupling located in the hydraulic control unit.
8.6.3.10 对其他液压顶推支撑液压缸单元重复以上顺序。
Repeat the procedure for the remaining hydraulic top bracing cylinders unit.
8.6.3.11 将电气控制箱上控制开关置于在“自动”位置上，液压顶推支撑系统准备就绪。
Set control switch in ‘AUTO’ position of the electric control box，the hydraulic top bracing
system is now ready.
第 19 页 / 共 38 页
9、服务和维护 service and maintenance

注意：所有与主机相关的服务和维护必须在停机情形下完成。因为液压系统被加压了，
所以请勿在没有泄压的情况下拆卸液压顶推支撑。
Important: All service and maintenance should be done with the main engine at standstill.
Do not disassemble the hydraulic top bracing unit without bleeding as the hydraulic
system is pressurized.
9.1 备件 spare parts
所有的备件必须按照所提供的图纸清点完毕，与单个活塞配套的一整套的密封圈和导向
环都在包含在标准交付里。
All spare parts should be ordered with reference to the supplying drawings. A set of
sealing rings and guide rings for one piston is included in the standard delivery.
9.2 服务检查 service inspection
9.2.1 每台液压顶推支撑单元应该在试航后进行检查，且从此以后必须进行定期检查。
Inspection of each top bracing unit should be carried out after sea-trial and
regularly of service hereafter.
9.2.2 根据 9.3 控制油压

Control the oil pressure according to 9.3。
9.2.3 根据 9.4 检查绿色位置带

Check the green position band according to 9.4。
9.2.4 根据 9.5 检查推力杆对齐度

Check the alignment of the distance rod according to 9.5。
9.2.5 取出橡皮保护罩并用布清洗油缸。如果有明显的泄漏和油压低于正常压力 7bar，根据

9.6 更换密封圈。如果安全阀泄油口有泄漏，应检查液压控制单元和蓄能器应是否有损坏。
Remove the rubber protect cover and clean the cylinder with a cloth. If clear signs of
leakage are observed and if oil pressure has dropped below the nominal pressure of 7 bar,
the sealing rings should be replaced according to 9.6. If oil is leaking from the safety valve,
the hydraulic control unit and accumulator should be checked for damage.
9.3 油压的控制 control of oil pressure
9.3.1 如果压力表显示低于 7bar 但又高于 4bar，液压缸单元缺少液压油，应该根据 8.6 立

即重新注油。
If the pressure gauge shows less than 7 bar but more than 4bar, the top bracing is missing
hydraulic oil should be refilled according to 8.6.
第 20 页 / 共 38 页
9.3.2 如果压力表显示低于 4bar，蓄能器缺少氮气，应该根据 8.6 立即重新加压。

If the pressure gauge shows less than 4 bar, the oil accumulator is missing nitrogen (N2)
and should be refilled according to 8.6.
9.4 调节绿色位置带 Adjusting green position band
9.4.1 推力杆上的绿色带正常情况下应该与缸体边缘持平。同时考虑到船体在各种负载条件
下会导致液压活塞偏出原始调整，在绿色和红色带之间的位置是可行的。然而，值得注意的
是液压顶推支撑不允许在处在红色带区域的情况下运行。
The green band on the distance rod should normally be in level with the edge of the
cylinder house. A position between the green and the red band may be acceptable,
having in mind that various loading conditions of the vessel will cause the hydraulic piston
to shift away from the original adjustment. However, it is important to note that the top
bracing shall never operate on the red band area.
9.4.2 根据 8.6 调整绿色带的位置

the position of distance rod to adjust within the green band according to 6.6.
建议在主机工作一段时间后，在主机处于热态情况下对安装长度机型调整。
We recommend a re-adjustment of the top bracing cylinders shortly after installation, at
normal loading condition of the vessel and with warm engine.
9.5 推力杆不重合度 Distance rod alignment
9.5.1 船体在各种负载条件下会导致船体侧和发动机侧产生位移。如果推力杆不重合度超过
10mm，顶推支撑应该被重新校准。校准应该在正常荷载和发动机启动的情况下进行。
Various loading conditions of the vessel may result in displacements between the hull side
and the engine side. If a misalignment of the distance rod exceeds 10mm , the top bracing
should be re-aligned. The alignment should be performed at normal loading condition and
with warm engine.
9.5.2 将电气控制箱上控制开关置于“停止”位置，电磁阀打开且系统压力被释放至最小工作
荷载 7bar，这个读数显示在压力表上。
pressure of the system is released to the minimum workload, 7bar, indicated on the
pressure gauge.
9.5.3 将空气排放软管与安装在最高处的测压接头连接，并将手摇泵的软管与安装在最低处
的接头连接。
Connect the air bleeding hose to the highest mounted minimizes coupling and the hose
from the hand pump unit to the lowest mounted minimizes coupling.
第 21 页 / 共 38 页
9.5.4 松开主机侧固定点上的 M20 螺栓并对液压缸单元进行垂直校准，完毕后紧上螺栓（扭

矩 200Nm）。
Loosen the M20 bolts at the engine fix point and adjust the top bracing unit for vertical
adjustment. Tighten the bolts (200Nm).
9.5.5 松开船体侧固定点上的 M20 螺栓并对顶推支撑进行水平校准，完毕紧上螺栓（扭矩

200Nm）。
Loosen the M20 bolts at the hull fix point and adjust the top bracing unit for horizontal
adjustment. Tighten the bolts (200Nm).
9.5.6 按照 8.6.3.3 继续
Continue from 8.6.3.3.
9.6 更换密封件 Replacing sealing rings

9.6.1 确保主机处在停机状态，将电气控制箱上控制开关置于“停止”位置。
Make sure that the main engine is at standstill. Set the control switch‘OUT OF SERVICE’.
9.6.2 打开手摇泵上的溢流阀，并将手摇泵软管与安装在最低处的接头连接，打开最低接头
处的截止阀卸去系统中的压力。
Open the overflow valve on the hand pump, connect the hand pump hose to the lowest
mounted minimizes coupling. Insure that the ball valve is pointing down in an oil can.
Open the ball valve to take off the pressure of the system.
9.6.3 拆下安装在最高处的测压接头并使系统中的油通过排放软管流出，断开电气控制，并
拆下液压控制单元，小心移除。
Remove the highest mounted minimizes coupling and let the oil in the system run out
through the bleeding hose. Disconnect the electric control system and dismount the
hydraulic control unit. Carefully lift the unit away.
9.6.4 安装两个运输用起吊工具
Mount the two lifting tools for transport.
9.6.5 在顶推支撑上安装一个 0.5 吨的手拉葫芦。安装运输用起吊工具到手拉葫芦上并拆除

8 个 M20 的安装螺栓。
Rig a 0.5 t chain block above the top bracing. Rig the lifting tools for transport to the chain
block and remove the 8×M20 installation bolts.
9.6.6 移走液压缸单元并将缸体安装面朝下放置在一个干净的表面上。
Lift the top bracing unit and place it on a clean surface with the mounting face of the
cylinder house downwards.
9.6.7 拆下运输用起吊工具并小心移走发动机侧部件（法兰、推力杆及调节螺母）。
第 22 页 / 共 38 页
Dismount the lifting tools for transport and carefully lift away the engine side parts (flange,
distance rod and adjusting nut).
9.6.8 移除橡皮保护罩和船侧的挡圈并移走推力杆。
Remove the rubber protect cover and the retaining rings at the hull side and lift away the
distance rod.
9.6.9 从工具箱里取出吊环螺钉 M10 并将其安装在活塞的中心螺纹孔内。

Take the lifting screw M10 from the toolbox and mount it in the centre-threaded hole in the
piston.
9.6.10 提出活塞并将其放在干净的表面上。
Lift the piston away and land it on a clean surface.
9.6.11 更换所有的导向环和密封圈。
All guide rings and sealing rings are should be replaced.
9.6.12 使用润滑油润滑球付的接触面，按拆卸的相反顺序进行组装。
Grease the contact surface of the spherical using molykote，assemble it according to the
opposition step of disassembly .
9.6.13 根据 8.3~8.6 重新安装液压顶推支撑。

Reinstall the top-bracing cylinder according to 8.3~8.6.
9.7 更换蓄能器 Replacing oil accumulator

9.7.1 蓄能器通过氮气加压。如果氮气压力低于 3.84bar，蓄能器必须重新加压。
The oil accumulator is pressurized by nitrogen (N2). If the nitrogen pressure is below 3.84
bar, the accumulator must be refilled.
9.7.2 将电气控制箱上控制开关置于“停止”位置，电磁阀被打开且系统压力被释放至压力
表上显示的压力。
pressure of the system is released to the pressure shown on the pressure gauge.
9.7.3 打开手摇泵上的溢流阀，并将手摇泵软管与安装在最低处的接头连接，打开最低接头
处的截止阀卸去系统中的压力。
Open the overflow valve on the hand pump, connect the hand pump hose to the lowest
mounted minimizes coupling. Insure that the ball valve is pointing down in an oil can.
Open the ball valve to take off the pressure of the system.
9.7.4 安装充气工具在蓄能器上(参照充气工具使用说明 HCHT26(40)-CQSM)。
第 23 页 / 共 38 页
Mount charge tool to accumulator（refer to explanation of charge to tool’s use

HCHT26(40)-CQSM）.
9.7.5 检查阀 A 和 B 是否关闭。

Check whether valve A and B are closed.
9.7.6 使用联接螺母 C 将加气软管安装在氮气瓶上。

Mount the filling hose on the nitrogen cylinder with the union nut C.
9.7.8 逆时针打开阀 A，可以在压力表 D 中读出蓄能器内部的实际氮气压力。顺时针关闭

阀 A。
open the valve A anticlockwise，It is now possible to read the actual nitrogen pressure in
the accumulator on the pressure gauge D. Close the valve A clockwise。
9.7.9 如果蓄能器需要重新用氮气加压，打开阀 B 并调节阀 A 出口压力高于 4bar 的补偿

压力 1-2bar。
If the accumulator needs to be refilled with nitrogen, open valve B and adjust the outlet
pressure on spindle A to 1-2 bar above the charging pressure4bar.
9.7.10 保持阀 B 打开直到蓄能器被加压完毕。

Keep valve B open until the accumulator is filled.
9.7.11 关闭阀 B
Close valve B.
9.7.12 等待 5 分钟让温度稳定下来。
Wait five minutes for the temperature to stabilize.
9.7.13 根据值为 4bar 的补偿压力检查表 D 上显示的蓄能器的压力。

Check the pressure in the accumulator on gauge D according to the charging pressure 4
bar.
9.7.14 缓慢调节充气工具上排气阀 E，使压力表读数达到要求的充气压力。

Adjust the vent valve E on the charge tool slowly until the pressure value reaching to the
required charge pressure.
9.7.15 卸下联管螺母 C 并拆除蓄能器上的充气工具。

Unscrew the union nut C to remove the charge tool from the accumulator.
9.7.16 连接电气部分。
Connect the electric control system.
第 24 页 / 共 38 页
10、故障分析 Trouble shooting

注意：所有与主机相关的服务和维护必须在停机情形下完成。因为液压系统被加压了，
所以请勿在没有排放的情况下拆卸液压顶推支撑。
Important: All service and maintenance should be done with the main engine at standstill.
Do not disassemble the hydraulic top bracing unit without bleeding as the hydraulic
system is pressurized.
问题 Problem 解决方法 Solution
如果报警信号出现，检查蓄能器内的氮气压力小于补偿压力
3.8bar。根据 9.7 中所述使用氮气对蓄压器重新加压。在这以后
用 8.6 所述对液压缸单元注油。
Alarm signal
If the alarm signal is on, the N2 pressure in the oil-accumulator
报警信号
is less than the charging pressure3.8bar. Refill the accumulator
with N2 as explained according to 9.7 and fill the hydraulic
system here after as explained according to 8.6.
如果压力表读数小于 4bar，参见上面“报警信号”一栏。
Pressure gauge < 4 bar
If the pressure gauge is less than 4 bar, see‘Alarm signal’
压力表读数<4bar
above.
如果压力表读数小于 7bar 但又大于 4bar，说明液压系统缺油。
根据 8.6 中所述向顶推支撑中重新注油。
Pressure gauge < 7 bar
If the pressure gauge is less than 7bar, but more than 4 bar, the
压力表读数<7bar
hydraulic system is missing oil. Re fill the top bracing as
explained as explained according to 8.6.
如果液压缸单元漏油，说明密封圈受损或损坏。根据 9.6 中所述
Oil leakage from cylinder
更换密封圈。
unit
If the cylinder unit is leaking oil, the sealing rings are worn or
液压缸单元漏油
broken. Replace the sealing rings as explained according to
9.6.
如果安全阀泄油口漏油，应该检查液压控制单元和蓄能器是否有
Oil leakage form safety
缺陷。
valve
If oil is leaking from the safety valve, the hydraulic control unit
安全阀泄油口漏油
and accumulator should be checked for deficiencies.
如果推力杆上的红色位置带接近缸体边缘，说明顶推支撑没有经
Red band near cylinder 过正确调节。参见 9.4 并根据 8.6 重新调节液压顶推支撑。
edge If the red position band on the distance rod is near the edge of
红带接近缸体边缘 the cylinder house, the top bracing is not correctly adjusted.
See 9.4 and readjust the top bracing in accordance with 8.6.
如果液压顶推支撑的主机侧部分和船体部分在任何情况下不对
Distance rod 齐超过 5°，这两部分必须 9.5 中所述重新校准。
misalignment If the engine part and hull part of the top bracing in any
推力杆不对齐 condition are misaligned more than 5°, the two parts should be
realign as explained 9.5.
No signal on control box 如果控制箱无信号，检查电路。
控制箱无信号 If the control box is without signal, check the electric circuit.
第 25 页 / 共 38 页
11、图纸 Drawings
图号名称
Drawing No. Title
液压顶推支撑布置图
HCHT26(40)-01
The arrangement diagram of hydraulic top bracing
液压顶推支撑外形尺寸图
HCHT26(40)-02
Outline dimensions diagram of hydraulic top bracing
液压顶推支撑焊接座板图
HCHT26(40)-02-01
Welding plate of hydraulic top bracing
液压顶推支撑系统图
HCHT26(40)-03
Hydraulic top bracing system diagram
电气控制箱外形图
HCHT26(40)-04
Electric control box outline diagram
电气控制箱原理图及外部接线图
HCHT26(40)-05
Electric wiring and connection diagram
压力传感器接线图
HCHT26(40)-05-01
Pressure transmitter wiring diagram
供货范围
HCHT26(40)-06
Scope of supply
工具清单
HCHT26(40)-07
Stool list
备件清单
HCHT26(40)-08
Spare parts list
液压手动泵
HCHT26(40)-09
Hydraulic hand pump
充气工具使用说明
HCHT26(40)-CQSM
Explanation of charge tool’s use
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User’s manual
User’s Manual
MMT330 Water in Oil Sensor
User’s manual for the MMT330 Water in Oil Sensor
P-MMT330/FE Rev. C 1
Water in Oil Sensor MMT330
Revisions
Rev. Written by Checked by Approved by

Date Sign. Date Sign. Date Sign.
A 2008-09-01 pbf 2008-10-07 pab 2008-10-07 mav
B 2009-03-18 pbf 2009-05-14 MaV 2009-05-14 MaV
C 2016-10-18 MaV 2016-10-28 MFa 2016-10-28 MaV
Document history
Rev. A First edition

Rev. B New chapters: 4.4 wiring of CAN based sensor implemented, 6.5 Test.
Rev. C Added appendix 8. Change alarm settings, added 3.5.4 +++
The information contained in this document is subject to change without prior notice.
Kongsberg Maritime AS shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or use of this
document.
© 2008 Kongsberg Maritime AS. All rights reserved. No part of this work covered by
the copyright hereon may be reproduced or otherwise copied without prior permission
from Kongsberg Maritime AS.
Kongsberg Maritime AS
NO-7005 Trondheim Telephone: +47 73 58 10 00
Norway Telefax: +47 73 58 10 01
www.kongsberg.com
E-mail: km.sales@kongsberg.com
2 P-MMT330/FE Rev. C
User’s manual
Table of contents
1 GENERAL INFORMATION ................................................................................. 5

1.1 About this manual...................................................................................................5
1.2 General safety considerations .................................................................................5
2 WARNING................................................................................................................ 6
3 PRODUCT OVERVIEW ........................................................................................7

3.1 Introduction to the MMT330 ..................................................................................7
3.2 Structure of the sensor ............................................................................................8
3.3 Inside the sensor .....................................................................................................9
3.4 Probe type used in MMT330 ................................................................................ 10
3.5 Wiring ...................................................................................................................11
3.5.1 Cable bushings .......................................................................................... 11
3.5.2 Grounding the cables ................................................................................ 11
3.5.3 Alternative grounding (KONGSBERG CAN cables) .............................. 13
3.5.4 Grounding the transmitter housing ........................................................... 13
4 INSTALLATION ................................................................................................... 14
4.1 Mounting the housing ...........................................................................................14
4.1.1 Standard mounting.................................................................................... 14
4.2 Wiring ...................................................................................................................14
4.3 Signal and power wiring for standard sensor .......................................................15
4.3.1 Procedure .................................................................................................. 15
4.4 Signal and power wiring for CAN based sensor ..................................................16
4.4.1 Procedure .................................................................................................. 16
4.5 Installing the sensor probe .................................................................................... 17
4.6 Ball valve installation ...........................................................................................18
4.6.1 Procedure for new installation .................................................................. 18
4.7 Installing probe without ball valve .......................................................................19
4.7.1 Procedure for new installation .................................................................. 19
4.8 Tightening the clasp nut .......................................................................................20
4.9 Alarm settings .......................................................................................................21
4.10 Water activity vs ppm, alarm limits...................................................................... 21
5 OPERATION.......................................................................................................... 22
5.1 General considerations .........................................................................................22
5.2 Using display / keypad (optional).........................................................................22
5.2.1 Basic display ............................................................................................. 22
5.2.2 Graphic history ......................................................................................... 23
5.2.3 Menus and navigation............................................................................... 25
5.3 Error states (for display option) ............................................................................ 29
6 CALIBRATION, MAINTENANCE AND TEST................................................ 31

6.1 Calibration ............................................................................................................ 31
6.2 Periodic maintenance............................................................................................31
6.2.1 Cleaning .................................................................................................... 31
6.3 Replacing / removing a sensor tip ........................................................................ 31
6.3.1 Procedure .................................................................................................. 31
6.4 Replacing the probe filter .....................................................................................32
6.5 Test .......................................................................................................................33
6.5.1 Test of sensor alarm .................................................................................. 33
6.5.2 Test of system alarm ................................................................................. 33
7 TECHNICAL SUPPORT ...................................................................................... 34

7.1 Return instructions................................................................................................ 34
8 APPENDIX ............................................................................................................. 35
8.1 MMT330 on MAN D&T 2-stroke engines...........................................................35
User’s manual
1 GENERAL INFORMATION
This chapter provides general notes for the manual and the
product.
1.1 About this manual

This manual provides information for installing and maintaining
of the Water in Oil sensor.
1.2 General safety considerations

Throughout the manual, important safety considerations are
highlighted as follows:
Warning Warning alerts you to a serious hazard. If you do
not read and follow instructions very carefully at
this point, there is a risk of injury or even death!
Caution Caution warns you of a potential hazard. If you do not

read and follow instructions carefully at this point, the
product could be damaged or important data could be
lost.
Note Note highlights important information about using the product.
2 WARNING
Warning The equipment to which this manual applies must
only be used for the purpose it was designed.
Improper use or maintenance may cause damage
to the equipment and/or injury to personnel. The
user must be familiar with the content of the
appropriate manuals before attempting to work
or operate on the equipment.
Kongsberg Maritime disclaims any responsibility

for damage or injury caused by improper
installation, use or maintenance of the
equipment.
User’s manual
3 PRODUCT OVERVIEW
This chapter introduces the features, advantages, and the product
terminology of the HUMICAP® Water in Oil Sensor MMT330.
3.1 Introduction to the MMT330

The MMT330 sensor is a microprocessor based instrument for
the measurement of moisture in terms of water activity for
example in the lubrication of circulation systems or in
transformer oil. The sensor incorporates a capacitive thin film
sensor. The operation of the sensor is based on changes in its
capacitance as the thin polymer film absorbs water molecules.
The sensor can be configured in many ways. It can either have a
blank cover or a cover with a local display and keypad with
which the user can operate the sensor. Two analogue output
signals can be scaled and the measurement ranges changed
within certain limits. The MMT330 sensor will be supplied with
five metre of probe cable.
The HUMICAP® Water in Oil Sensor MMT330 provides
reliable moisture measurement in a wide range of applications.
The MMT330 also provides for accurate temperature
measurement.
Note The 5m probe cable is part of the instrument and the sensor is
calibrated with this cable. Any damage or alternation to the
probe cable will lead to loss of accuracy and void of warranty.
3.2 Structure of the sensor
Figure 1. Sensor body
The following numbers refer to Figure 1:

1 Signal + powering cable gland.
2 Cable gland for optional module.
3 Cable gland for optional module.
4 Cover screw (4 pcs).
5 Display with keypad (optional).
6 Cover LED.
User’s manual
3.3 Inside the sensor
Figure 2. Inside the sensor (all options included)

1 Service port (RS-232).
2 DIP switches for analogue output settings.
3 Power supply and signal wiring screw terminals.
4 Relay, datalogger or RS-422/485 module (Not available).
5 Grounding connector.
6 Power supply module (Not available).
7 Relay datalogger or analogue output module (Not
available).
8 Humidity probe cable.
9 Output isolation module (standard with KONGSBERG)
10 Adjustment buttons with LED indicator. Purge is not
available.
NOTE KONGSBERG units may have a CANbus interface installed.
The CANbus interface is normally used to interface the
MMT330 to other KONGSBERG products installed on the
engine. See 4.4.
3.4 Probe type used in MMT330

For MMT330 from KONGSBERG a sliding fit probe is used as
standard.
The sliding fit design makes it possible to adjust the length of
the probe into the oil pipe line. The claps nut (1) and the fitting
body (2) are made to slide down the sensor probe. When the
input length is according to requirement, the two units, (1) and
(2), are tightened at a specified torque, fixing the position of the
sensor tip.
A ball valve and sliding fit probe is recommended when using a
water-in-oil sensor on pressurized tubes. If service of the probe
is necessary, the probe can be dismounted without disturbing the
process.
For installation details, see Chapter 4.
0510-028
Figure 3. Sliding probe

1 Clasp nut, 24 mm hex nut.
2 Fitting, 27 mm hex head.
User’s manual
3.5 Wiring
3.5.1 Cable bushings
A single electrical cable with screen and three to ten wires is
recommended for power and analogue/serial connections. The
cable diameter should be 8 to11 mm. The number of cable
bushings depends on the transmitter options. See the following
recommendations for the cable bushings:
0503-010
Figure 4. Cable bushings

1 Cable for signal / powering Ø8 to 11 mm.
2 Cable for optional module Ø8 to 11 mm.
3 Cable for optional power supply module Ø8 to 11 mm.
Note When there is a high electric noise level (for example near a
powerful electric motor) in the operating environment, it is
recommended to use a shielded cable or make sure that the
signal cables are separated from other cables.
3.5.2 Grounding the cables

Ground the screen of the electrical cable properly to achieve the
best possible EMC performance.
Dwg. 1
Dwg. 2
Figure 5. Grounding the screen of an electrical cable

Dwg. 3
To achieve the best possible EMC performance, please follow

this description:
1 Cut back outer sheat to desired length.
2 Cut back screen braiding or screen foil to dimension X
(see Dwg. 1).
User’s manual
3 Put the domed cap nut (item 1) and seal insert with contact
socket of the gland (item 2 and 3) onto the cable as shown
in the drawing.
4 Bend over the screen braiding or screen foil by about 90 ˚
(item 4).
5 Push the seal insert with the contact socket of the gland
(item 2 and 3) up the screen braiding or screen foil.
6 Mount lower part (item 5) on the housing.
7 Push the seal with the contact socket of the gland and
(item 2 and 3) flush into the lower part (item 5).
8 Fasten the domed cap nut (item 1) onto the lower part
(item 5).
3.5.3 Alternative grounding (KONGSBERG

CAN cables)
There are two fixed positions for grounding cable screen inside
the MMT330 housing. Drain wire (from cables with screen tape
and drain wire) may be terminated here. See 4.4.
3.5.4 Grounding the transmitter housing

In case you need to ground the transmitter housing, the
grounding connector is found inside the housing, see Figure 2.
Make sure that the probe is connected to the same potential as
the housing. Make sure that different groundings are made to the
same potential. Otherwise harmful ground currents may be
generated.
If it is needed to have galvanic isolation of the power supply line
from the output signals, MMT330 can be ordered with optional
output isolation module. This module prevents harmful
grounding loops.
4 INSTALLATION
This chapter provides you with information that is intended to
help you install the product.
4.1 Mounting the housing

4.1.1 Standard mounting
Mount the housing to the engine wall, a bracket or other fixed
point, by use of 4 screws, M6 (not provided).
0510-026
Figure 6. Standard mounting dimensions (in mm/inch)
4.2 Wiring
A single electrical cable with a single screened cable with more
than three wires is recommended for power and analogue/serial
connections. The outside cable diameter should be 8 to 11 mm.
The number of cable bushings depends on the sensor options.
Note In case of high electric noise levels (for example, near a
powerful electric motor) in the operating environment, it is
recommended to make use of a shielded cable or keep the signal
cables in safe distance from other cables.
User’s manual
4.3 Signal and power wiring for standard sensor

Connection inside box
183
+ Power +24V
169
- Power 0V
RxD RS-232, for test only For ch. 1
Height: 77
GND RS-232, for test only
4 mA = 0°C
TxD RS-232, for test only
20 mA = 100°C
Ch1+ 4 -20mA, temperature
Based on dwg. no. GP-062

4 -20mA, temperature For ch. 2
Ch1-
0.470 aw
Ch2+ Water activity (aw) 4 mA = 0.0 aw
24.0 T
°C
Ch2- Water activity (aw) 20 mA = 1.0 aw
28 H2O
ppm
119
Display/key pad (optional)

96
Connection to AMS (see note 2)

4x
Ø7
+ Power +24V
- Power 0V
4 -20mA, temperature
R1/2" ISO7/1
Ch1+
For cable: Ø8-11 Ch1- 4 -20mA, temperature
To AMS Ch2+ Water activity (aw)
Ø13.5
Ch2- Water activity (aw)
Ø12
14
54 154
(Adjustment range)
5000 252
Notes:
1. DIP switch inside the transmitter is set according to
specification and shall NOT be changed.
2. The two WIO sensors 4-20 mA outputs are powered
internally in the sensor. Therefore "External Source" /
passive connection is to be used on AMS.
Figure 7. MMT330 Water in Oil Sensor, cable connections (in mm)
Warning Make sure that you connect only de-energized

wires.
4.3.1 Procedure
Open the sensor cover by removing the four cover screws.
Insert the power supply wires and signal wires through the cable
bushing in the bottom of the sensor; see the grounding
instructions in the previous sections.
Connect the analogue output cables to the terminals:
Ch1 +, Ch1-, Ch2+, Ch2-. The two analogue -4 to 20 mA
outputs are powered from the sensor, and should be connected to
passive inputs on the automation system (AMS).
Connect the power supply wires to the connectors:
POWER 10...35V+ 24V~ (+) and (-) terminals.
Turn on the power. The indicator led on the cover is lit
continuously during normal operation.
Close the cover and tighten the cover screws. The sensor is
ready for use.
4.4 Signal and power wiring for CAN based sensor

Figure 8. MMT330 Cable connections for CAN based sensor
Note For termination of shield see 3.5.2 and 3.5.3
Warning Make sure that you connect only de-energized

wires.
4.4.1 Procedure
Open the sensor cover by removing the four cover screws.
Insert the power supply wires and signal wires through the cable
bushing in the bottom of the sensor; see the grounding
instructions in the previous sections.
Connect CAN and Power terminals on terminal B.
Turn on the power. The indicator led on the cover is lit
continuously during normal operation.
Close the cover and tighten the cover screws. The sensor is
ready for use.
User’s manual
4.5 Installing the sensor probe

Installation with ball valve
45°
(ran
ge)

4 Installation without ball valve
16
61
Recommended mounting
15
2
ISO228-G3/4
27
5
55
ISO228-G3/4
min. 36
min. 36
1
Qty Pos Name, type Article no Remark

1 1 Water in oil sensor MMT330 GP-062
1 2 Adapter ISO228 G3/4-G1/2 6581-016.3412 Male-male
1 3 Ball valve, ISO228 G1/2 5941-007.0102
1 4 Adapter ISO228 G1/2-G1/2 6581-019.0027 UP-359, male-female
1 5 Adapter ISO228 G3/4-G1/2 6581-019.0008 UP-359, male-female
Order number for ball valve assembly (pos 2-5): GP-064
Figure 9. Installing sensor probe (in mm)
The sensor probe is normally mounted on the existing standard

temperature sensor adapter, or a similar adapter, on the oil tube.
Necessary fittings are shown in Figure 9.
There are two ways of installing of the sensor probe:
• Installation with ball valve (recommended).
• Installation without ball valve.
The two methods are described in the following chapters.
4.6 Ball valve installation

Refer to Figure 9.
The ball valve installation kit is preferred when connecting the
probe to a pressurized process or a pipeline. If you install the
probe (Ø12 mm) in a process pipe, please note that the nominal
size of the pipe must be at least 1 inch (2.54 cm).
Follow the steps below to install the probe through a ball valve
assembly. After the installation, the probe should be mounted
inside the process chamber or pipeline as shown in Figure 8.
4.6.1 Procedure for new installation

1 Shut down the process.
2 Install the two adapters and the ball valve to the fitting of
the oil tube. Seal the threads as described in Figure 8.
3 Close the valve. (The process may now be started).
4 Slide the clasp nut of the probe toward the filter, as far as
possible.
5 Insert the probe to the fitting body, and tighten the clasp
nut to the fitting body by hand.
6 Open the ball valve.
7 Push the probe through the ball valve assembly and into
the process chamber. If the pressure is high, use the
pressing handle that is provided with the probe. If you
push the probe hard without using the handle, you may
damage the cable.
Note that the probe must be pushed so deep that the filter
is completely inside the process flow (see Figure 8).
8 Mark the fitting screw and the clasp nut.
9 Tighten the clasp nut with a fork spanner further
5 to 60 ˚ (approximately 1/6 turn). If you have a suitable
torque spanner, thighten the nut to maximum 45 ±5 Nm
(33 ±4 ft-lbs). See Chapter 4.9, Figure 10.
Note Take care not to tighten the clasp nut more than 60 ˚ to avoid
difficulties when opening it.
If you wish to remove the probe from the process, note that you
have to pull out the probe far enough. You cannot close the
valve as long as the groove on the probe body is not visible.
User’s manual
4.7 Installing probe without ball valve

Refer to Figure 9.
4.7.1 Procedure for new installation

1 Shut down the process.
2 Install the adapter to the fitting of the oil tube. Seal threads
with Loctite No. 542.
possible.
4 Insert the probe to the fitting body, and tighten the clasp
nut to the fitting body by hand.
5 Push the probe through the ball valve assembly and into
the process chamber. If the pressure is high, use the
pressing handle that is provided with the probe. If you
push the probe too hard without using the handle, you may
damage the cable.
Note that the probe must be pushed so deep that the filter
is completely inside the process flow (see Figure 8).
50 to 60 º (approximately 1/6 turn). If you have a suitable
torque spanner, tighten the nut to maximum 45 ±5 Nm (33
±4 ft-lbs). See Chapter 4.8, Figure 11.
If the pressure is above 10 bars, use the pressing handle (Mark 1
in Figure 10) that is provided with the probe.
Figure 10. Use of press handle tool
Note If you push the probe too hard without using the handle, you
may damage the cable.
4.8 Tightening the clasp nut

1 Adjust the probe to a suitable depth according to the type
of installation.
2 Tighten the clasp nut first by hand (without tools).
4 Tighten the nut further 50 to 60 ˚ (approximately 1/6 turn)
by using a wrench. If you have a suitable torque spanner,
tighten the nut to maximum 45 ±5 Nm (33 ±4 ft-lbs).
0505-276
Figure 11. Tighten the clasp nut

1 Probe.
2 Clasp nut.
3 Fitting screw.
4 Pen.
Note Take care not to overtighten the clasp nut to avoid difficulities
when opening it.
Caution Take care not to damage the probe body. A damaged

body may cause leakage and may also prevent the
probe body from going through the clasp nut.
Caution In pressurized processes it is essential to tighten all

nuts and screws carefully to prevent the probe from
loosening because of the pressure.
User’s manual
4.9 Alarm settings

Before the sensor is in operation the system has to be updated to
include the new sensor. See manual for automation system.
Recommended settings are as follows:
Temperature: 4 to 20 mA equals 0 to 100 ºC
Alarm limit: User specified
Water Activity aw 4 to 20 mA equals 0 to 1.00 aw
High alarm: 0.50 aw
High-high alarm: 0.90 aw
Note Above listed alarm limits are according to requirement by MAN
Diesel and Turbo. (ref. appendix 8.1)
4.10 Water activity vs ppm, alarm limits

KONGSBERG recommend use of water activity sensors rather
than ppm sensors on engines lubrication oil. The reason for this
is that water activity shows the true margin to saturation i.e. risk
of corrosion. The saturation point will vary with water content,
temperature, polution of the oil and age of the oil. Accurate ppm
measurements are often requiring frequent calibrations to adapt
with changes in oil quality. According to MAN Diesel and
Turbo, on whose engines water in oil monitoring is standard,
this is optional. MAN Diesel and Turbo describes the following
relation between aw and ppm: (ref. MAN D&T 5155892-8)
Note The MMT330 is marketed with ppm conversion as an option.

KONGSBERG do NOT offer this in the marine market as it will
not provide required accuracy over time unless frequently
recalibrated in order to adapt to changes in the oil quality.
5 OPERATION
5.1 General considerations

The water in oil sensor has two 4 to 20 mA outputs which are to
be connected to the automation system. No operation is
necessary on the sensor itself. Display and keypad is therefore
optional.
During normal operation the water content in the oil of a diesel
engine may vary, so do the water activity. Differences may be
seen from new to old oil and from warm to cold oil. The biggest
differences may occur after servicing the engine, but the values
should always be below the upper alarm limits.
Note If the sensor shows water activity above the upper alarm limit
0.92, there is a danger of free water in the oil. Free water will
cause damage to the engine.
Note If the sensor shows high water activity and the sensor for test is
put into a container with new still oil, it may take up to 10
minutes for the sensor to stabilize and show correct water
content.
5.2 Using display / keypad (optional)

Within a few seconds after power-up the led on the cover of the
transmitter is lit continuously indicating normal operation.
When using the optional display and turning the transmitter on
for the first time, the language selection menu window opens.
Select the language with ▼▲ arrow buttons and press the
SELECT button (the left-hand button).
5.2.1 Basic display

Display shows you the measurement values of the selected
quantities in the selected units.
User’s manual
0706-046
Figure 12. Basic display

1 The info short cut button, presents available information
such as unacknowledged alarms, settings, measurements
etc.
2 The graph shortcut button, see Chapter 5.2.2 Graphic
history.
3 Quantities selected for display.
Note From any view, a four-second press on the right-hand function
button takes you directly to the basic display.
5.2.2 Graphic history

The graphical display shows the data trend or min/max graph of
the selected quantities, one at a time. The graph is updated
automatically while measuring.
0706-047
Figure 13. Graphic display
Trend graph: Shows you a curve of average values. Each

value is a calculated average over a period.
Max/min graph: Shows you the minimum and maximum
values. Each value is the max/min over a time
period.
Observation Period Period for Trend/Max/Min

Calculations (Resolution)
20 minutes 10 seconds
3 hours 90 seconds
1 day 12 minutes
10 days 2 hours
2 months 12 hours
1 year 3 days
4 year* 12 days
* Shows the maximum logging period of the datalogger module (available
when datalogger module is installed)
Table 1. Periods for Trend and Max/Min calculations
Use the following functions in the graphical display:

• Press the NEXT button to change between the trend graph
and max/min graph for the quantities selected for display.
• Press the EXIT button to return to the basic display.
• Press the ▼▲ arrow buttons to zoom in and out of the graph
window.
• Press the ◄► arrow buttons to move the cursor (vertical bar)
along the time axis. The cursor mode allows you to observe
individual measuring points. The numerical value at the
cursor position is shown in the upper left corner. The upper
right corner shows the time from the present to the chosen
moment (without the logger module), or the date and time at
the cursor position (when the logger module is installed).
• If the optional datalogger module is installed, you can scroll
the cursor off the screen to move to a new point on the time
axis. The new date will be displayed, and the cursor will be
centered at the date where the cursor scrolled off the screen.
0706-030
Figure 14. Graphical display with datalogger
User’s manual
The time displayed below the graph is adjusted with the current
time offset of the transmitter. If you change the transmitter's date
and time settings, the displayed timestamps in the history graph
changes accordingly.
Message Interpretation
Power outage Power failure (also marked with a dashed,
vertical line)
No data Quantity has not been selected for the display
Device failure General device failure
T meas. failure Temperature measurement/sensor failure
RH meas. failure Moisture measurement/sensor failure
Adj. mode active Adjustment mode active (data recorded in the
adjustment mode are not displayed)
Table 2. Graph information messages in cursor mode
A question mark after the time tells you that at least one power
failure (a dashed vertical line) has occurred after the chosen
moment. In this case, the exact time difference between the
present and the cursor position is not exactly known.
5.2.3 Menus and navigation

You can change settings and select functions in the menus.
1 Open the MAIN MENU by pressing any of the ▼▲◄►
arrow buttons in the basic (numeric) display mode.
2 Move between the different main menus by using the ▲▼
arrow buttons.
3 Open a submenu by using the ► button.
4 Press ◄ to return to the previous level.
5 Function button EXIT returns back to the basic display.
0706-208, 0706-048
Figure 15. Main menus
Some menu items, such as Date and time in the System menu,
are only shown if supported by the transmitter and the installed
options.
5.2.3.1 Changing the language

1 Return to the basic display by keeping the right-hand
button pressed for four seconds.
2 Open the Main menu by pressing any of the ▼▲◄►
buttons.
3 Scroll down to the System menu option, and press the ►
button. The menu option is indicated with the wrench
symbol.
4 Scroll down to the Language menu option, and the left-
hand button. The menu option is indicated by the flag
symbol.
5 Select the language by using the ▼▲ buttons, and
confirm the selection by pressing the left-hand button.
6 Press the right-hand button to exit to the basic
display.
User’s manual
5.2.3.2 Rounding setting

Round off one decimal by using the Rounding function. By
default the rounding setting is “ON”. Rounding has no effect on
quantities without decimals.
1 Open the MAIN MENU by pressing any of the ▲▼◄►
arrow buttons.
2 Select Display and confirm by pressing the ► arrow
button.
3 Select Rounding and press ON/OFF button.
4 Press EXIT to return to the basic display.
5.2.3.3 Display backlight setting

As default the display backlight is “always on”. In the automatic
mode the backlight stays on for 30 seconds after the last press of
any button. When pressing any button, the light turns on again.
arrow buttons.
2 Select Display, press the ►arrow button.
3 Select Backlight, press the CHANGE button.
4 Select On/Off/Automatic, press the SELECT button.
5 Press EXIT to return to the basic display.
5.2.3.4 Display contrast setting

arrow buttons.
2 Select Display, press the ►arrow button.
3 Select Contrast, press the ADJUST button.
4 Adjust the contrast by pressing the ◄► arrow buttons.
5 Press OK and EXIT to return to the basic display.
5.2.3.5 Keypad lock (key guard)

1 Keep pressing the left-hand function button for 4 seconds
to lock the keypad (at any display).
2 To unlock the keypad, press the OPEN button for 4
seconds.
5.2.3.6 Menu PIN lock

You can prevent unauthorized changes of the device settings by
activating the menu PIN lock. As long as this function is
activated, the basic display and graphical view are available, but
access to the menus is locked. The key symbol indicates the
activation of this feature.
arrow buttons.
2 Select System, press the ►arrow button.
3 Select Menu PIN, press the ON button.
4 Enter a PIN code by using the ◄►arrow buttons. Press
OK to confirm the setting. Now the PIN lock is on and a
key symbol is shown in a display.
5 Press EXIT to return to the basic display. Returning to the
menu is possible only by entering the correct PIN code.
If you want to turn off the PIN lock, go to the menu by entering
the PIN code and select System, Menu PIN, press OFF button.
In case you have forgotten the PIN code, open the transmitter
cover and press the ADJ button once. Wait for a few seconds
and the adjustment menu opens. Select Clear menu PIN, press
CLEAR.
5.2.3.7 Factory settings

Use the display/keypad to restore the factory settings. This
operation does not affect the adjustments. Only settings
available in the menus are restored.
1 Press any of the arrow buttons to open the MAIN MENU.
2 Select System by pressing the ► arrow button.
3 Select Factory settings and press the REVERT button to
confirm your selection. Press the YES button to reset all
settings to the factory defaults.
5.2.3.8 Deleting the recorded files

You can delete the recorded data files by using the
keypad/display or the DELETE command on the serial line.
The deletion is always done for all data; you cannot delete
individual files.
User’s manual
Note The transmitter automatically overwrites the old data when the
memory is full, so manual deletion of the recorded files is not
necessary in normal use.
To delete the data files using the keypad/display:
1 Press any of the arrow buttons to open the MAIN MENU.
2 Select System by pressing the ► arrow button.
3 Select Clear graph memories by pressing the CLEAR
button. Press the YES button to confirm the selection.
Caution This function clears the entire data history of the
transmitter, including all graphs and the content of the
optional datalogger module.
5.2.3.9 Undelete
Similarly to the DELETE command, the UNDELETE
command is used without any arguments. It will recover all
deleted data that has not yet been overwritten.
5.3 Error states (for display option)

In error state the quantity is not measured and the output is
shown as follows:
− Analogue channel outputs 0 mA or 0 V.
− The cover LED is blinking.
− Optional display: error indicator is lit.
0706-008
Figure 16. Error indicator and error message
The following number refers to Figure 15:

1 Error indicator.
The error indicator disappears when the error state is ended and
you have checked the error message. Press the INFO button to
display the error message.
Error Message Action

Humidity sensor measurements Check the integrity of the humidity probe and the
malfunction. probe cable. Clean the probe from dirt, water, ice or
other contaminants.
Humidity sensor short circuit Check the integrity of the humidity probe and the
probe cable. Clean the probe from dirt, water, ice or
other contaminants.
Humidity sensor open circuit Check the integrity of the humidity probe and the
probe cable.
Temperature sensor open circuit. Check the integrity of the humidity probe and the
probe cable.
Temperature sensor short circuit. Check the integrity of the humidity probe and the
other contaminants.
Temperature measurement malfunction Check the integrity of the humidity probe and the
other contaminants.
Temperature sensor current leak. Check the integrity of the humidity probe and the
probe cables. Clean the probes from dirt, water, ice
or other contaminants.
Internal ADC read error Internal sensor failure. Remove the sensor and return
the faulty unit to Kongsberg Maritime.
Internal EEPROM read error Internal sensor failure. Remove the sensor and return
Internal EEPROM write error Internal sensor failure. Remove the sensor and return
Add-on module 1 (or 2) connection Turn off the power and check the module connection.
failure Turn on the power.
Device internal temperature out of Ensure that the operating temperature is within the
range valid range.
Operating voltage out of range Ensure that the operating voltage is within the valid
range.
Internal analogue voltage out of range Internal sensor failure. Remove the sensor and return
Internal system voltage out of range Internal sensor failure. Remove the sensor and return
Internal ADC reference voltage out of Internal sensor failure. Remove the sensor and return
range the faulty unit to Kongsberg Maritime.
Internal analogue output reference Internal sensor failure. Remove the sensor and return
voltage out of range the faulty unit to Kongsberg Maritime.
Configuration switches for analogue Check and re-set the switches.
output 1/2/3 set incorrectly
EEPROM failure on add-on module 1 Disconnect the power and check the analogue output
(or 2) module connection.
Communication module installed in Disconnect the power and change the
incorrect add-on module slot communication module to another module slot.
Unknown/incompatible module Ensure that the module is compatible with the
installed in add-on module slot 1 (or 2) MMT330.
Table 3. Error messages
User’s manual
6 CALIBRATION, MAINTENANCE AND TEST

This chapter provides information needed in basic maintenance
of the product.
6.1 Calibration
Normally the sensor shall not be calibrated or adjusted.
6.2 Periodic maintenance

Under normal use the sensor itself do not need maintenance. To
secure stable operation over time, it is recommended to reinstall
the sensor and check/clean the probe filter once a year.
6.2.1 Cleaning
Clean the sensor enclosure by use of a soft, lint-free cloth
moistened with mild detergent.
Clean the sensor before storing the MMT330 probe and before
calibration. For cleaning the probe you need instrument air and
heptane (C7H16) liquid. Use instrument air for drying to prevent
oxidation of the oil on the sensor. The oxidation of the oil on the
sensor can cause extended response time or drifting.
1 Blow the probe with instrument air (with filter attached) to
remove any remains of the oil.
2 Immerse the probe into heptane liquid and rinse out the oil
(for 1 minute maximum).
3 Dry the probe by use of instrument air. In case you are
going to calibrate the probe, remove the filter and dry the
sensor with instrument air. Check that the sensor is clean.
6.3 Replacing / removing a sensor tip

6.3.1 Procedure
1 If a ball valve is installed, shutting down the process is
only required if the process pressure is higher than 10
bars. If the pressure is lower there is no need to shut down
the process.
2 If a ball valve is not installed, shut down the process.
3 Measure the length of the probe from top of probe to the

top of the claps nut (Figure 10).
4 Loosen the torque between the fitting screw and the clasp
nut.
5 Pull the probe out until it reach the sliding limit.
6 For ball valve, close the ball valve.
7 Remove/replace/reinstall the sensor.
possible.
9 Insert the probe and tighten the clasp nut to the fitting
body by hand.
10 For ball valve installation, open the ball valve.
11 For installation without ball valve, the process may be
started again.
12 Push the probe through the ball valve assembly into the
process. The depth should be according to measurement
made in Point 3 of this procedure.
50 to 60 º (ca. 1/6 turn). If you have a suitable torque
spanner, tighten the nut to maximum 45 ±5 Nm. See
Chapter 2.8, Figure 10.
6.4 Replacing the probe filter

1 Remove the filter from the probe.
2 Install a new filter on the probe. When using the stainless
steel filter (for oil and fuel cell), take care to tighten the
filter properly (recommended force 130 Nm).
New filters may be ordered from KONGSBERG.
User’s manual
6.5 Test
6.5.1 Test of sensor alarm
To verify that the sensor is able to give alarm if the procedure is
as follows:
1. Connect the sensor to the system via the 4-20 mA outputs.
Set the alarm limits in the system.
(awHigh = 0.50, awHigh High = 0.90)
2. Disconnect the sensor tip from the oil tube.
3. Put the sensor tip into a can of clean water.
4. Wait until alarm is given on the system (may take up to 3
minutes)
5. Put the sensor tip back in place.
Note! After the sensor tip has been exposed to water, it may take
several minutes before the sensor output signal is back to normal
reading, up to 5 minutes in oil, 30 minutes or more if the sensor
is left in free air.
6.5.2 Test of system alarm

To verify that the system is giving alarm on a certain input
signal, the following procedyre has to be followed:
1. Check the alarm limits set on WIO in the system.
Standard: H alarm = aw 0.50, HH alarm = aw 0.90
2. Disconnect the sensor from the input board of the
system.
3. Connect an active 4-20 mA test generator to the input
(for Kongsberg RAI 16 + to terminal 0x2 and, – to 0x4).
4. To test H alarm set the generator to 13 mA (for aw = 0.5
H alarm = 12 mA)
5. To test HH alarm set the generator to 19 mA (for aw =
0,90 HH alarm = 18,4 mA)
6. Disconnect the test generator.
7. Reconnect the water in oil sensor.
8. Verify that the sensor reading is back to a normal value.
7 TECHNICAL SUPPORT
For technical questions, contact the KONGSBERG technical
support:
E-mail km.support@kongsberg.com
Phone 24 hours +47 815 35 355
7.1 Return instructions

If the product needs repair, please follow the instructions below
to speed up the process and to avoid extra costs to you.
1 Contact Kongsberg Maritime AS to get advice on further
procedings.
Please have the following information on hand:
a Serial number of the unit.
b Date and place of purchase or last calibration.
c Description of the fault.
d Circumstances in which the fault occurs/occurred.
e Name and contact information of a technically
competent person who can provide further information
regarding the problem.
If repair is an option procede with steps 2-4.
2 Pack the product into a strong box of adequate size, with
proper cushioning material to avoid damage.
3 Include the information specified in step 1 in the box
together with the faulty product. Also include a detailed
return address.
4 Ship the box to the address specified by the supplier.
NOTE Make sure that the unit is returned in one piece. Probe
with cable is part of the instrument and can NOT be cut,
shortened or disconnected from the electronics. Such
actions will make the unit irrepairable. It is also woid the
warranty.
User’s manual
8 APPENDIX
8.1 MMT330 on MAN D&T 2-stroke engines

Background
KONGSBERG Maritime AS supplies sensors (type MMT330--)
for measurement of water activity level (aw) in lubrication oil.
Like Bearing Wear Condition Monitoring this measurement is
mandatory in terms of avoiding open-up inspections of bearings
in MAN 2-stroke diesel engines. The maintenance aspect of the
MMT330 is therefore relevant when going into a survey
arrangement with Class on avoidance of open-up inspections.
For maintenance of the Bearing Wear Condition Monitoring

system see K-Chief user manuals.
MMT 330, Maintenance guidelines – MAN 2 stroke

Below guidelines are taylor-made for the specific use of
MMT330 sensors on the lubrication oil of a large bore 2 stroke
engine. Engines in mention have an oil treatment system that
opens for a specific maintenance schedule.
• As oil is not exposed to combustion chamber it remains
quite clean over time. Cleaning of sensr element is less
relevant.
• As the oil is exposed to air. Some moisture will always be
present. Aw > 0.2 is normal.
Maintenance schedules
Check of accuracy: Once every year or at any sign of
inaccuracy/false readings
Calibration: On demand (after check of accuracy)
Following aspects are relevant for the maintenance of the

MMT330 and to ensure a long term operation at required
accuracy.
Cleaning:
The MMT330 sensor probe should be cleaned
- At any sign of incorrect measurement
- Prior to verification of accuracy (only if dismounted)
- Prior to calibration (If sent to maker for calibration this is not

required)
Cleaning is done by dipping the sensor probe in adequate

cleansing fluid for no more than 1 minute then blow dry with
compressed air.
Recommended cleansing fluids are: Heptane or clean

automotive diesel.
DO NOT USE: Methanol, Ethanol or Acetone.
Verification of function and accuracy:

Function i.e. alarm output from alarm system can be verified
by:
1. Dismount the sensor probe from the oil pipe. Put the sensor
probe tip into water and stir. Alarm should come within a few
minutes. OR:
2. In the alarm system: Reduce alarm limits to below actual
measurement value.
Accuracy can be verified in two ways:

1. Compare with freshly calibrated WIO sensor.
a. Install the sensor probe of the calibrated WIO sensor in a spare
adapter on the oil pipe as close as possible to the existing WIO
sensor. Oil must be flowing. Wait for at least 10 minutes.
Compare the readings. OR:
b. Dismount the WIO sensor probe. Put it together with a
calibrated WIO sensor probe in a container of oil. Stir with both
probes for appr. 10 minutes. Compare the readings.
2. Compare with calibrated hygrometer.
User’s manual
a. Dismount the sensor probe. Clean and dry the probe, then leave
it in open air close to a calibrated Hygrometer. Compare the
readings. The aw value is equivalent to the relative humidity of
the air. E.g. If relative humidity of the air is 40% the aw reading
should be 0.4.
Calibration
When found inaccurate the WIO sensor is in need of calibration.
There are three lternatives:
1. Vessel to keep spare sensor onboard for rotation. (return to
maker for calibration)
2. Owner to keep spare sensor for rotation. (return to maker for
calibration)
3. On-site calibration (use calibration tool)
NOTE: the entire sensor unit including sensor probe and

electronic unit is subject to the calibration and must be shipped
to the maker for calibration. Instruction for return to maker and
information about on-site calibration is found on:
http://www.vaisala.com/
What is Water Activity (aw)

Water activity is the amount of water in a substance relative to
the total amount of water it can hold. It is defined as:
aw = p / p0 (0..1) where
p = the partial pressure of water in a substance above the

material
p0 = the saturated vapor pressure of pure water at the same

temperature
Absolute water content as mass (or volume) of water compared

to the total amount of oil is measured in Part Per Million (ppm).
By volume: 1 ppm(v)water= 1 ml of water / 1 m3 of oil
By mass: 1 ppm(w)water= 1 g of water / 1000 kg of oil
Water activity measurement in oil – Relation to absolute

water content
The Water activity is a presentation of the level of free water in
the oil. The scale goes from 0 to 1. Aw =0 means no water at all
in the oil while aw = 1 means that the oil is fully saturated with
water*. The measurement is relative and there is no fixed
relation with the absolute (ppm) content of water in the oil.
Dissolved oil represents no or negligible threat to the bearings of
a diesel engine. Free water can cause corrosion in the bearings
and the purpose of the WIO sensor is to detect this before it
reaches a critical level.
NOTE 1: The oils ability to dissolve water changes with the age
and quality of the oil. Pollution will also change this. The
relation between water activity and absolute water content
(ppm) is therefore under constant change. A ppm. conversion
(from aw) require frequent calibrations against oil
properties/quality while the water activity measurement remains
reliable regardless of this. I.e. Regardless of the saturation point
of the fluid the aw reading will always provide a true indication
of risk of free water formation.
Water content past saturation level cannot be monitored by

a water activity sensor.
NOTE 2: There is always some water in lubrication oil. Oil

exposed to air will draw water from the air and normal values
are from 0.3 – 0.5 even in new oil. Completely dry oil is only
found in laboratories. I.e. Oil exposed to air over time will reach
equilibrium with the relative humidity of the air.
E.g. as oil is exposed to air with relative humidity of 40% the

water activity of the oil will be 0.4. (when measured at the same
temperature. See note 3)
User’s manual
NOTE 3: The water activity changes with temperature. As

temperature decreases the water activity increases. I.e. the
measurement can reach alarm levels after engine shut down and
decreased oil temperatures. If the oil drains from the pipe thus
leaving the sensor exposed to air this can also affect the
measurement to the point of alarms. It is recommended that
WIO alarms are inhibited as the oil pumps are shut off. I.e:
warm oil (in use) exposed to air will draw more moisture from
the air. When the temperature decreases the water activity
increases. Cold oil (storage) will draw less water from the air
and at elevated temperature show a decrease in water activity.
NOTE 4: The alarm limits for the WIO measurement are set in
the alarm system to aw = 0.5 and aw = 0.9. These limits are
decided by MAN Diesel and Turbo with the purpose to avoid
corrosion of the bearings. Reference is made to MAN
specification 5155892-8.
8.2 MMT330 – Outline drawing
User’s manual
8.3 MMT330 – Installation drawing
8.4 MMT330 – Ball Valve assembly
User’s manual
8.5 MMT330 – CAN version
Kongsberg BWCM 600
Condition Monitoring System
Operator Manual - MAN Diesel
390250/B
September 2017 © Kongsberg Maritime AS
Document history
Document number: 390250 / Revision B
Rev. A February 2014 First version.
Added information on standard K-Chief functions, Bearing Wear
Rev. B September 2017
Service, Engine Monitoring log and Troubleshooting
The reader
This operator manual is intended as a reference manual for the system operator.
Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.
Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.
Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com
Kongsberg Maritime AS
www.kongsberg.com
Table of contents
Glossary..................................................................................................................5
1 SYSTEM DESCRIPTION .................................................... 7
1.1 System functionality...............................................................................................7
1.2 Home view..............................................................................................................8
1.3 Engine Monitoring..................................................................................................8
1.4 Rapid Wear ...........................................................................................................10
1.5 Slow Wear.............................................................................................................15
1.6 Bearing Wear Service ...........................................................................................20
1.6.1 Learning Mode ........................................................................................ 20
1.6.2 Readjust .................................................................................................. 24
1.7 Engine monitoring Log.........................................................................................27
1.7.1 Event log................................................................................................. 27
1.7.2 Class Report ............................................................................................ 29
1.7.3 Long term trend log.................................................................................. 31
2 USER INTERFACE........................................................... 32
2.1 Help ......................................................................................................................32
2.1.1 Context-sensitive help .............................................................................. 32
2.2 Top bar functionality ............................................................................................33
2.2.1 Top bar layout.......................................................................................... 33
2.2.2 Alarm information and handling ............................................................... 34
2.2.3 Toolbar compartment layout ..................................................................... 38
2.2.4 Menu button and menu structure ............................................................... 39
2.3 Alarm side bar functionality .................................................................................42
2.3.1 Alarm presentation................................................................................... 42
2.3.2 Alarm handling........................................................................................ 44
2.4 Tabular views........................................................................................................46
2.4.1 Common functionality.............................................................................. 46
2.4.2 Active alarms view .................................................................................. 50
2.4.3 Alarm history view .................................................................................. 52
2.4.4 Tag summary view ................................................................................... 54
2.4.5 Event history view ................................................................................... 56
2.4.6 Inhibit tags view ...................................................................................... 58
2.4.7 Offscan tags view..................................................................................... 60
2.4.8 Counters list ............................................................................................ 62
2.5 Trend views ..........................................................................................................64
2.6 System tools..........................................................................................................69
2.6.1 Print........................................................................................................ 70
2.6.2 Report Manager ....................................................................................... 72
2.6.3 Date and time adjustment ......................................................................... 75
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2.6.4 User access.............................................................................................. 77

2.6.5 Database backup ...................................................................................... 80
2.6.6 Software versions log ............................................................................... 81
3 SYSTEM PROCEDURES ................................................... 82
3.1 View......................................................................................................................82
3.1.1 Display mode .......................................................................................... 82
3.1.2 Palette sync ............................................................................................. 84
3.1.3 Display settings ....................................................................................... 84
3.2 Change user ..........................................................................................................85
3.3 DPU Replacement ................................................................................................86
4 OPERATIONAL PROCEDURES ......................................... 88
4.1 Alarm test .............................................................................................................88
4.2 Class Report..........................................................................................................90
4.3 Sensor replacement...............................................................................................92
4.3.1 Sensor replacement during Learning Mode ................................................ 92
4.3.2 Sensor replacement during Normal mode .................................................. 94
4.4 Bearing Check/Overhaul ......................................................................................95
4.4.1 Bearing Check/Overhaul during Learning Mode ........................................ 95
4.4.2 Bearing Check/Overhaul during Normal Mode .......................................... 99
5 TROUBLESHOOTING .................................................... 102
5.1 BW values ..........................................................................................................102
5.2 Communication ..................................................................................................103
5.3 Engine running direction ....................................................................................105
5.4 Bearing Wear Service .........................................................................................106
4 390250/B
Glossary
BW Bearing Wear
BWCM Bearing Wear Condition Monitoring
BWS Bearing Wear Service
CP Control Panel
DPU Distributed Processing Unit
LOS Local Operator Station
OS Operator Station
PSS11 Bearing Wear sensor
SCU Segment Controller Unit
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6 390250/B
System description
1 System description
1.1 System functionality

Purpose of the system
The bearing wear system measures the combined wear of all bearings in each crank train.
The system consists of sensors, processing units and a computer. Its main purposes are:
• Giving alarms in due time before bearing wear down causes a dangerous situation
and/or costly repairs
• Logging data and trough the long term log provide information on when to overhaul
the bearings and when to NOT overhaul the bearings
Learning Mode
Each engine and each measuring point (i.e. sensor) responds differently to the effect
of changing RPM; and the distance measured varies with the RPM. At the start-up of
each installation the system must “learn” this trough a pre-defined “learning period”.
The period consists of 2 separate steps that can/will be conducted by either yard/maker
or the end user with the BWS application
The BWS application is located under Tools and Bearing Wear View menu
Rough Learning
The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the rough compensation is
made to the system the alarms are activated.
500 Hour Learning
During 500 hours the system gathers data and calculates an average compensation value
for every RPM. When 1000 BW values corresponding to 1000 engine revolutions has
been sampled for a compensation level this level is valid and downloaded to the SCU, a
valid compensation level is then updated each 50 hours; the accuracy of the system will
increase until 500 hour of logging is done and the system is in Normal operation
Normal operation
After the Learning Mode the system will monitor the wear down of the bearings and
logging long trend and event data for later retrieval. During maintenance of the engine
and the system itself there are some situations that require the attention of the user.
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1.2 Home view

Figure 1 Home view
The Home view is used to give the operator direct access to the contents of the BWCM
600 system.
Access to the Home view is possible by clicking the Home button on the top bar.
1.3 Engine Monitoring

Engine Monitoring Overview
Engine Overview gives a quick overview of the engine an will indicate which cylinder
that has an problem and what function that has triggered alarm
8 390250/B
System description
Figure 2 Engine Monitoring view
Alarm indication
All bearing shells for a cylinder will indicate alarm and need to be checked for damage
or wear
• Bearing shell — Gray = Normal
• Bearing shell — Red = Alarm
390250/B 9
Kongsberg BWCM 600
Function in alarm indication
• Green dot = Normal

• Red dot = This function is indicating alarm, click button to open view for detailed
information
1.4 Rapid Wear

Purpose
The purpose of Rapid Wear is to detect a quickly developing bearing wear down situation
and alarm limits are set low to ensure an early detection. Rapid wear down of the
bearings are normally a clear indication of a bearing seizure. Full damage to the bearing
can occur within minutes of running time and is then followed by consequential damage
to other engine parts due to friction and heat.
Figure 3 Rapid Wear view
10 390250/B
System description
Rapid Wear values
Figure 4 Rapid Wear flow
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Kongsberg BWCM 600
• Single Rapid
Absolute value of Difference value

• Cylinder Rapid
Absolute sum of Fore and Aft Difference values
12 390250/B
System description
• Twin Cylinder Rapid
Absolute sum of Aft and Fore Difference values between cylinders

Note
For the first cylinder, last cylinder and cylinder against the drive there are no Twin
Cylinder Rapid value because there are no neighbor cylinder
Running status
Mimic text BWCM running status Action
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern
Engine stopped BWCM stopped
Engine running direction BWCM stopped BWCM stopped because
unknown engine running direction is
unknown for the system
Mode status
Different modes are used to deactivate/activate alarms
Mimic text State Action
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active
and logging data for 2nd
and 3rd compensation point
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Kongsberg BWCM 600

500 Hour Preliminary 500 Hour Learning running Alarms active
Learning
500 Hour Learning 500 Hour Learning running Alarms active
and curve deviation check
started
Normal Learning Mode done Alarms active
Alarm limits
To avoid false Bearing Wear alarms, the Rapid Wear is build up with dynamics alarm
limits. Dependent upon engine speed changes, the system will increase alarm limits
accordingly. The alarm limits are specified by MAN Diesel & Turbo and is set as default.
Single Sensor value
TAG name TAG description Basic value Max value
SR_ALIM SINGLE RAPID 0.4 0.8 (1.2)
ALARM LIMIT
Cylinder Sum value
CR_ALIM CYLINDER 0.18 (0.2) 0.36 (0.6)
RAPID ALARM
LIMIT
Main Bearing Sum value
TCR_ALIM TWIN CYLINDER 0.55 1.1 (1.65)
ALARM LIMIT
Note
The alarm limits in ( ) is for Mk9 and Mk10 engine with 60 bore or larger
How to use Bearing Wear monitoring parameters

State Action
Single Rapid value Alarm/Slowdown Gauge bearings for this
cylinder, check for metal
shavings and abnormal
high temperature
14 390250/B
System description
Cylinder Rapid value Alarm/Slowdown Gauge bearings for this

high temperature
Twin Cylinder Rapid value Alarm/Slowdown Gauge bearings for this
high temperature
Note
Follow engine manufacture instruction to check the bearings
1.5 Slow Wear

Purpose
Slow Wear is designed to detect slow developing wear as can occur during the life time
of the engine; still the operation can be considered normal. Alarms are a warning that
bearing overhaul is due and logged data and a long term trend log are used to support the
decision to do maintenance or not.
Figure 5 Slow Wear view
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Kongsberg BWCM 600
Slow Wear values
Figure 6 Slow Wear flow
16 390250/B
System description
• Devation
Sensor Deviation Fore and Aft value is Sensor value subtracted average value of all
other sensor values to remove change in engine frame due to temperature changes
Cylinder Deviation value is average of Fore and Aft Sensor value in same cylinder
subtracted average value of all other sensor values to remove change in engine frame
due to temperature changes and load conditions
• Sensor value
Zero adjusted Sensor value

• Prewarning
Prewarning value is the latest average value for Sensor Deviation in the long term log
Running status
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern
390250/B 17
Kongsberg BWCM 600

Engine stopped BWCM stopped
Engine running direction BWCM stopped BWCM stopped because
unknown engine running direction is
unknown for the system
Mode status
Different modes are used to handle alarm levels
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active, High alarm
and logging data for 2nd limit level
and 3rd compensation point
500 Hour Preliminary 500 Hour Learning running Alarms active, High alarm
Learning limit level
500 Hour Learning 500 Hour Learning running Alarms active, High alarm
and curve deviation check limit level
started
Normal Learning Mode done Alarms active, Normal
alarm limit level
Alarm limits
To avoid unnecessary/false bearing wear alarms the Slow Wear is build up with two set of
alarm limits, dependent upon Mode the alarm limit level is set.
Sensor value
Tag name: CYLxx_BWS-y
State LL L H HH
Normal – 0.7 – 0.5 0.5 0.7
Learning - 0.9 - 0.8 0.8 0.9
Sensor Deviation value
Tagname: SNSxx_y_DEV
State LL L H HH
Normal - 0.5 - 0.4 0.4 0.5
Learning - 0.7 - 0.5 0.5 0.7
18 390250/B
System description
Cylinder Deviation value

Tagname: CYLxx_DEV
State LL L H HH
Normal - 0.3 0.3
Learning - 0.4 0.4
Prewarning value
Tagname: SNSxx_y_PREW
LL L H HH
-0.5 -0.25 0.25 0.5
Engine speed curve deviation value
Tagname: CYLxx_yCURVE
LL L H HH
– 0.2 0.2
Note
The alarm limits for Slow Wear values is indicated in the bargraph
How to use Bearing Wear monitoring parameters

State Action
BWM sensor value Alarm Gauge bearings for this
cylinder at next opportunity
BWM sensor deviation Alarm Gauge bearings for this
value cylinder at next opportunity
BWM cylinder deviation Alarm Gauge bearings for this
value cylinder at next opportunity
BWM Prewarning value Alarm Keep a closer look at the
BWCM system
BWM RPM curve Alarm Indicating possible bearing
deviation wear under 500 hour
learning; gauge bearings
for this cylinder at next
opportunity
Note
Follow engine manufacture instruction to check the bearings
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1.6 Bearing Wear Service

Learning Mode
Learning Mode function in BWS application is used to zero adjust and log compensation
data, to compensate for installation offset and engine specific changes due to structural
elastic deformation taking place during engine speed changes.
Readjust
Used when system is in Normal mode after learning to zero adjust the sensor if it has
been changed or removed/reinstalled for a bearing check/overhaul
Alarm test
• Alarm test will activate alarm output used for horn and light
• Slowdown test will active slowdown output to engine
1.6.1 Learning Mode

Each engine and each measuring point (i.e. sensor) responds differently to the structural
elastic deformation taking place during engine speed changes; and the distance measured
varies with the RPM. At the start-up of each installation the system must “learn” this
trough a pre-defined “learning period”. The period consists of 2 separate steps that
can/will be conducted by either yard/maker or the end user.
Figure 7 BWS — Learning
20 390250/B
System description
User level
• User level to Start Learning: Chief or higher
• User level to Start new Learning: Master
Sensor Select
• Sensor selected for Learning
• Sensor not selected for Learning
Communication alarm on a sensor is indicated by a red circle:

• Not possible to start Learning with a selected sensor with communication alarm
• Not possible to select a sensor with communication alarm
Figure 8 Sensor select view for Learning
Time line
• Gray when engine is stopped
• Green when engine is running ahead and logging is active
Will display how fare the process has progressed
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IDC
Installation Distance Control is used to control the installation distance of the sensors in
BDC; if the sensor is outside the installation distance limit the sensor has to be adjusted
to correct installation distance before the Learning process can continue
When IDC values are accepted a IDC Repot is generated to document the
installation distance on the sensors, the report can be copied from the system by
running Full backup in System →Backup →Maintenance. IDC Report is located in
\ROS\Config\BWS\BW-Engine1\IDC in the backup Zip file
Figure 9 IDC view
• IDC index: If same letter index is set on both sensors in same cylinder it indicates
that the correct node id is set on the sensors; if there are different letter index in same
cylinder it indicates the sensor has wrong node id and the sensor should be checked if
it has corrected node id regarding to serial number/installation position
Note
Only available when IDC is used with the turning gear
• IDC [mm]: Displays the installation distance of the sensor, sensor shall be adjusted to
a installation distance of 3 ±1 mm from the cross-head when the cylinder is in BDC
– Installation distance rang limit when engine is stopped: 2 — 4.5 mm
– Installation distance rang limit when engine is running: 1.8 — 4.5 mm
Sensor outside correct installation distance
If value is outside installation distance when the values are accepted the sensors that
are not correct installed will be listed. Adjust these sensors to the correct installation
distance of 3 ±1 mm from the cross-head when the cylinder is in BDC and then click
Restart IDC to do the check again
Rough Learning
The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the first rough compensation
point is made to the system the alarms are activated.
22 390250/B
System description
Rough Learning will measure 3 compensation points to give the system a rough engine
speed compensation; the engine speed is divided in to 3 ranges and a compensation point
is logged in each range, these 3 Rough compensation points are spaced by minimum
20% of the RPM range. The Rough learning compensation is logged automatically, and
the engine can be used normally when logging compensation data.
Figure 10 Rough Learning engine speed areas
When a compensation point in one engine speed range are logged close to an other range,
the requirement for 20% spacing between the compensation points will affect the size of
the other range. This is indicated by a dark grey area and a new range limit in green.
500 Hour Learning

During 500 hours the system gathers data and calculates an average compensation value
for every RPM. When 1000 values corresponding to 1000 engine revolutions has been
sampled for a compensation level this level is valid and downloaded to the SCU, a
valid compensation level is then updated each 50 hours; the accuracy of the system will
increase until 500 hour of logging is done and the system will go into Normal operation
How-to
1 Set user access to Chief or a higher level
2 Open Home view by clicking and go to BWCM →Bearing Wear Service

→Learning Mode
3 Click Start
4 When status states Turn engine turn engine two revolutions on turn gear and click
Accept values button
Note
If engine is running IDC will be done automatically
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5 If there are sensors outside specified installation range, adjust the sensors to correct
installation distance and click Restart IDC
6 Learning will continue automatically and the engine can be operated normally
Note
If Learning have completed and ended up with bad compensations; a new Learning
period can be started by setting user level to Master or higher and click the Start new
Learning button, and then follow How-to
1.6.2 Readjust
Readjust is used when system is in Normal mode to zero adjust the sensor that have been
changed due to a sensor failure or removed/reinstalled for a bearing check/overhaul
Readjust type
Short Readjust:
Will be running for 50 hours to log average offset, and will be running if the sensor
failure date is not set.
Typical used when:
• Sensor have been removed/reinstalled without engine has been running
• Changed sensor that has failed/broken without engine has been running
Long Readjust:
Will check long term log for wear before sensor failed and then run for 500 hours to
add average offset and wear to sensor value. Long Readjust function is automatically
activated when failure date for sensor is set in Start process
Typical used when:
24 390250/B
System description
• When sensor has failed when engine is running
User level
• User level to Start: Chief or higher
• User level to Start new Readjust: Master
Sensor Select
• Sensor selected for Readjust
• Sensor not selected for Readjust
Communication alarm on a sensor is indicated by a red circle:

• Not possible to start with a selected sensor with communication alarm
• Not possible to select a sensor with communication alarm
Figure 11 Sensor select view for Readjust
IDC
Installation Distance Control is used to control the installation distance of the sensors in
BDC; if the sensor is outside the installation distance limit the sensor has to be adjusted
to correct installation distance before the Readjust process can continue
When IDC values are accepted a IDC Repot is generated to document the
installation distance on the sensors, the report can be copied from the system by
running Full backup in System →Backup →Maintenance. IDC Report is located in
\ROS\Config\BWS\BW-Engine1\IDC in the backup Zip file
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Kongsberg BWCM 600
Figure 12 IDC view
• IDC [mm]: Displays the installation distance of the sensor, sensor shall be adjusted to
a installation distance of 3 ±1 mm from the cross-head when the cylinder is in BDC
– Installation distance rang limit when engine is stopped: 2 — 4.5 mm
– Installation distance rang limit when engine is running: 1.8 — 4.5 mm
Sensor outside correct installation distance
If value is outside installation distance when the values are accepted the sensors that
are not correct installed will be listed. Adjust these sensors to the correct installation
distance of 3 ±1 mm from the cross-head when the cylinder is in BDC and then click
Restart IDC to do the check again
How-to
1 Set user access to Chief or at a higher level
2 Select sensor to be Readjusted
3 Click Start
4 If engine has been running with failed sensor, set the date when the sensor failed by
clicking on the calender symbol and select date in the pop-up. If engine have not
been running with failed sensor, continue without setting any date. Then click Next
5 When status states Turn engine turn engine two revolutions on turn gear and click
Accept values button
26 390250/B
System description
Note
If engine is running IDC will be done automatically
6 If there are sensors outside specified installation range, adjust the sensors to correct
7 Readjust will continue automatically and the engine can be operated normally
8 Offset set will get status OK when Readjust is finished

Note
To get back to Sensor select view to start new Readjust, set user level to Master or higher
and click Start new Readjust button, and then follow How-to
1.7 Engine monitoring Log

1.7.1 Event log
Event log lists all events and alarms for the BWCM System and saves all event's to file
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History
Show all events and alarms stored in file
How to set time frame

1 Click From
2 Select date
3 Click To
4 Select date
How to set filter

1 Check off Filter box
2 Click drop down box
3 Select filter parameter
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System description
• None
• Alarm
• Info
• Error
• Warning
Status log
Status for each cylinder to give a quick overview
Gives a overview if there has been a event or alarm on the cylinder with date and time
when the status has been set.
• Normal: Is set when Learning mode is finished
• Prewarning: A Prewarning has been activated and this can indicate that a wear has
started
• Alarm: There has been an alarm on this cylinder
• Unknown: Readjust on both sensors in the cylinder has been done at the same time;
initial reference point for the cylinder is lost
1.7.2 Class Report

Class report is generating a XML file with long term trend log, event log and status log
that will document wear condition of the crank train bearings. The file can be used by
Class or viewed in the BWCM Class Report viewer
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For How-to see Class Report on page 90
Class Report file

In the Zip file the Class Report is located in the Xml Reports folder at Ros\PdsLog\BWLog
The Class Report contains:
• Engine information: Contain information on the ship and engine
• Status list: To provide a quick overview of each cylinder
– Normal “N” : Indication that no wear has been detected beyond the Pre-Warning
limit
– Pre-Warning “W”: Indicating that wear has been detected beyond the Pre-Warning
limit
– Alarm “A”: Indicating that an alarm has been released from sensors connected to
this cylinder
– Unknown “U”: Indication that sensors in this cylinder has lost initial reference level
• Trend data list: Long tend log from filtered sensor value
• Logging: Event log of all changes of the system
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System description
1.7.3 Long term trend log

A long term log is running from the first time the system is started and is active when
the engine is running forward. The log saves 6 hour average of the BW values to disc
and included the data in the Class report to document long term Wear on the engine
crank train bearings.
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2 User Interface
2.1 Help
2.1.1 Context-sensitive help
Context-sensitive help is provided for the following items:
• Tabular views
• Operator dialogues
• Mimic’s
The context-sensitive help provides help linked to the current state of the system. If for
example accessing context-sensitive help when the Alarm history view is the active view,
the intended use of that specific view is explained.
Context–sensitive help is accessed by pressing the Help button or Help tab page
present on all tabular views and operator dialogues.
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2.2 Top bar functionality

2.2.1 Top bar layout
Figure 13 Top bar layout
The top bar and alarm lines will always be accessible. Hence it is not possible to cover
the top bar by for example dialogues.
The product name is displayed in the lower left corner of the top bar. Date and time is
displayed to the right of the product name.
System status
The top left corner of the screen shows system status is information, such as the name of
the Operator Station, user modes, special modes and so on. Other system information is
available in the system status extension. The system status area is expanded by clicking
the chevron button.
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The system status area will change

background colour if system faults
are detected.
• Yellow – OS in service mode.
• Red – Critical software system
fail in the OS.
System status
Product version of the K-Chief system can be found by selecting Menu→System→About.
2.2.2 Alarm information and handling
Alarm handling compartment

The alarm handling compartment in the top bar contains the following:
• Two alarm lines for the newest alarms
• A short-cut icon for unacknowledged alarms – showing the number of active
unacknowledged alarms in a list
• An alarm summary icon – showing the expanded alarm summary list view
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Figure 14 Top bar alarm handling compartment
Alarm status
The Alarm status button shows the importance of the alarm. This is indicated by
the colour of the button. Note that the button will always be flashing, as only
unacknowledged alarms are presented.
The alarm state is also displayed (high/low etc.). The alarms in the top bar are
time-stamped, but date is not given, as these are running alarms.
See on page for presentation of all alarm states.
Information short-cut function

Alarm information is presented in a pop-up window by clicking the Information short-cut
button.
This may contain the following information:

• Description of alarm (field, software, system alarm, system failure)
• Tag name
• Tag description
• Other information
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Figure 15 Alarm information pop-up window
Note that this information pop-up window will not cover the top bar or the alarm side
bar. Clicking anywhere on the screen will close the pop-up window.
Process view short-cut function

The alarm presentation includes a short-cut for direct access to the process view most
relevant to the alarm.
Note that such a view might not be available for all alarms.
The behaviour of the short-cut button is as follows:
• If no process view is available, the button is greyed.
• If one process view is available, clicking the button jumps to that view.
• If more than one process view is available, clicking the button automatically jumps
to the view of most relevance.
Unacknowledged alarms short-cut function

If there are more than two unacknowledged alarms in the list, the latest alarm is shown in
an extension view. The alarms are sorted by time with the newest alarm on top of the list.
The number on the alarm button indicates the total number of unacknowledged alarms
in the system.
The colour of the number is the colour of the most important unacknowledged alarm in
the system at the present time. An icon on the button will indicate if the list can expand
downwards. When the list is expanded, the icon changes to indicate that clicking the
button again will collapse the list.
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Expanded unacknowledged alarms list view

The expanded Unacknowledged alarms view is displayed when clicking on the Alarm
short-cut button. This list displays all unacknowledged alarms below the top bar alarm
presentation.
The expanded list is dynamically sized to contain the exact number of unacknowledged
alarms. If more than a default amount of 10 alarms are listed, a scroll bar will appear.
Figure 16 Expanded unacknowledged alarms list view
Alarm acknowledge
Alarms may be acknowledged in several ways. The most common methods are:
• Clicking the ACK short-cut button in the top bar. This acknowledges all alarms visible
in the alarm compartment and in the Active Alarms view.
• Clicking on the visible alarm status button in the top bar. This acknowledges the
single alarm selected.
• Using the Menu button by selecting Menu→Alarms→Acknowledge.
Alarm sound off

The alarm buzzer is silenced using the mouse on the dedicated short-cut button in the
top bar.
It is also possible to silence the buzzer using the Alarms>Sound off button on the Watch
Call panel.
This stops the sound on the CRP and on related DPU relays.
The Sound off button can also be pressed on the TCP. (Note that this depends on the
Touch Control Panel hardware version.)
Top bar alarm buttons tooltip

Tooltip information is available for all buttons in the top bar area.
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2.2.3 Toolbar compartment layout

Toolbar compartment short-cuts
The toolbar is positioned next to the menu in the top bar (right aligned). The following
tools are available:
• Acknowledge all visible
• Home view
• History navigation
• Split view / full view
• Swap view
• Sound off (may be hidden)
• Print (may be hidden)
As there is only room for some of the tools, a chevron appears in the bottom right corner
of the toolbar. Pressing the button will make the rest of the tools available.
Figure 17 Toolbar
The following short-cuts are as default part of the toolbar:

Note that this table shows toolbar icons as they appear when using the day palette.
Table 1 Toolbar short-cuts
Name Description Icon

Acknowledge all Acknowledge all alarms visible for at least 1
second within active view.
Home view Go to the Home view.
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Table 1 Toolbar short-cuts (cont'd.)
Name Description Icon

History navigation Navigate to previous/next view.
Maximum 20 steps are available for
Previous/Next buttons.
Split view / full view Toggle between split view mode and full screen
mode.
Swap view In split screen mode, select the active view.
Sound off Silence the audible alarm.
Print Open the Print dialogue.
Acknowledge all visible alarms in the active window

The Acknowledge All button is used to acknowledge all visible alarms in the active
window.
Note
On the top bar only the two visible alarms are acknowledged, even if there are more
unacknowledged alarms in the expanded view.
2.2.4 Menu button and menu structure
Top bar menu compartment functionality

The menu system is designed so that the operator effectively can navigate to actions
necessary for the daily use of the system. The Menu button is positioned at the right
hand side in the top bar.
The menu categories are by default hidden, but clicking the Menu button will expose
the menu categories just below the top bar. The menu categories are distributed in two
even rows.
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Note
If space allows it, the menu categories will be shown on the screen all the time.
When one of the menu categories is selected, its complete sub-menu appears.
Note
For larger display resolution, only the complete menu is visible.
Top bar menu structure

The following list shows the common BWCM 600 menu categories:
1 View: This category contains all commands affecting viewing properties (Display
mode, Palette synchronization).
2 Operate: This category contains operational modes (Mode select, Command
control, Watch Call).
3 Alarms: This category contains all alarm related functionality (that is the most
important commands for alarm handling with supplementary short-cut access).
4 Tags: This category contains all commands related to the sensors, tags and I/O
modules (find tag, tag summary, tag details and so on).
5 Tools: This category contains commands for measuring, collecting or monitoring
data in a way to better interpret the situation.
6 System: This category contains commands related to the general administration
of the system and general support functions (for example access to print, system
status, help, change user, tooltip on/off).
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Opening and closing the menu system

A menu category is opened by a left button single-click.
There are several ways of closing the menu:
• A menu command is selected
• The user clicks outside the menu
• The user re-clicks the menu category button
• The user selects a different menu category
• The user clicks an Operator Panel button that affects what is displayed on the screen
• The user clicks the Escape button
• The user clicks the centre mouse button
An open menu does not close by time-out. Clicking Sound off, Acknowledge or other
“irrelevant” buttons on the Operator Panel does not close the menu.
Menu operation
There is a clear visual indication of which menu category is open at any time. When the
menu is open, all menu categories are visible at all times. Consequently, menu selection
in the top row will not cover the lower row.
If the operator by a user context has temporarily deactivated a menu category or
command, these are visibly disabled, but not removed.
Some command may be grouped. These groups are visually supported in the menu area.
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2.3 Alarm side bar functionality

The main objective of the alarm side bar is to provide easy access to all active alarms in
the system. Both acknowledged and unacknowledged alarms and warnings are visible on
side bar. Alarms and warning are grouped according to Alarm group configuration
2.3.1 Alarm presentation
Side bar layout

The alarm group buttons are represented as a column along the left edge of the display.
Side bar expands when moving mouse pointer over to the left edge of the screen.
The number of active alarms in each alarm group is indicated on the alarm group buttons.
Alarm priority is represented by button colour.
Figure 18 Alarm side bar layout The alarm group button is coloured red
or magenta when there are one or more
active alarms in the group.
The alarm group button is coloured
yellow or light yellow in case of
warnings or if only local acknowledge
is possible. Actual acknowledge must
be done at the default location.
The alarm group button is coloured
grey if there are no active alarms in the
group or if responsibility for alarms is
on another location (for example cargo
alarms in the ECR).
Docking the expanded alarm group view to the sidebar

The expanded alarm group menu can be docked permanently by means of Dock button
or right click in the side bar area.
Dock button when side bar is collapsed:
Undock button when side bar is expanded:
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Number of alarm groups

All alarm groups are displayed on one page, as this gives the operator direct access and
overview of the alarms. The maximum number of alarm group buttons in one column
is 36.
Expandable alarm group information

The alarm group information is shown as an expandable menu on the left side of the
screen. An extended menu will appear when moving the cursor to the left side of the
alarm group bar. This menu contains buttons with the name of the alarm groups together
with the number of active alarms.
Figure 19 Expandable alarm group information
When clicking an alarm group, the list of active alarms will pop-up in a dedicated
secondary window.
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Figure 20 Alarm group pop-up window
Context menu for side bar alarm list

The context menu is accessible by right–clicking on an alarm group in the expanded
alarm view.
Selecting Show all tags in group will open the Tag summary view for the alarms in this
group.
2.3.2 Alarm handling

Alarm acknowledge
Unacknowledged alarms are indicated by blinking sidebar buttons.
Acknowledged alarms are indicated by steady sidebar buttons
Colour of the button indicates highest priority alarm in the group:
• Magenta button: Emergency alarm
• Red buttton: Alarm
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• Yellow button: Warning

• Light yellow button: Info
Click the button to open Side bar popup alarm with list of active alarms. Click on
blinking status button to acknowledge single alarm. Alarm priority depends on colour
and symbol:
Emergency alarm,
Alarm,
Warning,
Info,
Alternatively it is possible to acknowledge all visible alarms in the alarm group, by
means of dedicated button.
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2.4 Tabular views

Topics
• Common functionality on page 46
• Active alarms view on page 50
• Alarm history view on page 52
• Tag summary view on page 54
• Event history view on page 56
• Inhibit tags view on page 58
• Offscan tags view on page 60
• Counters list on page 62
2.4.1 Common functionality

Tabular view layout
The tabular view is built up as a typical spreadsheet application. It displays multiple
cells that together make up a grid consisting of rows and columns. Each cell in the grid
contains either alphanumeric text or numeric values. Some of the cells are editable. This
is clearly marked using square brackets [ ]. Static texts or values are coloured black ,
dynamic texts or values are coloured blue.
Figure 21 Tabular view layout
The operator can set the columns to “best fit” by double-clicking on the header right edge
of the column heading.
Selected rows in the tabular view are displayed with maximum contrast and visibility.
Rows not selected are shaded.
Scrolling buttons
The total number of alarm items listed in the view is displayed on the view header.
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If more than one page is necessary to display all items, use the ▲ (up) or ▼ (down)
buttons to go backwards or forwards in the list. The PAGE UP and PAGE DOWN buttons
on the Control Room Panel can also be used for this purpose.
Use the Top or Bottom buttons to go to the very first or last item on the list.
Note
On touch devices view can be scrolled horizontally and vertically by finger slide
View options
The Options button is used to customize which optional columns to be displayed or
hidden. Two options are available:
• Optional columns: Select or deselect singular columns using the check boxes (actual
columns selectable being dependent on the active view)
• Restore default layout: Restore to factory settings
The following example shows selectable columns for the Tag summary view.
Columns adjustments
Columns can be relocated by “drag and drop”
The column width can be adjusted by moving the border line between the column
headers.
If the text in the cell is not fully visible , tooltip provides full text when mouse pointer is
over the cell.
Note
The Status column cannot be relocated. It is always in the utmost left position.
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Data filtering
Operator can filter the data to limit the number of rows in the view.
Filtering is enabled by right-clicking on the requested column header and selecting
filter. On screen keyboard may be used to type the filter values. Some columns do
not contain filters.
Note
If the Operator station is equipped with TCP (touch control panel), the on screen
keyboard appears on TCP instead of main display.
Data sorting
The tabular view can be sorted in all columns. This is done by clicking on the requested
column header. Sorte column is highlighted in light yellow colour.
Context menu
Context menu is may be different for each tabular view. It depends on functionality
of each view.
Typical context menu functions:

• View history — view alarm history for single tag (selected one)
• Send to trend — single or multiple tags can be sent to trend. Multi select can be done
by mouse drag over the multiple rows.
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• Send to custom views— single or multiple tags can be sent to custom view. Multi
select can be done by mouse drag over the multiple rows.
• Select all — select all tags in the view.
Note
On touch devices use “touch and hold” to activate context menu.
Command control status view

To check which command control group contains the selected tag, select the tag ( single
row ) and click the Command Control button on the top bar. The relevant command
group will be selected in command control dialogue.
Context sensitive help

Context sensitive help and for the tabular view is accessible by clicking the ? (Help)
button located in the top right corner of the view.
Printing and saving

The tabular view can both be printed to paper or saved as a log to disk. These options are
available from Print button or the Menu →System→Report managerin the top bar.
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2.4.2 Active alarms view

Purpose
The Active alarms view is used to display the following alarms:
• Active acknowledged alarms
• Active unacknowledged alarms
• Unacknowledged alarms returned to normal
This is the main view for evaluation and acknowledging of incoming alarms. As soon as
a new alarm is generated, the information in this view is updated.
The list of alarms will always be synchronized with alarm information displayed on
other Operator Stations. If an Operator Station has been shut down for a while, it will
immediately show the same data as running Operator Stations after restart.
Figure 22 Active alarms view
Alarms state and priority

Alarm priority is represented by button colour and corresponding label character
— Emergency alarm,
— Alarm,
— Warning,
— Info,
— Alarm responsibility in another location

Alarm state is represented by status button symbol.
• Flashing colour: Alarm or warning not acknowledged .
• Steady colour with check mark: Alarm or warning acknowledged .
• Flashing colour with return arrow: Alarm or warning returned, not
acknowledged.
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View columns
The Active alarms view holds the following columns:
1 Status: The importance of the alarm is indicated using a dedicated colour and
a letter on the button.
2 Short-cut button to relevant process view.
This button is greyed if no such view is available.
3 Time: The time stamp of the alarm (local time).
Tip
Extend the column width to see both time and date.
4 UTC time: The time stamp in Coordinated Universal Time (UTC).

By default, UTC time is not displayed, but it can be enabled by clicking Option in
the top left area of the view, and selecting it from the Optional column dialogue.
5 Tag: A unique tag identifier.
6 Description: Detailed description of the alarm tag.
7 Function: Short code describing the function of the tag.
8 Alarm state: Description of alarm condition (system alarm, field alarm etc.).
9 Value: Measured value scaled to Engineering unit.
The value is at any time updated with the real time value.
10 Engineering unit: Unit of measurement.
11 Limit LL: Signal limit for low-low alarm.
12 Limit L: Signal limit for low alarm.
13 Limit H: Signal limit for high alarm.
14 Limit HH: Signal limit for high-high alarm.
15 Alarm group: The alarm group to which the alarm is connected.
If data is not defined for a tag, the corresponding field is left blank.
Note
Depending on project, more columns may be used.
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2.4.3 Alarm history view
Purpose
The Alarm history view is used to display the following alarms:
• Active acknowledged alarms
• Active unacknowledged alarms
• Acknowledged alarms returned to normal
• Unacknowledged alarms returned to normal
• Local time change events
This is the main view for investigation of the history of all alarm events in the system.
The view is event based, so every event has a time stamp in both local and UTC time.
Alarm history view holds the last 30 days alarm entries ( software version 12.14 or newer
). In older OS software versions Alarm history shows up to 2000 last entries.
The list of alarms is synchronized between stations.
Figure 23 Alarm history view
Alarm history is event based. Every entry represents one time-stamped event.
Symbols used in the Alarm history view:
Note
Symbol colour depends on alarm importance level.
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Alarm triggered event.
Acknowledge of non-returned alarm
Acknowledge of returned alarm
Return of non-acknowledged alarm
Return of acknowledged alarm
Link to process view mimic
View columns
The Alarm history view holds the following columns:
1 Short-cut button to relevant process view. Button is grayed out when view is not
available
Tip
Extend the column width to see the date.

By default, UTC time is not displayed, but it can be enabled by clicking Option in
the top left area of the view, and selecting it from the Optional column dialogue.
Note
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2.4.4 Tag summary view

Purpose
The Tag summary view is used to display all system tags. The following information is
given for each tag:
Tag summary is not meant for alarm handling, therefore there are no alarm buttons.
Figure 24 Tag summary view
View columns
The Tag summary view holds set of default and optional columns. The optional columns
are shown (or hidden) on demand by clicking the Option button in the top right corner
of the view and then selecting the Optional column dialogue to enable (or disable)
additional columns.
The columns are by default shown in following order:
2 Device no: Numbered identification of the device.
3 Device type: Identification of the device type.
4 Channel: Internal DPU or SYS channel number.
5 Channel type: Channel type (field, software or system).
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10 Alarm state: Description of alarm condition (system alarm, field alarm).
11 Function (optional): Short code describing the function of the tag.
12 Seg/Node: Segment number and node id (network identifier).
13 Signal type (optional): Displays the type of channel as text (for example 'digital
input, 4-20 mA', 'Positioner on/off steady' and so on).
14 Inhibit source (optional): Displays the tag inhibiting alarm.
15 Raw value (optional): Measured in mA, V, Hz etc.
17 Control group (optional): The control position group to which the alarm is
connected.
18 WCall group (optional): The Watch Call group to which the alarm is connected.
Horizontal scrolling may be necessary if the number of columns is too large for all of
them to be shown on the screen simultaneously.
Note
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2.4.5 Event history view

Purpose
The Event history view presents all digital events logged in the system. Such events as:
• Alarm events: triggered, acknowledged, returned
• Process events: start, stop, open, closed, connect, disconnect etc.
• Time change events
• Tag parameter change events
• User logon events
Figure 25 Event history view
View columns
The Event history view has following columns:
2 Event type: Description of what type of event is recorded.
3 Event sub-type: Next level description of event type.
5 Local time: The time stamp of the alarm (local time).
Tip
Extend the column width to see the date.
6 Source: Description of what is the source of the event (for example Operator
Station, DPU, SYS).
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9 Previous value: Displays previous value or previous state.
10 New value: Displays new value or new state.
Some columns may be shown on demand. Click Option in the top right corner of the
view and select the Optional column dialogue to enable or disable additional columns.
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2.4.6 Inhibit tags view

Purpose
To avoid unnecessary alarms, some alarms are conditional and will be inhibited when a
specified condition is present. The Inhibit tags view is used to display these alarms.
Figure 26 Inhibit tags view
View columns
The Inhibit tags view holds the following columns:
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15 Inhibit source: The signal defined as inhibit source for the specified alarm or group
of alarms.
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2.4.7 Offscan tags view
Purpose
To avoid unnecessary alarms, some alarms are not checked for alarm situations (offscan
alarms). The Overridden tags view is used to display these alarms.
Note that offscan alarms are visually highlighted by a light blue background colour. This
applies only when the alarm tag is represented in a tabular view.
Figure 27 Overridden tags view
Column properties
All columns can be relocated by the drag-and-drop function.
Data in the columns can be sorted in ascending or descending order by clicking on the
corresponding column header.
Note
Sorted data will be highlighted in a light yellow colour.
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View columns
The Overridden tags view holds the following columns:
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2.4.8 Counters list

Purpose
The following separate counter functions are available through the Counters list:
• Total count
• Lap count
This view is used to display active running hours for pumps, main engine, accumulated
values for analogue sensors and so on. The counter values are shown as 'hours : minutes'.
In addition it is possible to show accumulated flow and average values in this view.
Figure 28 Counters list
Column properties
Data in the columns can be sorted in ascending or descending order by clicking on the
corresponding column header.
Note
Sorted data will be highlighted in a light yellow colour.
View columns
The Counters list holds the following columns:
• Short-cut button to relevant process view.
• Tag: A unique code describing an alarm tag.
• System: Displays system name.
• Description: Detailed description of the alarm tag.
• State: Displays running state (Running/Stopped or Flow/No flow).
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• Total count: Displays amount of total counting.

• Lap count: Displays amount of lap hours.
• Type: Hours counter, volume counter, RPM counter and so on.
Counters list dialogues

The Lap count field can be edited or reset if the operator is logged on to the system as a
member of the 'power user' group (or as another user with higher privileges). Editable
cells are marked in the Counters view using square brackets [ ].
The Total count can be set or reset by Master users only.
Clicking on the requested cell opens the corresponding dialogue.
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2.5 Trend views

Purpose
The system automatically maintains a log of all changes to all tags for the last 7 days,
and stores them for use in the trend monitoring system. To display the data you can use
the trend display. The trend views are used to present trend data for selected tags.
Similar to the permanent system views, the trend views are accessible both from the
Navigation line and from the Home page.
Figure 29 Trend view
Trend view layout

The trend view is divided into two areas:
• Tools and options area (upper part of view)
• View area (lower part of view)
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Tools and options area
Active tags
Each tag logged in the view is represented by an information field above the trend plots,
showing tag name and colour representation.
For a given tag, clicking on the colour symbol will highlight its trend plot in the display
by using a bolder line. In addition alarm limits for the tag is shown, if relevant.
Which tag is highlighted is easily seen by its rectangular colour symbol changing form.
Interpolation
All plots are interpolated by default. User can turn off interpolation by right click on the
tag or from tag manager in the trend view.
Tag manager
The Tag manager is used to select which data to be shown by the current Trend view.
The Tag manager dialogue is opened by clicking the Tag manager button in the upper
right corner of the display.
The Tag manager holds the following functionality:

1 Visible: Tag becomes invisible in plot area when unchecked.
2 Interpolation: Check this box to switch interpolation On/Off
3 Colour: The colour representing each tag.
4 Scale: Default, manual or auto scale.
5 Go to process view: The tags having an alarm will have this button enabled. It will
send you to the process view relevant to the alarm.
6 Name: The short name of the tag.
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9 Unit: Engineering unit on the tag.
Add tag
A new tag can be added to a Trend view using the Add tags button inside the Tag
manager view.
This opens the Add tag to Trend view dialogue.
The list of available tags may contain thousand of items. Search functionality is therefore
implemented to help the operator to restrict the number of items listed.
• Alarm group: Search for tags belonging to a specific alarm group.
• Tag: Search by tag name (phrase 'contains', 'starts with', 'ends with', 'equals')
• Description: Search by tag description (phrase 'contains', 'starts with', 'ends with',
'equals')
After selecting the requested tag from the list, the Add tag button or just double clicking
the tag, places the new tag on the view. The new tag is automatically placed at the
bottom of the list.
It is also possible to add tags directly from the process view. Right clicking on the tag
you want to add will give you the option to add it to a trend view.
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Remove tag
Still inside the Tag manager view you mark the tag to be removed and click the Remove
tag button.
Tools and options area – lower part
The lower part of the Tools and options area holds the following functionality:
• Live/Static view: Select live view or a time span in the past.
• Forward/backward buttons: Move forward and backward in time in the static view.
• Zoom buttons: x button zooms the time, y button zooms the engineering unit span.
Reset scale gets you back to default scale.
Note
It is also possible to zoom by pressing and holding the centre trackball button while
moving the trackball. The cursor must be situated on the relevant axis.
• Hide grid: Hide or show the grid in your plot.

• Swap: Analogue and digital tags will be presented in different windows, here you can
swap which window is above the other.
• Stack: All tag values are plotted in separate windows.
• Select date/time: In static view the time span can be selected from this calender.
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View area
This area is used to display the trend plots. Up to eight plots can be monitored
simultaneously. The plots are recognizable by each one being assigned a unique colour.
The colour scheme is also shown in the Tag details area.
One vertical value scale is displayed for each alarm tag. The colour of the scale is
identical with the colour of the plot belonging to it. The button at the top of the scale
indicates the scale mode.
There are three different modes available for the value scale:
• Default scale : In this mode, range high and range low tag values are used for
the value scale.
• Auto mode : In this mode, the value scale is automatically adjusted for the plot to
fit the maximum scale range.
• Manual mode : In this mode, the value scale can be adjusted manually by the
operator. Values can even be set to exceed engineering high and engineering low
values.
The mode for a particular scale can be edited by clicking on the relevant button. This
opens the following dialogue:
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User Interface
Note
Scale can be also adjusted by trackerball drag and drop .
Hold the mouse over the scale and push the centre button
on the trackball, move the trackball in the relevant direction
to get the scale wanted.
2.6 System tools

This section describes various system tools. They can be accessed from the System
button in the top bar.
Topics
• Print on page 70
• Report Manager on page 72
• Date and time adjustment on page 75
• User access on page 77
• Database backup on page 80
• Software versions log on page 81
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2.6.1 Print
Purpose
The purpose of the Print dialogue is to print or save selected system data. It is possible to
print both process views and list views.
The printing function is activated by clicking the Print button in the top bar.
This opens the basic print dialogue.
Figure 30 Print dialogue
The print header is automatically generated, and includes information on ship, operator,
report type, time and date, as following.
Vessel: M/S Explorer Kongsberg Maritime K-Chief 600
IMO: 12355474556 Printed by: Chief 12 dec. 2009 08:12
UTC
Active alarms report Page 1 of 23
Options
• Name: Select a printer from the list of printers available.
Network printers can be selected from the list.
Depending on project configuration it may also be possible to print to K-Chief 600
PDF printer
• Status: Displays status information for the selected the printer.
• Orientation: Select page orientation.
• Copies: Select the number of copies to be printed.
Print
• Screenshot: Select print of process view.
• View: Select print of list view.
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User Interface
Time reference
• UTC: Tabular view data and header will use UTC time reference
• View: Tabular view data and header will use Local time reference
Page range
• All: Print all pages.
• Current page: Print only the current page.
• Page: Print range of pages in format “1st page— last page” , for exmple: 5–20
Footer
Customized footer text may be printed at the bottom of the printout.
Print preview
Print preview enables the operator to see the page before it is printed.
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2.6.2 Report Manager

Purpose
The Report Manager dialogue serves three main tasks:
• Open and view reports through the Report explorer tab.
• Export documents through the Report explorer tab.
• Print selected views through the Print scheduler tab.
The dialogue is opened by selecting Menu→System→Report Manager.
Report explorer tab

The Report explorer alows to open documents, delete them and export to external USB
drive. Reports are typically documents printed by K-Chief 600 PDF printer on local
drive.
Note
Only documents saved in PDF format are selectable.
Figure 31 Report explorer tab
After inserting a USB memory stick, the requested document can be exported by
selecting it from the list and then clicking the Send to USB button.
It is recommended to click the Release USB drive button before removing the USB
memory stick.
Print scheduler tab

The Print scheduler allows to schedule printouts of the live data ( typically Alarm
history logs ) . Sheduled task can be enabled, disabled on demand. User can also delete
unnecessary schedules.
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User Interface
• State: This button is used to Enable or Disable the task.

• View type: This field displays what type of view is selected.
• Device: This field displays which printer is selected.
• Time interval: This field displays the print interval selected.
• Starting: This field displays the start date and time for the print job.
Figure 32 Print scheduler tab
Print jobs are managed using the New
Figure 33 New print job dialogue
Set following data in the dialogue to set up new scheduled task:

• View type: Select tabular view from the drop-down list.
Select check box below dropdown menu if only alarms related to the current location
should be printed (for example only machinery alarms in the ECR, or cargo alarms
in the CCR).
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• Time reference
Select UTC or Local time.
• Device: Select printer from the drop-down list.
The built-in K-Chief 600 PDF printer or any external printer connected to the OS
network can be selected.
• Interval: Select predefined print interval from the drop-down list.
Selectable print intervals are: 1 hour, 3 hours, 6 hours, 12 hours, 1 day, 1 week,
1 month.
Alarm events are printed continuously by aggregating data and printing full pages
• Starting: Select start date and time for the print job
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User Interface
2.6.3 Date and time adjustment

Purpose
The purpose of the Date and time adjustment dialogue is to be able to adjust date and
time settings.
The dialogue is opened by selecting Menu→System→Date and time.
Figure 34 Date and time adjustment dialogue
Master clock status

LED indicates synchronization with a master clock interface:
• Grey: Synchronization with master clock is disabled.
• Green: Synchronization with master clock is enabled.
• Red: No synchronization with master clock. Possible communication failure.
UTC
This field displays UTC date and time.
To compensate computer time drift. UTC time may also be adjusted if necessary. This
can be adjusted with 1 second steps.
Note
Log on as Master user to change UTC time
Local
This field displays local date and time.
Offset adjustment
Local time can be adjusted only if the system is not synchronized with master clock.
This field holds the following information and buttons:
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If the master clock only provides UTC date, local time settings are still available for
adjustments.
Seconds are always synchronized with UTC time.
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2.6.4 User access
Purpose
The purpose of the User access dialogue is to manage BWCM 600 users and user
properties. Typical tasks are set default user, add/remove users, manage user passwords
and so on.
The following table presents the user groups defined in the BWCM 600 system. If
defining a new user, he must be set as member of one of the predefined user groups.
Table 2 User group definitions
User groups
Task Guest User Power user Administrator Administrator
description Master Kongsberg
View all tabular Yes Yes Yes Yes Yes
and process
views, and
dialogues
Access KM Help Yes Yes Yes Yes Yes
Add tags to No Yes Yes Yes Yes
Trend and
Custom views
Print No Yes Yes Yes Yes
Acknowledge No Yes Yes Yes Yes
alarms
Report Manager No No Yes Yes Yes
operations
Restart or No No Yes Yes Yes
shutdown
Operator Station
Offscan tags No No Yes Yes Yes
Lap counter reset No No Yes Yes Yes
Change tag No No Yes Yes Yes
parameters
Add and delete No No No Yes Yes
users
Set UTC time No No No Yes Yes
Total counter No No No Yes Yes
reset
Full system No No No No Yes
access
Basic operator dialogue

The basic operator dialogue is opened by selecting Menu→System→Change user. When
the dialogue opens, the latest user name is displayed.
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Figure 35 User The dialogue offers two methods for changing the user:
access dialogue (basic)
• Pressing the Change user button: This may change to any
user defined by the system. The user is selected from the
drop-down list in the combo box and the corresponding
password must be entered.
• Pressing the Change to default user button: This will
change to the default user, as defined in the extended
operator dialogue.
Note
By default the password is always equal to the user name
(not case sensitive). Each user can change its own password.
Extended operator dialogue

Note
Log on as Master user in order to add, remove user, or reset user password.
Figure 36 User access dialogue (extended)
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User Interface
The extended operator dialogue is used to manage users and user properties. This
dialogue holds two tabs:
• Users, with the following functions:
– Add user: creates new user. By default user will belong to “Users” group and have
same password as its user name ( password is not case sensitive )
– Remove user: deletes selected user
– Remove user: deletes selected user
– Password: each user can change its own password, Master logged on user can
reset any password.
– Group: assign group for each user name. Group determines privileges of the user.
– Timeout: in case of user inactivity, the system will automatically change to default
user. Time in minutes. 0 = timeout disabled. All users can change their own
password. Master user can change passwords without knowing the old one.
• Stations, with the following function:
– Master user can set default user for each Operator Station. Operator station will
log on automatically to this user upon reboot. This is user account used by Change
to default user button
Note
'Kongsberg' user is for internal Kongsberg Maritime use only.
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2.6.5 Database backup
Purpose
The purpose of the Database backup dialogue is to make it possible to take backup
configuration database, settings and log files.
This operation is only available for Power users or higher.
The dialogue is opened by selecting Menu→System→Maintenance→Backup.
Figure 37 Data backup dialogue
Using the dialogue

Insert USB memory device into USB port of the Operator station.
Select Full backup if a backup of a complete configuration is required.
Select or deselect individual items if only part of the configuration to be copied
When clicking Start the backup file is created and automatically zipped. The naming
convention of the zip file is as follows:
ProductName_Backup_Date_Yard_Hull_ShipName_OSNumber_IMO_Full.zip
or
ProductName_Backup_Date_Yard_Hull_ShipName_OSNumber_IMO_Partial.zip
Press Start to create backup file and copy it USB device.
Press Release USB to release USB device.
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User Interface
2.6.6 Software versions log
Purpose
The purpose:
• Give an overview or current software versions of all hardware and software
components.
• Track software changes and upgrades.
• Track hardware changes by serial number tracking
The view is opened by selecting Menu→System→Software versions log.
Figure 38 Software versions log view
Using the view

When opening the view, all entries are displayed as collapsed.
Entries may be manually expanded or collapsed using the ► or ▼ buttons on the left
side of the view.
Buttons functions:
• Expand current versions expands all entries with current software version only.
• Expand all expands all entries with current software version and update history.
• Colapse all collapses all rows
The view may be printed. The report will be printed as presented on the screen.
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3 System procedures
3.1 View
To accommodate for different light conditions in the operator's work space, the graphics
on the screen can be changed to one of the pre-defined color palettes under Display Mode.
3.1.1 Display mode

The operator can select one of the following palettes:
• Day palette with light gray background color (RGB: 239,239,239 )
• Dusk palette with dark gray background color (RGB: 34,34,34)
• Night palette with black background color (RGB: 0,0,0)
• Auto,
The selected palette affects all elements on the screen, as operator dialogues, static
and dynamic objects, buttons, cursors, etc.
Figure 39 Day palette Figure 40 Dusk palette Figure 41 Night palette
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System procedures
Note
On Control Panel the Night palette can get to dark to see function in bright ambient
light conditions, so to get out of Night palette press and hold in top-right corner to
change palette
How-to
1 Click the Menu button in the top bar.
2 Click View.
• A drop-down list is displayed.
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3 Select the wanted Display mode, Day, Dusk or Night by clicking the corresponding
text.
3.1.2 Palette sync

It is also possible to synchronize the current palette setting with palettes of other
Operator Stations.
• Local: All palette changes are executed only on the local Operator Station.
• Location: The palette change is synchronized between all Operator Stations having
this option selected and being within the same location (for example all Operator
Stations in the ECR).
3.1.3 Display settings

• Monitor calibration
To individually adjust the Day, Dusk or Night palette, go to Monitor Calibration.
• Auto display mode calibration

Adjust the transition levels between paletts and palettes will change automatically
based on light sensor on the Control Panel
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System procedures
• Screen lock
• Disable tough screen for cleaning

To avoid functions to be enabled when cleaning the tough screen on a Control Panel
the tough function can be disabled for 60 seconds
3.2 Change user

1 Click the Menu button.
2 Click System.
3 Click Change user in the drop-down list.
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• A dialogue is opened. It may look similar to the following:
4 Select the wanted user in the drop-down list.

5 Fill inn the password, and click Change user.
3.3 DPU Replacement

This procedure explains how to replace a DPU/sensor in the K-Chief 600 system.
1 Replace the defect DPU or PSS11 sensor regarding to installation manual and
register the serial number of the new unit.
2 Click the Menu button in the top bar.
3 Click Tools.
• A drop-down list is shown.
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System procedures
4 Click DPU Replacement.

• A dialogue is opened. It shows only units that are defect or not configured. It
may look similar to the following dialogue:
5 Right click the line with the unit you want to replace to get access to the Start scan
button.
6 Click Start scan.
• A dialogue is opened. It shows serial numbers for all new hardware.
7 Click the line holding the serial number for the new DPU, and click OK.
• The unit will be loaded with the relevant node address, software and
automatically configured. The process may take a few minutes.
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4 Operational procedures
4.1 Alarm test

Alarm test is used to verify alarm output from the BWCM system
• Alarm test will activate alarm output used for horn and light
• Slowdown test will active slowdown output to engine
How-to
1 Go to BWS →Alarm test
2 To activate test:
a Click button for the test that shall start
b Click Yes on warning
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Operational procedures
3 Button will turn red for the test that's active
Expected result
• Alarm Test: Horn and light to be activated
• Slowdown Test: Slowdown of engine to be activated
WARNING
Do not activate Slowdown Release test when engine is running
because this will cause the engine to Slowdown
4 Click button for active test to deactivate the test
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4.2 Class Report

How-to
1
Generate Report
a Open Home view or Navigation line
b Go to Bearing Wear →Engine Monitoring Log →Class Report
c Select time period for the report in Select time
d Click Generate Report button
e Report is ready when status is Report generated C:\Ros\PdsLog\BWLog\Xml
Reports\.........
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Copy Report to USB drive

a Connect USB drive into USB port on OS
b Go to Top bar Menu →System →Change user... and set user to Chief or higher
c Go to Top bar Menu →System →Maintenance
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d In Maintenance view go to Backup

e Select Bearing Wear Report
f When status is USB drive is ready click Start button
g When status is Backup completed successfully click Release USB button and
remove USB drive
Note
For information about report file see Class Report file on page 30
4.3 Sensor replacement

4.3.1 Sensor replacement during Learning Mode
Sensor replacement during Learning Mode
The new sensor is installed in the presumably same position as the old. However this
is not possible to achieve 100% correctly. The procedures for replacement address
this issue.
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This procedure must be followed when a sensor needs to be replaced during the Learning
Mode. Installation distance of the sensor is likely to change when a sensor is exchanged;
zero point need to be adjusted and Learning Mode need to be restarted to avoid offsets on
the compensation data.
Scope of work
• Replacement the defect sensor
• Set node id
• Restart of Learning Mode
How-to
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”
4 Safely remove all tools and the broken sensor from the crank case.
5 Go to K-Chief 600 OS
a Set user access to Chief or a higher level
b Open Menu →Tools →DPU Replacement and select sensor to be replaced with
new one
See DPU Replacement on page 86
c Open Home view by clicking and go to BWCM →Bearing Wear Service

→Learning Mode
d Click Cancel
e Click Start
f When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
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g If there are sensors outside specified installation range adjust the sensors to
correct installation distance and click Restart IDC
4.3.2 Sensor replacement during Normal mode

This procedure must be followed when a sensor needs to be replaced during Normal
Mode. Installation distance of the sensor is likely to change when a sensor is exchanged;
zero point need to be adjusted to avoid offset on measuring value; this is automatically
done by the Readjust function.
Scope of work
• Replacement the defect sensor
• Set node id
• Start of Readjust
Procedure
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
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Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”
4 Safely remove all tools and the broken sensor from the crank case.
5 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> DPU Replacement and select sensor to be replaced
with new one
See DPU Replacement on page 86
c Open Menu —> Tools —> BWS —> Readjust
d Select the sensors that is replaced
e Click Start
f Click Next in Select data view without setting date
g When status states Turn engine turn engine two revolutions on turn gear and
h If there are sensors outside specified installation range adjust sensors to correct
4.4 Bearing Check/Overhaul

4.4.1 Bearing Check/Overhaul during Learning Mode
This procedure must be followed when overhaul is done during the Learning Mode.
Both installation distance of the sensor and bearing clearance is likely to change when
a bearing is overhauled; zero point need to be adjusted and Learning Mode need to be
restarted to avoid offsets in the compensation data.
Case A: The overhaul does NOT require the removal of Bearing Wear sensors and
brackets (typical crank –and/or cross-head bearing overhaul). There might however be a
change in bearing clearance after the overhaul.
Case B: The overhaul requires the removal of sensors and brackets (typical Main bearing
overhaul); there will be a change in both bearing clearance and sensor position after
the overhaul.
Case A — Scope of work:

• Overhaul
• Cancel Learning Mode procedure and restart procedure
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How-to
1 Do bearing overhaul according to engine makers requirements
b Open Home view by clicking and go to BWCM →Bearing Wear Service

→Learning Mode
c Click Cancel
d Click Start
e When status states Turn engine turn engine two revolutions on turn gear and
f If there are sensors outside specified installation range adjust the sensors to
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Case B — Scope of work:

• Removal of the Bearing Wear Sensor and bracket
• Overhaul
• Reinstallation of sensor and bracket.
• Cancel Learning Mode procedure and restart procedure
How-to
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).
WARNING
DO NOT remove the sensor from the brackets
Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position
3 Do overhaul according to engine makers requirements
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4 Reinstall bracket with sensor(s) in it’s former position regarding to marks made
before bracket was removed
Note
Make sure that each bracket with sensors is reinstalled in the SAME POSITION as
before, then further adjustment of sensor position can be avoided
• Sensors should be 3 ±1mm from Guide shoe in BDC

• Fix cable connectors:
– Rotate the cable connector until it enters easily on the guide pin.
– Turn the nut by hand until stop and then turn a extra 30° or with 0.7 Nm torque
Note
If pliers are used be careful not to over tighten the nut on the connector
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b Open Home view by clicking and go to BWCM →Bearing Wear Service

→Learning Mode
c Click Cancel
d Click Start
e When status states Turn engine turn engine two revolutions on turn gear and
f If there are sensors outside specified installation range adjust the sensors to
4.4.2 Bearing Check/Overhaul during Normal Mode

This procedure must be followed when overhaul is done when the system is in Normal
Mode. Both installation distance of the sensor and bearing clearance is likely to change
when a bearing is overhauled; zero point need to be adjusted to avoid offset on measuring
value; this is automatically done by the Readjust function in BWS.
Case A: The overhaul does NOT require the removal of Bearing Wear sensors and
brackets (typical crank –and/or cross-head bearing overhaul). There might however be a
change in bearing clearance after the overhaul.
Case B: The overhaul requires the removal of sensors and brackets (typical Main bearing
overhaul); there will be a change in both bearing clearance and sensor position after
the overhaul.
Case A — Scope of work:
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• Overhaul
• Start the Readjust procedure
Procedure:
1 Do bearing overhaul according to engine makers requirements
b Open Menu —> Tools —> BWS —> Readjust
c Select the sensors that is affected by the overhaul
d Click Start
e Click Next in Select data view without setting date
g If there are sensors outside specified installation range adjust sensors to correct
Case B — Scope of work:
• Removal of the Bearing Wear Sensor and bracket
• Overhaul
• Reinstallation of sensor and bracket
• Start the readjust procedure
Procedure:
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).
WARNING
DO NOT remove the sensor from the brackets
Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position
3 Do overhaul according to engine makers requirements

4 Reinstall bracket with sensor(s) in its former position regarding to marks made
before bracket was removed
Note
Make sure that each bracket with sensors is reinstalled in the SAME POSITION as
before, then further adjustment of sensor position can be avoided

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b Open Menu —> Tools —> BWS —> Readjust

c Select the sensors that is affected by the overhaul
d Click Start
e Click Next in Select data view without setting date
g If there are sensors outside specified installation range adjust sensors to correct
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5 Troubleshooting
5.1 BW values
Problem Probable cause Solution
Alarm is activated on Bad compensation data on Restart Learning
specific engine speed levels a engine speed level
and return to normal when
engine speed is changed
Alarm from one sensor in a Sensor failure 1 Check
cylinder due to high or low
CYLxx_RAW—y
value from around ±1 mm
value(xx = cylinder
number and y =
cylinder position
where 1 = Fore and 2
= Aft)
2 If value is around ±3
mm replace the sensor
regarding to mounting
instruction and on
page
Slow Wear
High or low value around Sensor failure
1 Check
±3 mm after sensors has
CYLxx_RAW—y
passed IDC in Learning
value(xx = cylinder
number and y =
cylinder position
= Aft)
2 If value is around ±3
mm replace the sensor
instruction and on
page
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Troubleshooting
Rapid Wear
False alarm in beginning of Value changed due to RPM Change engine speed and
Learning period range is linear compensated check if value return to
between two measured normal, if the value returns
points to normal this will improve
when compensation values
is logged for the RPM
range.
5.2 Communication
Communication alarm on Loose connector
1 Check connectors
some sensors. for the sensor giving
Tag name: DPUxxyyCOM alarm
(xx = segment number and
yy = node id) 2 Fasten loose connector
Note
Turn the nut by hand until
stop and then turn a extra
30° or with 0.7 Nm torque
Damaged cable/connector 1 Check

connectors/cables
for the sensor giving
alarm
2 Replace damaged
parts and on page
Failed sensor Replace the sensor
instruction and on page
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Communication alarm on Loose connections • Check connections for
all sensors. cable running to SCU
Tag name: DPUxxyyCOM from the sensors
(xx = segment number and
yy = node id) • Check connections for
cable running from SCU
to connection box on
engine
Damage cable Check cable running from
SCU to connection box on
engine.
Loss of power on the Check power to the sensors
sensors in the connection box
on the engine, should be
between 18 — 32V DC
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Troubleshooting
5.3 Engine running direction

Engine Stopped status when Sensor failure, a sensor is
1 Go to Tag Details
engine is running ahead not sending engine speed and check which
value CYLxx_RPM-y(xx =
cylinder number and
y = cylinder position
= Aft) tag that is not
sending RPM value
2 Repower sensor and
check if it start sending
engine speed value.
3 If sensor is not sending
engine speed value
after it has been
repowered replace
the sensor regarding to
mounting instruction
and on page
Engine running astern Engine firing order is set in Correct the firing order
status when engine is reverse order for BWCM on the CYLxx-AVE-S(xx
running ahead = cylinder number) tags
by swap Next cyl no and
Prev cyl no in Tag details
under parameters or update
database with correct firing
order.
Engine running direction Wrong application SW on Open DIM application and
unknown status when sensors select PSS11 sensors and
engine is running click Download SW
Out of sequence alarm Wrong engine firing order Correct the firing order
Tag name: set for BWCM on the CYLxx-AVE-S(xx
BW_ERR_RATE = cylinder number) tags
Tag description: OUT OF by setting Next cyl no and
SEQUENCE % SEG Prev cyl no in Tag details
under parameters or update
database with correct
engine firing order.
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5.4 Bearing Wear Service

IDC alarm Sensor is not installed Adjust sensor with wrong
Tag name: BWS_IDC with correct installation installation distance and
Tag description: IDC distance. click Redo IDC in Bearing
FAILD Wear Service application
Alarm value: 200
Note
Alarm will reset when IDC
is done with sensor adjusted
to correct installation
distance
Rough Learning alarm Engine speed compensation Restart OS

Tag name: BWS_ROUGH data download failed
Tag description: ROUGH
LEARNING FAILED
Alarm value: 210
500 Hour Learning alarm Engine speed compensation Restart OS
Tag name: BWS_500L data download failed
Tag description: 500
HOURS LEARNING
FAILED
Alarm value: 210
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Index
A DPU N
Acknowledge, 37, 44 Replace, 86 Night palette
Active alarms, 50 bright light conditions, 83
Active alarms columns, 51 E
Active alarms view, 50
Engine Monitoring, 8 O
Add tag
Engine monitoring log
Trend view, 66 Overridden tags, 60
Class Report, 29
Alarm and Monitoring Overridden tags view, 60
Event log, 27
System
Status view, 29
Change user, 85
Event history, 56 P
Replace DPU, 86
Event history view, 56
Alarm handling, 44 Palettes
Event log, 27
Alarm history, 52 Day, 82
Alarm history symbols, 52 Dusk, 82
Alarm history view, 52 H Night, 82
Alarm presentation, 42 Password, 78
Help, 49
Alarm side bar, 42 Print, 70
Context-sensitive help, 32
Alarm side bar Options, 70
Home view, 8
functionality, 42 Print scheduler, 72
How-to
Alarm state, 50 Printing, 70
Alarm test, 88
Alarm test, 88
Bearing Check after
Alarms, 34
Seatrial, 95 R
Acknowledge, 37
Bearing Check during
Sound off, 37 Rapid Wear, 10
Learning Mode, 95
Bearing Check during Remove tag
B Normal Mode, 99 Trend view, 67
Bearing Overhaul during Replace DPU
Backup, 80 Learning Mode, 95 Alarm and Monitoring
Bearing Check after Bearing Overhaul during System, 86
Seatrial, 95 Normal Mode, 99 Report explorer, 72
Bearing Check during Class Report, 90 Report manager
Learning Mode, 95 Display Mode, 83 New print job, 72
Bearing Check during Sensor replacement Print scheduler, 72
Normal Mode, 99 during Learning Mode, 92 Report explorer, 72
Bearing Overhaul during Sensor replacement Report Manager, 72
Learning Mode, 95 during Normal Mode, 94 Restore layout, 47
Bearing Overhaul during Slowdown test, 88
Normal Mode, 99
Bearing Wear Service, 20 S
Learning Mode, 20 I Scaling
Readjust, 24 Inhibit tags, 58 Trend view, 68
Inhibit tags view, 58 Sensor replacement during
C Learning Mode, 92
Sensor replacement during
Change user, 85 L Normal Mode, 94
Class Report, 29 Layout Side bar, 42
Class Report file, 30 Top bar, 33 Slow Wear, 15
How-to, 90 Trend view, 64 Slowdown test, 88
Context menu, 48 Learning Software versions log, 81
Counter, 62 500 Hour learning, 20 Sorting, 48
Counters list, 62 Rough learning, 20 Sorting of data, 48
Edit, 63 Local time, 75 Sound, 37
Status view, 29
System functionality, 7
D M Bearing Wear Service, 20
Database backup, 80 Master clock, 75 Engine Monitoring, 8
Date and time adjustment, 75 Menu Home view, 8
Default password, 78 Top bar, 39 Rapid Wear, 10
390250/B 107
Kongsberg BWCM 600
Slow Wear, 15 UTC time, 75

System status area, 34
System tools, 69
Backup, 80 V
Date and time View area
adjustment, 75 Trend view, 68
Master clock, 75
Software versions, 81
Time offset adjustment, 75
User access, 77
T
Tabular view
Active alarms, 50
Alarm history, 52
Counters list, 62
Event history, 56
Filtering, 48
Inhibit tags, 58
Overridden tags, 60
Tag summary, 54
Tabular views, 46
Tag manager
Trend view, 65
Tag summary, 54
Tag summary view, 54
Time offset adjustment, 75
Toolbar, 38
Tools and options
Trend view, 65
Top bar
Alarm handling, 34
Alarm information, 34
Layout, 33
Menu button, 39
Menu structure, 39
Toolbar compartment
layout, 38
Trend view, 64
Add tag, 66
Layout, 64
Remove tag, 67
Scaling, 68
Tag manager, 65
Tools and options, 65
View area, 68
Troubleshooting, 102
U
User access, 77
Extended operator
dialogue, 78
User groups, 77
User interface
Alarm side bar, 42
Tabular view, 46
108 390250/B
Kongsberg BWCM 600
109 390250/B
©2017 Kongsberg Maritime
®
Mk 7 OIL MIST DETECTOR
INSTALLATION,
OPERATION AND
MAINTENANCE
MANUAL
59812-K007
PROPRIETY RIGHTS NOTICE
The information contained in this manual is the property of Kidde Products Limited and may not be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor stored
in any retrieval system or any nature without the express written authority of Kidde Products Limited.
© Copyright 2013 Kidde Products Ltd
July 14 Page i of ix 59812-K007 Rev 12

TABLE OF CONTENTS
Chapter Page
1 DESCRIPTION AND OPERATION ................................................................................ 1

1.1 INTRODUCTION 1
1.2 DESCRIPTION 2
1.3 TECHNICAL SPECIFICATION 5
1.4 SYSTEM OVERVIEW 7
1.5 SYSTEM CONTROLS AND DISPLAYS 8
2 INSTALLATION AND COMMISSIONING ...................................................................... 9

2.1 CONTROL UNIT MOUNTING 9
2.2 DETECTOR MOUNTING 11
2.3 DETECTOR CABLES 14
2.4 REMOTE DISPLAY UNIT 17
2.5 CONTROL UNIT 20
2.6 REMOTE DISPLAY UNIT 23
2.7 CONNECTING THE SYSTEM 26
2.8 SYSTEM CHECKS PRIOR TO SWITCHING ON 28
2.9 SYSTEM SETUP / CONFIGURATION – WITH A REMOTE DISPLAY UNIT 29
2.10 ISOLATION – USING THE REMOTE DISPLAY UNIT 45
2.11 TEST MENU & EVENT LOG 53
3 MAINTENANCE ...........................................................................................................60
3.1 ROUTINE MAINTENANCE 60
3.2 DETECTOR HEAD REPLACEMENT 61
3.3 DETECTOR HEAD REFURBISHMENT 62
3.4 FAN REPLACEMENT 65
3.5 CABLE REPLACEMENT 65
3.6 CONTROL UNIT MEMBRANE 66
3.7 CONTROL UNIT PCB REPLACEMENT 66
3.8 DECOMMISSIONING 66
4 FAULT FINDING ..........................................................................................................67

4.1 GENERAL 67
5 SPARE PARTS ............................................................................................................85

5.1 COMPLETE SPARE PARTS LIST 91
6 CATERPILLAR DETECTORS
6.1 53836- K269-03 C/W SHORT SAMPLE PIPE 95
53836-K269-02 C/W STANDARD SAMPLE PIPE 96
July 14 Page ii of ix 59812-K007 Rev 12

LIST OF ILLUSTRATIONS
Figure Title Page
Figure 1 Areas of Failure – 2 Stroke Engine ...................................................................... 1

Figure 2 Areas of Failure – 4 Stroke Engine ...................................................................... 1
Figure 3 Graviner Mk7 OMD Components ......................................................................... 2
Figure 4 Typical System Configuration – With Membrane.................................................. 3
Figure 5 Typical System Configuration – Without Membrane ............................................. 4
Figure 6 Relay Function Modes ......................................................................................... 8
Figure 7 Control Unit 53836-K270 (With Membrane) ......................................................... 9
Figure 8 Control Unit 53836-K276 (Without Membrane) ...................................................10
Figure 9 Ideal Mounting Position.......................................................................................11
Figure 10 Detector Head Installation ...............................................................................12
Figure 11 Detector Head Installation (Short Sample Pipe) ..............................................13
Figure 12 Detector Cable ................................................................................................14
Figure 13 Detector Cable Assembly (Straight Connector) ...............................................15
Figure 14 Detector Cable Assembly (Right Angle Connector) .........................................16
Figure 15 Flush Mounting Cut-out for Remote Display Unit .............................................17
Figure 16 Flush Mounting for Remote Display Unit .........................................................18
Figure 17 Bulk Head Mounting for Remote Display Unit ..................................................19
Figure 18 Control Unit PCB .............................................................................................21
Figure 19 Wiring Drawing ................................................................................................22
Figure 20 24v DC Socket Wiring Drawing .......................................................................23
Figure 21 Modbus Connector Wiring Drawing .................................................................24
Figure 22 Remote Display Unit 53836-K271 ...................................................................24
Figure 23 Intentionally Left Blank ....................................................................................25
Figure 24 Power cable ....................................................................................................26
Figure 25 Power cable through EMC gland .....................................................................26
Figure 26 Control unit relay cable assembly ....................................................................27
Figure 27 Detector cable assembly .................................................................................27
Figure 28 Control unit - Detector cable assembly ............................................................28
Figure 29 Screen Shot 1 .................................................................................................29
Engine Selection List ............................................................................................................31
Figure 38 Screen Shot 10 ...............................................................................................31
Detector Selection List..........................................................................................................34
July 14 Page iii of ix 59812-K007 Rev 12

Figure 53 Control Unit Membrane ...................................................................................36
Figure 55 Control Unit – USB Connector.........................................................................38
Figure 56 Computer Connection – USB Connector .........................................................38
Figure 57 USB Screen Shot 1 .........................................................................................39
Figure 60 Detect Engine Screen Shot 1 ..........................................................................40
Figure 65 Smoke Tester ..................................................................................................42
Figure 66 Smoke Test .....................................................................................................43
Figure 103 Screen Shot 60 ..............................................................................................55
July 14 Page iv of ix 59812-K007 Rev 12

Figure 119 Base Fixing Screw Removal............................................................................61
Figure 120 Cable Disconnect ............................................................................................62
Figure 121 Base Moulding Seal ........................................................................................62
Figure 122 Pulling Tool .....................................................................................................63
Figure 123 Fan Removal ...................................................................................................63
Figure 124 Cleaning Light Guide .......................................................................................64
Figure 125 Control Unit Spares .........................................................................................85
Figure 126 Display Unit Spares .........................................................................................87
Figure 127 Detector Spares ..............................................................................................89
July 14 Page v of ix 59812-K007 Rev 12

REVISION HISTORY
Issue Date Of Issue Revision History Amended by Approved by
1 Oct 2011 Draft – For Approval

M Daley A Willis
2 Nov 2011 Approved for Distribution

M Daley A Willis
Changes to Back Alarm
3 Jan 2012 operating philosophy and
Smoke Test procedure.
M Daley A Willis
Changes to Warranty section,

4 May 2012
addition of default values.
M Daley A Willis
Changes to Connector Push In

5 June 2012
part number.
M Daley A Willis
Updated Wiring Drawing and

Connector Drawings. Addition of
6 Dec 2012
Short Sample Base in Parts List.
Addition of Non Membrane units. A Willis
M Daley
7 Jan 2013 Changes to Page Numbers

M Daley A Willis
Modification of Power Supplies

required.
Addition of Modbus addressing
8 Jan 2013 via Membrane.
Update Fault Finding and Flow
Charts to include Error Detecting
Engines
M Daley A Willis
Additional note when setting

9 Feb 2013
Modbus address
M Daley A Willis
Change to Fan Connector and

10 July 2013
24VDC Touch Screen Cable.
M Daley A Willis
July 14 Page vi of ix 59812-K007 Rev 12

Figure 15 updated and specific
11 December 13 part numbers for Caterpillar
Control Unit added
P Darnell A Willis
New part numbers and drawings

12 July 14 included for Caterpillar in
Addendum 1 A
P Darnell Willis
July 14 Page vii of ix 59812-K007 Rev 12

OIL MIST DETECTOR WARRANTIES
1. Kidde Products Ltd (KPL) warrants, for a period of 3 years from the handover of the new vessel
which is installed with KPL Oil Mist Detector (OMD) system to the system owner, and for a period
(*)
of 2 years from the commissioning date of a retro fitted Mk7 Oil Mist Detector (OMD) system, that
any component forming part of the original OMD system manufactured by or supplied by KPL shall
be free from defects in workmanship or materials during normal usage (the “OMD System
Warranty”). If any such component does not conform to this warranty KPL will, at its sole
discretion and its cost, either repair or replace such component. Installation of the repaired /
replacement parts is not covered under the OMD System Warranty. Components replaced or
repaired under the terms of the OMD System Warranty shall continue to have the benefit of the
unexpired portion of the OMD System Warranty, unless that unexpired portion is less than 12
months, in which case the repaired / replacement parts shall have the benefit of a 12 month
warranty against defects in workmanship or materials during normal usage starting on the date of
delivery. OMD’s supplied as spares shall be warranted in accordance with paragraph 2 below
only.
2. KPL warrants for a period of 12 months from delivery that individual OMD’s supplied as spares
shall be free from defects in workmanship or materials during normal usage.
3. Performance of KPL’s repair or replacement obligations shall constitute an entire discharge of

KPL's liability under the warranties set out in paragraphs 1 and 2 above (“Warranties”).
4. The Warranties shall not apply to the following:

a. defects reasonably judged by KPL as being caused by the improper installation of the
OMD’s and/or OMD system;
b. defects reasonably judged by KPL as being caused by the failure to follow the
recommendations contained in KPL’s product manuals and/or other documentation
regarding the frequency of routine maintenance and testing of the OMD’s and/or OMD
system and/or the failure to have such routine maintenance performed;
c. defects which are attributable to careless handling or storage, accident, improper use of
the OMD’s and/or OMD system, or incorrectly completed repairs or routine maintenance
services;
d. damages or losses occurring as a result of any act or omission which is wilfully unlawful or
negligent;
e. defects arising from the use of non-genuine KPL parts or accessories, or the use of
materials not approved for use by KPL;
f. any modifications to or installations performed on the OMD’s and/or OMD system outside
the scope of normal routine maintenance or running repairs without the express prior
written approval of KPL;
g. deterioration, staining or corrosion of parts which will occur due to normal exposure and
usage;
h. alleged defects not materially affecting the quality or proper functioning of the OMD
system.
5. In addition the Warranties shall be limited as follows:

a. KPL shall be under no liability in respect of any defect in the OMD’s and/or OMD System
arising from any drawing, design or specification supplied by or at the request of the buyer
or system owner (not being a drawing, design or specification of KPL);
July 14 Page viii of ix 59812-K007 Rev 12

b. KPL shall be under no liability in respect of any defect or failure of the OMD’s and/or OMD
System to operate in accordance with specifications, illustrations, descriptions or other
particulars due to their combination or use with any incompatible equipment or product.
6. The Warranties are conditional upon:
a. the buyer or OMD system owner giving written notice to KPL of the alleged defect, such
notice to be given immediately when the buyer or OMD system owner discovers or ought
to have discovered the defect;
b. the buyer or OMD system owner affording KPL a reasonable opportunity to inspect the
OMD’s and/or OMD system;
c. the buyer or OMD system owner not altering or attempting to repair the OMD’s and/or
OMD system without the written consent of KPL.
7. The Warranties can be transferred to any new owner of the OMD system provided KPL is
informed in writing within 30 days of the transfer. The OMD System Warranty cannot be
transferred to another KPL OMD system.
8. Save to the extent amended by the provisions set out above, KPL’s standard terms and conditions
of sale shall apply.
* Commissioning is to be performed by a KPL approved service agent.
OMD Service Life

Oil Mist Detectors (OMD’s) are an integral part of critical safety systems designed to detect
certain conditions that could lead to crankcase explosions on large Diesel engines. They are
typically installed in harsh operating conditions - particularly with respect to temperature and
vibration - and are expected to provide continuous service over extended periods. They are
therefore subject to considerable wear and tear.
In order to ensure reliable performance, it is particularly important that OMD’s are properly
installed, operated and maintained in accordance with the manufacturer’s instructions and
guidelines. Given that they are components within key safety systems, as precautionary advice
the manufacturer recommends replacing or refurbishing OMD’s which are more than 10 years
old, even if they are functioning correctly at that time.
July 14 Page ix of ix 59812-K007 Rev 12

1 DESCRIPTION AND OPERATION
1.1 INTRODUCTION
High temperatures, in excess of 200ºC that occur on bearing surfaces under initial failure
conditions, can lead to a rapid generation of oil vapour When the hot vapour contacts the
relatively cooler atmosphere of the crankcase it condenses into a fine mist, with typical particle
sizes of around 0.5 to 5 microns in diameter. When the density of these particles reaches
between 30 to 50 mg/I (Milligrams per litre), depending upon the type of oil, an explosive
condition exists.
Piston Rod Seal
Cross Head Slides
Top End Bearing
Cross Head Bearing

Main Bearing
Bottom End Bearing
Figure 1 Areas of Failure – 2 Stroke Engine
Piston Seizure Top End Bearing
Cam Shaft Bearings Piston Blow By
Main Bearing
Bottom End
Bearing
Figure 2 Areas of Failure – 4 Stroke Engine

A fire or explosion needs three constituents: fuel, oxygen and an ignition source. Remove one of
these and no explosion will occur. Similarly, within the crankcase, the three constituents which
could cause an explosion are air, oil mist and an ignition source, the “hot spot’. Using optical
measuring techniques, oil mist density can be measured at levels as low as 0.05 mg/I and give
early warning of a rise in oil mist density.
Oil Mist Detection (OMD) techniques have been used to monitor diesel engine crankcases for
potential explosive conditions and early detection of bearing failures. The systems available rely
mainly on analysing the optical density of oil mist samples drawn from the crankcase
compartments, through pipes to the detector. While these systems proved successful in the past,
engine design has improved significantly over the years and oil mist detection techniques have
improved substantially to maintain adequate protection.
July 14 Page 1 of 96 59812-K007 Rev 12

The Graviner Mk 7 OMD provides the following benefits:
 Auto addressed system monitoring up to 10 detector heads per control unit
 Up to 10 control units per single system.
 Suitable for both 2 stroke and 4 stroke engines.
 Elimination of sample pipes - reduced installation costs.
 Engine mounted Control Unit.
 Remote Display Unit mounted in a safe area, typically the Engine Control Room (ECR).
Remote Display
Unit
Detector Detector Control Unit – Control Unit –

Cable With Membrane Without Membrane
Figure 3 Graviner Mk7 OMD Components
1.2 DESCRIPTION
The system comprises three main components (refer to Figure 3):
Detectors 53836-K269 (with base) / 53836-K272 (replacement head)
53836-269-01 (Short sample pipe)
Control Unit 53836-K270 (With Membrane)
53836-K276 (Without Membrane)
Remote Display Unit 53836-K271
And connecting cables
Control Unit to Detector cable (Straight) 43682-K286-XX
Control Unit to Detector cable (Right Angle) 43682-K285-XX
The Graviner Mk 7 OMD system can comprise up to 100 detectors directly mounted on the
crankcases of up to 10 engines, allowing both main propulsion and auxiliary generators to be
monitored at the same time.
Each detector communicates electronically over a serial data link via the engine mounted
Control Unit with the Remote Display Unit designed to be mounted within the Engine Control
Room. This eliminates the need to enter the machinery space in alarm conditions.
July 14 Page 2 of 96 59812-K007 Rev 12

Figure 4 Typical System Configuration – With Membrane
July 14 Page 3 of 96 59812-K007 Rev 12

Figure 5 Typical System Configuration – Without Membrane
July 14 Page 4 of 96 59812-K007 Rev 12

1.3 TECHNICAL SPECIFICATION
Detector
Mounting ¾ inch BSP
Enclosure Rating IP65
Material Sample Tube – Carbon Loaded PTFE
Detector – Black Du Pont Nylon 70G33L
Indicators Green Detector On
Red Alarm
Amber Detector Fault
Power Consumption 1.5W
o
Temperature Rating 0 – 70 C
Height 153mm
Width 90mm
Length 205mm
Weight 0.5kg
Control Unit
Material Aluminium
Max detector inputs 10
Output Relays Volt-free change over contacts rated at 30Vdc 1A

Pre Alarm 1 set (de-energised during normal operation)
Fault Alarm 1 set (energised during normal operation)
Engine Slow/Shutdown Alarm 1 set (de-energised during normal operation)
Back-up Alarm 1 set (de-energised during normal operation)
Alarm Ranges
Pre Alarm 0.5mg/l to 1.2mg/l (adjustable) (Default 0.9mg/l)
Engine Slow/Shutdown Alarm 1.3mg/l to 2.4mg/l (adjustable) (Default 1.8mg/l)
Backup Alarm 3.0mg/l (fixed)

o
Temperature Rating 0 – 70 C
Dimensions
Height 186mm (110mm mounting centres)
Width 318mm (240mm mounting centres)
Depth 90mm
Weight 2.8kg
July 14 Page 5 of 96 59812-K007 Rev 12

Remote Display Unit
Material ABS (PA-765+)
Max No. of detectors 100
Max No. of engines monitored 10
Power Supply 24Vdc (+30% -25%)
o
Temp Rating 0 – 70 C
Humidity level 95%
Dimensions
Bulkhead Mounted: Height 225mm (202mm mounting centres)
Depth 58mm
Panel Mounted: Height 225mm (202mm mounting centres)
Depth 55mm
Weight 1.0kg
July 14 Page 6 of 96 59812-K007 Rev 12

1.4 SYSTEM OVERVIEW
The Graviner Mk7 OMD is an auto addressed oil mist detection system capable of monitoring
up to 10 Control Units per system with each Control Unit having up to 10 detectors connected
to it. This is achieved without external sample pipes and with minimum cabling. Each detector
head monitors a single crank space and is a stand-alone device. On power up the detectors
gather oil mist density data and convert it to a digital signal for transmission via the data lines
in the detector cable to the Control Unit which is also mounted on the side of the engine.
Alarm levels and Alarm output requirements are all set from either the Remote Indicator
Display or a PC connected directly to the control unit.
The Remote Display Unit houses a 7.5” LCD Touch Screen display that shows, on demand,
the signal from each detector and indicates the oil mist level for each engine and when
required each detector as well as the status of the system. In the event of an alarm, the display
immediately shows the oil mist levels for the relevant engine. It also enables the individual
readings of each detector on the engine to be displayed on demand and automatically under
alarm conditions.
In the event of a detector fault, that detector can be isolated without affecting the function of
the other detectors on the engine. The system will continue to operate while the faulty detector
is replaced, repaired or maintenance is carried out.
The Mk7 detectors still use optical sensing; (light scatter) as it’s detection method and
continually monitors the oil mist density in the crank space to which it is connected. In addition,
it self-checks for any internal faults. The Control Unit interrogates each detector in turn,
identifies the position connected at the Control Unit, the oil mist density value and determines
the status of the detector.
Each detector is fitted with 3 LED indicator lights:
Green - Power on
Red - Alarm
Amber - Fault
As all detectors operate independently, the loss of one detector through a fault does not affect
the operation of the rest of the system. Individual detectors, or engine groups, can be isolated
from the rest of the system for maintenance while the rest of the system remains in operation.
The Control Unit can be supplied with or without a control membrane. The control membrane
has LED indication for detectors connected, push buttons for isolation and de-isolation of
detectors, as well as pushbuttons for Accepting and Resetting Alarms.
Alarm Philosophy
The system has 3 separate alarm levels as detailed below
1. Pre Alarm- This indicates that the oil mist levels are increasing in a particular crank
space and that investigation should be undertaken. This alarm will not operate the
slowdown/shutdown relays.
2. Engine Slow/Shutdown Alarm - When any detector reaches this threshold then the
slowdown/shutdown relay will be operated if they are connected.
3. Back Up Alarm - In the event of a failure of either the Pre Alarm or High Alarm, then
the Back Up Alarm will operate, but it will not operate the slowdown/shutdown relay.
This is an additional functional precaution added by Kidde Products Ltd which can be
connected in any way the customer requires. This is usually connected to a warning
beacon or siren; however the customer may choose to connect the relay to another
device or the engine slowdown or shutdown circuitry.
On receipt of either a Pre Alarm or High Alarm the engine should, unless connected to a
slowdown/shutdown relay, be stopped if safe to do so and allowed to cool down so that the
background oil mist levels reduce before entering the engine room.
When the oil mist levels have returned to normal then the Accept and Reset buttons can be
operated from the Control Unit membrane if fitted or alternatively form the Remote Display Unit
and the system will then return to normal operation.
July 14 Page 7 of 96 59812-K007 Rev 12

Fault Diagnosis
When a system fault is received, the information on the display should be noted and then the
appropriate Fault Finding procedure in Chapter 4 of the manual should be checked to enable
the fault to be rectified.
When the faults have been rectified the Accept and Reset buttons can be operated and the
system will return to normal
Event Log
All alarms, faults and events are recorded in an Event Log which is date and time stamped and
will indicate the type of event which enables analysis of the events at a later time. The Event
Log has a capacity of 1024 events and is a rolling buffer.
1.5 SYSTEM CONTROLS AND DISPLAYS

The Remote Display Unit and PC software is menu driven and provides a logical route to all
functions. It has three operating levels:
User
Engineer
Service
The User level is essentially for read only interrogation and does not allow any adjustments to
be made to alarm settings or system configuration.
The Engineer level is password protected and allows access to most functions and the full
range of programmable settings
When selected, a prompt for a password will appear, Enter 012345, when programming is
completed the Password should be changed by an authorised person to prevent unauthorised
access in the future. This process can be followed in Chapter 2.9 of this manual
The Service level is also password protected (different from the Engineer Menu) and allows
access to all functions. This is only available to authorised Kidde Fire Protection personnel and
authorised service agents.
Relay Slowdown/ Backup

Unit off Unit on Pre-Alarm Fault
Description Shutdown Alarm
Pre-Alarm
Engine
Slow/Shutdown
Alarm
Backup-alarm
Fault
Figure 6 Relay Function Modes
July 14 Page 8 of 96 59812-K007 Rev 12

2 INSTALLATION AND COMMISSIONING
OMD Mk7 Installation
2.1 CONTROL UNIT MOUNTING
The Control Unit 53836-K270 (53836-K270-01 Caterpillar only) or 53836-K276 is designed for
on-engine mounting and it is recommended that the Control Unit is installed as near to the
centre of the engine as possible to minimise detector cable lengths.
Mounting is via the four M6 locating holes in the box. Sufficient space must be left around the
Control Unit to allow access to the cable glands and the routing of the cables and to facilitate
easy access to all aspects of the Control Unit.
Figure 7 Control Unit 53836-K270 (With Membrane) (Caterpillar 53836-K270-01)
July 14 Page 9 of 96 59812-K007 Rev 12

Figure 8 Control Unit 53836-K276 (Without Membrane)
July 14 Page 10 of 96 59812-K007 Rev 12

2.2 DETECTOR MOUNTING
Each detector is mounted to an individual crankcase via a ¾ inch BSP threaded hole.
Ensure all detectors fitted to the engine are locked tightly in place by means of the lock nut
supplied.
It is recommended that the detector be located at the upper part of the crankcase wall not in
the direct line of the oil throw. On smaller engines it is permissible to mount the detector on the
crankcase door if desired or as installation dictates, subject to vibration levels.
Figure 9 Ideal Mounting Position
The detector must be fitted at a maximum of plus or minus 20 degrees from the vertical.
Horizontally the detector must be mounted level or with the detector body inclined towards the
engine to ensure oil drainage. Refer to Figure 10, and Figure 11.
Please ensure that Detector 1 is connected to position 1 on the Control Unit, Detector 2 to
position 2. Repeat for all Detectors fitted.
July 14 Page 11 of 96 59812-K007 Rev 12

Figure 10 Detector Head Installation
July 14 Page 12 of 96 59812-K007 Rev 12

Figure 11 Detector Head Installation (Short Sample Pipe)
July 14 Page 13 of 96 59812-K007 Rev 12

2.3 DETECTOR CABLES
Each detector must be connected to the Control Unit by way of a supplied detector cable.
Refer Figure 12.
Ensure that the cables are run in a suitable cable tray and clipped at regular intervals to
ensure they cannot be subjected to mechanical damage caused by vibration.
o
Cable Length 90 Connector Straight Connector
m Part No. Part No.
1.0 43682-K285-1.0 43682-K286-1.0
1.5 43682-K285-1.5 43682-K286-1.5
2.0 43682-K285-2.0 43682-K286-2.0
2.5 43682-K285-2.5 43682-K286-2.5
3.0 43682-K285-3.0 43682-K286-3.0
3.5 43682-K285-3.5 43682-K286-3.5
4.0 43682-K285-4.0 43682-K286-4.0
4.5 43682-K285-4.5 43682-K286-4.5
5.0 43682-K285-5.0 43682-K286-5.0
5.5 43682-K285-5.5 43682-K286-5.5
6.0 43682-K285-6.0 43682-K286-6.0
6.5 43682-K285-6.5 43682-K286-6.5
7.0 43682-K285-7.0 43682-K286-7.0
7.5 43682-K285-7.5 43682-K286-7.5
8.0 43682-K285-8.0 43682-K286-8.0
8.5 43682-K285-8.5 43682-K286-8.5
9.0 43682-K285-9.0 43682-K286-9.0
9.5 43682-K285-9.5 43682-K286-9.5
10.0 43682-K285-10.0 43682-K286-10.0
10.5 43682-K285-10.5 43682-K286-10.5
11.0 43682-K285-11.0 43682-K286-11.0
11.5 43682-K285-11.5 43682-K286-11.5
12.0 43682-K285-12.0 43682-K286-12.0
12.5 43682-K285-12.5 43682-K286-12.5
15.0 43682-K285-15.0 43682-K286-15.0
17.5 43682-K285-17.5 43682-K286-17.5
20.0 43682-K285-20.0 43682-K286-20.0
22.5 43682-K285-22.5 43682-K286-22.5
25.0 43682-K285-25.0 43682-K286-25.0
Figure 12 Detector Cable
July 14 Page 14 of 96 59812-K007 Rev 12

Figure 13 Detector Cable Assembly (Straight Connector)
July 14 Page 15 of 96 59812-K007 Rev 12

Figure 14 Detector Cable Assembly (Right Angle Connector)
July 14 Page 16 of 96 59812-K007 Rev 12

2.4 REMOTE DISPLAY UNIT
The Remote Display Unit part number 53836-K271 must be mounted in the Engine Control
Room (ECR) or similar safe environment, do not mount in an Engine Room as it is not
designed to be mounted in this type of environment. Additionally Class Society rules state that
any display must be mounted in a safe area away from the Engine Room.
For flush mounting details see below and Figure 15 and Figure 16.
For bulk head mounting details see Figure 17.
Figure 15 Flush Mounting Cut-out for Remote Display Unit
July 14 Page 17 of 96 59812-K007 Rev 12

Figure 16 Flush Mounting for Remote Display Unit
July 14 Page 18 of 96 59812-K007 Rev 12

Figure 17 Bulk Head Mounting for Remote Display Unit
July 14 Page 19 of 96 59812-K007 Rev 12

2.5 CONTROL UNIT
24v DC Input supply
A 24v DC +30% -25% rated at 1.0Amp continuous rated, with 2.5Amp surge for 1.5ms.
Cables should be segregated from high voltage cables and follow good installation
practice
2
Cable type-2 Cores + Earth, CSA 2.5mm (50/0.25mm), flexible stranded bare copper
conductors, low smoke halogen free insulation, cores laid up, braided screen, low smoke
halogen free sheath – grey, outside diameter 9.8mm, operating temperature 0ºC + 80ºC.
Suggested cables
2
Lapp Kabel CY cable 3 core 2.5mm
2
Prysmian LSM-HF 3 core 2.5mm
2
Helkama LKAM-HF 3 core 2.5mm
Refer Figure 18 for connector location.

Refer Figure 18 for wiring drawing.
Modbus
Cable type – Individually screened 2 pair data cable, 24AWG, low capacitance, low smoke
halogen free. Outer diameter 7mm (max)
practice
Suggested cables
FS Cables 2402PIFFH
Beldon 9729
Helkama RFE-HF(i) 2x2x0.75
Jinro 60V RCOP(IS)
The above cable should be used to connect between the Control Units and either the ships
AMS system or the Remote Display Unit.

Relay Outputs
The relay outputs are rated at 30v DC at 1amps.
2
2 Cores + Earth, CSA 2.5mm (50/0.25mm), flexible stranded bare copper conductors, low
smoke halogen free insulation, cores laid up, braided screen, low smoke halogen free sheath
– grey, outside diameter 9.8mm, operating temperature 0oC + 80oC.
practice
Approved cables
2
Lapp Kabel CY cable 3 core 2.5mm
2
2

USB Connection
Refer Figure 18 for connection location.
July 14 Page 20 of 96 59812-K007 Rev 12

End of Line
Jumper
Modbus
Connector
End of Line
Jumper
USB
Connection
Relay Output
Connectors
24v DC input
Connector
Figure 18 Control Unit PCB
All Detector connectors are prewired.
July 14 Page 21 of 96 59812-K007 Rev 12

Figure 19 Wiring Drawing
July 14 Page 22 of 96 59812-K007 Rev 12

2.6 REMOTE DISPLAY UNIT
24v DC Input supply
A 24v DC supply rated 1.5 amps should be connected via a Hirschmann GM216 NJ.
2
Cable type – 2 Cores + Earth, CSA 1.5mm , fine stranded bare copper wires, braided screen,
low smoke halogen free sheath, outside diameter 10mm (max), operating temperature 0ºC +
80ºC.
practice
Suggested cables
2
Lapp Kabel 1.5mm Ölflex Classic 110CH - 10035068
2
2
Refer Figure 20 for 24vDC Socket wiring drawing.

Refer Figure 22 for connection location.
Figure 20 24v DC Socket Wiring Drawing
July 14 Page 23 of 96 59812-K007 Rev 12

Modbus
Cable type – Individually screened 2 pair data cable, 24AWG, low capacitance, low smoke
halogen free. Outer diameter 7mm (max)
practice
Suggested cables
FS Cables 2402PIFFH
Beldon 9729
Helkama RFE-HF(i) 2x2x0.75
Jinro 60V RCOP(IS)
The above cable should be used to connect between the control unit and either the ships AMS
system or the Remote Display Unit
Refer Figure 21 for Modbus Connector Wiring Drawing.

NOTES
1. A & B Connections to use RED BLACK pair
GND connection to use BLACK wire from WHITE BLACK pair.
Trim WHITE wire.
Figure 21 Modbus Connector Wiring Drawing
24v DC
Connector Modbus
Connector
Figure 22 Remote Display Unit 53836-K271
July 14 Page 24 of 96 59812-K007 Rev 12

Intentionally Left Blank
Figure 23 Intentionally Left Blank
July 14 Page 25 of 96 59812-K007 Rev 12

2.7 CONNECTING THE SYSTEM
2.7.1 Input power
+24 V dc and 0 V dc power input cables for the Control Unit should be terminated onto Supply
Input (terminal block TB1).
practice
Note all terminations should be made using crimped wires.

For each of the power connections strip the power cable to the required length to connect to
the terminals in the control unit. Then remove approximately 1cm of the outer sheath to
expose the cable screen as shown below.
Exposed screen
Figure 24 Power cable
Feed the cable into the control unit via a metal IP65 EMC gland supplied, ensuring that the
metal prongs make contact with the exposed cable screen as shown below.
Cable gland
Earthing Prongs
Figure 25 Power cable through EMC gland
July 14 Page 26 of 96 59812-K007 Rev 12

2.7.2 Relay Cables
The connection to the slowdown/shutdown relay, pre-alarm relay, backup alarm relay and fault
relay and 24Vdc supply cables at the Control Unit should be made using screened cable. For
each of the relay connection strip the cable to the required length to connect to the terminals in
the control unit. Then remove approximately 1cm of the outer sheath to expose the cable
screen as shown below see Figure 26.
practice
Figure 26 Control unit relay cable assembly

Feed the cable into the control unit via a metal IP65 EMC gland supplied, ensuring that the
metal prongs make contact with the exposed cable screen as shown.
2.7.3 Control Unit to Detector Connections

At the detector, screw the connector to the top of the detector.
Figure 27 Detector cable assembly
July 14 Page 27 of 96 59812-K007 Rev 12

At the control unit, screw the connector to the input required.
Note: Numbering
indicates correct
Detector installation
position.
Figure 28 Control unit - Detector cable assembly
2.8 SYSTEM CHECKS PRIOR TO SWITCHING ON

2.8.1 Ensure that the 24v DC input power supply cable is connected correctly at each Control Unit (if
more than one installed).
2.8.2 Ensure that the Modbus Communication (if required) is terminated correctly at each Control
Unit (if more than one installed and/or Remote Indication Display installed or connected to
AMS).
2.8.2.1 If more than one control unit is installed, please ensure the End of Line (EOL) jumpers are
removed from all Control Units (refer Figure 18) except for the highest Modbus addressed
Control Unit.
2.8.2.2 Make sure that the Modbus address’s are set as required, refer section 2.9.1 for procedure.
2.8.3 Ensure that the Backup Alarm, Pre Alarm, Fault and Slowdown/Shutdown relays are
connected correctly at each Control Unit (if more than one installed).
2.8.4 Ensure the detectors are connected to each Control Unit in the correct number sequence.
2.8.5 Check the cable run of all Modbus Communication cables between all installed Control Units
to each other and to the Remote Indication Display (If Installed) or AMS to ensure that it is not
damaged.
2.8.6 Ensure all unused Glands are removed from all Control Units and replaced by Blanking Plugs.
2.8.7 Ensure that the Modbus Communication and power supply cables are connected correctly at
the Remote Display Unit (If installed).
2.8.8 Ensure that the input voltage at the Control Unit(s) and the Remote Display Unit (If installed) is
a clean 24 V dc +30%, - 25%
2.8.9 When all of the above have been checked and are satisfactory the system is ready to switch
on.
2.8.10 Allow the engine to reach its' normal operating temperature before continuing to System
Configuration and Commissioning.
Oil Mist alarm levels should be set to a level above the actual normal operating level
displayed,
July 14 Page 28 of 96 59812-K007 Rev 12

2.9 SYSTEM SETUP / CONFIGURATION – WITH A REMOTE DISPLAY UNIT
When all of the connections have been completed and checked, power up the Control Unit and
Remote Display Unit, the following power up screen will show for a few seconds on the
Remote Display Unit.
If there is more than one Control Unit connected to the display the Modbus address needs to
be set up via the USB connection on the control unit before it can talk to the display unit.
Please refer to section 2.9.1.1 for the Modbus setup
Figure 29 Screen Shot 1
After a few seconds the following will

be seen on the Remote Display Unit,
this shows one engine connected but
may show up to ten.
Press ‘OK’
Press the ‘Engineer’ button to log in

as an Engineer.
Note – To setup Engine and

Detectors and Save Logs, you
must be logged in as Engineer.
July 14 Page 29 of 96 59812-K007 Rev 12

Enter password 012345.
Press ‘Menu’ Button to display the

Engineers menu.
To set or change Engine Names

press ‘Engine Names’.
Press the up and down arrows to

cycle through possible Engine
Names, this figure shows one engine
connected but may show up to ten.
Please see below for the full list of
Engine Names.
Press ‘Save’ once your desired name
is selected for Engines.
July 14 Page 30 of 96 59812-K007 Rev 12

Engine Selection List
ME 1 – Main Engine 1 ME 2 – Main Engine 2 FSU – Fuel Supply Unit
G/E 1 – Generator 1 GEN 1 – Generator 1 AUX 1 – Auxiliary Engine 1
Press ‘OK’.
Figure 34 will then be displayed.
To change the Time & Date press
‘Set Time / Date
Use numeric keys to set the Time

and Date. Press ‘OK’ when complete
Note – Time and Date must be
entered even if the correct Time
and Date is displayed.
Press ‘OK’, Figure 34 will then be

displayed.
To change the Engineer PIN press
‘Change Engineer PIN’.
July 14 Page 31 of 96 59812-K007 Rev 12

Use numeric keys to enter new pin of
6 digits and then store in a safe place
where only authorised users can
access it
If the PIN number is lost, please refer
to Kidde Fire Protection
Use numeric keys to re enter new pin

of 6 digits.
Press ‘OK’.
To save the event Log press ‘Save
Logs’
July 14 Page 32 of 96 59812-K007 Rev 12

Press ‘OK’ to return to Figure 34.
Note – Once the Logs are saved,
only Kidde Authorised Service
Agents can download them.
Press ‘Exit’ to return to Engines
Overview screen (Figure 31)
To setup the Detectors on each

Engine, press the button under the
mg/l display for the Engine being
setup.
Press ‘Menu’ to display the Engine

Menu.
To set or change Detector Names

press ‘Detector Names’.
July 14 Page 33 of 96 59812-K007 Rev 12

scroll through possible Detector
Names, this figure shows one
detector connected but may show up
to ten detectors.
Please see below for the full list of
Detector Names.
Press ‘Save’ once your desired name
is selected for Detectors.

Detector Selection List
Detector 1 Cylinder 1 Fuel Supply Unit 1
Detector 6 Cylinder 6 Chain Case
Detector 7 Cylinder 7 Gear Box
Detector 8 Cylinder 8 Transfer Box
Detector 9 Cylinder 9 Thrust Bearing
Detector 10 Cylinder 10 Moment Compensator
Detector 11 Cylinder 11
Press ‘OK’. Figure 46 will then be

displayed.
Press ‘Exit’.
July 14 Page 34 of 96 59812-K007 Rev 12

To set the individual Detector
parameters, press the button under
the mg/l display for the required
detector.
Press ‘Menu’ to display the Detector

Menu.

select the desired Alarm and Pre
Alarm Levels.
Slow/Shutdown Alarm
Limits 1.3 – 2.4mg/l
Pre-Alarm Limits 0.5 – 1.2mg/l
Default Settings
Slow/Shutdown Alarm – 1.8mg/l
Pre-Alarm – 0.9mg/l
Press ‘Save’ once complete.

Press ‘OK’.
Press ‘Back’ to return to Figure 49.
Repeat setting Detector settings for
the number of Detectors connected.

Once Detectors on Engine 1 have been set, Press ‘Back’ to return to Engine Overview screen.
Repeat setting Engine Names & Detector settings for the number of Engines connected.
The OMD Mk7 System should now be setup.
July 14 Page 35 of 96 59812-K007 Rev 12

2.9.1 Control Unit Modbus Addressing
When more than one Control Unit is connected on 1 system, the Modbus address needs to be
set up in each Control Unit before the system will work properly.
NOTE – For multiple Control Units per system, each Control Unit must have its own
Control Unit Address and they must be sequential, i.e. 01. 02. 03 …..10
st
All Control Units will come shipped as Modbus address 01 (1 Control Unit)
There are 2 methods to change the Modbus address, the first is via the Membrane (refer
Section 2.9.1.1), the second is via the USB connection on the PCB (refer Section 2.9.1.2)
2.9.1.1 To change the Modbus address via the front Membrane
a. With no Faults or Alarms on the Control Unit to be addressed, press the Accept button for a
minimum 1sec. (Refer Figure 53)
b. Then press the Reset button for a minimum of 1sec. (Refer Figure 53)
NOTE – The Reset button must be pressed within 5sec of pressing the Accept button
Press ‘Accept’ button for a minimum of 1sec Press ‘Reset’ button for a minimum of 1sec
Figure 53 Control Unit Membrane
c. The current Modbus address of the Control Unit will now be flashing (1sec on, 1sec off) (Refer
Figure 54)
d. Press the numerical button required until the Green LED above the pressed button flashes. (ie
For Modbus address 03, press No. 3 button(Refer Figure 54)
NOTE – The numerical button must be pressed within 10sec of pressing the Reset
button
July 14 Page 36 of 96 59812-K007 Rev 12

Current Modbus address flashing Press required numerical button for 1sec

e. The Green LED above the button pressed will now be flashing. The Control Unit will
automatically store this new Modbus address.
f. When the address has been changed, the Control Unit returns to normal operation and
indicates the number of detectors connected.
Repeat the above for the number of Control Units installed per system.
After the addresses have been changed, please ensure that the EOL jumpers are fitted to the last
Control Unit, all other Control Units need to have the EOL jumpers removed.
Refer Figure 18 for EOL jumper positions.
NOTE – The Control Units 24Vdc Power Supply needs to be removed for a period of 10sec and
re-applied to ensure Modbus address changes are recognized on the Modbus network.
Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need to be
programmed to detect the required number of engines on the system (refer Section 2.9.1.4)
July 14 Page 37 of 96 59812-K007 Rev 12

2.9.1.2 To change the Modbus address via the USB connection on the PCB (Refer Figure 55)
a. Connect the 24Vdc power supply to the Control Unit to be changed.
b. Connect the USB-B end to the USB socket located on the PCB inside the Control Unit (refer
Figure 55)
USB USB
Connection Connection
Control Unit – With Membrane Control Unit – Without Membrane
Figure 55 Control Unit – USB Connector
c. Connect the other end of the USB Lead to a USB socket on your computer (refer Figure 56)
Figure 56 Computer Connection – USB Connector
July 14 Page 38 of 96 59812-K007 Rev 12

2.9.1.3 With the above cables connected, open the ‘Mk7 Oil Mist Engine Manager’ software on the
computer. (Ensure the USB Dongle supplied is connected to the computer)
Click ‘Login’, then ‘Engineer’
Figure 57 USB Screen Shot 1
Enter 012345 and press ‘Login’
Select the required Control Unit

Address (this is the Modbus address)
Repeat the above for the number of Control Units installed per system.
After the address’s have been changed, please ensure that the EOL jumpers are fitted to the last
Control Unit, all other Control Units need to have the EOL jumpers removed.
Refer Figure 18 for EOL jumper positions.
NOTE – The Control Units 24Vdc Power Supply needs to be removed for a period of 10sec and
re-applied to ensure Modbus address changes are recognized on the Modbus network.
Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need to be
programmed to detect the required number of engines on the system (refer Section 2.9.1.4)
July 14 Page 39 of 96 59812-K007 Rev 12

2.9.1.4 Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need
to be programmed to detect the required number of engines on the system.
Press the ‘Engineer’ button to log in

as an Engineer.
Note – To detect Engines, you

must be logged in as Engineer.
Figure 60 Detect Engine Screen Shot 1
Enter password 012345.
Press ‘Menu’ Button to display the

Engineers menu.

select the number of Engines/Control
units connected on the system.
Press ‘Detect Engines’
July 14 Page 40 of 96 59812-K007 Rev 12

After a few seconds the following will
be seen on the Remote Display Unit,
this shows one engine connected but
may show up to ten.
Press ‘OK’
July 14 Page 41 of 96 59812-K007 Rev 12

2.9.2 Detector Smoke Alarm Test
Commence the smoke alarm test as follows: with the detector(s) fitted, electrically connected,
functioning and configured as described in the instruction manual.
Note: Isolation of the output relays (Pre Alarm and Slow/Shutdown Relays) is
required before commencing the smoke alarm test. If the Back-up Alarm Relay
is connected to the engine slowdown or shutdown system this should be
disconnected.
Warning: Carrying out this test without isolation or disconnection of the output
relays will cause the engine slowdown or shutdown system to operate if
connected.
a. Cut a length of wick approximately 30 mm long. Assemble the smoke tester by pushing
the wick into the wick holder fitted with the pipette bulb. Press the nylon pipe into the pipe
connector (refer to Figure 65).
Pipette Bulb
Wick Holder
Wick
Pipe Connector
Nylon Pipe
Figure 65 Smoke Tester
b. Push the nylon pipe of the smoke tester into the connector on the side of the detector
base body (refer to Figure 66).
July 14 Page 42 of 96 59812-K007 Rev 12

Figure 66 Smoke Test
c. Dip the wick into the bottle of smoke oil and reseal the bottle firmly
Note: Only a small quantity of oil is required.
d. Ignite the wick of the smoke tester and blow out the flame. Squeeze the pipette bulb to
keep the wick smoking.
Note: Care to be taken with this activity at all times.
e. While the wick is still smouldering, insert it into the pipe connector and squeeze the
pipette bulb.
f. Observe the wick is still smouldering, insert nylon pipe into the pipe connector of the
detector and squeeze the pipette bulb.
g. After tests are completed the Detector Peak Level readings should be erased. This can be
done via the Engine Menu using Clear Peak. (refer Figure 46)
h. To release the pipe from the connector, press in the metal collar on the end of the
connector at the same time as pulling the pipe out
i. Remove the nylon pipe from the pipe connector for stowage purposes.
j. The wick is reusable and can be left in the wick holder. Fully extinguish the wick after use
at all times.
k. Refer to the Material Safety Data Sheet in the event of health or safety issues.
July 14 Page 43 of 96 59812-K007 Rev 12

2.9.3 Back Up Alarm
The backup alarm is a hard wired link from each Detector installed on the system. This facility
will allow any detector which is in a fault condition and sees an oil mist level of 3.0mg/I or
greater to produce a ‘Back Up Alarm. This will produce operation of the Backup Alarm Relay in
the Control Unit; the Backup Alarm will also override any detector or detectors that are
isolated.
Whilst any detectors are in a Backup Alarm condition the accept key is inoperative until
the oil mist level drops below 3.0mg/l.
It is possible for a healthy detector to produce a Backup alarm if the level of oil rises very
rapidly.
NOTE - The Backup Alarm will not operate the Slowdown/Shutdown Relay
July 14 Page 44 of 96 59812-K007 Rev 12

2.10 ISOLATION – USING THE REMOTE DISPLAY UNIT
If required, it is possible to isolate any individual detector, a complete engine, engine Pre-
Alarm or Slowdown/Shutdown relays. This allows maintenance to be carried out without
affecting the remaining system. Isolation inhibits all alarms and faults for the isolated item
except the Backup Alarm, which is a fixed level.
To prevent the possible activation of the Back-up Alarm Relay disconnect the cable from the
top of the detector unit.
2.10.1 Engine Isolation
To Isolate Engine or detectors on the

engine, press the button under the
mg/l display for the Engine to be
isolated. You must be in the Engineer
level to carry out this function
Press the ‘Menu’ button.
Press the ‘Isolate’ button.
July 14 Page 45 of 96 59812-K007 Rev 12

To Isolate All Detectors, press the
‘Isolate’ button.
Press ‘Yes’ to Isolate All Detectors.
Press ‘OK’
To De-Isolate All Detectors, press the

‘De-Isolate’ button.
July 14 Page 46 of 96 59812-K007 Rev 12

Press ‘Yes’ to De-Isolate All
Detectors.
Press ‘OK’
You will be returned to Figure 70.
To Isolate the Pre-Alarm Relay, press
‘Isolate’
Press ‘Yes’ to Isolate the Pre-Alarm

relay.
Press ‘OK’
July 14 Page 47 of 96 59812-K007 Rev 12

To De-Isolate the Pre-Alarm relay,
press the ‘De-Isolate’ button.
Press ‘Yes’ to De-Isolate the Pre-

Alarm relay.
Press ‘OK’
To Isolate the Slowdown/Shutdown
Relay, press ‘Isolate’
Press ‘Yes’ to Isolate the

Slowdown/Shutdown relay.
July 14 Page 48 of 96 59812-K007 Rev 12

Press ‘OK’
To De-Isolate the
Slowdown/Shutdown relay, press the
‘De-Isolate’ button.
Press ‘Yes’ to De-Isolate the

Slowdown/Shutdown relay.
Press ‘OK’
Press ‘Exit’ to return to Figure 69.
Press ‘Exit’ to return to Engine 1
overview screen (Figure 68).
July 14 Page 49 of 96 59812-K007 Rev 12

2.10.2 Detector Isolation
To Isolate single Detectors, press the

button under the mg/l display for the
required detector.
Press ‘Menu’
Press ‘Isolate’
Press ‘Yes’ to Isolate the Detector.
July 14 Page 50 of 96 59812-K007 Rev 12

Press ‘OK’
To De-Isolate the selected Detector,

press ‘De-Isolate’
Press ‘Yes’ to De-Isolate the

Detector.
Press ‘OK’
Press ‘Back’ button to return to Figure 87.
Press ‘Back’ button to return to Engine 1
overview screen (Figure 86).
Press ‘Back’ button to return to Engines
overview screen.
July 14 Page 51 of 96 59812-K007 Rev 12

2.10.3 Detector Isolation – Using the Membrane
To isolate a detector at the Control Unit fitted with a Membrane, press the detector number
button for 2 seconds until the amber LED is steady. (Refer Figure 94)
If using a Control Unit without Membrane then it is not possible to Isolate or

De-Isolate Detectors. (refer Figure 3)
Note: With the detector isolated the Back-up Alarm Relay may be activated if the oil mist level
increases above 3mg/l or light is introduced in to the detector. To prevent the possible
activation of the Back-up Alarm Relay disconnect the cable from the top of the detector unit.
Repeat the above to de-isolate a detector.
July 14 Page 52 of 96 59812-K007 Rev 12

2.11 TEST MENU & EVENT LOG
This section will show how to Test the components in the OMD Mk7 system, and how to view
the Event Log. The Test and Event Log instructions are the same for User Level and Engineer
Level with the exception that the User Level cannot Test the Slowdown/Shutdown Relay.
2.11.1 Test Menu.

Warning: Carrying out this test with the engine operating will cause the engine slowdown or
shutdown system to operate if connected.
Select the desired Engine for testing.
Press the ‘Test’ button.
To test the Slowdown/Shutdown

Relay, press the ‘1’ button.
July 14 Page 53 of 96 59812-K007 Rev 12

Press ‘OK’
You will be returned to Figure 97
To Test the Pre-Alarm Relay, press
the ‘1’ button.
Press ‘OK’
To Test the Fault Relay, press the ‘0’
button.
Press ‘OK’
To Test the Backup Alarm, press the
‘Test’ button.
Note – This is a software test only.
Press ‘OK’
To Test the Optics, press the ‘Test’
button.
July 14 Page 54 of 96 59812-K007 Rev 12

Press ‘OK’
To Test the Front Panel, press the
‘Test’ button.
Press ‘OK’
overview.
Note - This will also reset all Tests.

For Testing of detectors per engine,
press the button under the mg/l
display for the required detector.
Press ‘Alarm Test’
July 14 Page 55 of 96 59812-K007 Rev 12

Press ‘Test’
Press the button under the mg/l

display for the required engine.
Note: The Control Unit and

Detector tested will show ‘Alarm’.
Press ‘Accept’
Press ‘OK’
July 14 Page 56 of 96 59812-K007 Rev 12

Press ‘Reset’
Press ‘OK’
You will now return to Figure 96.
Press the ‘Back’ button to return to
Engine Overview, Figure 95.
July 14 Page 57 of 96 59812-K007 Rev 12

2.11.2 Event Log.
The Event Log enables the user to interrogate the past 1024 events and can be accessed via
the menus below. The Event Log is a rolling buffer and when the events exceed 1024 then the
oldest event is dropped off the Event Log.
To access the Event Log from Figure 96, press ‘Event Log’ button.
Use the Up and Down arrows to

scroll through the events in this
screen.
Press ‘By Date’ tab to view event log
by date.
Use the number buttons to select the

date to view events.
Press ‘Search’ once the correct date
is entered.

screen.
Press ‘By Event’ tab to view event
log by Event.
Note - If there are no Events matching your search then this screen will be blank.
July 14 Page 58 of 96 59812-K007 Rev 12

select the event to search.
Press ‘Search’ to view event log by
selected event.

screen.
Press ‘By Detector’ tab to view event
log by Detector.

select the detector to search.
Press ‘Search’ to view event log by
selected detector.

screen.
overview, Figure 96.
Press ‘Back’ to return to Engines
Overview screen. (Figure 95)
July 14 Page 59 of 96 59812-K007 Rev 12

3 MAINTENANCE
3.1 ROUTINE MAINTENANCE

Warning: Do not work on the system unless the power is
switched off or isolated.
Caution: Ensure that anti static handling procedures are

observed applied when working on the system, i.e. Anti- Static
Wrist Straps
The following checks are recommended to be carried out every 6 months , with the
system switched off. The checks should be carried out by competent personnel with
suitable skill levels.
3.1.2 Control Unit
1. Ensure that all connectors are tight to prevent ingress of oil and moisture and the screws
on the Control Unit are correctly tightened
3.1.3 Cables
1. Ensure all connections on the Control Unit are tight.
2. Check all cables. Replace any that are found to be damaged.
3.1.4 Detectors
1. Ensure that the detector base is screwed tight into the crankcase,
2. Remove the cable connector from the detector and check for damage.
July 14 Page 60 of 96 59812-K007 Rev 12

3.2 DETECTOR HEAD REPLACEMENT
Warning: Do not remove the detector base from the crankcase whilst the engine is in
operation. This operation should be carried out while the engine is stopped
to avoid the possibility of hot oil coming out of the base fixing hole.
If an in-service detector head is removed for any reason, the detector optics must be cleaned
before reassembling and replacing it.
3.2.1 To replace the detector:
1. Switch off the system (if safe to do so) or isolate the detector
2. Remove the cable connector fitted to the top of the detector
3. Using a 4mm hexagonal key, loosen the two fixing screws in the assembly base.
Figure 119 Base Fixing Screw Removal
4. Lift out the faulty detector head

5. Fit the new detector head onto its base and tighten up the fixing screws. Re-fit the cable to
the detector head.
6. If the system was switched off, switch back on and allow the system to initialise.
7. If isolated, then de-isolate, Press OK on the Remote Display Unit, display will then return
to normal
July 14 Page 61 of 96 59812-K007 Rev 12

3.3 DETECTOR HEAD REFURBISHMENT
1. Isolate the detectors as described in section 2.10 of the instruction manual.
2. Disconnect the cable from the top of the detector unit and remove the unit from the engine
casing (refer to Figure 120).
Figure 120 Cable Disconnect
3. Using a 4mm hexagon key, unscrew 2 off screws from the underside of the detector head
(refer to Figure 119). The screws are self-retaining.
4. Remove and invert the top part of the detector head. Examine the base moulding seal and
replace if damaged or perished (refer to Figure 121).
Screw Removal
Figure 121 Base Moulding Seal

Caution: Do not press the fan, only handle the outer housing.
July 14 Page 62 of 96 59812-K007 Rev 12

5. Using the Pulling Tool (refer to Figure 115), remove the Fan Retaining Plug by capturing
the shoulder and pulling. Carefully remove the Fan from its mountings (refer to Figure
122).
Figure 122 Pulling Tool
One Fixing
Screw
Fan Retaining
Plug
Figure 123 Fan Removal
July 14 Page 63 of 96 59812-K007 Rev 12

6. Examine the 4 off compression springs and the fan retainer plug; replace any bent or
damaged items from the spares.
7. Examine the fan for free running and clogging due to oil residues. If damaged, refer to
paragraph 3.4 in the instruction manual. Although not necessary for service cleaning,
spares of the M3 screw and the fan connector seal are included in the kit.
8. Using a foam bud with glass cleaner applied, wipe carefully around the inside of the
smoke detecting orifice (refer to Figure 124).
Figure 124 Cleaning Light Guide
9. Dry the inside of the unit.

10. Examine the base body cavity and sampling tube, and wipe clean where necessary.
11. Reassemble the fan to the detector using a fan retaining plug.
Caution: Do not press the fan, only handle the outer housing.
12. Reassemble the detector head and base body. Replace the detector and then de-isolate.
13. Repeat the procedure for all detectors to be cleaned.
Refer to the Materials Safety Data Sheet in the event of health or safety issues.
July 14 Page 64 of 96 59812-K007 Rev 12

3.4 FAN REPLACEMENT
Warning: Do not remove the detector base from the crankcase
whilst the engine is in operation. This operation should
be carried out while the engine is stopped to avoid the
possibility of hot oil coming out of the base fixing hole.
3.4.1 To replace the fan:
1. Switch off the system (if safe to do so), or isolate the associated detector.
2. Remove the cable connector from the top of the detector.
3. Using a 4mm Allen key, loosen the detector fixing screws on the base.
4. Remove the detector from its base and turn it upside down to reveal the fan.
5. Remove the fixing screw holding the fan socket to the mounting plate.
6. Using a pulling tool (Part Number D9131-002 available with service kit Part No.D9221-
027), remove the fan retaining plug holding the fan onto its mounting legs.
7. Lift the fan off of its mounting legs, ensuring the springs under the fan are not lost.
8. Discard the failed fan and fit a replacement fan in reverse order of disassembly.
3.5 CABLE REPLACEMENT

If changing a detector cable, isolating that detector will be sufficient (see section 2.10)
3.5.1 Detector Cable
1. Isolate the detector with the damaged cable.
2. Remove the cable connector on top of the detector.
3. Identify the cable to be removed at the Control Unit
4. Unscrew the cable connector at the Detector and discard the damaged cable.
5. Connect the replacement cable to the connector on the Control Unit ensuring it is screwed
in place.
6. Connect the cable connector to the detector
7. De-isolate the detector
8. Press OK on The Remote Display Unit
3.5.2 Power Supply Cable Replacement (Supplied by Others)
1. Switch off the system.
2. Disconnect the damaged power supply cable from the Control Unit or Remote Display
Unit.
3. Connect the replacement power supply cable to the Control Unit or Remote Indictor Unit
ensuring wires and cable screen are correctly fitted in the terminals.
4. Switch the system on and allow the system to initialise.
July 14 Page 65 of 96 59812-K007 Rev 12

3.5.3 Communications Cable Replacement (Supplied by Others)
2. Disconnect the damaged communications cable from the Control Unit.
3. Disconnect the damaged communications cable from the Remote Display Unit or AMS.
4. Connect the replacement communications cable to the Control Unit ensuring it is screwed
in place.
5. The replacement communications cable must be connected to the terminals in the Control
Unit and the Remote Display Unit or AMS.
6. Switch the system on and allow it to initialise.
3.5.4 Control Unit (Pre-Alarm, Slowdown/Shutdown and Back Up Alarm or Fault Relay Cable
Replacement (Supplied by Others)
2. Remove the Control Unit Lid by removing the 4 screws
3. Disconnect the damaged relay cable from the Control Unit.
4. Disconnect the damaged relay cable from the monitoring equipment.
5. Connect the replacement relay cable to the control unit ensuring it is screwed in place.
6. Connect the replacement relay cable to the monitoring equipment.
7. Switch the system on and allow it to initialise.
3.6 CONTROL UNIT MEMBRANE

A new Control Unit Lid will be supplied fitted with the Membrane.
1. Unscrew the 4 screws to remove the Control Unit Lid

2. Disconnect the 2 ribbon cables connecting the Control Unit Lid to the main PCB.
3. Fit new lid in reverse
3.7 CONTROL UNIT PCB REPLACEMENT

1. Power down the system
2. Remove the 4 screws from the lid
3. Disconnect the ribbon cables
4. Remove the top half of the terminal blocks for the Communications Cables, Pre Alarm and
High Alarm Cables and Fault Cables
5. Disconnect the detector connectors (1 through to 10) – Push sides to release.
6. Remove the 4 screws at the corners of the PCB
7. Remove PCB
8. Fit new PCB in reverse order to the above
3.8 DECOMMISSIONING
All the components of the Graviner Mk7 OMD system must be disposed of as
electrical/electronic equipment waste. i.e. using waste disposal methods in accordance with
current local waste disposal regulations.
July 14 Page 66 of 96 59812-K007 Rev 12

4 FAULT FINDING
4.1 GENERAL
The table below lists a series of failure modes and the likely faults that would be indicated
should that failure mode appear. Also listed are Actions, numbered 1 to 15, which should be
followed if the associated fault appears. On the following pages, Actions 1 to 15 are shown as
flow charts which will assist with fault finding on the Graviner Mk7 OMD system
Control Unit without a Remote Display
Failure Mode Fault Indication Fault Action
Supply Failure
Control Unit Power indicator is off All Control Unit LED’s off 1.
Membrane failure
Control Unit fault Control Unit fault LED on. Control Unit fault 2.
No indication on the
All detector Power On (Green) detectors.
Control Unit fuse.
indicators on the Control Unit are Control Unit fault LED on, all 3.
off. Detectors disconnected.
detector fault LED’s flashing
1sec on 1sec off
Detector fault LED on Damaged detector cable

A detector indicating Control Unit fault LED on, all Detector failure. 4.
communications fault detector fault LED flashing
1sec on 1sec off Damaged Control Unit PCB
Detector fault LED on Fan fault

Detector fault other than Control Unit fault LED on, all LED contamination fault 5.
communications fault. detector fault LED flashing
0.5sec on 0.5sec off Detector failure
Short circuit in Detector
detectors.
All detector Power On (Green) Cable
Control Unit fault LED on, all 13.
indicators are off. Component Failure in
Detector
1sec on 1sec off
July 14 Page 67 of 96 59812-K007 Rev 12

Control Unit with Remote Display
All Control Unit LED’s off
Control Unit Power indicator is off Communications fault with Supply Failure 6.
the engine indicated on the
Remote Display
Control Unit fault LED on.

Control Unit membrane
Control Unit membrane fault Front panel test failed fault 7.
indicated on the Remote
Control Unit PCB fault
Display

Control Unit memory fault External RAM indicated on Control Unit PCB fault 8.
the Remote Display

Control Unit watchdog fault Watchdog fault indicated on Control Unit PCB fault 8.
the Remote Display
detectors.
Control Unit fault LED on, all
All detector Power On (Green) Detectors disconnected.
indicators on the Control Unit are 3.
1sec on 1sec off Power Supply failure
off.
Remote Display indicates
communications fault on all
detectors for that engine.
Detector fault LED on

Control Unit fault LED on, all Damaged detector cable
detector fault LED flashing
A detector indicating
1sec on 1sec off Detector failure. 4.
communications fault
Remote Display indicates Damaged Control Unit PCB
communications fault on one
detector

Detector fan fault. Fan fault 9.
0.5sec on 0.5sec off
Remote Display indicates fan
fault on a detector

Detector sample area
Control Unit fault LED on, all requires cleaning.
Detector LED fault. 10.
0.5sec on 0.5sec off An LED has failed.
Remote Display indicates an Detector failure.
LED fault on a detector
Detector LED fault. Detector fault LED on Detector sample area 10.
July 14 Page 68 of 96 59812-K007 Rev 12

Control Unit with Remote Display

Control Unit fault LED on, all requires cleaning.
0.5sec on 0.5sec off Detector failure.
Remote Display indicates a

photodiode fault on a
detector

Detector watchdog fault. Detector software has reset 11
0.5sec on 0.5sec off
Remote Display indicates a
watchdog fault on a detector
Modbus communications
cable fault
Remote Display indicates a Remote Display indicates a
communications fault on all communications fault on all End of line termination 12
engines engines incorrect.
Remote Display failure
detectors.
Control Unit fault LED on, all Short circuit in Detector
All detector Power On (Green) detector fault LED’s flashing Cable
13
indicators are off. 1sec on 1sec off Component Failure in
Remote Display indicates Detector
communications fault on all
detectors for that engine.
Control Unit incorrectly

addressed.
No communications between a Engine oil mist bar graph
Communications cable
single engine and the Display shown crossed out on the 14.
wiring incorrect.
Unit. display.
Modbus end of line jumpers
incorrect.
Control Unit(s) incorrectly

No communications between Multiple consecutive engine addressed.
multiple consecutive engines and oil mist bar graphs shown 15.
the Display Unit. crossed out on the display. Communications cable
wiring incorrect.
July 14 Page 69 of 96 59812-K007 Rev 12

Action 1
No Is 24v present
at the supply
input terminals
(TB1)
Is the 24v input Yes

No power supply
cable connected
correctly
Yes
Correctly connect the 24v

Replace the Control
supply to the Control Unit
Unit
July 14 Page 70 of 96 59812-K007 Rev 12

Action 2
No Is 24v supply
between 18 –
31.2v
Reconnect the input Yes

supply to the correct
voltage
Cycle the power supply to
the Control Unit off then on.
No Do all of the
membrane LED’s
operate correctly
Yes
Replace the Control

Unit lid and membrane Replace the Control Unit
PCB
July 14 Page 71 of 96 59812-K007 Rev 12

Action 3
Check the connections from the Control

Unit PCB to the Detector connectors.
Check all detector cables are connected
correctly.
No Are all
connections
made correctly
Yes
Remove the power from the

Correct the
Control Unit for a period of 15
connections
minutes
No On power up are
the detector
power LED’s on
Yes
Replace the Control

Unit PCB
End
July 14 Page 72 of 96 59812-K007 Rev 12

Action 4
Swap the detector with an adjacent

working detector.
Yes Does the

communications
fault move with
the detector
No
Replace the faulty At the Control Unit swap the

detector. detector cable with an adjacent
working connection.
Does the
Yes communications
fault move with
the cable
No
Replace the faulty Replace the Control

detector cable Unit PCB
July 14 Page 73 of 96 59812-K007 Rev 12

Action 5
Remove the detector head and

check the operation of the fan.
No Is the fan
operating
correctly
Yes
Clean the detector sample

Replace the detector chamber and replace the
fan. detector head and reset the
Control Unit.
No Has the fault

been cleared
Yes
Replace the
detector End
July 14 Page 74 of 96 59812-K007 Rev 12

Action 6
No Is 24v present
at the supply
input terminals
(TB1)
Is the 24v
No Yes
input power
supply cable
connected
correctly
Yes
Correctly connect the

24v supply to the Replace the
Control Unit Control Unit
July 14 Page 75 of 96 59812-K007 Rev 12

Action 7
Switch the Control Unit power

off and on.
Observe the LED test
performed at power up
No Do all of the
LED’s operate
correctly?
Yes
Replace the Control Unit Replace the Control

lid and membrane Unit PCB
July 14 Page 76 of 96 59812-K007 Rev 12

Action 8
Replace the
Control Unit
PCB
July 14 Page 77 of 96 59812-K007 Rev 12

Action 9
Replace the Detector fan
Reset the fault on the

Control Unit
Yes After 30 seconds

does the fan fault
remain cleared.
No
Replace the
End Detector
July 14 Page 78 of 96 59812-K007 Rev 12

Action 10
Remove the detector head

and clean the sample
chamber
Replace the detector head

and perform an optics test No
(Repeat once)
Yes
Optics test
passed?
No
Replace the
End Detector
July 14 Page 79 of 96 59812-K007 Rev 12

Action 11
Clear the fault on the

Control Unit
No Does the
watchdog fault
reoccur?
Yes
Replace the
End Detector
July 14 Page 80 of 96 59812-K007 Rev 12

Action 12
Check the Modbus connections f rom

the Remote Display Unit to each of the
Control Units.
Are all
No
connections
made
correctly?
Yes
Correct the
connections
Press the Acknowledge key f or 1
second
Press the Reset key f or 1 second
No
Are all of the
Control Units
addressed
correctly?
Press a number key to

enter the correct Yes
address
Are the end of

No line jumpers
f itted in the last
Control Unit
only?
Correct the jumper

links Yes
Replace the Remote

Display Unit
July 14 Page 81 of 96 59812-K007 Rev 12

Action 13
Remove power from the Control

Unit
Disconnect all Detectors Cables

from the Control Unit
NOTE: Power needs to be removed

Apply power to the Control Unit for a minimum of 30sec.
Connect a Detector Cable to the

Control Unit
Yes Is the Detector green

power LED on?
No
Remove power from the Control

Unit
Disconnect the suspect Detector

from the detector cable
NOTE: Power needs to be removed

Apply power to the Control Unit for a minimum of 30sec.
Connect the detector cable to the

Control Unit
Yes Are the Detector green

power LED's on
No
Replace the Replace the

Detector detector cable
July 14 Page 82 of 96 59812-K007 Rev 12

Action 14
Check the Modbus connections f rom

the Remote Display Unit to the Control
Unit.
Are the
No
connections
made
correctly?
Correct the Yes

connections
second
No
Is the Control
Unit addressed
correctly?

enter the correct Yes
address
Are the end of

No line jumpers
f itted in the last
Control Unit
only?
Correct the jumper

links Yes
Replace the Control Unit

PCB
July 14 Page 83 of 96 59812-K007 Rev 12

Action 15

second
No
Are the Control
Units
addressed
correctly?

enter the correct
address
Yes
Replace the Communications cable between the

last communicating Control Unit and the f irst
f ailed Control Unit.
July 14 Page 84 of 96 59812-K007 Rev 12

SPARE PARTS
Figure 125 Control Unit Spares

(Refer page 86 for listing)
July 14 Page 85 of 96 59812-K007 Rev 12

Control Unit Spares
Item Description Part No.
Control Unit with Membrane 53836-K270
Control Unit with Membrane (Caterpillar) 53636-K270-01
Control Unit without Membrane 53836-K276
1. Printed Circuit Board c/w Ribbon Cables 43782-K172-00
1. Printed Circuit Board w/out Ribbon Cables 43782-K172-01
1. Printed Circuit Board c/w Ribbon Cables 44782-K190-01
(Caterpillar)
2. 25mm Blanking Plug 22540-K029
3. Metal Gland 22540-K028
4. Detector Connection Cap 27400-K303
Detector Harness Kit 53569-K003

5. 6 Way Detector Connection – Qty 1
Wrench Tool – Qty 1
Control Unit Connector Kit 53569-K004

6. Relay & Power Plugs – Qty 3
7. Modbus Plug – Qty 1
8. EOL Jumpers – Qty 2
July 14 Page 86 of 96 59812-K007 Rev 12

Figure 126 Display Unit Spares
Remote Display Unit Spares

Remote Display Unit 53836-K271
1. 24VDC Power Socket (no Cable) 27400-K304
2. Modbus Connector (no Cable) 27400-K305
3. Modbus Connector c/w 5m Cable 43682-K297
4. 24VDC Power Socket c/w 5m Cable 43682-K296
July 14 Page 87 of 96 59812-K007 Rev 12

July 14 Page 88 of 96 59812-K007 Rev 12
Figure 127 Detector Spares
Detector Spares
Detector Complete 53836-K269
Detector Complete (Short Sample Pipe) 53836-K269-01
1 Detector Head Assembly 53836-K272
2 Fan Assembly (1 Screw) D5622-005-02
Fan Assembly (2 Screw) 53569-K005
3 Base Unit sub-Assembly D5622-101
4 Connector Push In 21888-K073
5 Base moulding O Ring C1513-802
July 14 Page 89 of 96 59812-K007 Rev 12

Commissioning Kit D9221-026 consists of:
Description Part No. Qty Category
Wipes, Wet & Dry A7311-001 2 Consumables
Smoke Test Oil -30 ml D9221-028 1 Bottle Consumables
Wick - 150 mm 17100-H06 3 Consumables
Smoke Tester D9221-029 1 Tools
Materials Safety Data Sheet - 2 Information
Service Kit D9221-027 consists of:

Description Part No Qty Category
Fan Retainer B3741-902 5 Spares
Compression Spring B3721-006 5 Spares
Base Moulding Seal C1513-802 5 Spares
Fan Connector Seal (1 Screw) C1413-801 5 Spares
Fan Connector Seal (2 Screw) 35134-K037 5 Spares
M3 Screw 21833-H01 5 Spares
Glass Cleaner 500ml A7311-002 1 Consumables

Foam Buds Pkts B6910-217 2 Consumables
4mm Hexagon Key B691 0-219 2 Tools

Pulling Tool D9131-002 1 Tools
Materials Safety Data Sheet - 2 Information
Recommended Operational Spares

Description Part No. Qty
Commissioning Kit D9221-026 1
Service Kit D9221-027 1
For systems with more than 10 detectors, it is recommended that additional detector head
assemblies (53836-K272) are supplied.
July 14 Page 90 of 96 59812-K007 Rev 12

4.2 COMPLETE SPARE PARTS LIST
Part No. Description
53836-K270 Control Unit with Membrane for 10 detectors

53836-K270-01 Control Unit with Membrane for 10 detectors Caterpillar
53836-K276 Control Unit without Membrane for 10 detectors omly
53836-K271 Touch Screen Display Unit
53836-K269 Detector Complete
53836-K269-01 Detector Complete (Short Sample pipe)
53836-K279 Oil Mist Manager Software and Dongle
Cable Assemblies
90º Connector
43682-K285-1.0 1.0m Cable with 90° Connector 1.0 Metres
July 14 Page 91 of 96 59812-K007 Rev 12

Straight Connector
43682-K286-1.0 1.0m Cable with Straight Connector 1.0 Metres
July 14 Page 92 of 96 59812-K007 Rev 12

Spare Parts
17100-H06 Cotton Wick (1 hank = 10 meters)

21833-H01 M3 screw
21888-K073 Connector Push in
22540-K028 Metal Gland
22540-K029 25mm Blanking Plug
27400-K303 Detector Connection Cap
27400-K304 24VDC Power Socket (no Cable)
27400-K305 Modbus Connector (no Cable)
35100-K274 Mk5 - Mk7 Retrofit Plate
35134-K037 Fan Connector Seal (2 Screw)
43682-K296 24VDC Power Socket c/w 5m Cable
43682-K297 Modbus Connector c/w 5m Cable
43782-K172-00 Printed Circuit Board c/w Ribbon Cables
43782-K172-01 Printed Circuit Board w/out Ribbon Cables
53569-K003 Detector Harness Kit
Incl 1 x 6Way Detector Connection
Incl 1 x Wrench Tool
53569-K004 Control Unit Connector Kit
Incl 3 x Relay & Power Plugs
Incl 1 x Modbus Plug
Incl 2 x EOL Jumpers
53569-K005 Fan, Micronel type (2 Screw)
53836-K272 Mk7 Detector Head Assembly
Incl 1 x 53569-K005
Incl 1 x C1513-802
A7311-001 Wet Wipes
A7311-002 Glass Cleaner 500ml
B3721-006 Compression spring
B3741-902 Fan Retainer
B6910-217 Foam Buds Pkts
B6910-219 4mm Hex Key
C1413-801 Fan Connector Seal (1 Screw)
C1513-802 Base moulding O ring
D5622-005-02 Fan, Micronel type (1 Screw)
D5622-101 Base unit sub assy
Incl 1 x 21888-K073
D5622-102 Base unit sub assy – Short Sample Pipe
Incl 1 x 21888-K073
D9131-002 Pulling tool
D9221-026 Commissioning Kit
D9221-027 Service Kit
D9221-028 Smoke Oil
D9221-029 Smoke tester
July 14 Page 93 of 96 59812-K007 Rev 12

SECTION 6
CATERPILLAR DETECTORS
July 14 Page 94 of 96 59812-K007 Rev 12

Caterpillar Detector with Short Sample Pipe Part Number 53836-K269-03
July 14 Page 95 of 96 59812-K007 Rev 12

Caterpillar Detector with Standard Sample Pipe Part Number 53836-K269-02
July 14 Page 96 of 96 59812-K007 Rev 12

气缸油加热柜
Heating Tank For Cylinder Oil
认可资料
For Approval drawing
TAIXING HAICHENG MARINE EQUIMENT CO.,LTD.
1/6
目录 INDEX
1. 气缸油加热柜简介………………………………………………………………………………………………………….. 3
Instruction For Heating For Cylinder Oil ……………………………………………………………………………… ….3
2、气缸油加热柜外形图（HTJRG-0.37-00）………………………………………………………………………….7
External View Of Heating Tank For Cylinder Oil(HCJRG-0.37-00)………………………………………………7
3、气缸油加热柜电气原理图………………………………………………………………………………………………..8
Heating Tank for Cylinder Oil Electric Diagram…………………………………………………………………………8
4、气缸油加热柜备件清单…………………………………………………………………………………………………16
Spare Parts For Heating Tank For Cylinder Oil……………………………………………………………………….16
2/6
气缸油加热柜简介
Introduction for Pumping Station
气缸油加热柜主要适用于MAN B&W 主机的注油器系统，为注油器系统提供稳
定温度的汽缸油供汽缸润滑。
Heating Tank For Cylinder Oil is mainly used for oil injection pump system
for MAN B&W main engine. Cylinder Oil supplies steady temperature of
system, and lubricates the cylinder.
一、组成
Consisting
气缸油加热柜主要由油箱、过滤器、温控电加热器、温度表温度开关、液位
开关、球阀和电气控制箱等组成。
Heating Tank For Cylinder Oil consists of fuel tank,filters, ELEC. heater,
thermometer, temperature switch, lever switch and electric control boxes, etc.
二、电气控制箱控制开关和指示灯
Electric control box of Heating Tank indicator lamp
1、白色指示灯——电源指示灯
White lamp——Source lamp
2、红色指示灯——低液位报警指示灯
red lamp——low level alarm lamp
3、绿色指示灯——电加热运行指示灯
Green lamp——heater running lamp
三、主要技术参数
3/6
Main technical parameter
1、容积：37L
Volume: 37L
2、工作温度：40～50℃
Working temperature: 40～50℃
3、工作压力：3.0～4.0bar
Working pressure: 3.0～4.0bar
4、电加热功率：750W
Power of ELEC. heater: 750 W
5、电制：440V/60Hz/3P或400V/50Hz/3P
Voltage：440V/60Hz/3P or 400V/50Hz/3P
四、安装、调试（主机停车时）
Installation and commission (main engine stops)
1、按照外形图HCJRG-0.37-00 连接各管路，检查各阀件的开启状态。
According with external view HCJRG-0.37-00,connecting each pipeline and
checking the status of the valves opening.
2、按照电气原理图接线，确保接线的正确。
Connecting by the electric principle diagram to make sure the connection.
3、打开加热柜电气控制箱上的电源开关。
Open the power on the electric control box of heating tank.
4、加热柜进入正常状态。
Heating tank is put into the normal state
4/6
五、维护
Maintenance
1、汽缸油加热柜配有两只滤器，互为备用。当加热柜工作一段时间后，处
于工作状态的滤器滤芯内沉淀了一定的杂质。这时应通过三通球阀切换至另
一台滤器，使其工作。
Two strainers were equipped on the Heating Tank For Cylinder Oil being
alternate each other. After period of working time, there will be some deposit of
impurity inside the strainer which is at the active status. While this happens,
another strainer should be put in use by the shift of the three way valve
2、滤芯清洗步骤：
Cleaning procedure of the filter element
1）将滤器盖板上的四只内六角螺栓卸下，打开滤器盖板。
Dismantle the four socket head hexagon bolts on the cover of the strainer,
open the cover;
2）取出滤网压板后，将滤芯取出。
Take out the press plate and then take out the filter;
3）将取出的滤芯放入柴油,用软毛刷清洗，清洗完成后用压缩空气吹干。清
洗杂质时，应检查滤芯有无破损。如滤芯破损，需及时更换。
Dip the filter into the diesel and clean it with soft brush, then dry it with
compressed air. Check if there is any damage of the filter element while
cleaning the impurities and replace the filter in time if any;
4）将清洁的滤芯放入滤器壳体内。确认滤器放置到位后，将滤芯压板置于
5/6
滤芯的顶部，盖上滤器盖板，均匀拧紧螺栓。
Put the clean filter element back into the strainer shell and make sure it is fitted
in position, after this, put the press plate on the top of the filter element, close
the strainer lid, then fasten the bolts;
5）清洗或更换滤芯的同时检查密封件完好情况。
Check if the sealing gasket is still in good condition while cleaning or replacing
the filter element.
六、注意事项
Note
1、加热柜具有自动加热功能，出厂时温度已设定45℃加热，不得任意调整。
Heating tank can auto heating. The temperature has been set by 45℃ before
delivery and can’t be adjusted arbitrarily.
2、低液位时不得启动电加热器。
Do not turn on the ELEC. heater while the low liquid level.
6/6
TAIXING HAICHENG SHIPPING EQUIPMENT CO.,LTD.
附件/备件/工具清单
LIST OF ACCESSORIES/SPARE/TOOL
设备：气缸油加热柜选择： □附件 ■备件 □工具
Equipment：HEATING TANK FOR CYLINDER OIL Selection： □Acc. ■Spare □Tool
序号物品名称规格单位数量备注
NO. DESCRIPTION TYPE UNIT QT’Y NOTE
滤芯
1 Ф70×Ф50×L188 Set 1
FILTER ELEMENT
外压盖O型圈
2 O TYPE CIRCLE OF Ф90×Ф84×Ф3 Pcs 1
OUTER GLAND
滤器垫片
3 Ф78×Ф58×2 Pcs 1
Filter gasket
地址：江苏省泰兴市张桥镇工业集聚区同创路 299 号
Add：58,Shilidian Street,Yaowang town, Taixing City, Jiangsu, China
E-mail：txhc2011@163.com Tel：0523-89705288 Fax：0523-89705299
排气阀总成翻转台
使用说明书
Operation Instruction
for Turntable Machine of Exhaust Valve Assembly
1 概述
1.1 产品信息
TM 系列排气阀总成翻转台是为方便维修时拆装排气阀总成而设计的设备，适用于各型船用二冲程低速柴
油机排气阀总成拆装时的翻转操作。该设备结构简单可靠，操作快捷方便，体积小巧。
本说明书适用于 TM 系列排气阀总成翻转台设备的使用及维护保养，文中的图表仅用于本文的说明，保留
对设备和技术资料进行更新和改进的权力。
1.2 制造商信息
设计制造：上海齐耀系统工程有限公司
地址：中国上海市共青路 357 弄 1 号邮编：200090
电话：+86-21-65687121
传真：+86-21-65680330
1.3 安全事项
1.3.1 使用及维护保养人员应在使用或维护前仔细阅读和学习本手册，并遵守相关安全规定。
1.3.2 安全措施与注意事项
运输：
运输及装卸时应注意安全。
必须使用安全合格的吊装工具与设备，吊装螺钉确保无损坏及安装牢固。
吊装时不允许有人员站在设备下。
使用：
每次使用前检查各部件的连接应牢固，而且运转正常。
操作中应使用必要的劳动防护用品。
其它注意事项：
不要用水清洁设备。
设备闲置时定期在光滑的加工面涂防锈油保护。
1.3.3 安全说明及标识
安全说明包含在说明书各章节中，操作者应严格遵守，以免造成对人员、财物、环境等的损害。
安全标识包含如下几类：
危险!
可能造成严重人身伤害
乃至死亡的伤害。
警告!
可能造成财物或环境
损害。
注意!
要求正确使用设备，
否则可能有轻微伤害或
损失。
２产品介绍
2.1 设备特点：
本设备整体外形紧凑，重量轻，通用性好，整体焊接为主，刚性好，结构简单，可自锁，安全可靠。
2.2 结构简介
翻转台设备大致由以下几个部分构成：台架部件，传动部件，工件连接板，止动销和保护罩，如图 1
所示。
1. 台架部件 2.传动部件 3. 工件连接板 4. 止动销 5.保护罩

图 1 TM 型翻转台结构总图
2.2.1 台架部件是翻转台设备的支架，其底面在安装时加橡胶减震块以防止设备受震动的影响。
2.2.2 传动部件结构，如图 2 所示
传动部件包含一套蜗轮蜗杆机构，轴承机构，手轮等，它们整体固定在台架部件的上方支架内，实现
转动手轮翻转排气阀总成的目的。
1.蜗轮 2. 蜗杆 3. 手轮 4. 蜗杆轴承 5. 蜗轮轴承

图2
2.2.3 工件连接板是翻转台设备与需翻转的排气阀总成的连接件，通过螺栓紧固。
2.2.4 止动销是在翻转排气阀总成前、后固定在工件连接板的槽内，防止传动装置转动，确保安全。
2.2.5 保护罩是用来保护蜗轮蜗杆传动机构的外罩。
2.3 适用范围：
本设备适用于二冲程船用低速柴油机排气阀总成维修时的拆装。
3 设备的安装
3.1 安装地点的选择
应考虑选取经济有效的合适地点安装此设备。
该处应避免有强烈震动。
该处应方便吊装并有足够的操作空间。
参考认可的安装图纸要求，安装在
船内合适的地方。
图3 设备的安装
3.2 设备的安装
参考图 3，为了防止设备受到震动的影响，把备件箱中的橡胶减震块放置在客户安装基座和设备机座中间，
用 M20 螺栓螺母标准件紧固。
4 翻转操作前的准备
4.1 设备的检查：操作前应转动手轮，检查设备各部分正常，传动零部件应松紧合适，动作平稳。
4.2 把止动销旋入工件连接板的槽内，以防传动装置受力转动，确保安全。
5 翻转操作
5.1 根据柴油机制造商说明书中的要求从柴油机上拆出排气阀总成（参考图 4），检查排气阀总成，如需拆

解则使用本设备。
5.2 吊起排气阀总成，此时排气阀及排气阀座朝下，排气阀壳出气口部位对准翻转台的安装连接板，并拧
紧安装用的连接螺栓（参考图 5）。
5.3 注意此时止动销必须在工件连接板的销槽内，以防止排气阀总成意外转动，确保安全。
5.4 拆除排气阀壳上方的液压部件及气缸壳体，并吊离。剩下排气阀和阀座及阀壳等零部件。
5.5 将止动销从连接板的销槽内退出，缓慢、均匀转动翻转台手轮，使得排气阀盘及阀座翻转至上方。
5.6 将止动销再次旋入工件连接板的销槽内，以防止排气阀总成意外转动。
5.7 拆除卡环等锁住排气阀的零件，此时排气阀和阀座可使用吊具吊出，完成拆卸（参考图 6）
。
5.8 在翻转台上装配排气阀总成的操作按以上反向顺序进行。
警告!
翻转操作中注意安全!
切勿操作手轮转动太急!
图4 排气阀总成结构示意图
图5 翻转前示意图图6 翻转后示意图
6 翻转台的维护保养
6.1 每半年空转检查设备正常、灵活、可靠。
6.2 每年二次向传动部件蜗轮蜗杆内添加润滑脂，检查并保持蜗轮蜗杆在良好润滑状态。
6.3 每次使用后都必须清洁设备并在连接板上涂一层防锈油膜，用防水塑料布扎紧罩住设备以防灰尘和潮
湿，确保设备安全及状态良好。
7 备件工具(实际详见随机提供的清单)
7.1 减振垫块：设备安装件
7.2 内六角扳手：随机工具 S = 5mm，10mm 各 1 件

１GENERAL DESCRIPTION
1.1 Equipment information
The TM series of turntable machine is designed to overturn the exhaust valve assembly by hand. It is
applicable to some types of marine engine exhaust valve assembly. The device has the advantages of simple and
credible structure, convenient operation, small volume.
This manual is intended primarily for the operator of the valve and valve seat grinding machine of the type
DM. The charts and drawings are used in this manual and may be changed in the future.
1.2 Manufacturer information

Address：No.1 lane 357 Gongqing road , shanghai, china. Postcode: 200090
Telephone：+86-21-65687121 Fax：+86-21-65680330
1.3 Safety information

1.3.1 This manual must be carefully studied before using the equipment. It will help you to use
the equipment to its full capacity and to avoid costly mistakes. All safety instructions
must be complied with. Failure to do so can result in serious injury or damage to
equipment and the environment.
1.3.2 Safety precautions
Transportation：
Ensure that the equipment is transported safely.
Use the safe tools. Make sure the lifting eyebolts are undamaged and adequately fastened.
Do not carry loads above people.
Operation:
Make sure the correct type of the equipment. Check all fixed parts to be correct and run normally.
Use safety goods in operation , if necessary.
Other warnings:
Do not clear the machine with water.
Anticorrosive oil is necessary on the machining surface during idle time.
1.3.3 Safety instructions

Safety instructions with important information concerning risks associated with particular operations, or
recommendations in respect of suitable actions or measures, are include in the text.
Three different levels of safety instructions, as shown below, are used:

Danger! Warning! Caution!
Risk of serious or fatal injury to Risk of injury to personnel Use the equipment correctly.
personnel. Safety instructions in and/or damage of property . Safety instructions in this
this group indicate when there is Safety instructions in this group indicate when there is a
a risk of serious injury or injury group indicate when there is a risk of injury or damage if the
that could cause death as a risk of injury or damage to instruction is not obeyed.
consequence of misuse. property or the environment.
２EQUIPMENT DESCRIPTION
2.1 Features：
The overall appearance of the equipment is compact, light weight, good versatility, overall welding, good
rigidity, simple structure, safe and reliable self-locking.
2.2 Equipment structure
The machine is composed of several parts as follows: framework assembly, transmission assembly,
connecting plate, a stop pin and a protective cover, see figure 1.
1. Framework assembly 2. Transmission assembly 3. Connecting plate

4. Stopping pin s 5. protective cover
Figure 1
2.2.1 Framework assembly is the support part of the machine, there are six damping pads at the feet of the
framework assembly to prevent the shake while working.
2.2.2 The transmission part，see figure 2
The transmission part includes a set of worm and worm gear,bearing mechanism, hand wheel ect. They are
overall fixed on the bench component, achieving to overturn the exhaust valve assembly.
1.worm gear 2. Worm 3. Hand wheel 4. Bearing for worm 5. Bearing for worm wheel
Figure 2
2.2.3 The connecting plate is a connecting piece for exhaust valve assembly by several bolts.
2.2.4 Stop pin is fixed connecting plate in the gap to prevent the driving device to rotate, to ensure the safety
while turned over the exhaust valve assembly.
2.2.5 The protection cover is used to cover the worm and worm gear.
2.3 Application：
This equipment is suitable for exhaust valve assembly of two stroke marine diesel engine while repairing is
needed.
3 INSTALLATION
3.1 Location of the equipment
Carefully consider where to locate the machine in the most effective and economical use.
Avoid any area with strong vibrations.
Ensure availability of lifting facilities and enough operation space.
mount the machine on a suitable foundation according to the mounting
drawing by us
Figure 3
3.2 Installation
Mount the grinding machine on the damping pads supplied in the spare box to prevent the vibrations by
standard parts of M20 (figure 3).
4 PREPARATIONS BEFORE OPERATION
4.1 Turn the hand wheel before operating, check the equipment to be correct, the transmission parts should run
properly and smoothly.
4.2 The stop pin is screwed into the groove of the connection plate, in order to prevent the rotation by force, to
ensure the safety.
5 OPERATION OF TURNOVER
5.1 According to the diesel engine manufacturer’s instruction, dismantle the exhaust valve assembly from diesel
engine (see Figure 4),check the exhaust valve assembly. This equipment is necessary if the exhaust valve
assembly is needed repairing.
5.2 Lift the exhaust valve assembly, at the moment the exhaust valve and valve seat is downwards, exhaust valve
housing outlet is aligning with the connecting plate of the turntable, connecting and tighten the bolts (see Figure
5).
5.3 To be sure that the stop pin must be in the groove of the connection plate, to prevent exhaust valve
assembly to rotate accidentally, to ensure the safety.
5.4 Removing the hydraulic components and the cylinder shell above the exhaust valve, and hanging from the
assembly. There are the rest of the exhaust valve, seat and the valve shell parts.
5.5 Exit the stop pin from the pin groove on the connecting plate, turn the hand wheel slowly and smoothly, so
that the exhaust valve disc and valve seat turn to the top.
5.6 Screw the stopping pin into the connection plate again, to prevent exhaust valve assembly unintended rotation.
5.7 Remove such as the snap ring that locking the exhaust valve parts, then the exhaust valve and valve seat can
be hung out completely (see Figure 6).
5.8 the steps to install the exhaust valve assembly by the turntable is according to the above in reverse order.
Warning!
Ensure the safety during
operation!
Do not run the wheel too
quickly!
Figure 4 Exhaust valve assembly structure diagram
Figure 5 diagram before turnover Figure 6 diagram after turnover

6 MAINTENANCE
Check the following regularly in order to ensure a good condition and a safe operation:
6.1 Run idle to check the equipment normal, flexible and reliable every six months.
6.2 Add grease to the transmission parts such as worm , check and maintain the worm in good lubrication
condition two times a year.
6.3 Clean and coated with a layer of rust preventing oil after each operation on the connection plate, coat the
equipment to prevent dust and damp with a waterproof plastic cloth, ensure the safety of equipment and in good
condition.
7 APPENDIX TOOLS
There are following appendixes in the spare box along with the machine.
7.1 ：Damping pad ：used for installation of machine .
7.2 Hexagon wrench keys：S=5，10. 1 piece for each diameter，used for installing or removing the bolts.
乐春
hun（Shanghai） Tel:021-51961688 Fax:021-51961688-8007
LC-AVM-01
轴向振动监测仪使用说明书
（2017 版）
上海乐春重工机电设备有限公司
SHANGHAI LECHUN HEAVY MACHINERY & ELECTRONIC EQUIPMENT CO.,LTD
Instruction Manual of Axial Vibration Monitor LC - AVM - 01 / LC - AVM - 01 振动监控仪使用手册

目录
1. 序论 ......................................................................................................................... 3
1.1 系统说明 .......................................................................................................... 3
1.2 产品支持 .......................................................................................................... 3
2. 技术参数 .................................................................................................................. 4
3. 功能说明 .................................................................................................................. 4
4. 拆包（箱） ................................................................................................................ 5
5. 安装 ......................................................................................................................... 6
5.1 机械部分安装 ................................................................................................... 6
5.2 电子部分安装 ................................................................................................... 6
5.2.1 电缆 .............................................................................................................. 7
5.2.2 安装和登记 ................................................................................................... 7
6. 系统设置 .................................................................................................................. 8
7. 故障 ....................................................................................................................... 10
7.1 故障检测过程 ................................................................................................. 10
7.1.1 检查传感器电源 ......................................................................................10
7.1.2 检查通电状态下控制单元状况 ................................................................11
7.1.3 检查传感器输入和显示 ......................................................................... 12
7.1.4 检查报警系统电流输出 ......................................................................... 13
7.1.5 检查延迟设置点和输出 ......................................................................... 14
7.1.6 检查传感器 ........................................................................................... 15
7.2. 替换部件 ....................................................................................................... 15
7.2.1 替换传感器 ........................................................................................... 15
7.2.2 替换电路板 ............................................................................................ 15
8. 附录 ....................................................................................................................... 15
Instruction Manual of Axial Vibration Monitor LC - AVM - 01 / LC - AVM - 01 振动监控仪使用手册 1

1. Introduction ............................................................................................................. 19
1.1 System description ......................................................................................... 20
1.2 Product support .............................................................................................. 20
2. Technical parameters .............................................................................................. 21
3. Functional description ............................................................................................. 22
4. Unpacking ............................................................................................................... 22
5. Mounting ................................................................................................................. 24
5.1 Mechanical mounting ..................................................................................... 24
5.2 Electrical mounting ......................................................................................... 24
5.2.1 Cable ..................................................................................................... 25
5.2.2 Installation & registration ....................................................................... 25
6. System settings ...................................................................................................... 26
7. Trouble Shooting .................................................................................................... 28
7.1 Checking process ........................................................................................... 28
7.1.1 Check the probe power supply .............................................................. 28
7.1.2 Check the control unit during power on ................................................. 29
7.1.3 Check the probe input & display ........................................................... 30
7.1.4 Check the current output of the alarm system ....................................... 31
7.1.5 Check the slow down set-point and output ............................................ 32
7.1.6 Check the probe .................................................................................... 33
7.2 Replaceable components ............................................................................ 33
7.2.1 Replace the probe ................................................................................. 33
7.2.2 Replace the circuit board ...................................................................... 33
8. Appendix ................................................................................................................. 34

1. 序论
1.1 系统说明
LC - AVM - 01 轴向振动监测仪是一种控制和监测系统，该系统能够监测柴油机曲轴
轴向振动以确保柴油机安全运行。
LC - AVM - 01 能测量 0.00 ~ 10.00 mm 的位移峰－峰值，在控制单元的显示屏上能
显示出位移量，也能通过报警 / 监测输出端口读出。
为了方便设置和调整，在控制单元盖内贴有标签，显示接线端连接和设置过程。
1.2 产品支持
如果您需要安装或者服务，请与我们联系：
上海市浦东新区浦三路 4399 号 8 栋
电话：0086-21-51961688
传真：0086-21-51961601
为了能最有效帮助您，请准备以下信息：
1) 船名、厂名
2) 可疑部件（故障）名称
3) 部件识别号（序列号）

4) 问题故障说明
注意：由于每个轴向振动监测仪包含各自标定部件，因此，我们需要序列号来为您提
供正确的部件。
2. 技术参数
运行温度范围： - 10 ℃ ~ + 70 ℃
防护等级： IP55
测量范围：最大值：10.00 mm 峰－峰值（±5.00 mm）
线性度：5.00 mm 峰－峰值（±2.50 mm）
电源：电源电压：24 V±20 %
最大电流消耗：300 mA
传感器：型号：LC - AVM - P01 电缆长度：7 m
安装距离：8.5 mm
报警 / 监测电流输出：
输出：4 - 20 mA 最大载荷：250 欧姆
0 mm 峰－峰值=> 4 mA
5 mm 峰－峰值=> 20 mA
Iout [mA] = 1.6×（位移mm峰－峰值）+ 4
减速输出：点接触电位（NO）
最大载荷：50 V 100 mA
设置点调整范围：0.00 至 10.00 mm
减速延迟时间： 0 - 300 秒每次 20 秒
精确度：传感器输入至显示，曲轴位置输出报警 / 监测电流输出：±5 %
减速延迟时间：±15 %
3. 功能说明
传感器传送电流信号至控制单元（电流信号的强度直接与传感器和曲轴之间的距离成
比例），控制单元将来自于传感器的电流信号转换成每 mm 曲轴位移为 1 v 的电压。峰-
峰值位移量显示在具有 0.01 分辨率的四位显示屏上。并通过一个电压一电流转换器，将
一个 4 - 20 mA 电流信号发送至“报警/监测电流输出”端口。

当来自传感器的峰-峰值位移信号下降时，显示值和“报警 / 监测电流输出”不会立
即变化，但将会慢慢下降至实际位移值。
如果峰－峰值位移量超过设置点，减速输出将动作。设置点和“减速延迟时间”是可
以调整的。一旦峰－峰值信号下降至设置点，减速输出和减速延迟时间将会重置。通过按
住控制单元的设置点按钮，“减速输出”设置点可在屏上显示。
当该单元发生故障时（如：不足的电流电压、短路、传感器电缆断线等），屏上将显
示 18.88，此时“报警 / 监测电流输出”将为 0 mA。每当接通系统电源时，故障显示将
会维持 4 ~ 8 秒，然后进入正常状态。
4. 拆包（箱）
交货付款要检验以确保 AVM 系统没有损坏，包装内容如下：
1) 轴向振动监测仪安装、设置说明（文件）
2) 轴向振动监测单元
检查电路板上的识别码与 AVM 系统标准单上是否一致，如果不对应，请与我们联系。

3) 传感器
请检查传感器上的识别码与 AVM 标准单和传感器标准单上是否一致，如果不对应，
请与我们联系。
5. 安装
5.1 机械部分安装
传感器安装请参照附录 —— 机械安装说明图纸。为了保证峰 - 峰值的正确读出，
传感器与被测件之间的正确距离是非常重要的。LC - AVM - 01 传感器的正确安装间隙为
8.5 mm。
安装钢管，将便于电缆通过钢管连接到发动机外部侧壁上，轴向振动监测控制单元
装在电缆所能连接的范围内。
更多的细节请参阅所附图纸。
5.2 电子部分安装
LC - AVM - 01 振动监控仪控制单元的主板上安装有 K1 至 K6 的接线柱。每只接线柱
上标明引脚号。例如：在 K4 上的引脚 3 可特指为 K4.3。主板的接线如下图所示。接地标
志表明 K1.2、K3.2 和 K4.2 通过主板直接接地。

当控制单元接上电源后，控制单元将显示 18.88.，大约 8 秒钟后，仪器进入正常工作
状态，同时，控制单元将显示为 0.00 ~ 0.05 mm。若不是，则参照第 7 部分内容，判别
故障原因。
5.2.1 电缆
传感器电缆可以根据要求进行剪切，还可以用相同电缆和接线盒进行延伸。
报警 / 监测电流输出使用屏蔽线与发动机控制系统连接，电缆的屏蔽部分与接头的
连接按下图：
减速输出使用屏蔽线与发动机控制系统连接，电缆内的屏蔽可不接，减速和报警 / 监
测电流输出可以使用一根多芯屏蔽电缆来替代两根电缆。我们建议使用横截面为 0.75
mm2的电缆。
5.2.2 安装和登记
为了有效的提供帮助，我们提供登记表。详细填写相关信息并寄回给我们，当需要替
换故障部件时，我们可根据登记信息提供有效服务。

6. 系统设置
位于 AVM 控制单元盖内部的线路图，提供电路板安装总览。
线路图包含有接线说明，减速延迟时间设置，减速设置点调整和显示等信息。并且也
提供了传感器的安装间隙。在安装传感器和连接电路板之后，将准备设置轴向振动监测仪。
设置过程有两步：
根据你所使用的发动机型号，参考“发动机安全运行的轴向振动范围”。按住设置点
按纽通过旋转调节电位器（P4）来调整设置，直到屏上显示出要求的设置点。
1) 调节减速延迟波段开关以确定延迟时间，建议初始设置为 100 S（“5”）。

注意：电路板上有 3 个可调式电位器，（P1、P2、P3）他们的功能如下：
P1：对于传感器信号进行调整
P2：对于报警范围进行调整
P3：对于基准电压进行调整
通常情况下，严禁调整 P1、P2、P3

7. 故障
7.1 故障检测过程
当出现可疑故障时，通过下列步骤，将执行一个完整的系统检测以确定故障。
7.1.1 检查传感器电源
连接电源至 K1
显示屏会显示 18.88（错误码）
检查 K2 上的电压，此时读数为 14.0 ~ 16.0 V
否则，电路板有故障，需要替换（参见 7.2.2 替换电路板）。

7.1.2 检查通电状态下控制单元状况
连接 K2 至检测接线端 K5：K2.1 ~ K5.1，K2.2 ~ K5.2，K2.3 ~ K5.3。

当打开电源，屏上会显示 18.88（错误码），大约 8 秒后大约 8 秒后恢复正常并显示
0.00 ~ 0.05 mm，否则，电路板有故障，需要替换。（参见 7.2.2 替换电路板）。

7.1.3 检查传感器输入和显示
部分连接 K2 至检测接线端 K5：K2.1 ~ K5.1，K2.2 ~ K5.2

读数将会稳定在 6.5 mm±1 mm。此值与传感器的特性计算出的斜率相对应。否则，
电路板有故障，需要替换。（参见 7.2.2 替换电路板）。

7.1.4 检查报警系统电流输出
部分连接K2 至检测接线端K5：K2.1 ~ K5.1，K2.2 ~ K5.2，连接一个安培表至K3，

连接K2.3 ~ K5.3，关注输出电流和显示值之间的关系，控制单元显示值和输出电流Iout应
满足以下公式：
Iout (mA)＝1.6×（显示值）＋4
对于LC - AVM - 01，4 mA对应于 0 mm，20 mA对应于 10 mm，当出现故障或打开
电源（显示：18.88）时，Iout为 0.00 ~ 0.08 mA。
如果 Iout 值与公式值有较大区别，则电路板有故障，需要替换（参见 7.2.2 替换电
路板）。

7.1.5 检查延迟设置点和输出
连接欧姆表至 K4
调节减速延迟时间至“0”位
部分连接 K2 至检测接线端 K5：K2.1 - K5.1，K2.2 - K5.2
通过设置点按钮检查实际设置点，如设置点明显大于 5 mm，则调节 P4，减小设置点。
当初始显示高于调整后的设置点，减速继电器将被激活：Rsd = 0 Ω,
连接 K2.3 至 K5.3 并观察欧姆表上的读数。
当显示读数小于调整后的设置点时，减速继电器将断开， Rsd = ∞ 或 Rsd ＝
Rsupervisionif，一监控电阻安装于 K6.1 和K6.3 之间。
如果减速继电器有故障，则电路板需要替换（参见 7.2.2 替换电路板）。
注意：记住恢复设置的减速延迟时间和设置点至原始数值。

7.1.6 检查传感器
连接电源和安培表至传感器（如图）。
通过来回移动一块在传感器前的金属来检查，如果Ip没有任何变化，则传感器或者电
缆可能有故障，需更换（参见 7.2.1 替换传感器）。
7.2 替换部件
如果故障检测显示系统故障，我们可以提供新的电路板和传感器。
7.2.1 替换传感器
当传感器出现故障，可以向我们订购一个新传感器。
新电路板和传感器的安装请参照第 6 章系统设置。
注意：请记住替换旧的校准纸。
7.2.2 替换电路板
当电路板出现故障，请订购一块替换电路板，订货时注明传感器和电路板上的识别号。
替换电路将进行相应的校准。
取下 6 颗固定螺母，拆下旧电路板，然后安装上新电路板。
连线和设置请参照 5.2 节电子部分安装和第 6 章系统设置。
注意：记得替换包含旧序列号的 LC - AVM - 01 整机校准表。
8. 附录
附件在此页之后：
z 机械部分安装说明
z 登记表（请寄回给我们）
z AVM 整机校准表
机械安装说明
传感器与显示峰－峰值运动的控制单元相连并将信号发送至发动机控制系统。
传感器安装在减振器壳体上，既可安装在减震器上部，也可安装在下部。
登记表

请将空白处填写完整并寄至：
上海市浦东新区浦三路 4399 号 8 栋
电话：0086-21-51961688
传真：0086-21-51961601
振动监控仪
产品信息
型号（LC - AVM - 01）
完整的识别号
电路板识别号
传感器识别号
型号和标识号都可以在控制单元的电路板中找到。
船 / 工厂信息
船 / 工厂名称
劳埃德号船号
船厂
发动机型号发动机号
发动机制造商
安装日期安装由：船厂 / 承包商 / 首席工程师（请
注明）
备注：
振动监控仪校准表

LC - AVM - 01 序列号：
LC - AVM - 01 电路板序列号：
LC - AVM - 01 传感器序列号：
由于其它传感器的读数可能会不正确，请勿使用未经我们重新校准的传感器。
发动机安全运行的轴向振动限制
发动机型号检修报警减速
电路板测试及校准由：
签字：
1. Introduction

1.1 System description
Axial vibration monitor LC - AVM - 01 is a control and monitoring system which can
monitor the crankshaft axial vibration to ensure safe operation of the diesel engine.
LC - AVM - 01 can measure 0.00 ~ 10.00 mm displacement (peak - to - peak) and
the valve can be displayed on the control unit or readout through the alarm / monitor
output terminal.
For easy setup and adjustment, the control unit cover is labeled to display terminal
connection and setup process.
1.2 Product support

If you need to install or service, please contact us:
Shanghai Lechun Heavy Machinery & Electronic Equipment Co., Ltd
Building 8, No. 4399 Pusan Rd, Pudong New District, Shanghai
Tel: 0086- 21-51961688
Fax: 0086-21-51961601
Please provide the following information to obtain the help effectively:

1) Vessel name, plant name
2) Suspect component (fault) name

3) Component identification number (serial number ×××××-×)
4) Fault description
Note: Since each axial vibration monitor contains its own calibration components,
we need a serial number to provide you with the correct components..
2. Technical parameters
Operating temperature range: - 10 ℃ ~ + 70 ℃

Protection grade: IP55
Measurement range: Max. 10.00 mm peak to peak (±5.00 mm)
Linearity: 5.00 mm peak to peak (±2.50 mm)
Power supply: Supply voltage: 24 V±20 %
Max. current consumption: 300 mA
: Type: LC - AVM - P01, Cable length: 7 m
Installation distance: 8.5 mm
Alarm / monitoring current output: Output: 4 - 20 mA, Max. load: 250 Ω
0 mm peak to peak => 4 mA
5 mm peak to peak => 20 mA
Iout [mA] = 1.6×(displacement mm peak to peak) +
4
Slow down output: Point contact potential (No)
Max. load: 50 V100 mA
Set point adjustment range: 0.00 ~ 10.00 mm
Slow down delay time: 0 - 300 sec, 20 seconds each time
Accuracy: Probe input to display, crankshaft position output
alarm / monitoring current output: ±5 %
Slow down delay time:±15 %

3. Functional description
The probe transfers the current signal to the control unit (the intensity of the current
signal is directly proportional to the distance between the probe and crankshaft), and the
control unit will convert the current signal from the probe into a voltage of 1 V for each
MM crankshaft displacement. The peak-to-peak displacement is displayed on a
four-digit display with a resolution of 0.01 mm and a 4-20 mA current signal is sent to the
"Alarm/Monitoring Current Output" by a voltage-to-current converter.
When the peak-to-peak displacement signal form the probe decreases, the display
value and the ”Alarm/Monitoring Current Output” will not change immediately, but will
slowly decrease to the actual peak-to-peak displacement.
If the peak-to-peak displacement exceeds the set-point, the ”Slow Down Output”
will act. The set-point value and the Slow Down Delay Time” can be adjusted. Once the
peak to peak signal drops to the set-point value, the “Slow Down Output” and the “Slow
Down Delay Time” will be reset.
The “Slow Down Output” set-point value can be shown on the display by pressing
the “Set-point” button found under the control unit cover.
External faults, such as insufficient supply voltage or short-circuiting/disruption of
the probe cable, will be indicated on the display by 18.88., and the ”Alarm/Monitoring
Current Output” will be 0 mA. When the system is powered on, the fault display will last
for 4-8 seconds and then enter the normal state.
4. Unpacking
Delivery must be inspected to ensure that the AVM system package is complete
and undamaged. The contents of the package are as follows:
1) Axial Vibration Monitor Mounting and set-up instruction (This Document).
2) Axial Vibration Monitor Control Unit
Open the box cover and check whether the circuit board identification number is
consistent with the identification number on the AVM calibration sheet. If not, please
contact us.

3) Proximeter probe and cable
Please check whether the identification number on the probe and cable are
consistent with the AVM calibration sheet and probe calibration sheet. If not, please
contact us.

5. Mounting
5.1 Mechanical mounting
Please refer to appendix - Mechanical Mounting Instruction drawing for mounting
probes. The correct gap between the probe and the damper is very important in order to
ensure the peak-to-peak value is read correctly. The correct mounting gap of LC - AVM -
01 probe is 8.5 mm.
Mount the steel pipe which makes it easy for the probe cable to be connected
through the pipe to the outside of the engine side wall. The Axial vibration monitor
control unit is mounted on the engine side wall within the range of the probe cable
connections.
Please refer to the attached drawing for more details.
5.2 Electrical mounting

The terminals on the AVM circuit board are from K1 to K6, and pin numbers are
indicated as indexes, i.e pin No.3 on K4 is designated K4.3. The circuit board is to be
connected as indicated below. The ground symbol indicates that K1.2, K3.2 and K4.2
are directly grounded through the circuit board.
When the power is turned on, the system will display the error code 18.88.. After
about 8 seconds, it will return to normal operating condition and indicate 0.00-0.05 mm.
If not, refer to chapter 7 Trouble Shooting to identify the cause of the failure.

5.2.1 Cable
The probe cable can be cut off to desired length and also can be extended with the
similar cable and junction box.
The Alarm/Monitoring Current Output is connected to the engine control system by
a shielding cable. The connection between the shield and cable gland is as follows:
The Slow Down Output is also connected to the engine control system by a
shielding cable, and the shield is to be terminated in the cable gland.
The Slow Down and the Alarm/Monitoring Current Output can be replaced by a
multi-core shielded cable instead of two cables.
We recommends cables with a cross section of 0.75 mm². Please refer to the plant
specification for information on plant specific requirements.
5.2.2 Installation & registration

In order to assist in the most efficient way, we have a registration form. Please fill in
the relevant information in detail and send it back to us. When it is necessary to replace
the defective parts, we can provide effective service according to the registration
information.

6. System settings
A circuit diagram inside the AVM control unit cover provides an overview of circuit
board installation:
The circuit diagram contains terminal assignment, slow down delay time setting,
slow down set-point adjustment and readout, etc. And the probe mounting gap is
indicated for quick reference. After mounting the probe and connecting the circuit board,
the Axial Vibration Monitor is ready for set-up.
The set-up procedure has two steps:

First, the set-point for slow down has to be adjusted. Please refer to your engine
data on appendix “AVM Calibration Sheet” , press and hold the set-point button (S1) to
adjust the set-point by turning the screw on the set-point adjust potentiometer (P4) until
the required set-point is shown on the display.
Second, the slow down delay time has to be adjusted. This is done by turning the
arrow shaped slot in the slow down potentiometer. The recommended initial setting is
100 seconds ( “5” ).
Note: There are 3 adjustable potentiometers(P1, P2, P3) on the circuit board, their
functions are as follows:
P1 : Scaling of probe signal to meter
P1 : Internal adjustment for alarm limits
P3 : Internal adjustment for voltage reference
Normally, it is strictly prohibited to adjust P1, P2 and P3.

7. Trouble Shooting
7.1 Checking process
When a suspicious failure occurs, a complete system test should be performed
through the following steps determine the failure.
7.1.1 Check the probe power supply

Connect the power supply to K1
The display will indicate 18.88. (error code)
Check the voltage on K2
The readout should be 14.0 - 16.0 V
Otherwise, the circuit board is out of order and needs to be replaced (Please see
7.2.2 Replace the circuit board).

7.1.2 Check the control unit during power on
Connect K2 to the test terminal K5: K2.1-K5.1, K2.2-K5.2, K2.3-K5.3.
When the power is turned on, the display will indicate 18.88. (error code), after
about 8 seconds, it will return to normal and indicate 0.00-0.05 mm. Otherwise, the
circuit board is out of order and needs to be replaced (Please see 7.2.2 Replace the
circuit board).

7.1.3 Check the probe input & display
Partly connect K2 to the test terminal K5: K2.1-K5.1, K2.2-K5.2.
For LC-AVM-01, the readout will stabilize at 6.5mm±1mm, this value corresponds
to the slope calculated by the characteristics of the probe. Otherwise, the circuit board is
out of order and needs to be replaced. (Please see 7.2.2 Replace the circuit board).

7.1.4 Check the current output of the alarm system
Partly connect K2 to the test terminal K5: K2.1-K5.1, K2.2-K5.2, connect an
amp-meter to K3, connect K2.3 to K5.3 and pay attention to the corresponding values of
Iout and the display reading, the control unit display value and the Iout should satisfy the
following formula:
Iout [ mA ]=1.6×(display indication [mm] )+4
For LC-AVM-01, 4mA corresponds to 0 mm, 20mA corresponds to 10 mm, and Iout
is 0 ~ 0.08 mA when failure occurs or power is turned on (display: 18.88).
If Iout is quite different from the formula value, the circuit board may fail and needs to
be replaced (Please see 7.2.2 Replace the circuit board).

7.1.5 Check the slow down set-point and output
Connect an ohm-meter to K4.
Adjust the slow down delay time to position “ 0 ”.
Partly connect K2 to test terminal K5 : K2.1-K5.1, K2.2-K5.2
Check the actual slow down set-point by pressing the set-point button. If it is greater
than 5 mm, adjust P4 to reduce the setting point.
When the initial display is higher than the set-point after adjustment, the slow down
relay will be activated: Rsd = 0 Ω.
Connect K2.3 to K5.3 and observe the readings on the ohm-meter. If the display
reading is less than the adjusted set point, the slow down relay will be disconnected; Rsd
=∞ or Rsd＝Rsupervision, a supervision resistor is mounted between K6.1 and K6.3.
If the slow down relay fails, the circuit board needs to be replaced (See 7.2.2
Replace the circuit board).
Note: Remember to reset the slow down delay time and set-point to their
original values.

7.1.6 Check the probe
Connect the power supply and amp-meter to the probe.
First, check the connection by moving a piece of metal back and forth in front of the
probe. If no variation in IP is found, the probe or the probe cable have a failure and need
to be replaced (please see 7.2.1 Replace the probe).
7.2 Replaceable components

If the trouble shooting indicates system failure, we can provide new circuit boards
and probes.
7.2.1 Replace the probe

In case of probe failure, you can order a new probe and circuit board from us.
Please refer to Chapter 6. System settings for installation of the new circuit board
and probe.
Note: Please remember to replace the old calibration sheets.
7.2.2 Replace the circuit board

In case of circuit board failure, please order a replacement circuit board and
indicate the identification number of the probe and circuit board when ordering.
The replacement circuit board will be calibrated accordingly and delivered .
Dismount the old circuit board by taking out six screws holding the metal plate.

Then mount the new circuit board by using these six screws, please note not to loosen
the nuts on the circuit board!
For wiring and set-up, please refer to section 5.2 electrical mounting and Chapter 6.
System settings.
Note: Remember to replace the LC-AVM-01-COMOLETE Calibration Sheet
containing the old serial number.
8. Appendix
The following appendix are to be found on the next page:
z Mechanical mounting instruction
z Registration form (Please send to us)
z AVM Calibration Sheet
Mechanical Mounting Instruction

The probe is connected to the control unit that displays peak- to- peak movements
and sends the signal to the engine control system.
The proximeter probe is mounted on the damper housing, which can be installed
either on the upper part of the damper housing or on the lower part..
Registration Form

Please fill in the blanks and return this form to:
SHANGHAI LECHUN HEAVY MACHINERY & ELECTRONIC EQUIPMENT CO., LTD
Tel: 086-021-51961688
Fax: 086-021-51961601
Axial Vibration Monitor
Product information
Type(LC - AVM - 01)
Complete Identification No.
Circuit board Identification No.
Probe Identification No.
The type and identification number can be found on the circuit board of the control unit.
Vessel / Plant information

Vessel / Plant name
Lloyds No. Hull No.
Yard
Engine type Engine No.
Engine builder
Date of installation Installed by: Yard / Contractor / Chief
Eng (Please indicate)
Remarks:
AVM Calibration Sheet

LC-AVM-01 Serial No.:
LC-AVM-01 Circuit Board Serial No.:
LC-AVM-01 Probe Serial No.:
Please do not use the probe without our recalibration as other probes may cause
incorrect readouts.
Axial Vibration Limit for Safe Engine Operation

Engine Type Maintenance Alarm Slow-Down
Circuit board tested and calibrated by
Sig.

Technical Documentation for
Ø2700 X 380 Vibration Damper
Supplier: AAM
Component designation: Viscous Vibration Damper
Dimensions: Ø2700 X 380
AAM Document number: DOC002866
AAM part number: SPN047366
Engine: QMD-MAN 6G45ME-C9.5
Application: Main Propulsion Engine
Shipyard: SHANHAIGUAN
1
AAM
131 Parkinson Lane
Halifax
West Yorkshire
HX1 3RD
United Kingdom
Tel: +44 1422 395106
Fax: +44 1422 357234
Email: David.Whitaker@aam.com
HWW Reference: 36.06.482
Revision Date Comments Author

00 2018-11-13 Initial release Y. Mulla
2
DOC002866
TABLE OF CONTENTS
1 ABOUT THIS MANUAL ............................................................................................................................. 5
2 SAFETY REGULATIONS ............................................................................................................................. 6
2.1 INTENDED USE ........................................................................................................................................... 6
2.2 SYMBOLS AND WARNING SIGNS ..................................................................................................................... 6
2.3 STRUCTURE OF SAFETY MESSAGES.................................................................................................................. 6
2.4 PERSONAL PROTECTION ............................................................................................................................... 6
2.5 REQUIREMENTS OF THE OPERATING PERSONNEL ............................................................................................... 6
2.6 ENVIRONMENTAL PROTECTION...................................................................................................................... 6
3 PRODUCT DESCRIPTION .......................................................................................................................... 7
3.1 DESCRIPTION OF THE DAMPER ...................................................................................................................... 7
3.2 APPLICATION ............................................................................................................................................. 7
3.3 FUNCTIONAL DESCRIPTION ........................................................................................................................... 7
4 TECHNICAL DATA ..................................................................................................................................... 8
4.1 PRODUCT IDENTIFICATION............................................................................................................................ 8
4.2 TECHNICAL SPECIFICATIONS .......................................................................................................................... 8
4.3 TECHNICAL DRAWING .................................................................................................................................. 9
5 TRANSPORT AND STORAGE ................................................................................................................... 10
5.1 TRANSPORT ............................................................................................................................................ 10
5.2 CHECK FOR TRANSPORT DAMAGE................................................................................................................. 10
5.3 STORAGE ................................................................................................................................................ 10
5.4 UNPACKING ............................................................................................................................................ 10
6 INSTALLATION ....................................................................................................................................... 11
6.1 GENERAL ................................................................................................................................................ 11
6.2 HORIZONTAL LIFTING ................................................................................................................................ 11
6.3 HORIZONTAL TO VERTICAL LIFTING ............................................................................................................... 12
6.4 VERTICAL LIFTING ..................................................................................................................................... 13
6.5 ASSEMBLY TO ENGINE ............................................................................................................................... 13
7 OPERATION ........................................................................................................................................... 14
7.1 COMMISSIONING ..................................................................................................................................... 14
7.2 WARNING .............................................................................................................................................. 14
7.3 DAMPER COOLING ................................................................................................................................... 14
8 CONDITION MONITORING ..................................................................................................................... 15
8.1 DAMPER SERVICE LIFE ............................................................................................................................... 15
8.2 SAMPLING SILICONE FLUID FOR CONDITION MONITORING ................................................................................. 15
8.3 SILICONE SAMPLING PROCESS ..................................................................................................................... 15
8.4 RETURN SAMPLE TO AAM FOR ANALYSIS ...................................................................................................... 16
8.5 FURTHER SAMPLE INTERVAL ....................................................................................................................... 16
9 MAINTENANCE ...................................................................................................................................... 16
10 REPAIRS ................................................................................................................................................. 16
11 SPARE PARTS ......................................................................................................................................... 16
12 ATTACHMENTS ...................................................................................................................................... 17
12.1 DECLARATION OF INCORPORATION .............................................................................................................. 17
12.2 MATERIAL DECLARATION FOR IMO SHIP RECYCLING ........................................................................................ 18
3
DOC002866
12.3 REACH SAFETY DATA FOR SILICONE FLUID ..................................................................................................... 20
12.4 TRACTOL SAFETY DATA FOR GREY PRIMER ................................................................................................... 28
12.5 ENSIS-DW 2455 safety data for corrosion protection ......................................................................... 37
4
DOC002866
1 About this Manual
These operating instructions contain important information on the use of the product. Carry
out these instructions carefully and precisely. This helps to avoid hazards, downtime and
repair costs whilst also increasing the reliability and service life of the product.
These operating instructions are part of the product.
The operating manual contains information which is intended to support the user in his or her
work, and information that needs to be observed in order to ensure safe operation. This
information is intended to complement the experience and capabilities of the members of
staff who are responsible for:
 The system management.

 The operation, monitoring and checking.
 The maintenance and repair work of the component.
The operating manual must be available to the members of staff at all times. The members of
staff delegated with the task of operating the component must adequately familiarise
themselves with the structure of the operating instructions, so that they can find the
information they need without an extended search.
A prerequisite for the protection of the members of staff from dangers, for the prevention of
faults and for the operation of the component in a fault-free and safe manner is the
knowledge of the content of the technical documentation of the component.
 The operating manual must always be available (in the control room, for example).
 All persons who are responsible for the transport, assembly, initial commissioning,
operating, maintaining or repair of the component must be acquainted with the
operating manual. We recommend that the user has the operators confirm to him in
writing that they are acquainted with the operating manual.
 All requirements and instructions in this operating manual must be complied with.
 The documentation of purchased items is a constituent part of this operating manual. All
safety information in this operating manual and all other information must be observed.
 All relevant national regulations, regulations concerning accident prevention and
environmental protection as well as the confirmed technical regulations for safe and
proper working must be complied with.
If the product is transferred to a new owner, these instructions and all associated documents
are to be passed on to the new owner.
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2 Safety Regulations
2.1 Intended use
The vibration damper must only be used for the suppression of torsional vibration on a diesel
engine crankshaft.
2.2 Symbols and warning signs

The following terms and symbols are used in the operating manual for particularly important
information:
The text in the cell to the right of the WARNING symbol contains important
information that must be followed to avoid injury to the user.
WARNING!
The text in the cell to the right of the CAUTION symbol contains important
information that must be followed to avoid damage to the damper.
CAUTION!
2.3 Structure of safety messages

Safety messages and symbols are quoted at the relevant positions in the operating manual if
there is a danger to life or the danger of personal in-jury or material or the danger of
environmental damage. These safety messages must be strictly adhered to.
2.4 Personal protection

When working on or in close proximity to the vibration damper, the following protective
clothing must be worn
 Safety shoes
 Safety helmet
 Protective gloves for handling and fitting work
2.5 Requirements of the operating personnel

The staff members performing the tasks of operating, maintaining, inspecting and assembling
must have the relevant qualifications for this work.
The vibration damper should only be lifted, move and handled by personnel
who:
 Have been trained in safe working practices and any international,
national and local requirements and regulations that apply for
prevention of accidents.
WARNING!
 Have the required license to work with cranes.
 Are familiar with these transport and lifting instructions.
2.6 Environmental protection

All relevant national regulations concerning environmental protection and the technical
regulations for safe and proper working must be complied with.
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3 Product description
3.1 Description of the damper
The vibration damper is viscous torsional vibration damper.
3.2 Application
The damper is designed for use on the QMD-MAN 6G45ME-C9.5 Main propulsion engine and
is not interchangeable with other engines or applications.
Installation of the viscous damper on engine installations other than the

designated system may cause damage to the system and the damper.
CAUTION!
3.3 Functional description

The purpose of the viscous torsional vibration damper is to reduce torsional stresses in diesel
engine crankshafts and propulsion shafting. The vibration damper does this by reducing the
amplitude of torsional vibration by providing a damping torque that opposes the vibration.
The torsional damper consists of an inertia ring (seismic mass) surrounded by a thin film of
highly viscous silicone fluid, enclosed in a casing attached to the engine crankshaft. The inertia
ring is free to rotate within the casing and is supported on bearings. Relative movement
between the inertia ring and the damper casing caused by crankshaft torsional vibration
shears the silicone fluid which produces a reaction torque. The shearing of the fluid absorbs
energy from the torsional vibration and generates heat which is dissipated through the
external surfaces of the damper.
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4 Technical data
4.1 Product identification
Each vibration damper has an individual six digit serial number stamped on the case adjacent
to the silicone fluid sampling plug.
4.2 Technical specifications

Dimensions: Ø2700 mm outer diameter x 380 mm width
Ring inertia: 8421 kgm²
Case and cover inertia: 4808 kgm²
Effective inertia: 9014 kgm²
Damper surface area: 12.7 m²
Weight: 11635 kg
Oil cooling requirement 145 litres/min
Cover
Case
Radial bearing
Inertia ring
Axial bearing
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4.3 Technical drawing
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5 Transport and storage
5.1 Transport
AAM vibration dampers are transported in specially strengthened wooden packing cases and
protected from rust by a sealed polythene film.
The damper should only be transported in a horizontal orientation. The packing case should
not be tilted.
Impacts should be avoided during transportation.
5.2 Check for transport damage

Immediately after receipt, the delivery must be inspected for possible transport damage. Any
damage must be reported immediately to the shipping company. Any damage to the damper
case may affect proper operation, if there is damage then the damper must not be
commissioned.
If the delivery is incomplete, contact AAM immediately.
5.3 Storage
If storage is necessary, the damper should remain in the packing case and be stored in a dry,
well-ventilated area.
5.4 Unpacking
Remove the packing film and rust-inhibiting paper from the damper (if provided)
Take the damper out of the wooden packing case using eyebolts in the lifting holes provided
(see section 6.2)
Ensure that the packaging materials are disposed of properly in an environmentally friendly
manner. Contact AAM for details of or data sheets for the packaging materials used.
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6 Installation
6.1 General
The vibration damper should only be lifted and handled by personnel who:
 Have been trained in safe working practices and any international,
national and local requirements and regulations that apply for
prevention of accidents.
 Have the required license to work with cranes.
WARNING!
 Are familiar with these transport and lifting instructions.
No lifting equipment is supplied with the damper.
Selection of all lifting equipment should be determined by the damper weight

(see section 6.2) and local safety regulations
WARNING!
6.2 Horizontal lifting

The calculated weight of the damper is 11635 kg.
Selection of all lifting equipment should be determined by the damper weight

and local safety regulations
WARNING!
4 eyebolt holes are provided in the damper flange for lifting the damper while it is in a
horizontal orientation, such as removal from the packing case. The eyebolt holes are tapped
M48.
Before assembling the eyebolts into the eyebolt holes, the relevant tapped lifting holes must
be checked to ensure that they are suitable for use.
A tapped hole must not be used for lifting the damper if any of the following
is true:
 The thread is damaged in any way.
 The thread is corroded.
WARNING!
 There are signs that the tapped thread has been reworked.
Lifting of the damper when it is in a horizontal orientation should only be carried out using
suitable lifting equipment (slings, chains, ropes) that distributes the weight of the damper as
evenly as possible between the eyebolts.
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6.3 Horizontal to vertical lifting
A soft sling, (rope, leather, etc.) passed through the central bore of the damper can be used to
change orientation of the damper from horizontal to vertical.
When the vibration damper is in a vertical orientation, it must be secured to

prevent it from rolling or falling over.
WARNING!
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6.4 Vertical lifting
Sling guide
SPN047542
QTY: 04 NOS.
Flat belt slings or wire ropes should be used when lifting the damper in a vertical orientation,
such as when assembling the damper to the engine crankshaft.
Sling guide SPN047542 must be used when damper is in a vertical position.
Before assembly to the engine, all mounting surfaces should visually inspected to ensure that
they are clean and free from damage.
6.5 Assembly to engine

The vibration damper is mounted at the free end of the engine crankshaft, and is held in
position by 20 bolts.
For details of the method for assembling the damper to the engine, consult the
documentation provided by the engine manufacturer.
The vibration damper should only be assembled to an engine which has been
shut down and isolated so that it cannot be started during the damper
assembly operation.
WARNING!
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7 Operation
7.1 Commissioning
Each AAM damper is individually designed and manufactured to the specific torsional
requirements of the engine installation.
No adjustment or commissioning is required after installation, or during the lifetime of the

damper.
7.2 Warning
The vibration damper contains precision machined internal moving parts with very small
clearance gaps. Do not allow any object to impact the external casing or serious internal
damage may occur.
Damage to the damper casing can cause failure of the damper and the engine
crankshaft.
CAUTION!
IMPACT
CAUTION NOT
ALLOWED
INTERNAL
ALLOWED
DAMAGE
7.3 Damper cooling

Removal of heat from the damper is essential to maintaining the service life of the damper.
Effective cooling is very important as overheating can damage the silicone fluid and reduce
the life of the damper.
The damper is fitted inside the engine crankcase cover and is designed to be used with oil
spray cooling onto the external surface of the damper to increase the heat dissipation
capacity. The flow rate of oil required for effective cooling has been calculated by AAM (see
section 4.2). The design and installation of the necessary piping etc. is the responsibility of the
engine builder. Any restriction in cooling oil flow could lead to the damper overheating with
consequent significant reduction in the damper service life.
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8 Condition monitoring
8.1 Damper service life
The service life of viscous dampers fitted to 2-stroke engines can vary depending upon the
application. It can be influenced by engine application and loading as well as non-torsional
factors associated with the engine’s environment such as vibrations induced from adjacent
machinery, engine mountings, shafting systems and hull vibrations.
However, experience has proven that 50,000 - 75,000 operating hours is possible before
damper service is required.
Condition monitoring of the damper is an essential preventative maintenance practice to

ensure the torsional vibration system continues to function as per the original design
calculations for the application.
8.2 Sampling silicone fluid for condition monitoring

The internal condition and operating efficiency of the AAM viscous damper is monitored by
extracting small samples (1 cm³) of silicone fluid for laboratory analysis.
Removal of a silicone fluid sample should initially be carried out at 18 000 – 20 000 hours of
engine operation or at the first major engine service, whichever occurs first. Examination of
the first silicone sample will enable AAM to advise the subsequent sampling intervals, and by
following this procedure and AAM’s recommendations, the necessity for overhauling or
replacing the damper can be anticipated.
Special sampling kits complete with instructions for removal of silicone fluid samples are
available from AAM or appointed service agents.
8.3 Silicone sampling process

Removal of a silicone fluid sample is a simple process. Two removable sampling plugs are
located on the forward face of the damper for extracting samples of silicone fluid (see below).
Inspection windows should be provided by the engine builder to allow easy access to take
samples of silicone fluid from the damper for condition monitoring.
For further details of the process for taking a sample of silicone fluid, refer to the instruction
supplied with the AAM sampling kit.
Fluid sampling container
Up to 40 samples can be taken without affecting the performance of the damper.
15
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The AAM damper is filled with a precise volume of fluid, relative to the ‘free space’ within the
enclosed casing. This precise volume is strictly controlled during assembly and filling, to allow
for expansion during operation and the removal of a controlled number of 1 cc. fluid samples
for condition monitoring.
The damper design incorporates a reservoir to compensate for the fluid sample.
Replenishment of the small volume extracted at each sampling is not necessary.
Any excess loss of fluid during sampling may seriously affect the damper.
If this occurs, contact AAM for advice.
CAUTION!
8.4 Return sample to AAM for analysis

The sampling container with the sample of silicone fluid should be returned to AAM. for
analysis. It is essential that when any fluid sample is returned to AAM for analysis that the
damper serial number is provided (see section 4.1 for location of serial number).
8.5 Further sample interval

Following laboratory analysis of the silicone fluid sample, the internal mechanical condition
and operating efficiency of the damper can be established. The subsequent sampling interval
will be advised by AAM in a report detailing the damper condition and remaining service life. If
the reduction in fluid viscosity is excessive, or the condition of the fluid indicates internal
mechanical damage, the remaining safe service period before overhaul of the damper
becomes absolutely necessary will be advised.
9 Maintenance
The AAM damper does not require any regular maintenance (but see section 8 above).
However, it is recommended that at major engine services the flange mounting bolts
connecting the damper to the crankshaft are checked for tightness and that a visual inspection
is made of the damper, checking for signs of damage or leakage.
10 Repairs
There are no user serviceable parts inside the damper.
Removing the cover of the damper will render the damper inoperable.
CAUTION!
11 Spare parts
There are no spare parts for the AAM vibration damper.
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12 Attachments
12.1 Declaration of Incorporation
DECLARATION OF INCORPORATION
We, AAM Powertrain (UK) Ltd.
of 131 Parkinson Lane
Halifax
HX1 3RD
Phone: +44 (0)1422 357234
Fax: +44 (0)1422 354432
Declare under our sole responsibility that in accordance with EUROPEAN PARLIAMENT AND
COUNCIL DIRECTIVE 2006/42/EC on machinery, the Partly Completed Machinery identified as:
Description: Viscous torsional vibration damper

Function: Reduction of torsional vibration in engine crankshaft
Type: Ø2700 X 380
Part number: SPN047366
Serial number: According to shipping documents, marked on damper
Conforms to the following Essential Health and Safety Requirements (EHSR) of the Directive in
Annex 1:
1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.4, 1.5.4.
ESHRs not listed above are not considered to apply to this Partly Completed Machinery or
must be fulfilled by the assembler.
We also declare that:
 The above referenced damper is incomplete machinery and must not be put into service
until the final machinery into which it is to be incorporated has been declared in conformity
with the provisions of the applicable directives.
 The relevant technical documentation is compiled in accordance with Annex VII(B) of the
Directive.
 On receipt of a reasoned request to our authorised representative (The Quality Manager,
AAM) by an appropriate national authority, all relevant technical documentation about the
partially completed machinery will be provided in writing.
Signed:
Name: Yahyaa Mulla

Position in company: Assistant Product Development Engineer
Date: 13 Nov 2018
At: AAM, Halifax
Ref: HWW 36.06.482
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12.2 Material declaration for IMO ship recycling
Material Declaration
Date of Declaration
Date 2018-11-13
Supplier Information
Company name AAM Powertrain (UK) Ltd.
Division name Vibration Control Systems
Address 131 Parkinson Lane, Halifax, HX1 3RD, U.K.
Telephone no. +44 1422 395110
Fax no. +44 1422 354432
E-mail address Yahyaa.Mulla@aam.com
Product Information
Product total mass
Product name Part or drawing number Product information
Mass Unit
Vibration damper SPN047366 11635 kg Viscous torsional vibration damper
Material information per engine

Intentionally
If yes, If yes, detailed
Threshold added above
Table Materials name material mass material
level threshold level
information
yes/no Mass Unit
no No
Asbestos Asbestos threshold
level
Polychlorinated Polychlorinated No
50 mg/kg
Biphenyls (PCBs) Biphenyls (PCBs)
CFCs No
Halons No
Other fully No
halogenated CFCs
Carbon Tetra- No
chloride
Table A
1,1,1- No
(Materials
Trichloroethane no
listed in Ozone Depleting
(Methyl threshold
appendix 1 of Substance
chloroform) level
the
Hydrochloro- No
Convention)
fluorocarbons
Hydrobromo- No
fluorocarbons
Methyl bromide No
Bromochloro- No
methane
Tributyl Tins No
Organotin Triphenyl Tins No
2500 mg/kg
compounds Tributyl Tin Oxide No
(TBTO)
18
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Intentionally
If yes,
added above If yes, detailed
Threshold material
Table Materials name threshold material
level level mass
information
yes/no Mass Unit
Cadmium and Cadmium No
100 mg/kg
Compounds
Hexavalent Chromium Compounds 1000 mg/kg No
Lead and Lead Compounds 1000 mg/kg No
Table B Mercury and Mercury Compounds 1000 mg/kg No
(Materials Polybrominated Biphenyl (PBBs) 1000 mg/kg No
listed in Polybrominated Dephenyl ethers No
appendix 2 1000 mg/kg
(PBDEs)
of the
no threshold No
Convention) Polychloronaphthalanes (Cl=>3)
level
no threshold No
Radioactive Substances
level
Certain Short chain Chlorinated No
1%
Paraffins
We hereby confirm that the products we deliver to HHM are declared to our best knowledge.
_______________________
Signature
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12.3 REACH safety data for silicone fluid
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12.4 TRACTOL 816 safety data for grey primer
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12.5 ENSIS-DW 2455 safety data for corrosion protection
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8 7 6 5 4 3 2 1
ACN NO. REV REVISION RECORD DATE DWN ENG

380 2 EQUI SPACED FILLING ACN059662 00 INITIAL RELEASE 08/03/18 JD NU
H WEIGHT AND INERTIA H
99 PLUGS ON A 2130 PCD ACN059961 01

VALUES CHANGED
06/04/18 JD NU
ACN060519 02 'ENGINE SIDE' NOTE ADDED 18/05/18 NU PP

20 X45 $ 4 EQUI SPACED LIFTING HOLES
60 $ DRILL & TAP THRO M48
ON A 1300 P.C.D. SIZE OF LIFTING
HOLE TO BE STAMPED ON 20 HOLES EQUI SPACED
ADJACENT TO ONE OF THE HOLES. DRILL THRO n 42 ON A
ENGINE 1050 PCD 0.3 A
32
G
SIDE 1
G
20 X45 $
F F
8 X45 $ 8 X45 $
(950.026-950.116)
950 G7
WARNING
2680
1500
1500
2700
NOTE
AAM
88.5
E
C OF G E
100
100
R2
0
0
D D
R2
C C
PART SECTION X-X
B B
THIS DRAWING AND THE INTELLECTUAL PROPERTY RIGHTS AND OTHER INFORMATION CONTAINED OR DISCLOSED
HEREIN: (1) ARE THE EXCLUSIVE PROPERTY OF AAM AND NO LICENSES ARE GRANTED HEREUNDER, AND
2
(2) CONSTITUTE CONFIDENTIAL AND PROPRIETARY INFORMATION OF AAM WHICH MAY NOT BE USED,
DISCLOSED OR COPIED WITHOUT AAM'S EXPRESS WRITTEN AUTHORIZATION.
INERTIA OF INERTIA RING = 8421 kgm DRAFTED IN ACCORDANCE WITH

AAM ENGINEERING CAD AND
3RD ANGLE PROJ
DIMENSIONS ARE
FOR QMD-MAN 6G45ME-C9.5 ENGINE

DRAFTING STANDARDS CURRENT AT IN MILLIMETERS
2 INITIAL RELEASE
INERTIA OF CASING = 4808 kgm REFERENCE NO.: CUSTOMER NO.:
SHIPYARD = SHANHAIGUAN
2
CAD TYPE CAD LOCATION CAD FILE
SPN047366_OT
EFFECTIVE INERTIA = 9014 kgm
PRO/E HALIFAX
A0 METRIC
HULLS = TBD DESIGNER DATE DRAWING
A J.DOMAGALA 08-MAR-18 SPN047366

OIL SPRAY COOLING REQUIRED - APPROX 145 LITRES/MIN 2 CHECKED DATE TITLE
DAMPER SURFACE AREA = 12.7 m - - DAMPER OUTLINE
DRW SIZE
GENERAL TOLERANCES TO APPROVED DATE FOR QMD 6G45ME-C9.5
PERMISSIBLE DAMPER POWER = 38.2 kW TOTAL WEIGHT OF DAMPER = 11635 kg FOR ASSEMBLY SEE SPN047441 ISO 2768-mK - - IN SHANHAIGUAN SHIPYARD
SCALE SHT GROUP REVISION
ITEM STANDARDS - NUMBER AND NAME 1 -
- - 1:5
OF
1 VCS IS MASTER 02
8 7 6 5 4 3 2 1
Operation Manual / 1 Introduction
Table of contents
Introduction
1 Introduction............................................................................................................ 2
1.1 Purpose of the manual.................................................................................................. 2
1.2 Symbols, definitions...................................................................................................... 3
1.3 Storage of new turbochargers and spare parts ...................................................... 5
1.4 Contact information...................................................................................................... 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
1 Introduction / 1.1 Purpose of the manual
1 Introduction
1.1 Purpose of the manual
Fig. 1: Serial number (01) on the rating plate
This Operation Manual belongs to the turbocharger with the identical serial number (01), see
chapter 3 (Safety data sheet) and the rating plate on the turbocharger.
Page 2 / 7
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.
Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.
All persons operating or working on the turbocharger must have read and fully understood
the Operation Manual.
1 Introduction / 1.2 Symbols, definitions
1.2 Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates an action step.
1. Indicates a numbered action step.

→ Refers to a page number.
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
Page 3 / 7
are described in chapter Safety and must be complied with.
Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.
ABB Turbo Systems

ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.
Official service stations of ABB Turbo Systems

Official service stations are identified in this document as ABB Turbocharging Service Sta-
tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-
tact information →7.
1 Introduction / 1.2 Symbols, definitions
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning Pictogram Meaning

Tighten with specified torque Affix
Tighten over specified tighten- Measure

ing angle
Hand-tight, tighten without Note
tools
Oil Visually inspect
Apply screw locking paste (e.g. Please note text for numbered
Loctite) work step
Apply high-temperature grease See document
Apply other paste in accord- Dispose of in an environmentally

ance with specifications compatible, professional way and
in compliance with locally applic-
Oil free, grease free and dry able regulations
Table 1: Definition of pictograms

Page 4 / 7
1 Introduction / 1.3 Storage of new turbochargers and spare parts
1.3 Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts for up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months
from the date of delivery without additional mothballing measures, indicated by the VCI la-
bel on the package.
Fig. 2: Volatile Corrosion Inhibitor (VCI)
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Page 5 / 7
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6 months, the following mothballing measures are required:

u Open package.
u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Long-term storage of replacement turbochargers or spare parts

The turbochargers or cartridge groups will be prepared for long-term storage if requested in
the purchase order. The package is equipped with a hygrometer (see illustration).
Fig. 3: Package with hygrometer
Every 6 months, the following measures are required:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate to enable you to perform this check. If the 70% indicator field has changed colour,
the maximum admissible atmospheric humidity has been exceeded. In this case, the tur-
bocharger or cartridge group must be checked and repackaged by an ABB Turbocharging
Service Station.
u Check the package for damage. If the package is damaged, the turbocharger or cartridge
group must be checked and repackaged by an ABB Turbocharging Service Station.
Page 6 / 7
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
¡ Checking the component
¡ Replacing the desiccant
¡ Repackaging the component.
NOTICE
Replacement components which are ready for operation
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is not damaged, the replacement turbocharger or replacement cartridge
group can be put into operation without previously having been checked by
an ABB Turbocharging Service Station.
Unpackaging replacement turbochargers or spare parts

Once the material has been unpackaged from the VCI package, the corrosion protection is
no longer effective.
To prevent condensation, the temperature of the package contents must be the same as the
ambient temperature.
1 Introduction / 1.4 Contact information
1.4 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.
u Scan the QR code to access our website.
ABB Turbo Systems Ltd

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Page 7 / 7
Operation Manual / 2 Safety / A100-L, A200-L
Table of contents
Safety
1 Safety ...................................................................................................................... 2
1.1 Introduction .................................................................................................................... 2
1.2 CE conformity ................................................................................................................. 2
1.3 Definition of mandatory signs .................................................................................... 3
1.4 Definition of safety instructions ................................................................................ 3
1.5 Intended use .................................................................................................................. 4
1.6 Warning plates on the turbocharger.......................................................................... 5
1.7 Turbocharger rating plate........................................................................................... 6
1.8 Periodic check of the pressure vessels...................................................................... 7
1.9 Lifting of loads .............................................................................................................. 8
1.10 Prerequisites for operation and maintenance........................................................ 9
1.11 Hazards during operation and maintenance ......................................................... 10
1.12 Safe operation .............................................................................................................. 12
1.13 Safe maintenance ........................................................................................................ 13
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
1 Safety / 1.1 Introduction
1 Safety
1.1 Introduction
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and
health protection requirements are met. This ensures safe operation of the turbocharger.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡ Are caused by the turbocharger itself or its accessories.
¡ Are caused by the operating equipment used or supplies and materials.
¡ Are a consequence of insufficient compliance with safety instructions.
¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
Page 2 / 16
All further safety instructions contained and specifically identified in every chapter of this
manual (Definition of safety instructions →3) must also be observed.
1.2 CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
1 Safety / 1.3 Definition of mandatory signs
1.3 Definition of mandatory signs

To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table 1: Personal protective equipment to be worn at all times
To be worn specific to the respective task

Safety glasses Safety goggles
Safety gloves to protect Respiratory mask to protect

against against
- Mechanical hazard - Dusts
- Chemical hazard - Gases
- Thermal hazard
Safety helmet Ear protection
Page 3 / 16
Table 2: Personal protective equipment to be worn specific to the respective task
1.4 Definition of safety instructions
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
1 Safety / 1.5 Intended use
1.5 Intended use
Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging internal combustion engines.
The A...-L turbochargers are designed for use on 2-stroke diesel engines.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating
plate.
ABB accepts no liability and rejects all warranty claims for any non-intended uses.
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
Page 4 / 16
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder
State of the art

The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.
1 Safety / 1.6 Warning plates on the turbocharger
1.6 Warning plates on the turbocharger

Warning plates are attached to the turbocharger, which must be observed. The warning
plates must always be present in the intended locations and must be legible.
Fig. 1: Warning plate
If warning plates are not present in the intended locations or are not legible, they must be
replaced with new warning plates. The necessary information can be found in the Operation
Manual, Chapter 4 Product description.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
Page 5 / 16
1 Safety / 1.7 Turbocharger rating plate
1.7 Turbocharger rating plate
Fig. 2: Rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
Page 6 / 16
02 Turbocharger operating limits during operation
Recommended replacement intervals of turbocharger components

03 Replacement interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
1 Safety / 1.8 Periodic check of the pressure vessels
Explanations regarding the rating plate

The recommended replacement intervals and the corresponding operating limits are jointly
defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-
bocharging Service Station.
nMmax, tMmax normally apply only when running at overload (110%) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals increases the risk of unpredict-
able component failures.
Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product
description.
1.8 Periodic check of the pressure vessels
Page 7 / 16
The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are
so-called "simple pressure vessels".
¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡ The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
1 Safety / 1.9 Lifting of loads
1.9 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety helmet.

Page 8 / 16
Fig. 3: Attachment of loads on the crane hook
Fig. 4: Attachment angle
If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.
u Use a suitable edge guard if there are sharp edges.
u The assembly devices must be completely screwed in and must not unscrew during use.
u Use assembly devices only for the described applications.
u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.
1 Safety / 1.10 Prerequisites for operation and maintenance
1.10 Prerequisites for operation and maintenance
Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the turbocharger, who:
¡ Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡ Are equipped with the prescribed personal protective equipment
¡ Have read and understood the Operation Manual
¡ Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Only authorised personnel may remain in the vicinity of the turbocharger when the engine is
running.
Page 9 / 16
Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.
Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB Turbo Systems.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB Turbo Systems.
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur-
bochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.
1 Safety / 1.11 Hazards during operation and maintenance
1.11 Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission during operation is influenced by its installation and op-
erating conditions. A noise level exceeding 85 dB(A) is harmful.
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot
Page 10 / 16
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
1 Safety / 1.11 Hazards during operation and maintenance
WARNING
Hot surfaces on the non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
Wear safety gloves to protect against thermal hazards.
Hazards due to rotating parts
WARNING
Physical hazards
Contact with rotating parts can cause severe injury. The turbocharger must
Page 11 / 16
never be used without the filter silencer or the air suction branch. With the
engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.
Hazards due to electrical installations (if present)
WARNING
Dangers during work on electrical installations
Electrical installations use voltages that can lead to severe injury to person-
nel or accidents resulting in fatalities.
At the same time, electrical or electronic components and parts can also be
damaged or destroyed.
u Only specially trained personnel should perform work on, or with, elec-
trical components.
u Observe national regulations.
1 Safety / 1.12 Safe operation
WARNING
Absence of grounding on electrical installations
Missing or incorrectly fitted grounding conductors can lead to severe injury
to personnel or accidents resulting in fatalities.
Electric shock or elevated electromagnetic disturbances can damage or des-
troy electrical and electronic components.
u Ground electrical installations properly with grounding conductors.
u Check the grounding connections on a regular basis and make sure they
are properly connected.
u Switch off the power supply before working on any electrical installations.
u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge
and hot components to cool down.
u Ensure the power supply is switched off when working on electrical installations.
u Do not carry out any tests with regard to insulation resistance or voltage on the electrical
components.
1.12 Safe operation

Page 12 / 16
Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.
Safety during commissioning and operation

u Visually inspect your working environment before starting work.
u Remove any obstacles and objects littering the workplace.
u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
1 Safety / 1.13 Safe maintenance
1.13 Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Page 13 / 16
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
Wear protective clothing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u Comply with the general accident prevention regulations.
u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Power tools must be grounded and cables must be undamaged.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Keep the floor, equipment, and turbocharger clean.
u Have oil binding agents ready and provide or keep oil pans at hand.
u Clean up any spills.
u Have fire protection means and extinguishing agents available.
Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.
Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.
u Observe the material safety data sheet for the cleaning agent or solvent.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the electric cables for abrasion and damage before and after your cleaning work.
Safety during disassembly, assembly, maintenance and repair

Page 14 / 16
u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Safety when taking out of operation or preparing for mothballing

u Secure rotor against turning. The rotor can rotate due to the stack draught alone.
u Observe the material safety data sheet for the cleaning and mothballing agents.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
Mechanical hazards when working on the turbocharger
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
WARNING
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Page 15 / 16
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
Page 16 / 16
Hazards due to the handling of insulation materials
WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against chemical hazards.
Operation Manual / A1... / Safety data sheet
Page 1 / 1
Safety data sheet
A1... HT...
A1... HT...
... ...
... ...
...
... ... ... ... ...
...
© Copyright 2015 ABB. All rights reserved. HT... January 2015

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附件目录

2 盘车机 Turning Gear

3 盘车机控制箱 Turning Gear Control System

4 辅助风机 Auxiliary Blowers

5 辅助风机控制箱 Auxiliary Blowers Control System

6 HPS 泵控制箱 Instruction Book for HPS Starter Box

Exhaust valve and valve seat grinding

8 液压顶撑 Top bracing

9 油含水 Waterin oil sensor

10 轴承磨损监测系统 Bearing Wear Monitoring System

11 油雾探测器 Oil Mist Detector

12 气缸油加热柜 Heating Tank for Cylinder Oil

13 排气阀翻转台 Worktable for exhaust valve

14 喷油器试验台 Fuel valve test pump unit

15 轴向振动监测仪 Axial Vibration Monitor

Form Version：V1 Page1 / 1

Form Version：V1 Page1 / 1

the cooler consists of elliptcal core tubes with rectangular

threaded-on ﬁns or round core tubes with either wound-on ﬁns or

continuous flat plate fins. The bond between fin and tube is

achieved either by mechanical means or by soldering.

Qiyao Power Systems CO,.LTD

2 Principal Technical Parameters ......................... 2

6 Maintenance and Pionts for Attention ................... 6

7 Common Breakdown and Slovent ........................... 7

8 Operation of Manual Release Screw for Brake .......... 10

9 Part List for Order ................................... 10

10 Wiring Drawing for E-motor ........................... 14

speed diesel engines type 45/46/50 ME-B/ME-C.

2 Principal Technical Parameters

Rated power 3.0kw（3.45 kw）

Rated speed 940r/min（1145 r/min）

Power source 3×AC380v/50Hz（3×AC440v/60Hz）

Brake voltage DC99/400W

Brake moment of force ≥65 Nm

Heating voltage AC220V

Protection class IP55

2.1.2 Speed reducer（CP13）

Rated output torque 10600Nm

Max output torque 13200 Nm

Total speed ratio 934:1

Output speed 1. 01 r/min（1.23 r/min）

2.2.1 Electric motor（CP23/CP23P）

Rated power 4.0kw（4.6 kw）

Power source 3×AC380v/50Hz（3×AC440v/60Hz）

Brake voltage DC99/400w

Brake moment of force ≥65 Nm

Heating voltage AC220V

Protection class IP55

2.2.2 Speed reducer（CP23/CP23P）

Rated output torque 18500Nm

Max output torque 23000 Nm

Total speed ratio 934:1

Output speed 1. 01 r/min（1.23 r/min）

3 Construction (See Page 15)

stirring-bar interlocking mechanism, movable gear. The electric motor

The engagement and disengagement of gear with crankshaft gear are

performed by the disengagement and engagement mechanism. The

The two-position three-way valve is communicated with the starting air

is on and the two-position three-way valve is under such a condition that

this turning gear plays a part in interlocking mechanism.

Fill the speed reducer with L-CKD320 industrial gear oil(or

equivalent industrial gear oil with dynamic viscosity of 300-320 cst at

4 Installation (See Page 11)