NIIGATA a STRUCTION manuat REMOTE CONTROL DEVICE Contents SHIP No.: 9918 ZP TYPE: ZP2A PTO (OMEGA) NUNOTANI WORK No. 327(C)ADJUSTMENT METHOD FOR PROPELLER SHAFT RPM ADJUSTMENT PROCEDURE OF METER RELAY ADJUSTMENT PROCEDURE OF DC INDICATOR ADJUSTING METHOD FOR AMP OF E/P REGULATOR CARE OFTHE AIR FILTER MAINTENANCE (TYPE: F4000) CARE OFTHE AIR FILTER MAINTENANCE (TYPE: M4000) PNEUMATIC PARTS CONSTRUCTION OF GSO LEVER ZP DC CONTROLLER INSTRUCTION MANUAL 1" 14 19 20 24 39Adjustment method | | for [| Propeller snaft RRM Signal This control unit (FV113. 2PP) is designed to convert pulse signal to voltage. Pulse signal is detected propeller rpm by Pulse detect ing sensesr that fitted on clutch. Detected pluse signal is converted to voltage signal by this control unit, propeller rpm is indicated on analog indicator or digital indicator Adjustment method for the contro! unit of propeller shaft rpm signal is as follows. All adjustment is carried out at ZP alarm panel. Adjustment of control unit @. Turn ZP control electric source to “OFF. @. Terminal of propeller detecting senser is in ZP alarm panel Disconnect external cable that connected to terminal Mark on the disconnected cable. The external terminal mark is as follows. Port macine + PPL/PP2/PP3 Starboard machine ; SP1/SP2/SP3 ©. Turn the electric source of culse transmitter to ‘OFF, set pulse signal to “Dry pulse’ (Non-voltage signal). Connect the pulse transmitter to terminal for propeller detecting. Signal wiring of pulse transmitter ; Port machinr *PP2* Starboard machine *SP2* Conon wiring of pulse transmitter ; Port machin "PP3* Starboard machine “SP3* @®. There are Adjuster VRI/VR5/VRL1/VRIS on control unit. Turn to full counterclockwise direction (CCW) Bring your ears close to near the adjuster and confirm from click sound: a©. Turn ZP control electric source to “ON @. Set the select switch ‘NORMAL-TEST’ of control unit to ‘NORMAL position. Carry out the offset adjustment. When the initial adjustment by using iC, voltage occuer by leak current of IC. Offset adjustment is that this leak voltage is adjusted to ‘zero V". 1. Connect the digital meter. Connect the digital meter to IC “OP1/0P3* of this control unit and check terminal T1/TLL. Set the indication of digital meter to ‘OV by adjuster VR2/VR12. Port machine 3 Between 1C ‘OPI" and Tl, Adjuster VR2V Starboard machine ; Betveen IC “0P3" and T11, Adiuster VRI2V Ghange the connection of digital meter as follows. Connect the digital meter to check terminal 13/T13 and T1/TLI of this control unit. Set the indication of digital meter to ‘OV' by adjuster VR4/VRI4. Port machine i Check terminal between 13 and Tl, Adjuster VRAV Starboard machine ; Check terminal between T13 and T11, Adjuster VRI4V @. Turn the electric source of pulse transmitter to ‘ON. ®. Adjust the propeller rpm that correspond to max rpm of main engine. Give pulse of propeller max rpm by pulse transmitter. Refer to the finished drawing because the number of pulses is different according as gear ratio of propeller and main engine. Connect the digital meter to check terminal between 13/11 and 113 and TIL Set the indication voltage of digital meter to “10V" Adjust by adjuster VRI/VRLL. Port machine + Check terminal between T3 and Tl, Adjuster VRIV Starboard machine ; Check terminal between 113 and T11, Adjuster VRIIV Even if finish adjustment, leave the pulse transmitter as it is. You can remove digital meter. aya¥ ®. Carry out the indication adjustment of W/l propeller rpm indicator (analog or digital meter). Adjuster for propeller rom indicator is on the board for propel ler rpm indicator adjuster in the W/l! stand Turn this adisuter and adjust so that indication of propeller rom indicator will be indicated max rpm. ®. Carry out the indication adjustment of propeller rpm indicator (snalog or digital) of ZP alarm panel. Adjust by adjuster VH5/VRI5 of this contro! unit Turn this adisuter and adjust so that indication of propeller rpm indicator will indicate max rpm, ®. Input the pulse of rate rpm after finishing the above adjustment Confirm wheter al! propeller rpm indicator indicate rate revolution. {n case of not indicating rate revolution, return the first step and adjust again. ®. Shift the select switch “NORMAL/TEST” of this control unit to “TEST. Adjust the indication of propellr rpm indicator to rate revolution by adjuster VR3/VR13, Port machine 5 VRI3 Starboard machine ; VRI3 After complete adjustment turn the ‘NORMAL/TEST’ select switch to "NORMAL" position. Briance adjustment of digital meter Set the dimmer for digital propeller rom indicator of W/H stand to position that turnd 20~30° fran counterclockwise max position, Adjust to the position where indication of indicator disappear or not disappear by adjuster VR6/VRI6 of contro! unit Port machine 3 VRE Starboard machine ; YRI3 You can not use standard digital meter. Because digital meter is reorganized for disappear ing indication of indication part. Please care when repair.Dc-oc converter Input pulse Lepe VRB VRIS vrig vein swe Dimmer adjustment port | /R indication adjustment Simulation signal adjustment FV output voltage adjustment 4 Simulation — Normal 1890 Input pulse Dimmer adjustment Leo vRe ves vera vrei swt C/R indication adjustment Simulation signal adjustment — FY output voltage adjustment be 0G Simulation — Normal ci ONVERTER ala- 1 [ Adjustment procedure of meter relay | Meter relay receives revolution signal and supply a voltage/electric current signal, pulse signal and contact signal proportional revolution speed to outside. It mentions about this adjustment method. Principal items Pulse quantity of the revolution detection sencer with kind of engine is different. Refer to table 1. Table 1 BLISHK BL22HX 6L25HX 6L26HX 6L26HLX BL28HX Swing angle of the main engine rpm indicator is unified at 240° and is adjusted to output of DC1O voltage 10VDC at max index of the main engine rpm indicator. You do not need to adjust again, but adjust the following in case of use to different engine type of mux index. Adjustment process Refer to parts arrangement diagram. Adjust after reading the adjustment process. 1, Adjustment of main engine rpm indicator voltage signal @ Remove the fix screw of upper side name plate (M3 x 4pcs) of meter relay. @ Remove the fix screw of terminal boards (M3 x 2pcs/one terminal board). @ Draw out two terminal boards from the case at the same time as the terminal board with PCB. Pay attention to draw out PCB because there are no gap between the case and PCB. @ Connect O0C24V battery electric source to the terminal (+/~) of NIO1PCB. © Connect the magnet feeld pick up sencer to the terminal (P1/P2/PE) of N1OL PCB. © Turn DC24V battery source to “ON. Do not touch PCB to other equipments because PCB does not fix. Gu© There is the adjuster VR4 at the side of N102 PCB. Turn the magnet feeld pick up sencer by the max index puise of needful main engine type. Turn the adjuster VR4 with this condition. Adjust the voltage of main engine rpm indicator terminal (MI/M2) to 10V. Turn DC24V battery source to ‘OFF. © Installed two terminal boards with PCB at the same time to the case. Do not touch PCB to the case because there are no gap between the case and PCB, @ Fix the terminal board after fitting the name plate into the terminal board, and fix the nane plate. Adjustment of the electric current signal @ Remove the fix screw of upper side nae plate (M3 x dpcs) of meter relay. @ Remove the fix screw of terminal boards (M3 x 2pcs/one terminal board). © Draw out two terminal boards with PCB from the case at the same time. Pay attention to draw out PCB because there are no gap of the case and PCB. @ Connect DC24V battery electric source to the terminal (+/-) of NIOLPCB. © Connect the magnet feeld pick up sencer to the terminal (P1/P2/PE) of N1O1 PCB, © Connect the current meter to the N102PCB terminal (A1/A2). Turn DC24V battery source to ‘ON’. There are adjuster VRI/VR2 at the side of N1O1 PCB, confirm that pulse signal is ‘0. Adjust the electric current value to “Ama” by adjuster VR2 with seeing the current meter. Turn the magnet feeld pick up sencer by the max index pulse of needful main engine type. Turn the adjuster VR1 with this condition. Voltage of the main engine rpm indicator terminal is 10V. Adjust the electric current value to “20mA" by adjuster VR1 with seeing the current meter. e Turn 0C24V battery source to “OFF. ® Installed two terminal boards with PCB at the same time into the case. Do not touch PCB to the case because there are no gap between the case and PCR. @ Fix the terminal board after fitting the name plate into the terminal board, and fix the name plate. Adjustment of the contact signal 1. Connect DC24V battery source to NIL PCB terminal (+/-). 2. Connect the magnet feeld pick up sencer to terminal (P1/P2/PE). ae3. Turn DC24V battery source to ‘ON’. 4, Adjustment of ‘LOW’ turning. @ Turn the magnet feeld pick up sencer by “LOW turning pulse of needful main engine type. @® Light LED lamp by the adjuster ‘LOW of meter relay. Adjuster should not turn quickly because of occuring discrepancy at LED lighting position. LED is upper left of the adjuster “LOW. 5. Adjustment of “MIDDLE’ turning. @ Turn the magnet feeld pick up sencer by “MIDDLE turning pulse of needful main engine type. ® Light LED lamp by the adjuster “MIDDLE” of meter relay. Adjuster should not turn quickly because of occuring discrepancy at LED lighting position. LED is upper left of the adjuster "MIDDLE". 6. Adjustment of ‘HIGH @ Turn the magnet feeld pick up sencer by “HIGH turning pulse of needful main engine type. @ Light LED lamp by the adjuster ‘HIGH’ of meter relay. Adjuster should not turn quickly because of occuring discrepancy at LED lighting position. LED is upper left of the adjuster ‘HIGH. 4, TEST There is a ‘TEST’ on the surface of meter relay. “TEST is a simulation voltage transmitter. This simulation voltage transmitter “IEST” is possible to operate main engine rpm indicator until max index and is possible to set “LOW/MIDDLE/HIGH' contact signal at desired rpm. Main engine rpm indicator is turning, Adjust the contact signal of “LOW/MIDCLE/HIGH’ according to the fol lowing method. In case of “LOW revolution, set the main engine rpm indicator to e.g.300rpm . And, light LED lamp by ‘LOW adjuster. “MIDDLE/HIGH’ revolution is possible to adjuster in the same process as ‘LOW revolution. ‘0" rpm at right max position and increase by left Set the simulation voltage transmitter “TEST” to right turning max position certainly after using. In case of discrepant position, it is added "TEST" voltage to actual rpm. Pay attention to make an error of indication and contact signal of main engine rpm indicator by above reason.5. Another There is ‘K1/K2" terminal at the meter leray. This terminal have a voltage signal that exchanged the pulse signal of magnet feeld pick up sencer to the voltage. Valtage/electric current signal or pulse signal can be made by use additional signal converter. Parts arrangement fig Oe a 2 o@ @ So $ : | 5 | 3 8 NIo2 LR! TS, t—— a a) S v a 2 RY3 R2 = ee 228 faa Rye VvR3 sf re x ce RYI vRa 6 PCB Terminal board for external wire connectionoerori-iwe fan] eezeret fore] wa CANE=¥) mars Ee ro AV13a YBLIN TeEoT 210Adjustment procedure of DC indicator | | UC indicator avail to indicate turning position of Z-peller. DC indicator is drived by DC motor, indicate predetermined turning position of Z-peller. DC motor of indicator is drived by differencial degree signal between sencer of following up transmitter and sencer of DC indicator. When differencial signal become zero, OC motor is stopped. Adjustment method of this C¢ indicator is as follows. 1 Adjustment of indication sencer in follow up transmetter. Follow up transmitter have sencer for contro! and indicator. It is necessary to adjust sencer for indicator, but in case of touching indicator sencer, you can adjust indicator sencer after confirmation whether for control or for indicator. (There are name plate for control or indicator near the sencer.) If discrepancy of turning position occurs, adjust it accordeng to adjustment procedure of OC controller. Type of sencer : Potentiometer SFCBS0A 2ka Adjustment of DC indicator Refer to assembly drawing of DC indicator. UC indicator is made up of DC motor, potentiometer and contro! board. DC motor and potentiometer is unnecessary to adjust. Shift both the ahead-astern control handle and the whee! to neutral position DC indicator indicate colt position of Z-peller by supply on Z-peller control source. When indicator of colt position is different, adjust according to the following prosess. @ Remove OC indicator cover ‘@". Cover is fixed by four screws. @ Remove (pull up) the pointer ‘@". Fit the top of pointer to neutral position and insert the pointer into there. The chink between index plate ‘®" and pointer is about 1m. Small discrepancy is possible to adjust minutely by turning the pointer. In any othere cases, do over again. @ Fix the cover of DC indicator. Measure the colt position after operate ahead~astern control handle to : ahead 90° position. Confirm the pointer of DC indicator whether indicate measured colt position. In case of measured colt position is not indicate, turn the adjust on control board. There is a contro! board with cable connector at the bottom of indicator. Operate to astern 90° position, anc confirm the colt position and the pointer position of indicator if it can not adjust by adjuster. In case of it occurs discrepancy, turn the adjuster or the pointer and adjust minutely to the position that is well balanced ahead 90° and astern 90°. =44—It should pay attention at here, if an indicator error of other position is within about 11°, use it as it is because ahead 90° position is a basic point of indicator. In case of occur big indicator error, measure voltage of connector on control PCB. In case of voltage drop, it occurs zn indicator error. Valtage is a 12pin connector on control PCB. Measurment position is a neutral position. @-@ : ov ©-@ : -10V @-@ : +1v — @-@ : -1v measurment for your information @®—® : 24V (® is common) ~ If a measure value have difference cf 18, indication of DC indicator occures discrepancy of 1%. This value is condition that follow up transmitter side is a normal value. In case of this, it needs countermeasure to thicken external electric cable or connect two lines against one signal line. -12-Thrust direction indicator T | 0d antap 20104 | 91 owoztevzeosrin | 40x0u 9 | EF — ; = area a sass) Z| yeyoos auey | rr a “aus 6009 | of OTa gz naz00 [2 = owe [5 | wi vezsosd \ T s93a00! u9I04 ie : Pape | ] | “08 | | T 10300 50 ayeje BuI3a14 | ¢ 20T-9 : aay 7 9 yomosz 40 aacy | a3eja xapyy | y Sy “mus of | T saauiog | z | It zan0g |r yiewey [ao] owen ease a €1 21 wo)(o BOOOCOOG t soworpur 38) 49 28uU09 40}89!puy 40 409@UU0) a esAdjusting method for _Anp of Electro - pneumatic regulator (E-P valve) _ E-P valve control amp are designed that Propeller shaft r.p.m control of omega area Main engine r.p.m control of main engine area Main engine r.p.m upper limit function with working etc. are controlled. Signal to E-P valve can be selected from following Two (2) kind of signal. Voltage signal 0-10 VIC Current signal 4-20m ADC A. Preparation 1, Turn the time function select switch (SW2) to test position, 2 Select voltage signal or current signal by V-I select switch (SW1). 3, Connect the digital meter to check terminal CH1 and CHOV. 4, Shift the main engine control handle to “OFF” position, Loosen fix screw of potentiometer. Turn the body of potentiometer until digital meter indicate zero volt. : Confirm zero volt of digital meter and tighten screw of potentiometer. This adjustment already finished at work shop. 5. Shift the main engine control handle to “0” position, Adjust the VR2 of PCB until LED (L1) is lit, (Variable resister YR3 sho1ld be setted to middle point. ) B. Omega control 1, Shift to main engine control handle to “OFF” position. 2, Adjust required pressure (or voltage) by VR4. 3. Set the main engine contro! handle until LED (Ll) gone off.4, Adjust required pressure (or voltage) by VR5. Note If When adjust omega at the main engine control handle “0” position (Not “OFF” position), pressure of “ON” position change little bit by adjustment of VR5. Therefore, repeat adjustment of item 1~4, C. Adjustment of main engine control 1. Shift the main engine control handle to “O” notch. (Confirm LED (L1) is lit.) 2 Adjust required pressure (or voltage) by VR6. 3. Turn the time function select switch (SW2) to test position. Turn the shaft of VR7 and ¥R8 to unclockwise direction. 4, Shift the main engine control handle to “10” notch. 5, Adjust required pressure (or voltage) by YR3. 6. Measure voltage of between check terminal No. C3 and CHOV. (This is need for setting of time function. ) Note. Setting point of VR2 change little bit by adjustment of VR3. Therefore repeat adjustment of item 1~S. vR2: for omega and main engine area setting. D. Adjustment of time function Setting of valiable speed to main engine rating r.p.o from idle. Adjust following r.p.m increase direction. VRT (2sec ~ 35sec) Adjust following r.p.m decrease direction. VR8 (Isec ~ 15sec) 1, Connect. digital meter to check terminal No. CH3 and CHOY (common).2. Setting of increase direction Shift the main engine control handle to “10” position from “0” and measure time that digital meter indicate measurement value of item C-6. If not required time, adjust VR7 until required time is got. After finish of time setzing, measure/record voltage of check terminal CH6. 3. Setting of decrease direction Shift the main engine control handle to “0” position from “10” and measure tine that digital meter indicate zero volt. Tf not required time, adjust VR8 until required time is got. After finish of time setting, measure/record voltage of check terminal CH7. E. Upper setting of main engine r.p.m This upper setting is apllie to working and upper limit of main engine r.p.m is used udner normal r.p.m. Shift the main engine control handle to “10” position, Turn the “cruising-working"change over switch to “working” . Adjust VR9 until required r.p.m is got. After adjustment, relation of the main engine control handle and air pressure is shown on in-out standard characteristic figure of E-P valve which attached fig. Perr(5.Okg/em*) (4, 0ke/em*) ae _ (Cruising) OFF So, set the switch(SW2) to OFF in normal operation. = Example = Monitor on channel 5 Set_the switch(SW3) on position 5. Set the switon(s <-Swtich(sw4) is not available sw3 sw 48= Example = Monitor on channel 16 Set tne ent ten )on_posi OQ. “e) 12 — Set the switch(SW4) on position 5 sw3 7 ay (Position 1 indicate channel 12 ) Namely, SW3 is available on channel 1 ~ 12 $W4 is available on channel 18 ~ 23 When the switch(SW4) set on channel 13°23, the switeh(SW3) should be set. on position 12 (channel 12) 3.2 MOnitor ZP controller has the following two monitor. 3.2.1 LED monitor Some LEDs indidate the state of ZP controller. (1) LED 1 Indication : +15 V power source This LED indicates the internal power source of ZP controller. Statee Lighting in normal (2) LED 2 Indication : -15 V power source This LED indicates the internal power source of ZP controller. States Lighting in normal (3) LED 3 Indication : No.-of engine revolution States Blinking frequentry in proportion to the engine revolution (in PTO system) Blinking constantly (in Electric motor system (4) LED 4 Indication : Alarm in the hydraulic system trouble This LED lights in the hydraulic system trouble. States. : Not lighting in normal (5) LED 5 Indication : Alarm in the ZP controller trouble This LED lights in the ZP controller trouble. States : Not lighting in normal (6) LED 6 Indication : ALarm in the handle potentiometer trouble States not lighting in normal (7) LED 7 Indication : Alarm in the follow up transmitter potentiometer trouble States : Not lighyt in normal (8) LED 8 Indication : Alarm in the pick up trouble States : Not Lighting in normal 5 -49-3.2.2 Digital monitor Digital monitor indicates the state of ZP controller in the numerical value on the panel. The following channel No. is lected by the switches (SW3 & SW4). The symbol "+" is omitted on the digital monitor. (1) Channel 1 Indication : No. of engine revolution. this value is changed by turning the volume RI). For example 7.77 ---> 777 rpm (in PTO system). Value (2) Channel 2 Indication : Order signal to steer ZP. The order value is given from the steering handle in normal or from the volume (VR2) in the steerring test mode. Value : -15.00 > +15.00 (3) Channel 3 (Used only in PTO system) Indication : Changeable steering speed range adjustment. value The same engine revolution No. as this value is the starting point of the changeable steering speed range. This value is adjusted by turning the volume (VR6). Value : for example, -5.00---> 500 rpm (4) Channel 4 (sed only in PTO system) Indication : Clockwise steering speed adjustment value in the changeable steering speed range This value is adjusted by turning the volume «vRT). Value : 0.00 ~ 410.00 (only PTO system) 0.00 in normal (only electric motor system) The clockwise steering speed is faster, as this absolute value is larger. (5) Channel 5 (used only PTO system) Indication : Counterclockwise steering speed adjustment value in the changeable steering speed range This value is adjusted by turning the volume (vrs). Value 20,00 ~ -10.00 (only PTO system) 0.00 in normai (only electric motor system) The counterclockwise steering speed is faster, as this absolute value is larger. (6) Channel 6 Indication : Clockwise steering speed adjustment value in the fixed steering speed’ range This value is adjusted by turning the volume (VR4) Value : 0.00 ~ +10.00 ‘The clockwise steerilng speed is faster, as this absolute value is larger. (7) Channel 7 Indication : Counterclockwise steering speed adjustment. value in the fixed steering speed range This value is adjusted by turning the volume (VRS). value : 0.00 ~ -10.00 The counterclockwise steering speed is faster, as this absolute value is larger. -50—(8) «a) (10) ay 2) (13) a4) as) (16) a7) cs) Channel 8 Indication Value Channel 9 Indication : Value 7 Channel 10 Indication Value 7 Channel 11 Indication Value Channel 12 Indication Value Channel 13 Indication Value Order signal to slant the swashplate of the hydraulic pump 10.00 ~ +10. 00 Difference between the order and the reality of the swashplate angle of the hydraulic pump =1.00 ~ +1.00 at rest If this value is in excess of "3.00", then the alarm light LED4 shines. Output. electric current to the servo valve This value is in proportion to the output electric current from ZP controller to the servo valve on the hydraulic pump. The output amperage is one hundredth of this value. If there is no change in this value when the steering handle is operated, the alarm light LEDS shines. Swashplate angle of the hydraulic pump This value is the swashplate angle signal from the potentiometer. ‘this value is in proportion to swashplate angle. +15 V internal power source +14. 007+16.00 in normal -15 V internal power source 14. 00*-16.00 in normal Tf these value 1s out of the range, the power cirouit must be checked. Channel 14 Indication Value H Channel 15 Indication Value Channel 16 Indication : Value Channel 17 Indication Value Channel 18 Indication Value _ +10 V internal power source +9.95 ~ +10.05 in normal -10 V internal power source 9.95 ~ -10.05 in normal Voltage of handle potentiometer (SIN) This value is signal from the potentiometer of control handle. +10.00 ~ -10.00 Voltage of handle potentiometer (COS) This value is signal from the potentiometer of control handle. +10.06 ~ -10.00 Voltage of follow up transmitter potentiometer (SIN). This value is signal from the potentiometer of follow up transmitter. +10.00 ~ -10.00 Sa(19) (20) (21) (22) (23) Channel 19 Indication Value Channel 20 Indication Value Channel 21 Indication Value Channel 22 Indication Value Channel 23 Voltage of follow up transmitter potentiometer (COS) This value is signal from the potentiometer of follow up transmitter. +10.00 ~ -10.00 Steering arithmetic value SIN (A-B) Deviation signal is achieved comparing with handle signal and follow up transmitter signal. Arithmetic result of handle and follow up signal is indicated In case of follow up signal agree with handle order signal, zero is indicated. If not, deviation value is indicated. Steering arithmetic value COS (A~B) Deviation signal is achieved comparing with handle signal and follow up tramsmitter signal. Arithmetic result of handle and follow up signal is indicated. Output voltage 1 for the potentiometer 0 ~ +10.00 Indication : Output voltage 2 to the potentiometer Value °o ~ -10.00 abo4. ADJUSTMENT at a) (2) 4) 4.2 a Switches 2P controller has the following four switches. swi Function : Select the steering mode of nearest turn This switch is on the panel. Setting : ON --- nearest, turn OFF -- not nearest. turn sw2 Funetion : Select the steering mode. This switch is on the panel Setting : OFF -- in normal ON --- in the steering test sw3 function : Select the digital monitor number This switch is on the panel. Setting : Select the number of this switch from No.1 ~ 12 swa Function : Select. the digital monitor number This switch is on the panel. Setting : Select the number of this switch from No. 13 ~ 23 Volumes ZP controller has the following 10 volumes. These volumes are used at the adjustment of ZP steering speed ete. ) Volume VR1 Function : Adjustment of No. of engine revolution Usually, the adjustment is finished by the maker. Value : Indicated at the channel 1 (2) Volume VR2 (a. ics (5 Funetion : ZP steering test 7P can be steered by this volume in the not fol lowing up mode. This volume is effective when the switch(SW2) is changed from OFF to ON. (the pointer of this volume) (steering direction) -In neutral Stop “Right side of neutral — Clockwise “Left side of neutral Counterclockwise Value _: Indicated at the channel 8 ) Volume VR3 Function : Adjustment of the following sensitivity of steering When turning this volume to clockwise, the following sensitivity is stronger. lf this sensitivity is too strong, ZP occures hunt ing. Value: Usually, the 5. © pointer of this volume indicate on 2 ~ ) Volume VR4 Funetion : Adjustment of the clockwise steering speed in the fixed steering speed range value : Indicated at the channel 6 The clockwise steering speed is faster, as this absolute value is larger. ) Volume VRS Function : Adjustment of the counterclockwise steering speed in the fixed steering speed range Value : Indicated at the channel 7 The counterclockwise steering speed is faster, as this absolute value is larger. 9 —53—(6) Volume VR6 (sed only PTO system) Function : Adjustment of the changeable steering speed range Value Indicated at. the channel 3 For exsample, -6.00 ---> 600 rpm The same engine revolution No. as this value is the starting point. of the changeable steering speed range. (1) Volume VRT (used only PTO system) Function : Adjustment of the clockwise steering speed in the changeable steering speed rang Value: Indicated at the channel 4 The clockwise steering speed is faster as this absolute value is larger. (8) Volume VR8 (used only PTO system) Function : Adjustment of the counterclockwise steering speed in the changeable steering speed range Value indicated at the channel 5 the counterclockwise steering speed is faster, as this absolute value is larger. (9) Volume VR9 Function : Adjustment of the sensitivity to the output signal of servo valve If this sensitivity is too weak, ZP occures no turning. Value : Confirmation of sensitivity (10) Volume VR10 Function : Balance correction of port and starboard turning VR10 is used to correct balance of port, and starboard turning. Value : Value is indicated on channel 11 of digital monitor. In case of value is large, correction value became large. Normally, adjust value of channel 11 to 0.00. Do not. adjust more than +0. 10 Please refer balance correction of port and starboard turning on item 4.3.7. 4.3 Adjustment process Hereinaft the process of adjustment of ZP controller is mentioned. This adjustment is done by the maker usually. lf you need the additional adjustment, please adjust the ZP cont- roller regardless of this process. Use the volume and the monitor when adjusting ZP controller. A stop watch is needed for the adjustment. of ZP steering speed. Adjust. ZP steering as follows. 4.3.1 Checking item Make sure the followings 1) Lock pin position Remove the lock pin from the lock pin guide and set it at the side of gear case upper. 2) No. of engine revolution (only PTO system) Start the main engine and No. of engine revolution is fixed at. idle speed. (only Electric Motor system) Start the electric motor. The clutch is to be disengaged. 10 —54—3) 4) 5) 6) Charge pressure of the hydraulic pump Be sure that. the charge pressure of the steering hydraulic pump is normal. Power supply Turn on power supply switch. Control switen on the alarm panel ZP steering is at rest when the control switch on the alarm pane] is changed from the "W/H" to "E/R" position. Manual control zP can be steered with the manual lever of the servol valve on the hydraulic pump. 4.3.2 Preparation Make the following preparation 1) Control switch on the alarm panel The control switch on the alarm panel is changed from "E/R” to "W/H". 2) Volume setting -Turn the volume VR7 and VR8 fully to counterclockwise until the volume make a sound "Kachi*. Turn the volume VR9 and VR10 and set the value of the digital 4.3.3 No. of engine revolution « only in PTO system) Confirm the No. of engine revolution on the digital monitor channel 1. If the valve of channel 1 is different from the real No. of engine revolution adjust the value of channel 1 by the volume (VR1). O Change the switch (sW2) 4 Change the switch(SW2) from "OFF" to "ON". Steering test Turn the volume(VR2) to clockwise or counterclockwise. The pointer of this volume(VR2) is relation to the ZP steer- ing direction as follows (the pointer of the volume VR2) (steering direction) In neutral Stop -Right side of neutral Clockwise Left side of neutral Counterclockwise If the steering direction is different from the above mentioned, there are miswirings. It needs to change the wirings. © Change the switch(sw2) 8 Change the switch(SW2) from "ON" to "OFF". Switch (Sw1) The position of switch(SW1) is set in "OFF". Steering direction The ZP thrust direction follows the steering handle position. If it doesn't follow, change the connections each other. i —55—4.3.7 4.3.8 4.3.9 Balance correction of port and starboard turning Incase of sensitivity of port and starboard turning is balanced, advance to 4.5.8. Sensitivity of port and starboard turning is unbalanced, adjust. VR10 according to following method. 1) Set SW3 to channel 2. 2) Operate ZP to ahead + neutral, when ZP stop, read value A. (Example) A = +0. 80 3) Operate ZP to astern + neutral, when ZP stop, read value B. (Example) B= -0.20 4) Good condition is that value A and B is same and signe +,- is different. (Example) A = +0.50 B = -0.50 5) Set SW3 to channel 11, adjust VR1O to +0.02 8) Repeat above mentioned item 1) ~ 4) 7) When value of A and B change as example, balance became good condition. (Example) A = +0.80 + +0.60, B = -0.20 > -0.40 Set SWS to channel 11, adjust VRI0 to +0.20 > 40.40 and repeat item 1) ~ 4). 8) When value of A and B change as example, balance became bad condition. (Example) A = +0.80 + +1.00, B = -0.20 > -0.00 Set SW3 to channel 11, adjust VRI0 to +0.02 > ~0.02 and repeat. item 1) ~ 4). 9) Corect balance of port and starboard turning by repeat above mentioned method several time. Balance can not adjust. perfectly. So fin: adjustment at a proper value. sh balance Following sensitivity If the following sensitivity is too weak, turn the volume VRS and VR9 to clockwise. If the following sensitivity is too strong, turn the volume VR3 or VR9 to counterclockwise. When the sensitivity is too strong by VR3, the over running of ZP steering occurs. If the sensitivity is too strong by VR9, the hitting sounds occurs from the steering gear and in case of the opposite, 4P cannot be steered. Fixed steering speed range (used only PTO system) Change the switch(sWa) to channel 3. The volume of the channel 8 is setted by turning the volume (VR6). The same engine revolution No. as this value is the end points of the fixed steering speed range. 4.3.10 ZP thrust direction The position of steering handle is setted in neutral position (0°). And adjust the ZP thrust. direction to neutral position(0") by turninfg the synchromotor in the follow up transmitter mechanically. 12 5g4.3.11 Counterclockwise steering speed in the fixed steering speed range Adjust the counterclockwise steering specd by the volume (VR5) and the digital monitor channel 7. The counterclockwise steering speed is faster, as the absolute value is larger. When turning the VRS to clockwise, the counterclockwise steering speed is faster. When turning the VR5 to counterclockwise, the counterclock~ wise steering speed is slower. 4.3.12 Clockwise steering in the fixed steering speed range ‘Adjust. the clockwise steering speed by the volume (VR4) and the digital monitor channel 6. The clockwise steering speed is faster, as the absolute value is larger. When turning the VR4 to clockwise, the clockwise steering speed is faster. When turning the VR4 to counterclockwise, the clockwise steering speed is slower. . 18 Counterelockwise steering speed in the changeable steering speed range (used only PTO system) Adjust the counterclockwise steering speed by the volume (VR8) and the digital monitor channel 5. The counterclockwise steering speed is faster, as the absolute value is larger. When turning the VR8 to clockwise, the counterclockwise steering speed is faster. When turning the VR8 to counterclockwise, the counterclock- wise steering speed is slower. 4.3.14 Clockwise steering speed in the fixed steering speed range (used only PTO system) Adjust. the clockwise steering speed by the volume (VR7) and the digital monitor channel 4. When turning the VR7 to clockwise, the clockwise steering speed is faster. When turning the VR7 to counterclockwise, the clockwise steering speed is slower. 4.3.15 Confirm of ZP neutral Confirm ZP position is agree with control handle order position by turning degree index plate on ZP turning table. lf position is different, readjust according to 4.3.8 ion of nearest way -+ Do nearest way turning -4+ Do not nearest way turning 4.3.16 ON/OFF select SON" "OFF" ~ (CAUTION) Service engineer carry out adjustment of controller. If custmer carry out adjustment/readjustment, please inform us it. 13 es5. TROUBLE 5.1 Alarm ZP controller gives an alarm when there is a difference between the steering handle position (order) and ZP thrust direction. And, ZP controller gives an alarm when the handle signal line, follow up transmitter signal line, and/or magnetic pick up line is broken. The alarm is shown that LED shines and the voltage signal output. ZP controller has the following five type of alarm. () Hydraulic system alarm zP controller gives an order to the hydraulic system for stcer- ing ZP. But the hydraulic system has a trouble. So, ZP can not be steered. (2) ZP controller trouble ZP controller does not give a order to hydraulic system for steering ZP. Please check the signal line between ZP controller and the servo valve on the hydraulic pump. If there is nothing wrong with them, ZP controller has a trouble. NOTE : An alarm LED shines in the following cases. 1) the main engine stops (only PTO system) the electric motor stops (only Electric Motor system) 2) steering ZP by the manual lever (3) Handle potentiometer line broken The signal of handle potentiometer is trouble. Check the breake of handle potentiometer line. (4) Follow up transmitter line broken The signal of follow up transmitter is trouble. Check the breake of follow up transmitter potentiometer line. (5) Magnetic pick up line broken The signal of magnetic pick up is trouble. Check the break of magnetic pick up line. 5.2 Trouble shooting This section will give users expedient aids in correcting minor problem: a s 1 Not. steered ZP cannot be steered by the steering handle. O In steering test mode (Change the switch(SW2) from "OFF" to "ON") 1) Give the power supply ? Yes : Next. No: Give the power supply and check that LEDI and 2 shine. 14 58 —2) 3) 4) 5) 6) 1 8) The main engine runs ? (only PTO system) The electric motor runs ? (only Electric Motor system) Yes : Next, No: Start the main engine and check the LED3 blinks frequently. (only PTO system) Start the electric motor. (only Electric motor system) The charge pressure of the hydraulic pump is normal ? Yes : Next. No: Inspec the check valve of the hydraulic pump or the suction filter. ZP can be steered by the manual lever on the pump ? Yes : Next No : Inspec the by-pass valve on the oil tank unit. If there is nothing wrong with then, the hydraulic pump, the hydraulic motor or the servo valve has a trouble. LEDS lights 7 Yes : There is no output signal from ZP controller. Inspect. the servo valve and the lines between the servo valve and ZP controller. No: Next LED4 lights ? Yes : ZP controller gives orders to the hydraulic system. But the hydrawlic system has a trouble. No: Next Set the switch(SW3) on channel 2 and turn the volume (VR2) Is there a change of the value on the digital monitor? Yes : Next No : ZP controller has a trouble. Set the switch(SW3) on channel 9,and turn the volume (VR1) Is there a change of the value on the digital monitor? Yes : Next, No: If the value is "0.00", turn the volume(VR2) to the clockwise. Though ZP cannot be steered. 2P controller has a trouble. O In normal mode (Change the switch(SW2) from "ON" to “OFF") 9) Set the switch(SW3) on channel 2 and operate the steering handle. Is there a change of the value on the digital monitor? Yes : Inform the maker No: Check the potentiometer of the steering handle and the potentiometer in the follow up transmitter. 15 ~59—5.2.2 Not stop ZP cannot. stop and continues to be steered. O In steering test mode (Change the switch(SW2) from "OFF" to ON") 1) Give the power supply ? Yes : Next. No : Give the power supply and check that LED1 and 2 shine. 2) LEDS lights ? Yes : There is no output signal from ZP controller. Inspect the servo valve and the lines between the servo valve and ZP controller. No: Next, 3) LED4 lights ? Yes : ZP controller gives orders to the hydraulic system. But the hydraulic system has a trouble. No : Next 4) Set the switch(SW3) on channel 2 and turn the volume (VR2) Is there a change of the value on the digital monitor? Yes : Next No : ZP controller has a trouble. 5) Set the switch(SW3) on channel 9 and turn the volume (VR2) Is there a change of the value on the digital monitor? Yes : Next No : ZP controller has a trouble. O In normal mode (Change the switch(SW2) from "ON" to "OFF") 6) Change the control switch from the "W/H" to "E/R". ZP stop? Yes : Next. No: The servo valve or the hydraulic pump has a trouble. 7) Set the switch(SW3) on channel 2 and operate the steering handle. Is there a change of the value on the digital monitor? Yes : Inform the maker No : Check the potentiometer of the steering handle and the potentiometer in the follw-up transmitter. 16 —60—2.3 Hunting ZP doesnot stop and is steered like a pendulum. O In steering test mode (Change the switch(SW2) from "OFF" to "ON") 1) Give the power supply ? Yes : Next. No :Give the power supply and check that LEDI and 2 shine. 2 There is no output signal from ZP controller. Inspect the servo valve and the lines between the servo valve and ZP controller. No : Next, 2) LEDS light: Yes 3) LED4 lights ? Yes : 4P controller gives orders to the hydraulic system. But the hydraulic system has a trouble. No : Next, 4) Set the switch(SW3) on channel 2 and turn the volume (VR2) Is there a change of the value on the digital monitor? Yes .: Next. No : ZP controller has a trouble. 5) Set the switch(SW3) on channel 9 and turn the volume (VR2) Is there a change of the value on the digital monitor? Yes : Next No: ZP controller has a trouble. 6) LEDS blinks frequently ? Yes : Next. No: ZP controller does not receive the pulse signal of the engine revolution. Check the pulse pick up of the engine revolution and the lines between the pulse pick up and the ZP cont~ roller. 7) Set the switch(sW3) on channel 1. Is there a correct value of the engine revolution on the digital monitor? (only PTO system) Yes : Next. No: Set the switch(SW3) on channel 1 and turn the volume (VR1). Adjust the value of the digital monitor on the engine revolution. If adjusting is imposs- ible, ZP controller has a trouble. 8) Only PTO system Set the switches(SW3 & 4) on channel 22. The value of the digital monitor is in proportion to the value of the channel 1. (0.5 * value of the channel 1) Only Electric Motor system Set the switches (SW3 & 4) on channel 22 The value of the digital monitor is "4. 10(#0.1). Yes : Next. No : ZP controller has a trouble. iT ier9) Only PTO system Set the switch(SW3 & SW4) on channel 23 The value of the digital monitor is in proportion to the value of the channel 1. (-0.5 x value of the channel 1) Only Electric Motor system Set the switches (SW3 & 4) on channel 23 The value of the digital monitor is *-4.10(¢0.1)7. Yes : Next. No : ZP controller has a trouble. 10) Set the switch(SW3) on channel 2 and operate the steering handle. Is there a change of the value on the digital monitor? Yes : Next No: Check the potentiometer of the steering handle and the potentiometer in the follow up transmitter. 11) Turn the volume(VR3) to counterclockwise The hunting of ZP stop ? Yes : 0.K No : Inform the maker NOTE :When the ship has two engines and two ZP, please change the connecters of the ZP controller between the port side to the starboard ‘The trouble change fron the port side to starboard (or the opposite), the trouble is caused by the ZP controller. If not , it is caused by the others. 6 EXCHANGE OF ZP CONTROLLER When exchange ZP controller by something reason, carry out according to following method. 1) Keep on record adjustment value of old controller on final item "DIGITAL MONITOR VALUE LIST" 2) Remove old controller and install new controller. Adjust value of channel according to value of old controller. Channel 3 Adjust VR6 Channel 4 ~- - Adjust VRT Channel 5 - Adjust VR8 Channel 6 ~ Adjust. VR4 Channel 7 ~- Adjust VRS VR3 Adjust. index vRo ~ Adjust index 3) Carry out adjustment from 4.3.4 to 4.3.15. When adjustment, if adjustment value is different, don't care. Turning speed of ZP adjust. according to another ZP turning speed which does not replace controller. 18 —62_DIGITAL MONITOR VALUE LIST Ship name _ Date_ ZP_Controlle (Engine is idling -Clutch is disengaged-ZP stops at neutral position) (PTO) (Electric Motor is driving:Glutch is disengaged-Zp stops at neutral position) --- (MOTOR) ric Motor) Kevolutior = | 5 1g Channel No. of Digital Monitor Channe} (Che Channel Channel _— mo Charge Press. of the pump (kg/cd) _ Set of Volume No. Set. of Volume No. 9 19 ~ 63—