Top_Bracing_HCAHT300-30

泰兴市海诚船舶设备有限公司
TaixingHaicheng Marine Equipment Co.,Ltd
主机气动-液压顶部支撑装置
M/E Air-Hydraulic Top Bracing Device
认可资料
For Approval drawing
型号 Type： HCAHT300-30
数量 Qty.： 4 sets/ship
主机厂 Engine maker： DMD
机型 Engine type: 9X92-B HPSCR
CSS065~073
目录
1. 简介 Introduction .............................................................................................................. 3
2. 安全 Safety ........................................................................................................................ 4
3. 主要技术参数 Main parameters ...................................................................................... 5
4. 系统组成 System parts ..................................................................................................... 6

4.1 气动-液压顶撑单元 Air-hydraulic top bracing units ................................................ 6
4.2 压缩空气调节单元 Compressed air regulate unit ................................................... 6
4.3 安装工具 Fitting tool ................................................................................................ 6
4.4 液压手摇泵 Hydraulic hand pump ........................................................................... 6
5. 工作原理 Working principle.............................................................................................. 7
6. 安装 Installation .............................................................................................................. 10
6.1 安装准备 Preparation for installation .................................................................... 11
6.2 焊接法兰的安装 Installation of welding flanges ................................................... 11
6.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders ....................... 14
6.4 液压阀块和蓄能器的安装 Installation of hydraulic control block and accumulator
15
6.5 调整活塞位置、充油、充气 Piston adjust & Oil filling & Air filling ..................... 16
7. 服务和维护 service and maintenance ............................................................................ 18
7.1 备件 spare parts...................................................................................................... 18
7.2 服务检查 service inspection ................................................................................... 18
8. 供货范围 Scope of supply ............................................................................................... 23
9. 图纸 Drawings ................................................................................................................. 24
1. 简介 Introduction
主机气动-液压顶部支撑装置（以下简称气动-液压顶撑）是安装在主机和船体结构之间，
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。
M/E Air-Hydraulic top bracing device（shortened form：air-hydraulic top bracing）are
installed between the engine and the hull, to detune the natural frequencies of the engine and thus
lower the impact of the vibrations. The air-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（排气侧）；如果更方便的话，也可以安装在主机左
侧(凸轮侧)，一般只需安装在一侧即可。
The standard installation is on the starboard side（exhaust side） of the engine, but port
side（camshaft side）installation can alternatively be used if this is more convenient. Generally
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。

气动-液压顶撑液压缸设计直径为 300mm.
The standard installation features two or four or six air-hydraulic top bracing units, depending
on engine size and cylinder number. The design cylinder diameter of air-hydraulic top bracing is
300mm.
2. 安全 Safety
气动-液压顶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。
Air-Hydraulic top bracing 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.
3. 主要技术参数 Main parameters
型号 Type： HCAHT300-30
液压缸直径 Cylinder diameter： 300mm
安装长度 Installation length： 649mm
最大安装公差 Max. installation tolerance： +15 mm
最大支撑力 Max. force： 200kN（28.3bar）
液压油容积 Volume of oil： 6L/cylinder
压缩空气气源压力 Compressed air： 25~30bar
蓄能器设定值(氮气)Accumulator set pressure（N2）：15 bar(制造厂预充 Precharge by
manufacture)
溢流阀设定值 Relieve valve set pressure： 28.3 bar
空气调节器设定值 Air regulator set pressure： 12 bar
最大操作温度 Max. working temperature： 75℃
缸体组件重量 Weight： Approximately 230 kg/cyl (with oil)
液压油要求 Type of hydraulic oil： ISO VG 32
油漆颜色 Paint color： Munsell 7.5BG 7/2
4. 系统组成 System parts
气动-液压顶撑系统主要由以下几部分组成（参照系统原理图 HCAHT300-30-XTYL）：
The air-hydraulic top bracing system are forming by following parts（Refer to principle
diagram HCAHT300-30-XTYL）:
4.1 气动-液压顶撑单元 Air-hydraulic top bracing units

根据主机型号的不同，气动-液压顶推支撑系统由 2 套、4 套或 6 套顶撑单元组成。每
套顶撑单元主要由一组液压缸、一套液压阀块、一只蓄能器和一套安装法兰组成（参照气动
-液压顶撑外形图 HCAHT300-30-WX）。
The air-hydraulic top bracing system consist two,four or six sets of air-hydraulic top bracing
units, depending on the engine type.Each unit consisting of: a cylinder unit, a hydraulic control
block, an oil accumulator and a set of mounting flanges(refer to air-hydraulic top bracing outline
diagram: HCAHT300-30-WX).
4.2 压缩空气调节单元 Compressed air regulate unit

参照图纸 HCAHT300-30-KQTJ
Refer to diagram HCAHT300-30-KQTJ
4.3 安装工具 Fitting tool

正确定位焊接法兰的安装工具.
Fitting tool for correct position of welding flanges.
参照图纸 HCAHT300-30-AZGJ
Refer to diagram HCAHT300-30-AZGJ
4.4 液压手摇泵 Hydraulic hand pump

参照图纸 HCAHT300-30-SYB
Refer to diagram HCAHT300-30-SYB
5. 工作原理 Working principle
气动-液压顶撑初始设定值 Air-Hydraulic top bracing initial pressure set：

蓄能器设定值 Accumulator set pressure： 15 bar
溢流阀设定值 Relieve valve set pressure： 28.3 bar
空气调节器设定值 Air regulator set pressure： 12 bar
（注：以上设定值可以根据船舶状态进行调整）
（Remark：Above pressure set is adjustable depends on ship’s condition）
气动液压顶撑主要有三种工作状态：
轻载状态
重载状态
反向负载状态
Air-Hydraulic top bracing have three working status:
a) Low load
b) Heavy load
c) Reverse load
5.1 轻载状态 Low load
当顶撑受到主机或船体侧压力小于 85kN 时，顶撑处于预调整状态；当压力逐渐增大

超过 85kN 但小于 200kN 时，第一级油腔体积减小，油腔内压力增大，第一级油腔内液压
油会流进蓄能器，由蓄能器吸收压力波动。
When the force from engine and/or hull is less than 85 KN, top bracing keeps preadjusted
condition. But when the force is between 85 KN and 200 KN, oil pressure in primary chamber will
be increased. In this case, accumulator absorbs the force.
轻载状态示意图 Low load schematic diagram

5.2 重载状态 Heavy load

当顶撑受到主机或船体侧压力超过 200kN，第一级油腔压力超过溢流阀设定值（28.3
bar）时，溢流阀打开，液压油由第一级油腔流入第二级油腔，第二级油腔压力升高，二级
活塞会向空气腔一侧移动，压缩空气腔，空气腔吸收压力波动。
When the force from engine and/or hull is higher than 200 KN, the pressure of primary oil
chamber higher than setting pressure of relief valve(28.3 bar), the relief valve is open. Oil in
primary chamber flows to secondary oil chamber, the secondary piston move to air chamber
until the pressure of secondary oil chamber and air chamber are equaled. In this case, air
chamber absorbs the force.
重载状态示意图 Heavy load schematic diagram
5.3 反向负载状态 Reverse load

当主机和船体相互远离时，第一级油腔内压力降低，空气腔将驱动二级活塞，第二级油
腔内液压油通过单向阀流回第一级油腔，直到两个油腔和空气腔三者压力平衡为止。
When engine and hull moves away from each other, the oil pressure in primary chamber is
decreased. Compressed air in air chamber push the secondary piston and the oil in secondary
chamber flows to primary oil chamber through the check valve until the pressure in primary
chamber, secondary chamber and air chamber is equal.
反向负载状态示意图 Reverse load schematic diagram

6. 安装 Installation
气动-液压顶撑正常工作的前提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。顶撑正确的安装长度和两焊接平行法兰之间的平行度非常重要，其安
装标准如下：
The air-hydraulic top bracing will only work correctly if the supporting hull structure has
sufficiently rigid. When this is not the case, the structure should be sufficiently reinforced. It is
important that the air-hydraulic top bracing be installed with correct build-in length and with
two welding parallel flanges without misalignment. The installation parameters are as following:
安装长度公差：649+15mm
安装平行度：≤1°
Installation tolerance: 649+15mm
Installation parallelism: ≤1°
运行不重合度：
Service misalignment:
Hmax-Hmin≤10mm
Emax-Emin≤10mm
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 air-hydraulic top bracing cylinders shortly after
installation, at normal loading condition of the vessel and with warm engine.
6.1 安装准备 Preparation for installation

6.1.1 检查所有零部件和安装工具是否齐全和完好
Check that all parts and installation tools are present and in good condition.
6.1.2 检查气动-液压顶撑安装点及其对应的船体侧结构或支撑在同一水平线上，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 sufficient strength and rigidity of the installation.
6.1.3 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 theconnection line.
Control the distance between the fix points.
6.2 焊接法兰的安装 Installation of welding flanges

6.2.1 将焊接法兰用 8 个 M16x35 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 welding flanges on the fitting tool, using the 8xM16x35 bolts.The tool should be
adjusted to the correct build-in length.
6.2.2 在液压顶推支撑上方布置 0.5 吨的手拉葫芦，将安装工具提升到安装位置。

Rig a 0.5t chain block above the top bracing position. Rig the fitting tool in thechain block
and elevate it to the correct height with the large mounting flangefacing the hull side.
6.2.3 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 largemounting flange.
See the sketch below.
6.2.3.1 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 bycutting or grinding
the hull fix point-alternatively the engine fix point.
6.2.3.2 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 thesupporting
bracket. If the build-in length becomes too long, make a steel shim tocompensate for the gap.
We recommend placing the shim on the engine sidebetween the top bracing and the mounting
flange and tack weld the shim to themounting flange, it is necessary to install longer bolts in all 4
holes.
6.2.4 安装长度和平行度符合要求
Build-in length correct, parallelism correct
6.2.4.1 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.
6.2.4.2 将焊接法兰点焊在船体安装点处。
Tack welds the flange to the hull fix point.
6.2.4.3 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 minimizedeformations. It
is recommended to apply as little heat as possible.
6.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders

6.3.1 将手拉葫芦安装到液压缸的吊环上。注意：不要用液压缸单元的推力杆起吊，确
保临时支撑安装到位，安装完成前不要拆除临时支撑，否则液压缸单元会散架。
Rig the chain block to the lifting ring of the hydraulic cylinder. Note: Do notlift the top
bracing cylinder in the distance rod. Do not remove the temporary supporter (the unit will fall
apart), until thetop-bracing unit installation finished.
6.3.2 把液压缸单元调到正确的位置，并用 6 个 M16×90（8.8 级）的双头螺栓将其

安装在船体安装点处，在垂直方向上调整液压缸，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 thehull fix point
with 4xM16x90 double end bolts（8.8G）. Adjust the cylinder in the verticaldirection so that the
mounting bolts are in the middle of the slotted holes. Tightenthe bolts.
6.3.3 在主机侧安装点用 4 个 M16x85（8.8 级）的双头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 4xM16x85（8.8G）
double end bolts, but do tighten them.
6.3.4 拆除靠近主机侧临时支撑上的螺栓，确保零件不散架。
Remove the bolt on temporary supporter nearest to the engine fix point, making sure that
the partsdo not fall apart.
6.3.5 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，最后拧紧所有十颗紧固螺栓（扭矩：100Nm）。
Tighten the bolts at the engine fix point making sure the distance rod isaligned in both
horizontal and vertical direction. It might be necessary to loosenthe bolts at the hull part for a
final correction. Finally tighten all ten installationbolts (100Nm).
6.3.6 拆除临时支撑
Remove the temporary supporter.
6.4 液压阀块和蓄能器的安装 Installation of hydraulic control block and
accumulator
6.4.1 确保液压阀块的安装底座和安装表面都是干净并清洁的，液压阀块和蓄能器是整
体起吊。
Ensure that the mounting base of the hydraulic control block and the mountingsurface of
the hydraulic unit are clean and in good condition. The hydraulic control block and the oil
accumulator are delivered as one unit.
6.4.2 在液压阀块底部的沉孔里安装 O 形圈。

Install the O-ring in the counter bore at the bottom of the hydraulic control block.
6.4.3 在液压缸安装基座上安装液压阀块，用 4 个 M10x50（8.8 级）的螺栓安装并

拧紧（扭矩：25Nm）。
Mount the hydraulic control block on the mounting base of the hydraulic cylinder unit,
Mountwith4xM10x50（8.8G）and tighten the bolts（25Nm）.
6.4.4 利用充气工具检查蓄能器内氮气压力，如果氮气压力低于 15bar，需对蓄能器进

行补充氮气，蓄能器内氮气压力正常为 15bar。
Check the pressure by nitrogen in the accumulator, if the pressure is lessthan
15 bar, the oil accumulator must be re-charged, the accumulator pressureis
normal 15bar。
6.5 调整活塞位置、充油、充气 Piston adjust & Oil filling & Air filling
检查一级活塞指针，根据活塞指针位置采取以下步骤调整活塞，并充油、充气
Check the position of the primary piston position indicator, adjust piston by following
procedure, and then fill oil and supply compressed air.
6.5.1 一级活塞指针位于绿色指示带中间
The primary piston position indicator in the center of green band
6.5.1.1 将透气软管与液压阀块上一级油腔透气接头连接,打开透气软管上的阀，将手摇
泵出油软管通过快速接头接到一级油腔注油口，打开注油阀，向一级油腔注油，当透气软管
处有油溢出时，停止泵油拆下透气软管，将透气软管接至二级油腔透气接头上。关闭一级油
腔注油阀，将注油管接至二级油腔注油口。
Connect air vent hose to primary oil chamber air vent connection on hydraulic
control block, open the valve on air vent hose, connect the oil outlet hose of
hydraulic hand pump to the oil filling coupling of primary chamber. Open the oil
filling valve and pump oil to primary oil chamber until oil flow out from air vent
hose. Remove air vent hose and connect it to secondary oil chamber air vent
connection on hydraulic control block, close primary oil filling valve, connect the
oil outlet hose of hydraulic hand pump to the oil filling coupling of secondary
chamber.
6.5.1.2 连接空气管路，打开空气进口阀，向空气腔通入压缩空气直至二级活塞指针位
与近缸体侧红色指示带与绿色指示带之间，关闭空气进口阀。
Connect air supply pipe, open inlet valve on compressed air regulate unit,
supply compressed air to air chamber until the secondary piston position
indicator is between red band (near cylinder side) and green band. Close air inlet
valve.
6.5.1.3 打开二级油腔注油阀，打开透气软管上的阀，泵油直至透气软管处有油溢出，
拆下透气软管，关闭透气接头，继续泵油直至二级活塞指针指在绿色指示带中间。
Open the oil filling valve, open the valve on air vent hose and pump oil to
secondary oil chamber until oil flow out from air vent hose. Remove air vent hose
and close air vent connection and keep pumping oil until the secondary piston
position indicator comes to the center of green band.
6.5.1.4 打开空气调节单元上充气阀，向空气腔充气至 12bar。

Open inlet valve on compressed air regulate unit, supply compressed air to air
chamber until the pressure reaches 12 bar.
6.5.2 一级活塞指针位于绿色指示带与红色指示带(近缸体侧)之间
The primary piston position indicator between green band and red band(near
cylinder side)
6.5.2.1 拆下定距片，松开推力杆和锁紧螺母。
Remove distance plate and loosen up the transfer barrier & lock nut.
6.5.2.2
将透气软管与液压阀块上一级油腔透气接头连接,打开透气软管上的阀，将手摇泵出油
软管通过快速接头接到一级油腔注油口，打开注油阀，向一级油腔注油，当透气软管处有油
溢出时，停止泵油拆下透气软管，将透气软管接至二级油腔透气接头上。继续泵油，直到一
级活塞指针指在绿色位置中间。关闭一级油腔注油阀，将注油管接至二级油腔注油口。
Connect air vent hose to primary oil chamber air vent connection on hydraulic
control block, open the valve on air vent hose, connect the oil outlet hose of
hydraulic hand pump to the oil filling coupling of primary chamber. Open the oil
filling valve and pump oil to primary oil chamber until oil flow out from air vent
hose. Remove air vent hose and connect it to secondary oil chamber air vent
connection on hydraulic control block. Keep pumping oil until the primary piston
position indicator comes to the center of green band close primary oil filling valve,
connect the oil outlet hose of hydraulic hand pump to the oil filling coupling of
secondary chamber.
6.5.2.3 紧固推力杆和锁紧螺母，使定距片安装螺栓孔对齐，安装定距片。
Tighten up the transfer barrier & lock nut, make sure that the installation
bolt hole of distance plate is in position, then install the distance plate.
6.5.2.4 连接空气管路，打开空气进口阀，向空气腔通入压缩空气直至二级活塞指针位
与近缸体侧红色指示带与绿色指示带之间，关闭空气进口阀。
Connect air supply pipe, open inlet valve on compressed air regulate unit,
supply compressed air to air chamber until the secondary piston position
indicator is between red band (near cylinder side) and green band. Close air inlet
valve.
6.5.2.5 打开透气软管上的阀，泵油直至透气软管处有油溢出，拆下透气软管，关闭透
气接头，继续泵油直至二级活塞指针指在绿色指示带中间。
Open the oil filling valve, open the valve on air vent hose and pump oil to
secondary oil chamber until oil flow out from air vent hose. Remove air vent hose
and close air vent connection and keep pumping oil until the secondary piston
position indicator comes to the center of green band.
6.5.2.6 打开空气调节单元上充气阀，向空气腔充气至 12bar。

Open inlet valve on compressed air regulate unit, supply compressed air to air
chamber until the pressure reaches 12 bar.
6.5.3 一级活塞指针位于绿色指示带与红色指示带(远缸体侧)之间
The primary piston position indicator between green band and red band (far cylinder
side)
6.5.3.1 拆下定距片，紧固推力杆和锁紧螺母直至一级活塞指针指在绿色指示带中间位
置，注意微调使定距片安装螺栓孔对齐，再重新安装定距片。
Remove distance plate. Tighten up the Transfer barrier & Lock nut until the
primary piston position indicator comes to the center of green band. Slightly
adjust lock nut, make sure that the installation bolt hole of distance plate is in
position, then install the distance plate.
6.5.3.2 按照 6.5.1 步骤进行操作。
Do as the procedure of 6.5.1.
6.5.4 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 air-hydraulic top bracing cylinder unit.
7. 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.
7.1 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.
7.2 服务检查 service inspection

7.2.1 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.
项目检查点如何检查检查周期

Item Check Point How To Check Check Period
漏油一级、二级活塞位置两个指针均位于两一个月
Oil Leakage 指针红色色带之间 Every one month
密封状况 Primary and The end of two
Seal Condition Secondary piston indicators have to be
position indicator between the red
bands
氮气情况蓄能器顶部使用充气工具检查六个月
N2 Condition Top of the 氮气压力 Every six months
accumulator Check N2 pressure
by charge tool
7.2.2 检查推力杆不重合度 Check the misalignment of the transfer barrier
运行不重合度
Service misalignment:
船体在各种装载状态下顶撑不重合度会产生变化。我们建议在船舶正常压载状态下，主
机运行完停止一段时间后，测量不重合度。
The misalignment of the top bracing transfer barrier brought about change
from various loading conditions of the vessel. When main engine is warm up and
vessel is normal loading conditions, we recommend to measure the misalignment
after main engine stops for a moment.
如果运行不重合度超过 10mm，需重新调整顶撑，调整需要在正常压载且主机处于热
机状态时进行。
If a misalignment of the transfer barrier exceeds10mm, the top bracing
should be re-aligned. The alignment should be performed at normal loading
condition and with warm engine.
调整垂直方向不重合度：稍微松开船体侧法兰螺栓，垂直方向调整液压缸，测量垂直方
向不重合度，如果在公差范围内，把紧螺栓。
Adjust vertical misalignment: loosen hull side flange bolts and move
hydraulic cylinder in vertical direction slightly, measure the misalignment. If the
misalignment within the tolerance, tighten hull side bolts.
调整水平方向不重合度：稍微松开主机侧法兰螺栓，水平方向调整轴承座，测量水平方
向不重合度，如果在公差范围内，把紧螺栓。
Adjust horizontal misalignment: loosen engine side flange bolts and move
bearing seat in horizontal direction slightly, measure the misalignment. If the
misalignment within the tolerance, tighten engine side bolts.
7.2.3 检查活塞位置 Check the position of pistons

一级、二级活塞位置指针正常情况应位于绿色指示带上。考虑到船体在各种负载条件下
会导致液压活塞偏出原始位置，一级、二级活塞位置指针在绿色和红色带之间的位置是可行
的。如果一级、二级活塞位置指针到达或超出红色指示带，需要重新调整活塞位置。
Primary and secondary piston position indicators should normally be in the
green band. A position between green band and red bands may be acceptable;
take consideration of the vessel will cause the hydraulic piston to shift away from
the original adjustment. However, readjustment should be done if piston indicator
reach or exceed the red bands.
根据 6.5 步骤调整活塞位置，调整前需先泄压。
Adjust piston position according to 6.5; the pressure of oil chambers must be
released.
泄压程序：打开手摇泵上的泄压阀，将手摇泵软管与油腔接头连接，打开油腔注油阀门，
泄放油腔内压力。先泄一级油腔压力，再泄二级油腔压力。
Pressure release procedure: Open the overflow valve on the hand pump;
connect the hand pump hose to the oil chamber coupling. Open the oil filling valve
to take off the pressure of the system. Release the primary chamber first, then
release the secondary chamber.
7.2.4 更换密封件 Replacing seal rings
7.2.4.1 确保主机处在停机状态。
7.2.4.1 Make sure that the main engine is at standstill.
7.2.4.2 打开手摇泵上的泄放阀，并将手摇泵软管分别与一级油腔和二级油腔接头连接，
打开接头处的截止阀卸去系统中的压力。
7.2.4.2 Open the drain valve on the hand pump, connect the hand pump hose to the primary
oil chamber and secondary oil chamber minims coupling. Insure that the ball valve is pointing
down in an oil
7.2.4.3 关闭球阀，调节调压阀，并将气压设定在 0bar,移除气管。

2.2.4.3 Close ball-valve of the control panel, accommodate pressure regulating valve, make
the air pressure about 0bar,remove air-pipe.
7.2.4.4 安装临时支撑 Mount thetemporary supporters.
7.2.4.5 在顶推支撑上安装一个 0.5 吨的手拉葫芦。用吊环到手拉葫芦上并拆除 12 个 M16

的安装螺栓。
7.2.4.5 Rig a 0.5 t chain block above the top bracing. Rig the hand ring to the chain block and
remove the 12×M16 installation bolts.
7.2.4.6 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。
7.2.4.6 Lift the top bracing unit and place it on a clean surface with the mounting face of the
cylinder house downwards.
7.2.4.7 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）。
2.2.4.7 Dismount the lifting tools for transport and carefully lift away the engine side parts
(flange, distance rod and adjusting nut).
7.2.4.8 拆除压盖，提出活塞并将其放在干净的表面上。
2.2.4.8 Dismount the cylinder cover,Lift the piston away and land it on a clean surface.
7.2.4.9 更换所有的导向环和密封圈。
7.2.4.9 All guide rings and sealing rings are should be replaced.
2 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 .
根据 6.3~6.5 重新安装液压顶推支撑。
Reinstall the top-bracing cylinder according to6.3~6.5.
7.2.5 更换蓄能器 Replacing oil accumulator

7.2.5.1 蓄能器通过氮气加压。如果氮气压力低于 15bar，蓄能器必须重新加压。

7.2.5.1 The oil accumulator is pressurized by nitrogen (N2). If the nitrogen pressureis below
15 bar, the accumulator must be refilled.
7.2.5.2 确保主机处在停机状态。
7.2.5.2 Make sure that the main engine is at standstill.
7.2.5.3 打开手摇泵上的放泄阀，并将手摇泵软管分别与一级油腔和二级油腔接头连接，
打开接头处的截止阀卸去系统中的压力。
7.2.5.3 Open the drain valve on the hand pump, connect the hand pump hose to the primary
oil chamber and secondary oil chamber minims coupling. Insure that the ball valve is
pointingdown in an oil can. Open the ball valve to take off the pressure of the system.
7.2.5.4 关闭球阀，调节调压阀，并将气压设定在 0bar.

7.2.5.4 Close ball-valve of the control panel,accommodate pressure regulating valve,make
the air pressure about 0bar.
7.2.5.5 安装充气工具在蓄能器上(参照充气工具使用说明 HCHT300-30-CQSM)。

Mount charge tool to accumulator （ refer to explanation of charge to tool’s use
HCHT300-30-CQSM）.
7.2.5.6 检查阀 A 和 B 是否关闭。

7.2.6.1Check whether valve A and B are closed.
7.2.5.7 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.
7.2.5.8 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 nitrogenpressure in the
accumulator on the pressure gauge D. Close the valve Aclockwise。
7.2.5.9 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 15bar 的

补偿压力 1-2bar。
7.2.6.4If the accumulator needs to be refilled with nitrogen, open valve B andadjust the
outlet pressure on spindle A to 1-2 bar above the charging pressure15bar.
7.2.5.10 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.
7.2.5.11 关闭阀 B
Close valve B.
7.2.5.12 等待 5 分钟让温度稳定下来。
7.2.5.12 Wait five minutes for the temperature to stabilize.
2.2.5.13 根据值为 15bar 的补偿压力检查表 D 上显示的蓄能器的压力。

7.2.5.13Check the pressure in the accumulator on gauge D according to thecharging pressure
15bar.
7.2.5.14 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。

7.2.5.14Adjust the vent valve E on the charge tool slowly until the pressure valuereaching to
the required charge pressure.
7.2.5.15 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.
8. 供货范围 Scope of supply

供货范围、安装工具、备件清单参照图纸：HCAHT300-30-GH/FJ/BJ
Scope of supply, tool list and spare parts list refer to drawing: HCAHT300-26-GJ/FJ/BJ
9. 图纸 Drawings
图号图名
Drawing No. Drawing Name
部件说明
Parts INFO
系统原理图
HCAHT300-30-XTYL
System diagram
外形尺寸图
HCAHT300-30-WX
Outline Drawing
焊接法兰
HCAHT300-30-01、11
Welding flange
压缩空气调节单元
HCAHT300-30-KQTJ
Compressed airregulate unit
安装工具
HCAHT300-30-AZGJ
Fitting tool
液压手摇泵
HCAHT300-30-SYB
Hydraulic hand pump
供货范围
HCAHT300-30-GH
Scope of supply
工具、附件清单
HCAHT300-30-FJ
Tool&accessories list
备件清单
HCAHT300-30-BJ
Spare parts list
备件清单图
HCAHT300-30-BJ-01
Drawings of Spare parts list
充气工具使用说明
HCAHT300-30-CQSM
Explanation of charge tool’s use
部件说明
Parts INFO
1.船体侧焊接法兰 Hull side welding flange 2.液压缸缸体 Hydraulic cylinder

3.活塞杆 Piston rod 4.一级活塞 Primary piston
5.二级活塞 Secondary piston 6.缸盖 Cylinder cover
7.推力杆 Transfer barrier 8.锁紧螺母 Lock nut
9.调节杆 Adjust barrier 10.轴承 Bearing
11.主机侧轴承座 12.主机侧焊接法兰
13.O 型密封圈 “O” ring 14.油嘴 Grease nipple
15.防尘环 Seal guard 16.防尘圈 Seal ring
17.挡圈 18.斯特封和格莱圈 Step ring & Glyd ring
19.斯特封和格莱圈 Step ring & Glyd ring 20.导向环 Rider ring
21.导向环 Rider ring 22.防尘环 Seal guard
23.O 型密封圈 “O” ring 24.液压阀块 Hydraulic control block
25.蓄能器 Accumulator
26.一级活塞位置指示 Primary piston position indicator
27.二级活塞位置指示 Secondary piston position indicator

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泰兴市海诚船舶设备有限公司

TaixingHaicheng Marine Equipment Co.,Ltd

主机厂 Engine maker： DMD

机型 Engine type: 9X92-B HPSCR

3. 主要技术参数 Main parameters ...................................................................................... 5

4. 系统组成 System parts ..................................................................................................... 6

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。

3. 主要技术参数 Main parameters

4. 系统组成 System parts

4.1 气动-液压顶撑单元 Air-hydraulic top bracing units

4.2 压缩空气调节单元 Compressed air regulate unit

4.3 安装工具 Fitting tool

4.4 液压手摇泵 Hydraulic hand pump

5. 工作原理 Working principle

气动-液压顶撑初始设定值 Air-Hydraulic top bracing initial pressure set：

5.1 轻载状态 Low load

当顶撑受到主机或船体侧压力小于 85kN 时，顶撑处于预调整状态；当压力逐渐增大

轻载状态示意图 Low load schematic diagram

5.2 重载状态 Heavy load

重载状态示意图 Heavy load schematic diagram

5.3 反向负载状态 Reverse load

反向负载状态示意图 Reverse load schematic diagram

6.1 安装准备 Preparation for installation

6.2 焊接法兰的安装 Installation of welding flanges

6.2.2 在液压顶推支撑上方布置 0.5 吨的手拉葫芦，将安装工具提升到安装位置。

6.2.3.2 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

6.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders

6.3.2 把液压缸单元调到正确的位置，并用 6 个 M16×90（8.8 级）的双头螺栓将其

6.3.3 在主机侧安装点用 4 个 M16x85（8.8 级）的双头螺栓安装液压缸单元，但不

6.4 液压阀块和蓄能器的安装 Installation of hydraulic control block and

6.4.2 在液压阀块底部的沉孔里安装 O 形圈。

6.4.3 在液压缸安装基座上安装液压阀块，用 4 个 M10x50（8.8 级）的螺栓安装并

6.4.4 利用充气工具检查蓄能器内氮气压力，如果氮气压力低于 15bar，需对蓄能器进

6.5.1.4 打开空气调节单元上充气阀，向空气腔充气至 12bar。

6.5.2.6 打开空气调节单元上充气阀，向空气腔充气至 12bar。

7. 服务和维护 service and maintenance

7.1 备件 spare parts

7.2 服务检查 service inspection

项目 检查点 如何检查 检查周期

7.2.2 检查推力杆不重合度 Check the misalignment of the transfer barrier

7.2.3 检查活塞位置 Check the position of pistons

7.2.4 更换密封件 Replacing seal rings

7.2.4.3 关闭球阀，调节调压阀，并将气压设定在 0bar,移除气管。

7.2.4.4 安装临时支撑 Mount thetemporary supporters.

7.2.4.5 在顶推支撑上安装一个 0.5 吨的手拉葫芦。用吊环到手拉葫芦上并拆除 12 个 M16

7.2.5 更换蓄能器 Replacing oil accumulator

7.2.5.1 蓄能器通过氮气加压。如果氮气压力低于 15bar，蓄能器必须重新加压。

7.2.5.4 关闭球阀，调节调压阀，并将气压设定在 0bar.

7.2.5.5 安装充气工具在蓄能器上(参照充气工具使用说明 HCHT300-30-CQSM)。

7.2.5.6 检查阀 A 和 B 是否关闭。

7.2.5.7 使用联接螺母 C 将加气软管安装在氮气瓶上。

7.2.5.8 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

7.2.5.9 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 15bar 的

7.2.5.10 保持阀 B 打开直到蓄能器被加压完毕。

2.2.5.13 根据值为 15bar 的补偿压力检查表 D 上显示的蓄能器的压力。

7.2.5.14 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。

7.2.5.15 卸下联管螺母 C 并拆除蓄能器上的充气工具。

8. 供货范围 Scope of supply

1.船体侧焊接法兰 Hull side welding flange 2.液压缸缸体 Hydraulic cylinder

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项目检查点如何检查检查周期