‘SERVICE AREA kona | “see ae a DHS SS nea | STEERING STAND PR-4507-DH RRM ATYS SICKYOKEICOLID. on QPTIONAL UNIT MARS BLEEDcusrermine oa ren cre. CZECHS] te a, no ‘a srmnye um mer cima, 12 (GAG. 19, CEST we WO. 2 GONTROL Box NO: 2 SURO vaw od aaa | | fesisistoa ¢ ! ] 37902 POTION ex, 1 Bo wpa nse ae 1. mm oa up's nom wTE CoDIMENT comer | 1 71S ISENTIL ma Camaros At GRP SOWIE SERLESTRADA TRARY THIEL, OF | — > PR—4505-048 pete is eel BLT 142981 5'0)STEERING STAND { 2 tra ae et ni 7 ll - | | | all [os ser aryen eran emg = ; ‘parm etn rca ¢ ZESIY, 0. CEE a 20 amas cu oct cet, e GES. 10, CEE eamemnnze = Cae Cam. mom NO: } Soha~was 22 NO. + CONTROL BOx | NO. 2 GovTROL sox NO: S9no amy 9% fame fae See Fi $ fh | Le 2 PGE MOTORS BLL bny ens UREN 290.2 POTATS ETL OWL 1) Fr.) wey 9k AL NO. 2 RPM wok oT No.2 2 8 ae “en Moo aOR OnE 5) SMI pp es REN PR=4507-0H8 INTER UNIT WIRING O1AGRAM nur site RT 3 = oh [r1429816:0z were AG Ani avisSEE See eee eee epee eee ee | A= 4000-OMISTEERING STAND | wintne o1acram (1.07 SIDE} i Frowvo «Ei co.OOSPH ZH LL g few. armed] 2° ryiorerp Ess “DETOO PHAN OAMOLE WvyOv1d ONTUIM (NOILd0) ‘GNI aLvy Nn GNviS SNINIIIS 000% -¥e Lo ove a ey gos dana uclinow PEE eee eee eeAUTO PILOT PI ELECTRIC PARTS LIST TABLE OF CONTENTS Title Steering Stand Monitor Panel ....sees Peele Penal paler ie eoets| ceaestet acacia teeta ceed ee Helm unit . Switch Panel Amplifier Unit & Alarm Unit ....+ Relay Unit seeeeeesee eee sp. Power Supply Unit . Off Course Power Supply Unit . S.F.A. Power Supply Unit ...eeseeeeeeeeee Repeat Back Unit .. PageMONITOR PANEL Symbol No. Part No. Nomenclature Description PLIONW1G2 114290200 Lamp Ass'y iw crtomi12 075030800 Diode vo3c s 101 100309370 Push Button Switch Red s 102 100309390 Push Button Switch Yellow s 103 93113112 Toggle Switch STAIANLIS vRio1 042115205 Resistor, Variable 2a, 1/40 vri02 042115104 Resistor, Variable yooRe, 1/4W _ 114293751 Printed Circuit TURN RATE Board Assy FACIA PANEL ‘Symbol Part No. Nomenclature Description B 201 103590810 Step Motor pe7ov B 202,203 100380051 Linear Synchro Motor ‘892382 PL201 081019011 Lamp 6.3v Bz201 100308470 Buzzer pe1av vR201 109316940 Resistor, Variable 2Kn, 0.38 R202 100316950 Resistor, Variable 20Ki, 0.250 vR203 100336970 Resistor, Variable 200K, 0, 258 R204 100316960 Resistor, Variable 100K, 0.250 $201 111600360 Toggle SwitchHELM UNIT “Symbol No. Part No. Nonencigture beseription PL301 osiolsuLt Lap 6.39 R 301 o430uv611 kesistor li, 2W ¥y 301 114506781 ‘Trausrorwer 301x303 LoUsB0051 Linear Syuehre Nocor 1892382 8 301 414202010 kotary Switch R301 044126500 Resistor, Variable 502, 10¥SWITCH PANEL Symbol No. Part No. Nomenclature Description PLSO1.407 2100370152 Lamp 6.3 R 401 043000612 Resistor in, 2H T 401 114504781 ‘Transformer 8 401,402 100307873 Rotary Switch vRAOL 100317020 Resistor, Variable 1Kn, 0.88 YRAO2,,403 044118500 Resistor, Variable son, 10W VRIO4 100326980 Resistor, Variable 10KR, 0.80 s 403 093222115 Toggle Switch STSLEN225 R 402 049111223 Resistor 22K0, 1W R401, 075030960 Diode 181887 PLAOB 100330341 Lamp (LED) Green B 401 202525121 Synchro Controlled Transformer AMPLIFIER UNIT & ALARM UNIT ‘Symbol No. Part No. Nomenclature Description MA 114291510 MALN DE 116291523 DENODULATOR AU 114291540 AUTO-L Ps 114291573 POWER SUPPLY RA 100083870 RUDDER AMP LD 114291581 LAMP DRIVER AL 114292510 eerie ALARM 1 oR 114291610 TURN RATE op 114292530 o/c POWER on 114291980 o/c aw. sp 114291950 S.FLA, POWER SA 114292570 S.FLA, AMP.RELAY UNIT Symbol No. Part No. Nomenclature Description P 601 100305460 Fuse 250, 1A $ 601 111600360 Toggle Switch FL6OL 100377030 Noise filter T 601 100377371 Transformer K 601, 602 091122016 Relay Acioov K 607, 608 091112017 Relay AcLISY K 609 091112015 Relay pe1ooy K 610 091112013 Relay pe2av 35 STEP REP. 9112014 Relay Dessv 70V STEP REP. cRoOL 100330270 Rectifier R 601 048252122 Resistor 1,2K9, 1.20 R 602 048121301 Resistor 3002, 2W 35V STEP REP. 048121122 Resistor 1.2K TOV STEP REP. AMP. POWER SUPPLY UNIT Symbol No. Part No. Nomenclature Description F 701~704 100305480 Fuse 250V, 3A F 705,706 100305460 Fuse 250V, 1A FL701,702 100377030 Noise filter T 701,702 124513251 TransfornerOFF COURSE POWER SUPPLY UNIT Symbol No. Part No. Nomenclature Description F 801 100305460 Fuse 250v, 1A T 801 100377080 ‘Transformer 1 802 100377070 Transformer Q 801,802 100350200 Transistor 2sp103-0 Q 803 100350680 Transistor 2sp110-0 S.F. R SUPPLY UNIT Symbol No. Part No. Nonenclature Description F 901 100305460 Fuse 250V, 1A FL9OL 100377030 Noise filter 7 901 100377371 TransformerREPEAT BACK UNIT “Symbol No. Part No. Nomenclature Description B 101 100380051 Linear Synchro Motor ¢ 101,102 100325360 Capacitor 1F, 4oovDe R 101 048121300 Resistor 2W, 30% $ 101,102 093019012 Micro Switch — 2114293601 Printed Circuit BUFFER AMP Board Ass'yE. D. TYPE (PR-4000/5000) REPEAT BACK UNIT @ INSTRUCTION MANUAL % TOKYO KEIKI CO,LTD.CONTENTS Repeat Back Unit ....... Follow-Up Linear Synchro Outside Limit Switch ..... Check and Maintenance so... sseeeeeeeeeee essences Repeat Back Unit .. Replacement of Parts of Repeat Back Unit.......... Limit Switch Follow-Up Linear Synchro... Spare Parts .....0+ Repeat Back Unit ..... APPENDIX 1 APPENDIX 21 Repeat Back Unit The repeat back unit is connected with the cylinder by a link mechanism above mentioned, and transmits feedback signals to the steering control stand, This device has a follow-up lenear synchro and buffer amplifier for the system, limit switches and cams for stopping at both hard over positions, two condensors and a resistor for noise quenching of solenoid valve in a water-proof alminium cast case. Linear synchro } Le if J Z { [ Resistde (oN and condensor | : com | pecs Buffer amplifier Cover a ‘ rminal board ‘Cable A gland Limit switch Fig. 1lal Follow-Up Linear Synchro The follow-up linear synchro is installed on the shaft and is turned directly. Adjustment ‘The zero point can be adjusted by following methods. With the rudder angle at zero, unfasten the three fixed screws of the linear synchro and turn its case until the dot mark of the © agrees with the arrow mark on the top of the linear synchro shaft. Then tighten the three fixed screws. 1.2 Outside Limit Switch Outside limit switches are provided for the purpose of opening the electric circuit of the solenoid valve slightly before the piston reaches the maximum travel, thereby protecting the steering gear, The contacts of these limit switches are always in a closed State, and are connected in series to the electromagnetic circuit of the solenoid valve. The switches are installed inside the unit, and controlled by means of the cam on the follow-up potentiometer shaft. By adjusting the cam position relative to the shaft, the angular position of the helm that actuates the limit switches can be obtain~ ed.2. Check and Maintenance 21 Repeat Back Unit MAINTENANCE Frequency Procedure 1} Every six Apply a small amount of grease to the months shaft and the bearings of the link mechanism of the repeat back unit.3 Replacement of Parts of Repeat Back Unit 3.1 Limit switch Disconnect the wire connected to the limit switch, and unscrew the screws that hold the limit switch. Pull off the fitting screws in the limit switch, replace it with a new one, and install it in position in the reverse manner. Then, do the wiring. Move the piston rod from the midship position of the rudder, and see at which position the limit switch is actuated. Re-adjust the cam position so that it follows the given movement of the piston. (This adjustment must be carried out when the ship is at anchor, and be sure not to do it while the rudder is being steered.) 3.2 Follow-up Linear Synchro Unscrew the three fixed screws for the synchro case and two set screws for synchro shaft to detach the linear synchro. Assemble it in the reverse manner. In reinstalling it, the neutral position of it must be set to the center position of the rudder. With the rudder angle at zero, turn the synchro case until the dot mark of the case agree with the arrow mark of the synchro shaft. Then tighten the three fixed screus.4 Spare Parts 4.1 Repeat Back Unit Name Number | Number ie ‘ruse | of spare | Parts No. | Rating Remarks Limit switen | 4 2 093019013 For Repeat Back UnitREPEAT [OUANTHTY] NAME | “Back unit | #¢ # | _2 em | pesca | ee | 8sks DWE AD ToeaTION| STEER eS [114399950 PRET) mame 4 x2 Ro mn STINDHRD «200 om 4 Mm FR» 250mm R = 300 ae R= 350 a8 R= 400 me as ee ab 7 4 1S | 4 Seta \ CABLE GLAND ARE BEN REPEAT BACK UNIT @ TOKYO KEIKI CO,LTD. | x ia [prawnere CHARGED RavED ae Koruge 9995 e Kariswasang Z x 3 8 LINA MOVE LW ad3y E TYPE REPEAT BACK UNIT WIRING DIAGRAMDH-TYPE SINGLE LOOP AUTO PILOT CONTROL BOX e@ OPERATOR’S MANUAL % TOKYO KEIKI CO,LTD.CONTENTS 1, INTRODUCTION oes eeeeeeeee eens PERIL Pate Hale ete tla-t fats so stot 1 3. CONSTRUCTION AND FUNCTION .. 1 4, ADJUSTMENT ....... 3 5. TROUBLESHOOTING .. 4 6. SPARE PARTS LIST ....esecseeeceeeeeeeereenes 4 FIG.1 CONTROL BOX GENERAL VIEW . seeees 114298030 FIG. CONTROL BOX WIRING DIAGRAM ......++.+2.++0++ 114295000 ELECTRIC PARTS LIST1. INTRODUCTION ‘The control box controls the swash plate angle of the hydraulic pump in the steering gear through the torque motor by the rudder error signals from the pilot stand. The control box is used together with the steering gear made by Hitach Shipbuilding Co., Ltd. PRINCIPLE OF OPERATION ‘Turn the power switch of the control box and turn on the steering gear pump motor starter; the control box becomes ready operation. yy GYRO and HEAD steering (FOLLOW-IP steering) In case of GYRO and HAND steering, the control box receives rudder error signal from the pilot stand and with amplifier, it drives the torque motor fitted on the main steering gear. A potentiometer axially connected to the torque motor feeds back the difference between the order angle and that of torque motor. The amplifier controls turning angle of the torque motor with the feed back signal. 2) LEVER steering (NON-FOLLOW UP steering) NON- FOLLOW UP steering is not connected with the amplifier and the NON- FOLLOW UP lever switch on the helm unit directly controls the torque motor. When the lever is turned either side, a relay in the control unit is operated and it permits DC voltage to torque motor. ‘Then the torque motor turns as far as the mechanical stopper, delivering oil pressure to the steering gear. When released, the lever returns center with spring and the DC power to the torque motor is stopped and then the linkage connection to the steering gear is also released to center.rc - mn CATTION Se Although the lever switch on the pilot stand is released to the center when the required rudder angle is obtained, the | rudder does not stop immediately but overruns since it | takes time to rerorn the swash plate control lever to the | center. Therefore, in the non-follow up steering | immediately return anni Tew switch to the center when the | ecangle {snore th degree to prevent the rudder from colliding with the i mechanical stopper. “the limit switch in the follow up unit is operated, the | power line to the torque motor turns off and the same i | | | pucder “indica situation described above results. Especially when the tudder is operated fast due to two pump operation, etc., the rudder overrun exceeds ? degrees. Take special care when steering around hard Limic. The operator should carefully study the characteristics of the steering gear. Be CONSTRUCTION AND FUNCTION ‘The power switch and the ship's supply lamp are mounted on the surface of the control box. When roughly classified, the electrical components for the following functions are stored in the control box: D amplifier and power supply for torque motor 2) torque motor control amp a) operation delay circuit 4) torque motor control signal changeover circuit_--Ship's supply lamp (white) _—Power switch Control amplifier PCB Fuse Power transformer OSE | = : | terminal Sar poara External Fig. 3-1 Control boxal Amplifier and Torque motor power supply Regulated power supply circuit is mounted in control amp. PCB and calibrated with two potentiometers. The output of control circuit is amplified with two power transistors mounted on the heatsink. 3.2 Control Amp ‘The control amp is of servo amplifier controlling the turning angle of the torque motor with rudder error signal from the steering stand. Following adjustments are provided. a. 4200 b. -20V c. ANGLE; adjustment for torque motor maximum turning angle rudder speed is adjusted with this adjustment. d, GAIN: to be adjusted somewhere the torque motor is not hunting. 3.3 Power supply delay circuit The main steering gear motor is desired to start at no load condition, so the operation of torque motor is started 5 seconds after the starting of pump unit with the timer relay. 3.4 Changeover circuit At GYRO and HAND steering, it permits control signal to the torque motor and at NFU steering, it isolates control amp output from torque motor and permits plus/minus NFU output to the torque motor with K3 or K4 relay. 4. ADJUSTMENTS When operating the control box for the first time, adjust the following: vy ‘Time adjustment for delay circuit Pilot lamp PL 11 turns on 5 seconds after the starting of pump unit. Adjust with setting on the delaty relay. The pilot stand has to be off in this adjustment. 2) Adjustments in PCBa) b) c) 5. -20 V Power supply for amplifier 20V O.5V 20V 0.5V ANGLE; adjustment of torque motor maximum turning angle Speed of steering gear hardover to hardover to be adjusted. At LEVER steering, the speed is determined by mechanical stopper of the torque motor. GAIN; Sevo gain adjustment of torque motor control Gain to be adjusted not to cause hunting. ‘TROUBLESHOOTING Firstly check the steering stand. Check the control box with the chart here inafter.@) CHECK OF POWER SUPPLY POWER SUPPLY Steering gear Motor starter = ON No Check of main switchboard Motor starter-ON PLI Light after about 5min. YES FL, F2 check Transformer NO TL Control amp. 110 Terminal TP1-TP2=+20r ACLIOV Defective Defective Defective 1 PLL pce,(®) CHECK OF RELAY (K2 ~ K4) In case of GYRO and Hand mode, K2 relay is operated and in case of LEVER mode, it's OFF. In case of LEVER mode, K3 and K4 relay are operated and K3 or K4 relay is operated by turning lever switch on pilot stand. 6 SPARE PARTS LIST oir eae eS ane] tay Ramis Incase AC220V: ; Fuse 082030290 4 AC500V 3A 082030292 081012032 2 115V SW \ Incase AC440V: a eee Fuse 082030290 4 AC500V 3A 082030291 4 AC500V 5A 081012032 2 | 115V 5WwELECTRIC PARTS LIST Symbol No. Part No. Nomenclature Description 100081360 Printed Circuit Board Qt, @ 100350050 Transistor 2sp1i3y @ 100350140 Transistor 33000 Qs 100350130 Transistor 32501 cR1.cRI0 075030702 Diode aeceiz R11, cRI2 076010780 Diode 18279 cl, cz 100320830 Capacitor Ri, R2 100310030 Resistor pl, D22 114108970 Surge Absorber RS 048252104 Resistor 100k PLL 081012032 Lamp Lisy SW Ti 100377540 Transformer KL H3Y-16034 Timer Relay 1oovac K20K5 Ly4-1109A Relay ioovac Fl, F2 082030290, Fuse 3a F3, F4 082030291 Fuse 5a Cacé4ov) si 093212028 Rotary switch 104 (Ac220V) R3, RG 048131102 Resistor 1k 3\ 4-14 MOUNTING HOLES KTR QAMING (50 150) T=7b 3-297 2 | PORE Om UP enTED mauris) a LOCATION | STEERING GEAR ROOM SHIP'S SUPPLY SWITCH 1 Sigaee aatm| 2 22 NAME ¢ : [se Sm AAS & 2) kg ay CONTROL BOX (OH TYPE) TOKYO KEIKICOLTD. [~ 32 ho ks TCHS) ona Pe 2. cree jae at wal Tao9 BOs0Setting Repeater Open Course Scale Card Indicator Labber Line Course Setting Pointer Repeater Card Course Setting Knob Integral Switch Fig. 2.7 Main Parts of GYRO Steering 2-9The above is illusirated below. (a) {b) «e) Fig. 2.8 Operation of Automatic Course Changing (a) Prior to course changing, the ship is sailing straight on the zero degree course. (b) Turn the integral switch to the OFF position. (e) The setting knob is pushed in and turned to match the pointer to the desired course at 30-degrees and the knob is released. (a) The pointer and repeater card turn together and stop on the lubber line. Then the ship sails Straight on the 30-degree course. ce) When the ship's enters into the desired course and begins to sail straight, turn the integral switch to the ON position. ‘The operation of the integral switch is not needed when the automatic weather adjusting function (Optional) is provided. Be sure to keep it at the ON position. CAUTION 1. Ordered course changing of 180 degrees or more will cause the vessel to turn in the wrong direction. 2. Do not set a course change of more than 140 degrees for best performance of the system. NFU STEER (NON-FOLLOW-UP CONTROL WITH LEVER) 1. Turn the steering selector switch to the NFU positi: 2+ 102. The rudder moves, only when the lever is turned to P (PORT) or S (STBD) and held at the same position. When the lever is returned to the center, the rudder remains at that position. ‘To return the rudder to amidship, turn the lever to the opposite direction. 3 This NFU steering requires watching the rudder angle indicator, since NEU steering is non-follow-up control. —- WARNING [EMERGENCY OPERATION] 1, If trouble occurs during GYRO or HAND steering. (1) Turn the system selector switch to other side position (No. 1 to No. 2 or No, 2 to No. 1). (2) Turn the mode selector switch to HAND position and steer by HAND wheel. If it still fails to operate, (1) Turn the mode selector switch to NFU position, and steer by LEVER. Furthermore, in case of continuous condition, (1) Operate the TRICK HANDLE of the STEERING GEAR so as to cantrol the ship's rudder, by referring to instructions for the steering gear. Turn the mode selector switch to the HAND position. Set the pointer of rudder order indicator to midship. 3. Place the system selector switch in OFF. 4. Confirm that the lights remain as follow: NO, 1 & NO, 2 POWER on lamp (green). 2-u2.3 ADJUSTMENT FOR AUTOMATIC STEERING There are rate adjustment, rudder adjustment, weather adjustment, pilot watch adjustment and rudder limit adjustment in automatic steering. The control knobs for these adjustments are normally set by the service engineer at the time of sea trial within a ship yard. ‘The control knobs are reset according to ship's loading conditions and sea conditions, and in reference to their initially set values. Pilot watch ADJ. Rudder ADJ. ~Rate ADJ. —— Rudder limit ADJ. Repeater synchronizer Repeater switch Weather ADJ. Fig. 2-9 No.1/No.2 System ADJ. 2-12RATE ADJUSTMENT | During installation, the value for the rate adjustment is given according to cargo condition (full, half and ballast) by a service engineer. With this value as reference, the optimum setting is obtained according to the procedure given below. RUDDER ADJ ATHER ADJ: Set to 4. Set to zero. Let the ship run straight course for 30 minutes at each of settings indicated below. Compare the record by the course recorder and use the best setting as the optimum setting for RATE ADJ. a Set on the value corresponding to the cargo loading condition at that time. ‘This value was recommended by a service engineer. (2) Set to the position obtained by adding one division to that of (1) above. (3) Set to the position obtained by subtracting one divisions from that of (1) above. R ADJUS' MENT | n most cases, the rudder adjustment can be set to the 4 position, When the sponse is good, no further adjustment is required as below. RATE ADJ : Set to the optimum position WEATHER ADJ: Set to zero. Let the ship run straight course for 30 minutes at each of settings indicated below. Compare the record by the course recorder and use best setting as the optimum setting for RUDDER ADS. a) Set on 4 reading. (2) Set on 3 reading. (3) Set on 5 reading. 2-13When the difference is not large, set to 4 position. WEATHER ADJUSTMENT In calm weather, set to zero position. A high setting is desirable to minimize unnecessary rudder activity; a low setting is desirable for accurate course keeping. The optimum setting for a particular sea condition is a pointer setting equal to the number of degrees of natural yaw from the selected heading. In the case of this position, no adjustment is required. ISTMENT This control knob is for setting a limit angle of deviation to be alarmed when the reading of the gyrocompass or the auto pilot is much different from the azimuth of the set course at time of trouble. The course deviation alarm angle can be set optionally within 5° to 15°. PILOT WATCH Generally, however, the alarm angle is set within 10° to 15°, RUDDER LIMIT ADJUSTMENT Position, as desired, to set the limit of rudder movement in GYRO opera- tion, Fifteen degrees is sufficient for course keeping and normal course chonges. But, if a great number of degrees course change is required, its necessary to set the limit to 30 degrees. 2-162.4 OFF COURSE ALARM (OPTIONAL) The OFF COURSE ALARM is a course deviation alarm in which the heading information is based on a magnetic compass. ‘The operation should be performed as follows. a) By turning the course setting knob, set the course setting card to correspond with an azimuth indication of the magnetic compass. ‘Then the setting is the base for the deviation alarm. @) Set an alarm range of the ship's deviation, the range of 5 - 20 degrees is available. (3) With above operations, if the ship's deviates the course more than the setting because of any failure in a gyro compass, autopilot or steering gear, the OFF COURSE ALARM provides an audible and visual alarm through the alarm indication system. (4) By turning the alarm limit switch to OFF, power supply to the OFF COURSE ALARM is off. Course setting card Alarm limit for | Off course alarm | Course setting knob Fig. 2-10 Switch Panel2.5 8, F.A (STEERING FAILURE ALARM) (OPTIONAL) In HAND steering, the S.F.A provides an alarm detecting any trouble in a total steering system including steering gears, Operation of the S.F.A is extremely simple, just turning the power supply switch to ON. Then the power supply lamp lights. The power supply switch has the position of CHECK for adjustment and maintenance of the S.F.A amplifier. S.F.A. Power switch sau Fig. 2-11 Switch Panel 2- 162.6 ALARM SYSTEM ‘The alarm system is of an audible and visual type and totally displays any alarm condition onto the Alarm Panel. a When any trouble or failure occurs the alarm system provides warning with a buzzer and a lamp identifying the failure starts flickering. (2) Push the alarm silence switch provided then the buzzer stops and the alarm lamp keeps on lighting. (3) When the failure is recovered the light stops. (4) ‘Testing for the lamps and the buzzer can be done with the lamp test switch. (5) Illumination for the lamps can be dimmed by the panel dimmer, Panel dimmer Lamp test switch Alarm silence switch Fig. 2-12. Monitor Panel2.7 Turn Rate Indicator (Optional) The Turn Rate Indicator displays ship's turning rate as a deg/ min with LED indication in HAND and NFU steering. For attention, while the system selector switch is tripping the positions it might make a brief unstable indication. Turn rate i indicator \ Ind. dimmer Fig. 2-13 Monitor PanelCHAPTER 3 MAINTENANCE 3.1 GENERAL () For safe and sure steering in all faulty conditions, the pilot is provided with three steering systems, GYRO, HAND and NFU. Further- more, to make use of each item of equipment selectable, No. 1 and No. 2 systems are provided. For these reasons, at least once each day select and operate each steering system and confirm that each system is in standby condition. (2) By observing the indication lamp and alarm device, the auto pilot system can be checked for normalcy during operation. (3) System maintenance on the part of the operator generally involves Jamp and fuse replacement; the spare lamps and fuses are provided in a spare part box. 4 For a yearly overall inspection of the auto pilot system, kindly ask TKC for its service engineer who can take charge of the overall inspec- tion; the overall inspection will be made at some cost to the customer. 3.2 PILOT SYSTEM [pany crmcK] No. | Check items Checking procedures ae | Check and perform normal operation at GYRO | HAND and NFU steering positions for No. 1 | and No. 2 systems. 1 Pilot 3-13.3 INDICATION LAMP AND ALARM DEVICE, No. | Check items Checking procedures 1 Lamp and buzzer | Press the LAMP TEST switch to check if all ON/OFF per- lamps will light (except in cases where no formance lamp is furnished) and the buzzer sounds. 2 Alarm lamp Make sure that the alarm lamps do not light (red lamp) at the time of normal conditions. 3 Operating lamps | Make sure that the operating lamps light in (green lamp) the following cases. 1) When the system selector switch is at OFF position, standby lamp of each system lights. 2) The operating lamp, on the side selected by the system selector switch for Nos. 1 and 2 systems, turns on and the STANDBY lamp goes out. 3) The lamp, on the side selected by the MODE SELECTOR switch for gyro, hand and NFU steerings, turns on.3.4 REPLACEMENT LAMP AND FUSE, 3.4.1 Monitor Panel Lamp Replacement Before replacing the indication lamp, set the MONITOR SW S103 (lamp replacement service switch) behind the panel to OFF. ‘The lamps are fixed with sockets, Pull out them and insert a new lamp with a socket. 3.4.2 Course Setting Device Lamp Replacement Push and turn the lamp counterclockwise. ‘Then pull out the lamp and insert a new one. ‘This is a bayonet base type. 3.4.3 Helm Unit Lamp Replacement This is a bayonet base type. 3.4.4 Pilot Switch Panel Lamp Replacement ‘The lamps are inserted in the grommet. To replace, cut lead wire and solder the new one. -5 Relay Unit Fuse Replacement Extract the fuse from the fuse holder, and fit the new fuse. ‘This fuse is a tube type. 3.4.6 Amplifier Power Supply Unit Fuse Replacement ‘This fuse is a tube type. 3.47 OFF COURSE Power Supply Unit Fuse Replacement This fuse is a tube type. 3-33.4.8 S.F.A Power Supply Unit Fuse Replacement This fuse is a tube type.3.5 SPARE PARTS FOR STEERING STAND Qty PART NUMBER RELAY UNIT 2 100305460 OFF COURSE POWER SUPPLY UNIT (OPTIONAL) 2 100305460 S.F.A POWER SUPPLY UNIT (OPTIONAL) 2 100305460 DESCRIPTION Course setting unit att ostoigort Lamp, 6.3V HELM UNIT 2 osyorgott Lamp, 6.3V MONITOR PANEL 38 114209200 Lamp, 12V SWITCH PANEL 10 100370180 Lamp, 6.3V AMP, POWER SUPPLY UNIT 8 100305480 Fuse, 250V 3A 4 100305460 Fuse, 250V 1A Fuse, 250V 14 Puse, 250V 1A Fuse, 250V 1A bd4.1 a) (2) (3) (4) (5) (6) (7) (8) (9) CHAPTER 4 TROUBLE SHOOTING GENERAL The monitor panel of this autopilot has not only indication lamps to display the operating conditions, but also many alarm devices to display failures. By always checking the display, a failure can be located and remedied quickly and easily. ‘The amplifier unit of this autopilot uses solid state devices. Printed circuit boards are arranged for the respective functions. Therefore, a failure can be spotted by checking the test points of the respective printed circuit board. ‘The autopilot can be operated in three ways: GYRO steering, HAND steering and NFU steering. Completely learn the respective operating functions so that you can quickly take countermeasures when a failure occurs. ‘This autopilot consists of two complete systems. When a failure occurs with the No. 1 system, use the No.2 system for steering. To detect a failure quickly, check by comparing the No. 1 and No. 2 systems. Ifa failure is complicated, contact a service station and ask a service engineer to check and repair. ‘The failures, and how to check and remedy them are shown in the flow chart. Check according to it. When troubleshooting, see Fig. 1-1 "Typical Autopilot Steering System Block Diagram" and Fig. 1-2 "Simplified Indication Lamps and Alarm Device Block Diagram." On how to troubleshoot, see Sheet 1 "Voltage Chart of Main Sections", and Sheet 2 "General Troubleshooting Chart." In the way, roughly locate the failure and proceed to the next step. Before inserting and pulling the PCB (printed circuit board) in the amplifier unit, set the System Selector Switch to OFF. 4-1(10) (uy ‘This does not apply when inserting or pulling the PCB of the No. 2 system amplifier unit when the No. 1 system is operating. Before inserting or pulling the PCBs (POWER SUPPLY, LAMP DRIVER, ALARM-1, ALARM-2 and TURN RATE) of the circuits of the alarm device and the indication lamps, set the Alarm Function Service switch ($601) to OF Fy ‘To check, prepare the following instruments and tools: a. General screwdriver and monkey spanner. b. Circuit tester (to check the general circuit). c. Digital circuit tester (to check the amplifier unit), Sketches of flow charts () : Condition <> + Decision, operation ©) : Bauipment name, preparation, operation Checking, adjusting, treatment, cause Cheek item oO ProcessingTROUBLESHOOTING SHEET Sheet 1, Voltage Chart of Main Sections Sheet 2. General Troubleshooting Chart @® Main power supply ® Limit circuit in the repeat back unit ©) Linear synchro motor in the repeat back unit ® Linear synchro motor for hand steering ® Linear synchro motor for gyro steering Table 1. Test points of the amplifier PCB for autopilot function Table 2. Test points of the amplifier PCB for alarm device and display function @ MAIN amplifier PCB 2) AUTO-L amplifier PCB @) POWER SUPPLY PCB (4) RUDDER AMP PCB &) LAMP DRIVER amplifier PCB (6) ALARM 1 amplifier PCB @ OFF COURSE POWER PCB (Optional) () OFF COURSE AMP — PCB (Optional) 8 Ss A,POWER PCB (Optional) S.F.A.AMP PCB (Optional)[samo ovan6vo= | Siv-rni [poston ovaotrs2n-Ta¥ (oaase 2° 0) © daaod 20 O=G9-{ zo 19 Qaane = ~aé—+ed suotz9eg wren Jo 232119 aeaToA T 288NS Peet To sors Trday pues Burson) ayun yoeq awa OVAOTT/OOT OWAOLT~Z9¥Z-TOV zon OVAOTI~ZOVT~TOVT T'ON Bap /nSz*0=297-197 Z°ON ‘Sap /acz"0=20T- TOT TON septs par ~oqavys 10 310d 1 pareaqe uayH OV AZTAO=PNT-ENT OVAST=@NI-INT duyIONPUOD@ZI-ZID 8ur3 9npu0ey=19-199 aenopaey 50 fuer uryaTs soy aappnx 1,azvyg Buyrooysatgnozy Ters¥e9 7 I9%S (2098) ae _Sursosns SaK a Raat aenod ured setdeyp wiep? peveorpur Zuoya9aryp 9uo ut kTuo saacw zappnz ‘samrjamos aaezado you sop Teppnx aus ‘squny Zeppnz au sreqn8ai2t sy quewonom Zappnz ayy, ‘eaow 30U S9op Teppnz au@®) Main power supply Check engineroom switch board switch / (iain power supply ___NO/ control box ACI-AC2=L1OVAC er fperective |[Check _] [Blow transforner|| terminal} |fuses (101) and 01, F104 Gece : eeting stand viring | [Ga) Mepeminrs NO.1 LACL-1AG2"110VAC At time of NO.2 2AC1-2AC2=110V Al Poor continuity between control box and steering stand haplitier power supply No.l FL701 ©- @=1iovac No.2 FL702 @-.@ =110vac, YES C= Blown fuses Main power AMP FUSE supply is No.1 (F701=34)| normal No.2 (F702=3)| 4-6Limit circuit in the repeat back unit Repeat back unit Measure while actuating Jimit switch by hand when operating col Clana C2 ++ C2 when not operating YES Measure while actuating limit switch by hand when operating 1. Defective cable between Limit switch and terminal 2, Defective limit CO Clana switch replace COs Co=0 when necessary. when not operating co+ cl=280 cos Limit switch is norwal Defective control motor© Linear synchro motor & Buffer amplifier in the repeatback anit Linear synchro motor Buffer Amp. Set the Node selector SW to HAND Turn the Steering wheel PORT H/o to $1810 H/O and then check voltage LN1-LN2= 15 VAC constant INS-IN4= 0 © 12VAG variable ves. Check wiring between steering stand and repeatback unit. = Check DEMO PCB ) linear synchro Buffer Amp f See Normal | Set the Mode ew. to OFF. Disconnect the wiring of linear synchromotor and buffer amp. Cheek conductive of Linear Defective buffer amp Replace when necessary Defective Linear synchro~ motor. Replace when necessary@® Linear synchro motor for hand steering Linear synchro motor B301(No.1), B302(No. 2) Check exciter volt Rd (BK) -R2 (WH) =15VAC Turn slowly steering wheel Check output volt | S1(RD)-$2(BL)=0%1 7VAC 1. Check wiring between linear synchro motor to DEMODULATOR PCB. 2. Defective DEMODULATOR PCB. Replace when necessary. Defective linear Linear synchro synchro motor. motor is normal Replace when necessary® Linear synchrn motor for gyre sl ring Tinear synchro motor B202(No.1), B203(No.2 No. ‘ R1(BK)=82( 1. Check wiring between linear synchro moter Gheck exciter volt svac Tarn slowly course setting knob and present diviation by course pointer from to DEMODULATOR PCB. 2. Defective DEMODULATOR PCB. Replace when necessary. oO Defective linear Replace when necessary. to 35° Check output voit S1(RD)~S2 (BL): Livac YES Linear synchro motor is normalTable 1. ‘Test points of the amplifier PCB for autopilot function — eee. fee St Ou Standard value Description name NO. TP-1 | ov Amplifier common base | | Tp-2 | risveoay ] Power supply for att PCB Tp-4 | MAIN TP-5 AMP. | TP-6 TP-7 | TP-8 | TR-9 | TP-10 | +5.0V40.1V i} Reference volt for amplifier TP-11 | -10Vs0.1V power failure alarm LeMopU| TP-1 | ov | Amplifier common base -LATOR | rp-2 15va.c. 400H2 square | Exciting volt for all linear wave synchro motor re. [ov \Amplifier common base TP-2 | 0.25Videg Heading error signal volt | TP-3 | 0,25¥ /dew Heading error signal volt TP-4 0.25V lage | Proportional + Differential | | sutput signal volt | TP-5 -2.0¥(at LGM) 40012 |} Convert LGM or HGM Vat GM} square |} signal volt wave RUDDER | TP-1 eV common i AMP | TP-2 | 0.25V /deg | HAND signal TP-3 0.25 deg HAND signal (Limit out) TP-4 | 0.25V faeg F/B signal TP-5 0. 25V /deg (Proportional + Differential) X Wea. Adj. signal TP-6 0.25V /deg | GYRO Integral signal TP-7 0.25V /deg | Spare 4-1Table 2. ‘Test points of Amplifier PCB for Alarm device and display of function PCB name POWER SUPPLY AMP ee ce | 1 | LAMP | DRIVER | AMP Test eit Standard value TP-1 ov vp-2 | +15V20.1V TP-3 -18V40.1V TP-4 1 ov TPs | 45 TP-6 | +12 TR-7 +24 TP-1 TP-2 | OV at OFF state |to TP-3 | 110V a,c. at ON state (port is ON) TP-3 OV at OFF state toTP-4 | 110V a.c. at ON state (STBD is ON) TP-3 | HOV at ON state to TP-10 open at OFF state 0 to +5V 2012 square wave Description | Amplifier common base Power supply for SOL. JSTICK and TURN RATE PCB Alarm circuit common base Power supply for ALARM=1 & ALARM-2 PCB Power supply for buzzer circuit Ship's battery supply | Alarm circuit common base PORT and STBD operation input signal volt | RUDDER LIMIT alarm input signal volt For service engineer ‘Alarm circuit common be power supply for IC for | lamp flicker signal volt