CHONG QING XIN RUI TECH COMPANY LTD.

KCM-IIA INSTRUMENT PANEL FOR

MARINE G-DRIVE ENGINE

BULLETIN
 KCM-IIG instrument panel bulletin index

1. Foreword

2. Gauges and Switches of KCM-IIA

A. Instrument gauge
B. Control switch

3. Warning lamps equipment

A. Prime warning by gauge

B. Stop warning

4. Engine electronic control governor 4913988

5. Relay warning output interface and control connect board

6. Auto Connection

7. KCM-IIAR remote instrument panel

8. Requirements and attentions of instrument panel operation and

mounting

A. Operation condition

B. Mounting and safety method

9. Operation and attentions for KCM- IIA instrument panel

Manual control

A. Check before starting

B. Observe when supplied power

C. Start

D. Run

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 E. Stop

Automatic control

F. Alarm analysis and handling method

G. Notes

10. Trouble shooting

A. No display or instable flash after supplied power

B. G-set couldn’t start

C. Incorrect tachometer reading or stop engine for over speed

warning

D. G-set speed is unstable

E. After supplied power, one of the STOP, OTH, A.P, SPA alarm lamp

is lighted (Not flash)

F. After supplied power, one of the SPH, WTH, OPL, RUN, B.V alarm

lamp is lighted (Not flash)

G. If engine runs to higher speed, one of the WTH, OPL, OTH alarm

lamp flashes but engine didn’t stop

H. No reading, unstable reading or full scale on oil pressure gauge,

and caused alarm

I. No reading, unstable reading or full scale on coolant and oil

temperature gauge, and caused alarm

J. No indicating on remote panel, and can’t start or stop engine

remotely

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 K. L·oil pressure alarm at IDLE or engine can not run normally

11. Attachments

A. Switch’s set of G·SET type and speed alarm point

B. KCM-IIAR figure and installation hole dimension..

C. KCM-IIA electrical circuit figure and connect figure (For 4913989).

D. KCM-IIA & KCM-IIAR connection.

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1. Foreword
KCM-IIA/AR instrument panel is designed according with the specification of
CCS and the requirements of modem shipbuilding. And it used for all marine
G-drive engines.
It contains two types:
KCM-IIA is a instrument panel beside of engine. P/NO: 4913989
KCM-IIAR is a remote instrument panel. P/NO: 4913986 (optional)
Remark: AUTO-III type control panel can be optioned to meet the automatic
requirement of G-set.
Notes:
1. The control circuit of this instrument panel can be operated separately
from instrument system by setting the “normal/ exceed control” switch
onto “exceed control” position to start engine directly.
2. “Normal/ exceed control” switch is designed to make warning stop
protection effective. And it is usually set onto “normal” position to protect
engine not running on supper limitation.
3. In the “stop protection” of this instrument monitor and control system,
low oil pressure stop and high coolant temperature stop are all
controlled by separate switch connected to relay which connect to fuel
valve. So if a mistake warning occur, removing it will not affect
instrument system working.
4. Over-speed warning stop is controlled by speed meter monitor. It is very
important to set the option switch and over-speed test button, or mistake
warning will occur.

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2. Gauges and Switches of KCM-IIG

A. Instrument gauge

1. Tachometer 0r/min ～ 3000r/min ±2(digital

indicator)50r/bar (Light bar)
2. Hour gauge 0h～9999h 1h
3. Water temperature gauge 60℃ ～ 120℃
2℃/bar
4. Oil temperature gauge 60℃ ～ 150℃
3℃/bar
5. Oil pressure gauge 0MPa～0.8MPa
0.02MPa/bar (P＜0.4MPa) ；0.04MPa/bar (P＞0.4MPa)
6. Battery voltage gauge 20V～32V 0.4V/bar
NOTE:
All gauges’ accuracy is better than 2.5%F·S.
Power source: 24V DC±4V

B. Control switch

1. Automatic/Manual switch—Choice of manual or automatic engine

start-up
2. Power switch: control power ON/OFF and stop engine normally.
3. ‘M. power’ / ‘A. power’ switch—select main or auxiliary power Source for
panel.
4. Remote ST- 0 –Start switch—select to crank engine on machine or remote.
5. Protect ON/protect OFF switch—select “protect ON” for normal
running or “protect OFF” for
running in an emergency.
6. Run/IDLE switch—select engine to run at high speed or idle.

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 SWITCH SET OF KCM-IIAR (Ref·Panel)

1、 Power/start switch—control power OFF or ON and start engine

remotely.
2、Stop switch—use to stop engine remotely.
3、Quit switch—to cut off alarm sound.
4、Reset button—use to make meters reset when they are full scale

3. Warning lamps equipment

A. Prime warning by gauge

1. Water temperature high (WTH—Yellow lamp) T＞98℃±2℃
2. Oil pressure low (OPL—Yellow lamp) P＜0.12MPa±0.02MPa
3. Oil temperature high T＞115℃±3℃
4. Battery voltage high or low (B·V—2 Colors Lamp) V＜22V-Yellow lamp
V＞30V—Red Lamp
5. Running indictor (RUN—Yellow lamp) when n＞680r/min
6. Stop indictor (STOP—Red Lamp) when push down the emergency stop
button.
7. Automatic light (AUTO—Yellow Lamp)(automatic status mode)
8. Automatic fault (A.F—Red Lamp)(three unsuccessful start-up in
the automatic mode)
9. Auxiliary power (AP—Red Lamp) when auxiliary power is used.
10. Three auxiliary alarm indictors (Supply warning item can be selected by
customer, and input warning single by customer.)

B. Stop warning
1. Over speed (SPH—Red Lamp)
(controlled by tachometer to monitor)
N＞1725r/min 50Hz
N＞2070r/min 60Hz

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 2. Water temperature high (WTH—Red Lamp)
(controlled by temperature alarm switch monitor)
T＞106℃±2℃
3. Oil pressure low (OPL—Red Lamp)
(controlled by pressure alarm switch monitor)
P＜0.1MPa±0.02MPa

4. Electronic fuel control governor 4913988

This module used in panel to control engine speed. Adjust “RUN” to adjust the
rated speed according to G-set frequency, but it is usually not in need. If
combine G-set or inspect over speed function and so on, and need to adjust
this module, the following should be noted:
1. A 5.1K 1W potentiometer should be connected to No.7, No.8 and No.9
terminal to realize speed adjustment by hand or automatic.
2. The quality of potentiometer must be good, especially its contact.
3. When applying all other type combining module to automatic speed
adjustment, it should meet the requirement of Cummins system. For
example, when applying GAC module, another module should be added.
4. All other adjust points should be adjust carefully, especially the gain and
droop adjustment. Gain usually be set to 50%, and droop usually be set to
1~2 scale.
5. ‘IDLE’ and ‘RUN’ adjusting potentiometer is without limit, so when being
adjusted, should take care, or can’t reset.

5. RELAY ALARM OUTPUT INTERFACE AND CONTROL

CONNECT BOARD
This board supplies alarm output terminals for customer (See attachment)
1. 8 terminals used to connect the KCM-IIAR remote panel.
2. 2 terminals used to connect PC computer when want to transmit the

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measuring data from KCM-IIA to it (should use a RS485/232 transducer and a
programmer according to the agreement of KCM-IIA).
3. 2 terminals to connect auxiliary power for panel.
4. 4 terminals to connect the emergency “stop button” and indicator from
outside.
5. 26 terminals without power are the alarm signals to connect out. (The alarm
relay’s contacts capability are AC 250V 5A and DC 32V 2A, and they can
be used to connect sounder and indictor.)

6. AUTO CONNECTION
① A pair of regular close contact switch connect to 1# and 2# in AUTO-III
board .the switch is automatic signal.
② The switch closing signal connect to 4# and 5# in AUTO-III
board.
③ The switch opening signal connect to 7# and 8# in AUTO-III
board.

7. KCM-IIAR remote instrument panel

The function of remote KCM-IIAR instrument panel:
1. KCM-IIAR can indicate same monitor and alarm information with KCM-IIA
synchronously.
2. KCM-IIAR works with KCM-IIA by date communication, so any other
sensor isn’t in need.
3. Use the power switch can to control power ON or OFF and start engine
remotely in pilot house and other monitor rooms.
4. Quit switch can cut off alarm sound.
5. Power switch can control remote instrument
panel circuit.
6. Stop switch can stop engine remotely.
7. HB/LB switch to select the display brightness of gages.

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8. Requirements and attentions of instrument panel operation

and mounting
A. Operating environment:
1. Temperature: ≤57℃±3
2. Humidity: ≤95%
3. Vibration: ≤±39m/s²
4. Power voltage: 24V±4V
B. Mounting and safety method
1. IF the space of engine room is small, should improve ventilation or mount
the instrument panel off engine.
2. When connect to remote panel or computer monitor system, should use
shield cable and connect one end of the shield layer to ground. And can’t
lay with power cable side by side.
3. Can’t connect other power supply and gauges into this panel.
4. If the vibration is heavy, the panel should be mounted off engine.

9. Operation and attentions for KCM- IIA instrument panel

Manual control
A. Check before start.
1. Check the ‘M. power’ / ‘A. power’ switch: it should be set onto ‘M. power’
position.
2. Check the Protect ON/Protect OFF switch: it should be set onto ON
position.
3. Check the RUN/IDLE switch: it should be set onto IDLE position.
B. Observe when supplied power
1. Turn on the power supply switch, the alarm indicator except the battery
issue indicator will light for 1 second.
2. Observe if any indicator lights before start. If one is lighting, there is a stop
button pushed down, and should reset it, or can’t crank engine.

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C. Start operation
Turn the switch to START to crank engine, when the speed is up to
350r/min the controller will cut off the motors circuit.
D. Run
After engine is started, let it to run at IDLE speed 2～3minuts, then turn
RUN/IDEL switch to RUN, engine will be running at high speed. And after a
while, the coolant temperature and oil temperature will indicate on gauges.
NOTE: Only engine speed up to 575r/min, “RUN” lamp is lighted and all
alarms sets are activation.
E. Stop
1. Normally to stop engine just turn power switch to OFF.
2. At a urgent condition to shut down engine can use the “Stop” switch on
KCM-IIAR or “Stop” button somewhere it is installed.
3. Engine will be stop automatically when over speed, high water temperature
or low oil pressure alarm is happened.
Note: if couldn’t shut down the engine at urgent condition, put the switch to
“protect OFF” position.

Automatic control
1. Put automatic/manual switch to automatic ,at this time
automatic light.
2. When found automatic signal 5 seconds ,automatic start-up
engine.
3. After the success of start-up , the engine will run 10 seconds
in IDLE mode.
4. After IDLE mode 10 seconds , the engine will run in RUN mode
and the panel output the switch closing signal.
5. When the automatic signal disappears , the panel will output
the switch opening signal and control stopping engine after 2
minutes.

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6. If automatic signal is founded again in the engine stopped, the
engine will start-up again.

NOTES FOR OPERATION

How to open and close the panel of box:

Push down the two bars on panel and turn a inside 90° by hands
to open.
Otherwise push down bars and turn outside 90° to close the
panel of box.
Don’t turn ON and OFF the power switch frequently, have to 5
seconds to turn “ON” again after turn “OFF”, otherwise the
meters may be damaged.
Don’t take in and off the connectors of engine wiring with
power, specially for 3P connector.
F. Alarm analysis and handling method
1. Three possibilities:
z Main circuit board has trouble or a switch’s position is not correct.
z The alarm switches or transducers broke down.
z Engine running at over limit.
2. Handling:
1. Check instrument panel
z Disengage the alarm switch or transducer from the connector, if alarm still
has happened, it is caused by the main board trouble.
z When over speed alarm happened, check the switch’s position if it is in
correct position and if the over speed test button is pushed down.
2. Check switch
z Check the high temperature alarm switch should off with a Ω meter to
measure at normal temperature.
z Check the low pressure alarm switch should be on with aΩ meter to

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 measure but when pressure is over the limit, it be off.
3. Engine adjusting problem or other problem
z Check engine’s level of oil and water.
z Check the adjustment of “IDLE” speed.
G. Notes:
1. How to open and close the panel:
Push down the two bars on panel and turn 90° inside by hands to open.
And push down bars and turn 90° outside to close the panel.
2. Don’t turn ON and OFF the power switch frequently, should wait for at least
5 seconds to turn “ON” again after turn “OFF”, otherwise the panel may be
damaged.
3. Don’t take the connectors of engine wiring in or off with power, especially
for 3P connector.

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10. Trouble shooting
A. Symptom: No display or instable flash after supplied power

Cause Solution
1、 Battery connection error. 1、 Change the battery connection wires.
2、 Engine wire’s connector doesn’t 2、 Take off and push it again.
touch well. 3、 Put the switch to M·power’s side.
3、 M·P/A·P switch set A·power. 4、 Replace a main circuit board.
4、 24V/5V power transducer has 5、 Change pressure sensor
trouble on main circuit board.
5、 Short circuit at pressure sensor

B. Symptom: G-set couldn’t start

Cause Solution
1、 No fuel to cylinder head. 1、 Loosen fuel line to cylinder head while cranking
2、 Issues on start circuit. There is not engine. Check fuel line and valve.
24V voltage on starter solenoid. 2、 Check corresponding circuit.
3、 Issues of motor or its relay. 3、 Change the motor or motor relay.
4、 The gap of speed sensor to flywheel 4、 Adjust the gap.
teeth is too big. 5、 Check corresponding circuit.
5、 There is not 24V voltage on fuel 6、 Change fuel valve.
valve. 7、 Change speed sensor.
6、 Fuel valve broke down. 8、 Change EFC governor.
7、 Speed sensor broke down. 9、 Change temperature switch.
8、 Electric fuel control governor
broke down.
9、 Temperature switch broke down,
there is no alarm indicating when
starting.

C. Symptom: Incorrect tachometer reading or stop engine for over speed

warning

Cause Solution
1. The switch at main circuit board 1. To set the switch again as attachment 1.
for G·SET type chosen isn’t set 2. Free the button when the power is off.
correctly.
2. The over speed test button at main
board is pushed down.

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 D. Symptom: G-set speed is unstable

Cause
1、 Fuel system issue
2、 The gap between speed sensor and
flywheel teeth becomes bigger.
3、 Speed sensor issue
4、 “GAIN” potentiometer on speed
governor is not adjusted correctly.
5、 Actuator issue
6、 Compatibility issue between EFC
governor and fuel system.
Solution
1、 Check fuel line、pump and actuaor.
2、 Check and adjust the installation of speed sensor.
3、 Change speed sensor
4、 Adjust the “GAIN” potentiometer again when
engine is running.
5、 Clean actuator or change actuator.
6、 Change the EFC governor and try again.

E. Symptom: After supplied power, one of the STOP, OTH, A.P, SPA alarm
lamp is lighted (Not flash)

Cause Solution
One IC with red mark on display board Replace with a new one.
broke down.

F. Symptom: After supplied power, one of the SPH, WTH, OPL, RUN, B.V
alarm lamp is lighted (Not flash)

Cause Solution
One IC with blue mark on display Replace with a new one.
board broke down.

G: Symptom: If engine runs to higher speed, one of the WTH, OPL, OTH
alarm lamp flashes but engine didn’t stop

Cause Solution
One IC with yellow mark on display Replace with a new one.
board broke down.

H. Symptom: No reading, unstable reading or full scale on oil pressure gauge,

and caused alarm

Cause Solution
The pressure sensor broke down. Replace with a new one.

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 I. Symptom: No reading, unstable reading or full scale on coolant and oil
temperature gauge, and caused alarm

Cause Solution
Temperature sensor broke down. Replace with a new one.

J. Symptom: No indicating on remote panel, and can’t start or stop engine

remotely

Cause Solution
1、 The DB+ and DB- on power cable 1、 Connect again.
or communication cable connect 2、 Set the switch to remote start position.
oppositely. 3、 Check and connect wirings.
2、 The switch on KCM-IIG panel is
set incorrectly.
3、 Wiring connects incorrectly.

K: Symptom: L·oil pressure alarm at IDLE or engine can not run normally

Cause Solution
1. Oil level is not enough. 1. Add oil to H·level.
2. IDLE adjustment is too low. 2. Up turn the point of IDLE.
3. Oil pressure is up low (K38、K50). 3. Put the switch to “protect off ”to start engine, after
4. Low oil pressure switch broke it’s running reset the switch to “protect on” side.
down. 4. Replace with a new one or take off temporal.
5. The yellow IC at main board 5. Replace with a new one or take off temporal.
broke down.

NOTE: Above judgments are based on more gages work well, otherwise
check the power or replace a main circuit board.

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11. Attachments
A. Switch’s set of G·SET type and speed alarm point
KCM-IIG
NG-50Hz NG-60Hz

N 2 N 2
O 1 O 1

KG-50Hz KG-60Hz

N 2 N 2
O 1 O 1

NOTE: ① 1# Switch to set speed alarm point of G.SET

② 2# Switch 2# to set G·SET type.

③ If the switch’s position is not correct ,It will make the
tachometer to error or alarm.
Switches:
1# to set speed alarm point.
2# to set G-SET type.

Push down this button to decrease

over speed alarm point for customer to
check the over speed alarm function of
panel easily when engine come from
IDLE to RUN.
After checking should push it again at
power if off!

B. KCM-IIAR figure and installation hole dimension.

C. KCM-IIA electrical circuit figure and connect figure (For 4913989).
D. KCM-IIA & KCM-IIAR connection.

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