Installation manual THE DOCTOR DM-5. by International Technology GmbH. Copyright 2012 International Technology GmbH, All rights reserved

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1 Installation manual THE DOCTOR DM-5 by International Technology GmbH

2 THE DOCTOR DM-5 Installation manual All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of International Technology GmbH. Products that are referred to in this document may be either trademarks and/or registered trademarks of the respective owners. The publisher and the author make no claim to these trademarks. While every precaution has been taken in the preparation of this document, the publisher and the author assume no responsibility for errors or omissions, or for damages resulting from the use of information contained in this document or from the use of programs and source code that may accompany it. In no event shall the publisher and the author be liable for any loss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by this document. Printed: kesäkuu 2012 in Switzerland

3 THE DOCTOR DM-5 Table of Contents Part I Introduction Preparation Basic setup... for two stroke engines Basic setup... for four stroke engines 8 Part II Crank-angle Dual pickup... installation Distances Inductive... pickup Mounting 2.4 Optic pickup Cables Junction box Part III Cylinder pressure Part IV Fuel pressure Fuel valve Fuel sensor Quick coupling Index... 23

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5 Introduction I

6 6 Introduction 1 Introduction The Doctor DM-5 is a classic hand held data collection unit for easy engine condition monitoring. With this unit you can measure: Cylinder pressure Fuel pressure Crank shaft position This DM-5 installation manual provides the necessary information you need to install THE DOCTOR DM-5 diesel engine analysis system into engine room for crank-shaft's position and cylinder and fuel pressure measurements. Installing and using THE DOCTOR DM-5 is straight forward and easy. Basic material needed for the installation is supplied by the official THE DOCTOR dealers. In addition to that you need brackets and drill as explained in the Preparation sub topic. 1.1 Preparation To start the installation have to prepare the following tools and materiel for the installation: Basic material is supplied by the official THE DOCTOR dealers. Additionally it is needed brackets for pickup sensors The diameter of the pickup = 18mm, drill a 19mm hole in bracket.

7 7 Introduction 1.2 Basic setup for two stroke engines

8 8 Introduction 1.3 Basic setup for four stroke engines

9 Crank-angle II

10 10 Crank-angle 2 Crank-angle Find a convenient place to install the position sensors on the main- and auxiliary engines.

11 11 Crank-angle 2.1 Dual pickup installation Two stroke engines have usually two pickups (dual pickup installation), one pickup is for detecting the TDC position of cylinder no. 1 and the second pickup is for sensing the teeth on the flywheel. The teeth may be sensed either radially or axially (see drawing below). Flywheel teeth and TDC pickups should be at least 50 mm apart from each other to avoid signal interference. The flywheel teeth pitch should be at least 5 times the diameter of the pickup used. It is important that the flywheel (teeth) pickup senses a machined surface on the teeth. An as-cast surface will not provide a sufficiently regular surface. 2.2 Distances On main engine usually brackets have to be installed Important Installing pick up: Setting proper distance! Be aware: Higher speed lowers distance 3-8mm

12 12 Crank-angle 2.3 Inductive pickup Installation on flywheel axial or radial plane: Axial plane Radial plane Mounting Fitting the inductive pick up to the bracket.

13 13 Crank-angle Fitting the nuts. These nuts allow for precise location of the pickup relative to the inducting part. Tightening the nut on the pickup body. NOTE: The inductive field is 8mm. A LED blinks. In this way, using the turning gear, you can check the installation distances are correct.

14 14 Crank-angle 2.4 Optic pickup Fitting the optic pickup to the bracket. Fitting the nuts. Tightening the nut on the pickup body. Note the two pins on the surface. These must align into their sockets on the fiber optic extension if one is in use. The fiber optic extension with brackets. (5mm hole) NOTE: The optic range is 150mm. There is a LED which blinks when power is supplied to the pick up (connect EPU and switch on) and it is reflecting. There is a potentiometer to adjust the optic beam strength. Turning clockwise increases the strength.

15 15 Crank-angle 2.5 Cables There are two ways to install the pickup sensors: Temporary with a flying cable as in the picture on the left Permanent installation with fixed cables and a junction box (J-Box) as in the picture on the right

16 16 Crank-angle Junction box 1. Find convenient place for the junction box 2. Check cable length to THE DOCTOR EPU 3. Install J-Box (Check wiring plan from Product Data Sheet) 4. Test connection Connect EPU to J-Box and press ON Check the lighting on Pickup when turning gear J-Box

17 Cylinder pressure III

18 18 Cylinder pressure 3 Cylinder pressure Thomson adapter and cylinder pressure sensor Tighten the pressure sensor into the head of the Thompson adapter. This must be checked often as the sensor can work itself loose through heat changes and vibration. The heat dissipation piece is not yet Threading on the heat dissipation piece.

19 Fuel pressure IV

20 20 Fuel pressure 4 Fuel pressure 4.1 Fuel valve The fuel valves have to be installed on the fuel pump or on the distribution block Distribution block Fuel pump Positioning washers 1. Important to set proper position of the valve using washers with different thickness. The Pitch of threat is half millimeter. 2. By using different thickness you can find different position angle of the fuel valve. 3. For every cylinder screw valve without washer and check position. 4. Select the washer to find correct position, if not correct use different washer

21 21 Fuel pressure 4.2 Fuel sensor It is important to mount fuel sensor and quick coupling washer properly. 1. Take out sensor 2. Take out washer 3. Put some grease on sensor 4. Put the washer with correct angle on the top of the sensor 5. Screw sensor in quick coupling WARNING: You get a leakage if you put it the fuel sensor or quick coupling wrong way. 4.3 Quick coupling Demonstration to fit the quick-coupling, carrying the sensor, onto the nipple of the fuel valve: Demonstration how the «mushroom» is used to protect the sensor mounted into the quick-coupling. A pressure look can occur when the needle is closed. The only way to free the quick-coupling is to take a spanner and crack the nipple from the valve slightly Note the marking of the batch no on the valve body. There are several threads to cover the range of engine types

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23 23 Index Index -BBasic setup for four stroke engines Basic setup for two stroke engines 8 7 -CCables 15 Junction box (J-Box) 16 Crank-shaft's position measurement Distances 11 Dual pickup installation 11 Cylinder pressure measurement Cylinder pressure sensor DDual pickup installation 11 -FFuel pressure Quick coupling 21 Fuel pressure measurement Fuel sensor 21 Fuel valve IInductive pickup 12 Mounting 12 Introduction 6 -JJunction box (J-Box) 16 -OOptic pickup 14 -PPickup distances Preparation 6 11

24 24 THE DOCTOR DM-5 Index -QQuick coupling 21 -TThomson adapter 18

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