Finished Plan For Flutek-Kawasaki Type Steering Gear

FINISHED PLAN FOR FLUTEK-KAWASAKI TYPE STEERING GEAR HULL NO. : H6126 1. SHIPYARD : HYUNDAI MIPO DOCKYARD oe F Sorta ENGINEER L 2. HULL No. : H6126 A SENIOR ENGINEER 3. SIGEAR TYPE : FE21-102-T050 4. KIND OF SHIP : 56k Bulk carrier ASST. SENIOR ENGINEER 5. CLASSIFICATION : DNV 6. OWNER : E.R.Schiffahrt ENGINEER %] -& —> 3° DRAWING NO. : FMS45-1651 DATE : 2011. 04. 27 FLUTEK, LTD.** CONTENTS ™ Specifications . . 4-1. Particulars 4-2. Rule and regulations . 1-3. Material for main parts .. 1-4. Spare parts and tools . . 1-5. Test and inspection 1-6. Painting 1-7. Delivery of steering gear . 4-8. Drawings and documents . . Scope of supply . Fig. 1 Schematic diagram of control system Fig. 2 Wiring diagram of pump control unit . Fig. 3 Automatic isolation system .. Hydraulic circuit diagram Arrangement .... . Installation |. Piping arrangement . . . . Tiller ~ Detall of tiller inner dia. . Connection of tiller to rudder stock . Key & keyway . . Installation of repeat back unit and rudder angle transmitter . Arrangement of limit switch for rudder angle limit . . Oil level switch . List of spare parts and tools . Electric motor for main pump . Electric motor for servo pump : . Technical specification for electric circuit ........ . Name plate for operating instructions . .. . Storage tank for steering gear... .. ). Level gauge for storage tank . . . Filling pump for storage tank . Recommendation of hydraulic oil for S/Gear . . Grease pump for rudder carrier. . No.1 & No.2 Starter panel for Sigear & Ararm panel in WIH & E.C.R Automatic isolating contro! panel for S/gear . Shop test record for steering gear... . Test report for elec, Motor No. 1 & 2 FLUTEK, LTD.1. Specifications 1-1, Particulars Steering gear type : FE21-102-T050 H6126 2-Rams, 4-Cylinders Construction Rapson-Slide type Power units (100% x 2sets) 2 identical type (Lunit stand-by) Control system (Refer to Fig.1) Electrical pump control system (2 systems) Steering method 1) Remote control from the bridge by auto-pilot system 2) Local control by pump control knob Steering gear torque at max. working pressure at 35 deg. 1,000 kN.m (102 tm) Starboard : 35 deg. tumin, eee Port 35 deg. ‘Mechanical limit rudder angle Seen ede Port: 37deg. Rudder tuming speed by one power unit 65 deg. / 28 sec. Normal radius of tiller arm 580 mm Ram diameter 212 mm Max. working pressure 19.2 MPa (196 kg/em?) Safety valve set pressure i puianiitis 24.0 MPa (245 kg/em’) Hydraulic pump (main pump) Type LV-090-410R10 Max. tilting angle (stroke) ent axis type axial piston pump) 23.2deg. (31.1mm) Max. outlet flow 121 litimin Electric motor Main | Output 30kW pump | Source AC440V-60H2-30 Synchronous speed 1800 rpm, Rating 25% continuous, Overload at safety valve set pressure 100% hour, 200% 30sec. 186% FLUTEK, LTD.3 (FE21-102-T050) Hydraulic pump Type JP10-3F21-S2-R (Gear pump) Servo Electric motor pump | Output 0.4 kW Source AC440V-60Hz-30 Synchronous speed 1800 rpm Rating 100% continuous Torque motor Rated torque (current) ‘Max. torque (current) Pump | Rotative angle 39N.m (4.0 kgfem) (DC 1.6A) 78N.m (8.0 kgfcm) (DC 3.2A) #30 deg. cian Cable connection Connector with plug LWDT Cinear variable differential transformer) Cable connection Connector with plug Unloading device Source AC100(110)V-60H2-10 Rush current 4.8 (5.28)A Holding current 0.44 (0.5)A Cable gland KS V 8811-A15b or JIS F 8801-A15b ‘Automatic isolating valve Source AC220V-60Hz-10 Rush current 2.644 Holding current 0.254 Cable gland KS V 8811-A15b or JIS F 8801-AI5b Level switch with two positions Switching direction Low OFF (open) : Normal condition Switch rating ACSOVA, Max. 3A. Cable gland KS V 8811-A20b or JIS F 8801-A20b Working fluid to recommend Description Hydraulic fluid or Anti-wear type hydraulic fluid Grade ISO VG 68 or VG 56 Oil viscosity 50~75 mm’/s (cSt) at 40°C Required oil quantity of steering gear 510 Lit. Required oil quantity of storage tank 255 Lit. ‘Name plate Language English Operating instruction plate: Language English Grease pump for rudder carrier Discharge port : 4 ports (MSK-602-T5M : motor driven type) Tank capacity : 5 Lit. FLUTEK, LTD.1-2, Rules and regulations 1) DNV 2) KS (Korean Industrial Standard) 1-3. Materials for main parts Symbol Name Material KS, (JIS), Tiller Carbon steel casting $480 (SC480) Key Carbon steel forging SF590B (SF590B) Roller Carbon steel SMSSC (S55C) Ram Carbon steel SMS55C (S55C) Ram pin Chromium molybdenum steel SCM440 (SCM440) Cylinder Nodular graphite casting High press. Pipe | Carbon steel (Seamless) SPPH410 (STS410) 1-4. Spare parts and tools (Refer to the List of spare parts and tools) 1) Spare parts Percentage of spare Name to working quantity \V-packing for hydraulic cylinder 100% Spring for safety valve 50% Solenoid for unloading device 50% O-ting & oil seal 100% 2) Tools Name Quantity Spare parts box 1 set FLUTEK, LTD.1-5. Test and inspection 1) The test of hydraulic pumps shall be performed in accordance with our standard based on the rule of KS V 6731(JIS F 6721) 2) The shop test of the steering gear shall be performed in accordance with the rule of KS V 6730 (JIS F 6720) "Shop Test Method for Ship's Hydraulic Steering Gears" in the presence of surveyor of the classification society and/or the inspector of the shipowner and the shipbuilder. 3) The test and inspection of the steering gear components shall be performed in accordance with Classification Society requirements. 4) Ifabnormal condition is not noticed at 1) and/or 2), the overhaul of pump and/or steering gear shall be omitted. 1-6. Painting 1) Finished Color : RAL 6019 (Munsell 2.5BG 8/3) 2) Method : Under coating : Zine chromate anticorrosive Finish coating : Alkyed resin enamel 1-7. Delivery of steering gear : H6126('11.04.29) 1-8. Drawings and documents 1) Language : English 2) Number of copies 2 coats (35ym x 2) Leoat (30pm x 1) Drawing and document for Approval for Installation for Finished plan Specifications Hyéraulic circuit diagram Arrangement Installation Piping arrangement Tiller Detail of tiller inner dia. Key List of spare parts & tools 15 15 “7ifirst ship 5 /ship ‘Shop test records 3 /ship Instructions manual 5 /ship FLUTEK, LUD.1-9. Scope of supply (per one ship) : Hyundai Mipo H6126 (DNV) (FE-T050 standard) Item} Name Quantity | Our supply Ra I T_ [Steering gear Tset O° 1) Tiller & Key (set) oO (Refer to the drawing in detail) 2) Ram, ram pin & roller beating Q sets) ° 3) Cylinder (4 sets) ° 4) Oil tank with accessory Q sets) 3 5) Level switch with two level positions (2 sets) oO 6) Main pump with chain coupling Q sets) 3 7) Valve unit (2 sets) O° 8) Pump control unit Q sets) 3 9) Servo pump unit (including electric motor) Q sets) 3 10) Chain coupling & seat for elec. motor Q sets) ° 11) Pressure gauge 6 sets) O° 12) Air vent valve A sets) ° 13) Piping and pipe bands (1 set) ° 14) Rudder angle indicator plate & pointer (1 set) ° 15) Limit switch for rudder angle limiter (4 sets) ° 16) Junction box & electric cable wiring (2 sets) Oo 2. | Pole & linkage between repeat-back units 2 sets ° and tiller 3. | Operating instructions plate 2 pes Oo 4 | Spare parts and tools 1 set ° 5 | Seat for R.A.transmitter & R.B.units 2 pes ° 6 | Platform with handrail for local steering 2 pes oO 21 | Electric motor for main pump 2 sets O° 22 | Starter panel of electric motor 2 sets Oo for main pump and servo pump 23 | Control panel for auto-isolating system 1 set ° 24 | Alarm panel in W/H & ECR 2 pes ° 25 | Auto-pilot system 1 set ° 26 | Control box (Refer to Fig.1) 2sets 3 27 | Rudder angle transmitter and indicators 1 set 3} 28 | Pole & linkage between rudder angle Lset Oo transmitter and tiller 29 | Storage tank ass'y with filling band pump, 1 set ° level gauge & accessories 30 | Rudder carrier 1 set ° 31 | Grease pump for rudder carrier 1 set ° 32 | Control panel for grease pump 1 set } 33 | All copper pipe for rudder carrier I set O 34 | Foundation bolts and nuts for hyd. cylinders iset ° 35 | Stoppers & cotters for cylinder 1 set ° 36 | All seat and lines for cylinder set ° 37 | Working fluid and lubricant Lset 3 38 | Installation work 1 set oO 39 | Piping supporting L set O 40 | Test operation on board and sea trial set Oo 41_| Wirin; 1 set O ‘NOTE : Other components excepting mentioned above should be supplied by shipbuilder. FLUTEK, LTD.WISAS TOLLNOD JO WVEOVIG OLVRAHOS Babs a CNVLS TONLNOD £05 ae amis nn < oe AN Faw Bidar Io Wiss eMCZN AN JUNCTION BOX CONTROL BOX GLAND (JIS. F8801) TORQUE MOTOR 250V-MPYCS—2 A B 250V—MPYCS—4 BY FLUTEK BY_SKIPBUILDER SURGE ABSORBER (SUPPLIED BY FLUTEK) 1. TYPE : ERZV20D560 2. MAKER :PANASONIC(JAPAN) 3. Q’TY : 2SETS/SHIP Hs) tows & MN @ |[*8) 7a MARINE MACH. DESIGN 21 & | .*FE* TYPE STEERING GEAR aoa WIRING DIAGRAM OF PUMP CONTROL UNIT (FOR LV030/060/090) (FOR RAYTHEON) Y50952612 LOUTERK, LED. Ad (210X297)Hull No. : H6126 S/GEAR WIRING DIAGRAM (FOR #1 v.8.) HYUNDAI MIPO * S/GEAR TYPE : FE21—***-T050 JUNCTION Ox #1 8-1 (wPres-2) 150 2 15C A R STED TORQUE MOTOR (from/to No.1 control box i if vee Low ‘5/6 ROOM (No. #) for autopilot system) Zoey 2408 tes: i 5 300u, c0°e aware {et f- J “ChiTAgH CABLE) (weves-4) 200 2 cA er sTe0 wor (FemZe Nol control box 1 3 a _fu woe |e Tale 5/0 ROOM (No.1) for auto~pilet system) 4 S AWG18 ‘ : Ss | canacn cree) et H Ww et LI (eres 20b ! 14206 1 Suiew —)STAO HY'D LOW,LOW-LOM] (rom/te control pone! : Wee ToS Isvonoou oe.) for cuto~isolating system system) 3 z 3 1°3%} (upye-2) _15e | [rise ‘STBD RUDDER LIMITER (FemZee Noy contrat box tea are (pre-2) 2. (Rs1) Wes) for auko~ pilot systern) Ho t+ 5/6 ROOM (wpre-2) 18 1156 PORT RUDDER LIMITER (from/to Ne) contol box eee ne (were-2) (RPI) (ha) for auto~pilot system) 13 sjonniu (upro-2)__18e = 1152 'STBD UNLOADING S/V Fram /to No.} control box 1 7 Z 5/6 ROOM (No.1) SPE Se) ifs op a J wrre-2) Le (wpyc~2) 186 1s 1 STBD ISOLATING S/V Grom/to controipore’ [7 | 18 | 7 wre La] | serio 0 aon for autoisolating system) 17 BY SHIPYARD BY_FLUTEK DREW [DESIGN [-GHEGK | APEROVE CRAVING NG. PAGE ir ioments Liebe gid D.S.S€0 [S\ vin cnsiaeet Engineering 10.0807, dy FLUTEK. LTD.Hull No. : H6126 S/GEAR WIRING DIAGRAM (FOR #2 J.B.) HYUNDAI MIPO 8-2 * S/GEAR TYPE : FE21—***-T050 JUNCTION BOX #2 (MPYCS-2) 156 7 1507 R PORT TORQUE MOTOR: {from/to No.2 control box \ } TUL style '$/6 ROOM (No. for auto~pilot system) l {2 2408 oe "i 3 citi ARAEAEHEH EH 7 J “(HITACH! CABLE) @ > (MPYCS—4) 20¢ 7 5c (\ Pec PORT LVDT ram/to No control box OL 2aee Roou (No, Ee RF as 3 Rae [etal] wen ma R 3 (HITACHI CABLE)| L ql a of (weyers) 20 t 1, 208 1 Siew PORT HY'D LOW,LoW-LOM| (from/to control panel z (MPvc—4) 2 3 fe Js/o ROOM (No. 2) for eute~isolating system) 8 : ao 2 oH (wpyo~2) ___15¢ | 7 |, ise qatar PORT RUDDER LIMITER (fomte Nop contrat box} r cuPre-2) Lz. (RP2) (No.2) for auto-pilot system) EE inl t + s/s Roow (wPye-2) 156 7 4186 1 ‘STBD RUDDER LIMITER (from/to No.2 control box 1 1 = Srrstkerptck stem) Us pie J wea Te eee (MPYC-2) 15 ra 4 15¢. 4 PORT UNLOADING S/V_ from/to No contra bor t 1 mo Grane Nee Sater) Gotti J wren, Ta Ld) semen on 4 weed. 156 ie. 4 15¢ 4 PORT ISOLATING S/V From/to control ponel t 1 = $72 Roou (We. 2) (2) Fevecscaing yee 7 wore) La e ar BY SHIPYARD BY _FLUTEK Marine Equipments Engineering DRAW DESIGN [CHECK [APPROVE DRAWING NO- PAGE D.s.S€0 "10.08.07 MP it - mr-neore-2 Bs FLUTEK. LTD.ettrg Gpsicnvewrc Z roa VAN Mee => —hassd Syyoouous Soe ara shemetresrtme| <éewanba ner co z é eler| 6 # | #aee [eal ISZXSIXOLEKOLZ | I | WSS ¥3A09 t 1g 2x00! xo0exo0z | F | 1¥Ss ‘x008 z we 1 | vss | 3ivig s10aIN £ #1 ‘GNVYD TEV ¥ is X0¢ x02 | [tess avid $ oe S138 2: BRN 2 ONTSIN alms: dIW IvaNNAH Og NOUONAP z > LON 92196 + “ON MH.(FE21-T050) DWG No. : 00901884 FIG. 3 AUTOMATIC ISOLATION SYSTEM 1.General This steering gear is so arranged that in the event of loss of hydraulic fluid from one system, the loss can be detected and the defective system is automatically isolated within 45 seconds so that the other actuating system shall remain fully operational (50% torque remained). 2. Construction This system comprise a standard 2—rams, 4—cylinders steering gear controlled by one or two power units. In addition to the steering gear, it would be necessary to provide the following equipment: 1) 2 ~ Isolating valves 2) 2 — Level switches with "LOW" & "LOW-LOW" level positions with test bar 3) Electric control panel for automatic isolation system (supplied by FLUTEK) 4) Alarm panel for automatic isolation system in W/H & E.C.R (supplied by FLUTEK) 3. Operation Two identical power actuating systems with either one or two power unit act simultaneously in normal operation. 1) Failure mode operational sequence in one power unit running : With No.1 power unit running and No.2 power unit stopped if loss of oil occurs, the following sequence will take place. a) The oil level in No.1 oil tank goes down to "ALARM & LOW" position and audible and visual alarms are given on the navigating bridge and in the machinery space. b) And No.1 isolating valve (IV-1) is automatically energized and the hydraulic system associated with No.2 power unit is isolated. FLUTEK, LTD.10 c) If the oil loss is in the hydraulic system associated with No.2 power unit, steering is being carried out by No.1 power unit and its two related cylinders (No.1 & No.2) giving 50% torque. d) On the other hand, if the oil loss is in the hydraulic system associated with No.1 power unit, the oil level in No.1 oil tank goes down to "LOW-LOW" position and No.1 isolating valve ([V—1)is automatically de-energized. And also No.1 power unit is automatically stopped, No.2 isolating valve ([V~-2) is automatically energized and No.2 power unit is automatically started, then the hydraulic system associated with No.1 power unit is isolated. Steering is now being carried out by No.2 power unit and its two related cylinders (No.3 & No.4) giving 50% torque. If No.2 power unit running and No.1 power unit stopped, No.1 and No.2 of power unit, No.1 and No.2 of isolating valve are replaced in above sequence. 2) Failure mode operational sequence in both power units running : If oil level in No.1 or No.2 oil tank goes down "LOW-LOW" position, the isolating valve will be operated suitably and No.1 or No.2 power unit will be automatically stopped. 8) In case one power unit is running, if the low alarm in oil tank of stand—by power unit is activated, stand-by power unit is automatically started. Then both power units are running. FLUTEK, LTD.10-1 4. Block diagram NO.2 PUMP RUNNING RUNNING NO.1 LEVEL SWITCH NO.2 LEVEL SWITCH “Low Level | *LOW' LEVEL ENGINE CONTROL ROOM NAVIGATION BRIDGE ALARM. ALARM NO.8 & NO.4 CYLINDER ISOLATION | [ NO.1 & NO.2 CYLINDER ISOLATION (V1 EON) (iV-2 = ON) NO.1 LEVEL SWITCH NO.2 LEVEL SWITCH "LOW-LOW" LEVEL "LOW-LOW" LEVEL Yes | NO NO Yes No.1 PUMP [No.1 Pump No.2 PUMP | | No.2 pune STOP RUNNING RUNNING i ‘STOP NO.1 & NO.2 CYLINDER ISOLATION NO.3 & NO.4 CYLINDER ISOLATION (IV-1 + OFF) & (IV-2 : ON) | (-2: OFF) & (IVI: ON) pean y NO.2 PUMP: NO.1 PUMP’ START START FLUTEK, LTD.ISOLATING VALVE IV=2] (AC220¥) uw Sun Foe uooER aac UMER "UNLOADING DEVICE(AC! 10V) FILTER OPERATING INSTRU CTION ‘CONDON WORK. PUMP WORK, CWL. ISOLATING VALVE, SOLENOID [BUTTON Wet | v=2} Wat | W=2 NORMAL NOt NOZ ALL OFF FREE THO PUMPS USE NOT & NOD a OF FREE FAURE OF PIPING SYSTEM (AUTOMATIC) Nod NOa_& NO, 2 [on | OFF a NOZ NO.3_& NC, 4 ON FAILURE OF PIPNG SYSTEM (MANUAL) NOT NO.1_& NO, PUSH] FREE NOZ NO-3 a NO, 4 FREE | PUSH. EMERGENCY, GENERATOR POWER NO.2 ALL FREE ISOLATING _VALVE W=IKAc220v) FROM STORAGE No.1 OIL. Tani AWA CSOT) ATIWNYON SMOHS +++ “CAVOEVIS 40 NOLOIYIG JLVOIGNI SMOMY - + UNLOADING DEVICE(AC110V) No.t_MAIN_ PUMP) REMARKS, 1. THE CASE OF IS ORDINARY USE AND®. © 4 @ ARE EMERGENCY USE. 2, IN CASE OF @ , @ THE SPEED OF VESSEL SHOULD BE HALF OF FULL SPEED. 13. IN CASE OF @ USING EMERGENCY GENERATOR, ‘THE ‘SPEED OF VESSEL SHOULD Of HALF OF FULL SPEED AND THE RUDDER ANGLE SHOULD BE UMITTED WITHIN 15 DEGREES. FLUTEK, UTD. No.1 SERVO_PUMI MARINE MACH. DESIGN | Te | FE21->**-T050 TYPE eae | Prasccnon| wr a a HYDRAULIC CIRCUIT DIAGRAM AAW [pean ] SHE [osrae FMS45-0275CABLE GLAND FOR RAL. SW Tse) PLATFORM WITH HANDRAIL “FOR LOCAL STEERING | ne FORWARD UDDER ANGLE IND, PLATE AB_VENT VAL bislaaal a wah w 8 2 ins w w AIMS SUS ISA BE 2 12 Puy CONTROL NT NO.2 JUNCTION BOX. T mit SwiTCH FOR No.1 cvUNDER i /RUDOER ANGLE UNITTER MATERIALS FOR MAIN PARTS Lt ea, l [PART WO] NAGE 1 ‘MATERIAL [SVuBOL 15,(715) RAM ‘CARBON STEEL Tsusse_(S55C) Gan “ ‘CYLINDER TNODULAR GRAPHITE CASTING | Pune cont [@) THIGH PRESSURE PIPE| CARBON STEEL{SEAMLESS) [SPPH410 (STS410) No.2 CYLINDER _NO.1 JUNETION BOX 3 ig HIGH PRESSURE PIPE, NO.1 PUMP & TANK 1075 (CABLE GLAND FOA UNLOADING DEVICE (ise-2ea) CABLE GLAND £08 ISOLATING VALVE Tise-zeal aaa i e—]} | ge 254 PI Pose ieee carols nar or ro stone ine ouse [ misoueren irs 515. | 3 / No.2 ISOLATING VALVE / Tua ace200) e 3 is iee SE Sh a NO.1 MOTOR, NOTES 1, ARROWS SHOW DIRECTION OF MOTION TO PUT RUDDER TO STARBOARD. BUT ROTATIONAL DIRECTION OF MOTOR IS CONSTANT IN ANY CASE. MOVED TO STARBOARD. 8, OIL QUANTITY OF CYLINDERS, PIPES & TANKS : 510 Lit, 4, OlL QUANTITY OF STORAGE TANK MIN. 255 Lt 5, TOTAL WEIGHT (EXCLUDING ELECTRIC MOTORS) : 10,600k9.f 5450258 FLANGE SUPPLIED BY FLUTEX PRESSURE GAUGE [SAFETY VALVE FOR ‘SERVO PUMP ‘SOLENOID VIV FOR UNLOADING DEVICE acto) 1186 2, SHADED PIPES INDICATE PRESSURE LINES WHEN RUDDER IS BEING Alp BREATHER, KNOB FOR LOCAL STEERING. aaemeuoroal 8 Sao 3 i Ei i AIP VENT VALVE SAFETY val I BLOCK VALVE. TEERING GEAR FLAT ac aun stock, FLUTEK, LTD. MARINE MACH. DESIGN | 21 = | Fe21-102, 126-1050 TYPE | REMARKS [OTinws rox crunoex TEEN —@ SUPPLIED BY SHIPBUILDER SOE ios corm ad HEAGON BOE Grace 68 esaeo_WOT]_—_~[ see -HEMACON NONE) S500 THR UP BOLT MARINE MACH, DESIGN FE21-053 ~ FE21-207. TYPE ‘SCALE _[enauecron] UT | 3a INSTALLATION $ Peay | Soe See ELECTROHYDRAULIC STEERING GEARbisjuae FORWARD MARES! 14 ‘LPIPING SHOULD BE CARRIED OUT IN ACCORDANCE "ym THs DRAWING. 24KUL PIPES ARE DELIVERED IN PRE-SET STYLE, ‘RADIUS OF PIPE BEND 15 4S FOLLOWS . ‘OUT Dia. OF PIPE | RADIOS OF PIPE BEND. 34: osm (OfiaRS ake NOT 70 BE LESS THAN THREE IMMES THE NOMINAL OUT DUMETER OF PIPE. ‘e.EYDROSTAMIG TESTS FOR WAD' PIPES ARE CARRIED oF PENG, ‘LocaTioN RE i a a a S oi WOE 0, = No? CADE ‘SPIPE BANDS & PIPE SUPPORTS ARE DELIVERED ied WET, ~ Na CRE! By PUTER biog WHE U.— No CTUNDEE! ALL PIPES ARE DELIVERED WITH BLIND PLUGS ies We = Hed BY FLUTE EEEEEEEE SRRSRE [Not TANK ~ No.2 TANK No CYL. = Nod TANK o2 CY = Not TANK NstALuINe_MeTHOD OF PIPE BANDS, Ineo CY _— TPIPE BAND SHOULD BE INSTAIDED A? NEAR PODT INDICATED IN THIS DRAWING. ‘REQUIRED NUMBERS OF PIPE BANDS. (PPE OUT DIAN. 40112 8.USE THE ANGIE BARC So=50<8t OR ABOVE) FoR ‘IPE SUPPORT AND INSTALL Tt-ON THE STEERING Guim SEAT AS MUCH AS POSSIBLE AFIPE SUPPORT SHOULD BE ARRANGED AS SHOWN Iv Fi Bees Beas ae bese (TO BE SUPPLED BY FLUTEK) STEERING GEAR SEAT MARINE MACH. DESIGN FE21~102,126-T050 TYPE a=[ee@le a PIPING ARRANGEMENT PAE 20 ECTRO-HYDRAULIC STEERING GEAR aa ELECTRO“ io ic @ Y20950886C-HDDSee fe REESE) 28 (52 ¥8 sa (UV. ies 88) ons VOY .12 36) Toon 2 229.18 ean aa 0 UNE #608 S & eo! 8] a} 8 “lool g a 580 580. BASE LINE & INDICATION MARK FOR INSTALLATION. 600 115. 16-018 HOLES(M16) SFE COUNTER SOAS (x3 PUNCHED HOLES) (760) [TIGHTENING TORQUE, 0K: 15 REMARKS, 1, TILLER IS TO BE MADE FROM MATERIAL IN ACCORDANCE WITH THE REQUIREMENTS OF ‘THE CLASSIFICATION SOCIETY. 2, MATERIAL TEST AND INSPECTION FOR TILLER ARE TO BE CONDUCTED IN THE PRESENCE OF THE SURVEYOR. 3. MACHINING OF THE BORE AND KEYWAY IS SHOWN IN OTHER DWG. (DETAIL OF TILLER INNER DIA.) 4, TILLER IS TO BE SUBJECTED TO NONDESTRUCTIVE TEST (UT & MT). 6. EYE BOLTS ARE FURNISHED BY FLUTEK. FOL: UD EoKs aa a 3 g ats ~(vi W) 5 sore sort [souess] © | wie xeson ela 1004] ‘SOCKET BOLT }SCM435 | @ | M16 x 150L. S| SB] S] feos HARD. STEEL PLATE |somars | ® | PHSP=126 id 1002 EYE BOLT sz0c | 4 M36 4 oer Tuenre= | sceo [1 Tee a dal fesleaee |e aiasPels =] #2 TIS [MARINE MACH, DesiGN [718 F102,126-K13 | ==[sele* | ead | ow TILLER 22 DIMENSIONS OF INNER DIA. ANO_KEYWAY ARE tees ag] SUBCTRO“HYDRAULIC STEERING GEAR SHOWN IN “DETAL OF TULER NNER DIA meat aaa Faz = [309512288-01L]# + LTD. ‘! ‘4. (210X297)SM] cate [ereroveo ‘CONTENTS REVISION $ t 2xPT3/8-14/18 2-M20-29/37(BOTTOM_SURFA 16 PTS /8— : - aN (FOR REPEAT BACK UNIT) TILLER 3 120H7*8%5 = al RBs ete i a) S| 2 SECTION 62-62 ' 5| Z| 1.3 s ime SECTION _G1-G1 ef i ata FORWARD RUpOER g “a DETAILS OF OIL GROOVE ee EEE KEY_WAY. (9316.58) (315.58) | 4 ONLY FOR TILLER DISMOUNTING. 2-M20~29/37(BOTTOM SURFACE) (FOR RUDDER ANGLE TRANSMITTER ) AIR VENT PORT T DETAIL “A” (TAPER 1775_ON DIA] (0315.58) BY _FLUTEK A 5 Penn nce cE ERIE ieee a iS Se —~ = | oF aie = 7 Arettit \ i RS OlL_PORT. 0214.5°8'] | BY FLUTEK 9359.58°3°°" BY FLUTEK 9359.78 MACHINED BY SHIPYARD 9360 AETER ASSEMBLING 8Y SHIPYARD FLUTEK, REFERENCE DATA OF TILLER FITTING 1. FITTING METHOD __: DRY FIT 2, PUSH-UP DISTANCE : ABT. 3.25~3.65 mm 3. PUSH-UP FORCE BASED ON PUSH-UP DISTANCE OF 3.2mm 1) MIN. PUSH-UP FORCE (U=0.1) : ABT. 481 TON 2) TARGET PUSH-UP FORCE (U=0.17) : ABT. 734 TON 8) MAX, PUSH-UP FORCE (l=0.2) : ABT. 842 TON REMARKS 1. TILLER WITH CONICAL BORE WOULD BE DELIVERED LEAVING ALLOWANCE OF 0.42mm ON DIA. (0.42mm ON DIA. = SCRAPING ALLOWANCE OF 0.2mm + FITTING ALLOWANCE OF 0.22mm ) 2. KEY WAY OF TILLER WOULD BE DELIVERED LEAVING (2x0.1mm) ALLOWANCE. 3. SPOTTING OF TILLER BORE AND KEY WAY ARE SHIPBUILDER’S RESPONSIBILITY. 4 OIL GROOVES AND OIL PORTS WOULD BE MACHINED BY FLUTEK. AND, OIL PORT SHOULD BE USED ONLY FOR DISMOUNTING OF TILLER 9325 mm : 280 N/mm? UPPER RUDDER STOCK RULE DIA. YIELD POINT OF RUDDER STOCK MARINE MACH, DESIGN TPE FE21-102 TYPE SCALE [praiecron| UN Ne 3.AD Mid AAW Bese ood b.s.se0] ie LTD. me wa no. DETAIL OF TILLER INNER DIA. SHEET] TILHe126 [PKS ‘A2(594x420)CALCULATION OF CONNECTION OF TILLER TO RUDDER STOCK ©‘ * Shipbuilder : HYUNDAI MIPO DOCKYARD CO., LTD. * Hull No. : H6126 e516 + Sat | ieariancene a dmbeo336 "| i ts sh un aaa [3 5 0360 i | =6820 1, Rudder stock material : Forging steel (A) Yield point (os) os:min. 280 N/mm? (2) Modulus of elasticity, (E1) El : 2.06E+05 N/mm* 2, Tiller material : SC480 (1D) Tensile strength,(otts) rmin. 480 N/mm* (2) Yield point, (ot) Gt:mMin. 260 N/mm? @) Modulus of elasticity, (E2) E2: 2.06E+05 N/mm? 3. Key material : SF590B (D) Tensile strength, (okts) okts:min. 590 N/mm? (2) Yield point(ok) ok:min. 335 N/mm? (@) Material factor, (fk) fk= 1.3046 4, Connection method of tiller to rudder stock ~ Dry fit with key 5. Steering gear torque ) Btfective steering gear torque at max. working pressure, (Tw) 1,000 KN-m (2) Design torque of steering gear at safety valve set pressure, (Tdes) 1465 kN-m 6. Geometry data (2) Length of cone, (L) L: 660 mm (2) Effective length of cone, (Le) Le: 640 mm (3) Taper of cone, (K), K=L/(d-du), K: 15 mm (4) Out hub diameter, (D) D: 820 mm (5) Bottom contact diameter, (4) di. 360.mm (6) Mean contact diameter, (dm) ‘dm: 338.00 mm (7) Top contact diameter, (du) du: 316,00 mm16-2 7. Surface pressure (1) Required surface pressure, (Pr) 6 Be 2 See Or 2 51.22 N/mm* mxdm? xLex u : Coefficient of friction = 0.17 : Dry fit (2) Max. surface pressure, (Pmax) 1-Ce? 63.68 N/mm* V3+C where, k= 0.5 for keyed connection Ce=du/D= 0.385 Comin = dm/D= 0.412 ‘Pmax => Pr: 6368 «> 51.22 Pmax=kxotx: 8, Shrinkage allowance, (A) (2) Min, shrinkage allowance, (Amin) (2) Max. shrinkage allowance, (Amin) duxPmax 2 Amax ==: 1-ce? ‘9. Pull-up length, (6) : 3.25 mm — 3.65 mm (D Min. pull-up length, (min) Smin-K x{mint 2x(Raj +Rae)x10-} = 3.25 mm Rags (2) Max, pull-up length, (6max) SmmKx [Amax+2x(Raj +Rae)x10~} = 3.65 mm sémex > Gmin 3.65 > 3.25 (3) Target pull-up length, (6t) + ot= 3.3 mm ‘Target surface pressure, (Pt): Pt=52.05 N/mm* 10. Pull-up force based on Pull-up lenght of 3.3 mm (F) (1) Min. pull-up force, (Fmin) Mmin= 0.1 Btag = 0.17 ee = 0.2 1 Fmin~2 xdmxLexP, + mi 4,717 kN oie a 481 ton16-3 (2) Target pull-up force, (tag) 1 ag Rag =7 x dmxLexP, vt tag 0 eae aetaN 2xK = 734 ton (3) Max, pull-up force, (Fmax) Fnac acamcLex {+ sax 0 = 6,254 kN 2xK 842 ton 11, Shear stress and side pressure of key and keyway ) Key: -Sizei p= 120mm = Corner chamfer cl= 8.5 mm $0 mm Ly= 635 mm (2) Keyway = ~ Effective depth in tiller Hy* 45.51 mm. - Bffective depth instock: . Hs™ 44.99 mm (3) Shear stress,(1) = 80 *Tdes —Kkey *Tw 196 OK incase of Tir 2 Tw, ok dm/2xL, x b 100.7 N/mm* < 193.4 N/mm* Sc : Safety factor = 15 Kkey : factor determined by expected accuracy of the method for verification of fitting = 0.9 b: breadth of key(mm) ok : yield point of key &) Side pressure, (op) 1) Key Sc xTges —Kkey xT, Okey =e ey W108 <1. 0x0k ‘dm/xLqx sel) 331.2 N/mmt < 335.0 N/mm* 2) Key way (tiller side) So xTyes Key Ty a Se *Taes “Rey Tw, keyway.t -— GaxL gx (Hel) 326.5 N/mm? < 335.0 N/mm* OK x10 <1.Sxotok 3) Key way (rudder stock side). Se x Ties -Kkey XT dm/2xLy x (Hs) 331.2 N/mm? < 336.0 N/mm* OK. Okeyruay: x10° <1.2xo3,0kAVA XL XD Raat aortas ZONvNOTY 1S SNISINIS JB ‘ATddOS UNO BUY AI od SUIOM LIS ‘ONMAIT YOM LIOK BAT HLA GHYAATIS TE OL St KOH ‘sd, NI SONVAOTIV ONIHSINE UU GeO DNIAVET GSUUATIRG Ba OL St AD 1? AON dO AMNYOD " SRE Oat | O5=ZmN-8S [oMN-as|se7Te=OIM 5 SOx 06 SEI] am co xn oa aos] azs | 4/0 ben | He Lon Mog 135 log 343 (QB ANBO)NOISNAWIG se anawsnsesoete aa SI rane Ser aeaearer[ eae rat ee RRAE( —)anwWa SmIDIMENSIONS (mas) rR |Ho| w | m FE-102 | 580 | 660 | 265 | 830 | R370 S/G TYPE RUDDER ANGLE : REPEAT BACK UNIT(2sets) [5 DIMENSIONS(zamn) TRANSMITTER (1 set) r : (MAKER : SPERRY) gine Ba | La | Ha (MAKER: : HERIANA) | FE-102 100 | 1144 | 612 u OuvMYOs SPOT WELDING POLE FOR R.AFEEDBACK UNIT & RAT (2 POINTS) (SUPPLIED BY FLUTEK) SUPPLIED BY SHIPBUILDER --—— 25,50 25, q € OF RAM & HYD.CYtT SPLIT PIN DETAIL _"A” (3SETS) DETAIL_”B” i HEX.NUT(M8) fen! i [a LEVER OF RAT wn DETAIL_COLLAR * ARE SUPPLIED BY SHIPBUILDER MARINE MACH. DESIGN FE21~102-T050 S/GEAR TYPE DETAIL _"C” aelee INSTALLATION OF REPEAT BACK UNIT & 5 ef o-G| aa RUDDER ANGLE TRANSMITTER RE ae ( FOR SPERRY & HERIANA ) ee Lew lo] | : "AZ(594X420)CGT Lo ot (c6zxo1z)_ Pep mee [as Pe = qwun yovg qwodoy yf aeLBP Lae eee vayrammenve wor was |_™ [mes [ov waa owuiaie [ee | Noss0 Hon Sua as CO} = Lear le Aesassqoross aid ss oes | ‘Casievone alo WS 20S Ra beni aie er OFT HAAR NSA SRS BRK ave a len [aanfend oem_-3aUIN aTONY_waGaN od TANS UNFT JO LNERAONVERT WANS SEAL Ma BH | ae o6e 928 ogs— etd org. Sev—aa' Wal OL 00v— aia Wal Se ose—aa'Nd 089 eeg—aa NA 399 eve-aa' Wad oc9 20z—aa' Wa 969 2at/OvT—aa Na 09g 921/z0T-aa' Ka ger 060-aa' Wat NS sor v (uru)sNOISNaWIG HOLIMS LIATT 40 TWNIMQ]__voe-tte-szooxa—fon'DAa) GNIMAANIONS VMHaVG HOMMS ‘THAT aun, | i (aso)yeaa0 iva ‘osa|__-oag| wt | mms ig suo ava [ox| “sav | ao koe Twnas| avo aiava| @ (asoywago sowria| © T ata aaino| + (axon asd "TART ROT av + [roosns [waaaois avoral 2 [saa woul e «MOT-KOT, OT, vaos [AHF wouas oaau| 2 (sousa owssy, wo) anya aM ssn: BA ame] 6 ® T [aise | aura aren] 6 © | ih, fear ae asa] os @ | ASSK, [somaa oman | sr (hrwaquoo ou wan my 3 oor malv (eeponmeac (AKL ONIENHON GOI) SaNIES yOL-S1 + BAK HOLIMS THAST 10k ATAVL ‘OndS21 LIST OF SPARE PARTS & TOOLS FOR 2-RAM, 4-CYLINDER TYPE ELEC.-HYD. STEERING GEAR S/GEAR TYPE : FE21-102-T050 MARINE ‘MACHINERY: WORKS: ENGINEERING DEPARTMENT. F RCH 4. SHIPYARD : HYUNDAI MIPO DOCKYARD eee co., LTD SENIOR 2. HULL No.: 1H6126 ENGINEER ASST. SENIOR ENGINEER 3, SIGEAR TYPE : FE21-102-T050 ENGINEER A a an | DRAWING NO. : FMS45-1147 DATE : 2010. 02. 26 FLUTEK, LTD.22 SPARE (FEQ1~*«» TYPE) PAGE 13 SPARE PARTS OF STEERING GEAR SHIP NO. FE21~102, 126 TYPE (FOR ONE VESSEL) BOX NO. SUPPLY DRAWING INO, NAME SKETCH materia |_PER SHIP REMARKS |WORI PART WEIGHT: kof ing [SPARE NOT no. 0237 V-PACKING || p22 10 |FOR -itHyorauuic |X Y)| Heme 20 | 20 | Pe0ossa} 1210) PvP-212k CYLINDER ie RUBBER 0.065 FLUTEK, LTD23 SPARE (FE21-*** TYPE) PAGE 23 SPARE PARTS OF STEERING GEAR SHIP NO FE21~102, 126 TYPE (FOR ONE VESSEL) BOX NO. ‘SUPPLY DRAWING INO} NAME ean mareriaL |_PER SHIP REMARKS |WOR PART| WEIGHT: kal ing SPAR NO. | no. od SYNTHETIC, 20 |O-RING oO —o-—-7 3} RuBBER N25004¢ (N.B.R) JISB2401 od x ow [O-RING 20 |For 29.434 i 8 |e » — |1218) QoRBaso =1 |CYLINDER 1221 PLUG 001 9 esBiNs 20 |For 9.8x1.9 * ” ‘OORBPI0 ~2 |AIR VENT f 4 eo IVaLvE [ooo )-RIN( 20 Pan a 29.4x3.1 7 o|2 ” 14639] OORBG3O ~3 Jor. Tank PLuG| aor oy Paget 29.4x3.4 i ela » — |4652} OORBG3O OIL TANK O07 )=RINC 1821 20 /eon Leanna i 14] 14 ipza|_ ASSEB 55 NO.219 PIPE FLANGE. o.0012 1823 }O-RING SYNTHETIC 20 |For 19.8x2.4 N25004C| OORBP20 -7 |PRESS.GAUGE RUBBER 6 6 4013. IvaLvE foxcoe | _(N-B.R) }O-RING 20 |For 15.8 x24 ‘i : OORBP16 —8 |VALVE UNIT 4 it 2907, PLU [oro008 FLUTEK, LTD24 SPARE (FEQ1—s»« TYPE) PAGE 3/13 SPARE PARTS OF OIL BLOCK VALVE SHIP NO. 0B20-V1. 0/201-810 TYPE (FOR ONE VESSEL) BOX NO. SUPPLY DRAWING NAME eat MATESIALSE teint aienn REMARKS WOR! PART WEIGHT: fof ng [SPAR NO. Tyo. od cc | SYNTHETIC O-RING ooTE—o—T 3) Ruser N25004C| i (N.B.R) JISB2401 os x ow Jo-RING 34.4x3.4 _ a lia » | 461 | OoRBGss [enor O-RING 39.4x3.1 ” mata » | 462} OORBG40 [poate O-RING 34.4x3.1 ” e |e » | 463 | OORBGSS [ovate lo-rING WB x24 i a|4 » | 44} CoRsP12 [oroooe O-RING Het aia " a|4 * | ser | OORBP16 [oro00s lo-RING 9.8x1.9 ” ai ” ee OORBP10 fooo0e O-RING 24.7x3.5 * ce ttt ” (goo) OORBP25 oxo008 O-RING 33.7x3.5 7 4 4 7 ea OORBP34 o-00r3 IsPrING (600)} FOR - 4c) 8 w SAFETY VALVE ea nin FLUTEK,. LTD25 SPARE (FE21-+** TYPE) PAGE ang SPARE PARTS OF SOLENOID CONTROLLED VALVE SHIP NO. DE10P-10-204 TYPE BOX NO, SUPPLY DRAWING NAME aoa MaTeRIAL |_PER SHIP REMARKS WOR PART WEIGHT: Koff ing [SPAR NO. To. 08 St] svwtueric jo-RING 8 | “puaser | 4 | 4 |wescosc] 105 | ws 8240" (NBR) 012 4 (01N8770) O-RING 9: ” 10 | 10 113] 12x2 o.0008 Nf St =a U-PACKING: si Sr fi 4a}4 104 | vzso10ses7 1 Soc sw Kewrt sounoo = | 3) Ei se.5 2]4 Stee a FLUTEK, LTD26 SPARE (FE21-»»* TYPE) PAGE 53 ‘SPARE PARTS OF SOLENOID CONTROLLED PILOT OPERATED SHIP NO. DEH22P-10-207D TYPE DIRECTIONAL CONTROL VALVE BOX NO. SUPPLY DRAWING No, NAME ian materia. |_PER SHIP REMARKS WOR PART| WEIGHT kof ing SPARG NO. Two. 3 [ +, | SYNTHETIC 50 |o-RING jo— Fo 3 | “rupeer N2s004¢| NBR uISB2401 ed x ow ist O-RING. 41.7x3.5 fm " " ” 161 | OORBP42 [osoors ry O-RING. 29.4x3.1 7 als ” 162 | OORBG30. (o.00% a O-RING. 20.8x2.4 if 6 6 ” 163 | OORBP21 0008 na O-RING 68x19 " 2|2 ” 464| OORBP7 o-s002 i O-RING 2.8x1.9 id 2 2 ” 165 | OORBPS [o.0007 he O-RING. 11.8%2.4 adhe ” 261 | OORBP12 [oco00e 5 O-RING. 20.8x2.8 405 | OORBP21 [e.0008 50 DIN 3770 83 |o-RING 113 | oe 50 = |U-PACKING 104 | vzs0105297 10 FLUTEK, LTD27 SPARE (FE21—++s TYPE) PAGE ea SPARE PARTS OF KAWASAKI AXIAL PISTON PUMP (L SERIES) ‘SHIP NO. LV-090-410R10 TYPE (FOR ONE VESSEL) BOX NO. SUPPLY DRAWING No} NAME an MATERIAL |_PER SHIP REMARKS. |WORt PART] WEIGHT: kof iN tere] eres INO! 3 SYNTHETIC 60 |O-RING ok RUBBER, N25004¢ JISB2401 (N.B.R) od x ow 80 Jo-ring 104.4 x3.1 fl it ital » | 347 | OORBG105 oro04s o O-RING 29.7X3.5 i 4 4 ” 216 | OORBP3O a.001 hey O-RING 94.7x3.5 fe 8 8 ” 260 | OORBP3S e004 2 O-RING. 15.8x2.4 ha 4 4 . 264 | OORBP16 a.0008 88 lo-rINe i ala » | 97} CORBGSO 60 ” 83 Jou SEAL 2 | 2 |p2ocaic} 103] Provas 60 SYNTHETIC P3BP-34— £0 Jeack-uP RING: resIN | 8 | 8 | p2008e| 263) — Se201 60 SYNTHETIC P3BP-34- “8 |BACK-UP RING RESIN 8 8 P20085 | 267 ‘$4161 a.008 $20.8 a COPPER °° leackina pate | 8 | 8 | p2oog2| 203] puPt7 i J0.001 FLUTEK, LTD28 SPARE (FE21-*** TYPE) PAGE TAB SPARE PARTS OF SERVO PUMP UNIT SHIP NO. UP10~GF21-S2-R (FOR ONE VESSEL) BOX NO. SUPPLY DRAWING No} NAME hii MaTeRIAL [PER SHIP REMARKS |WORT PART| WEIGHT: kof ng Praha NO. | no; 047.35, OR JP10 70 EXCEPT FOR STATEMENTS SPECIFIED ON THIS SHEET, ANYTHING ELSE SHALL BE IN ACCORDANCE WITH | APPUCATION STANDAROS—| | KS, NEMANGI, IEC 1. THESE DATA ARE ONLY DESIGN VALUES AND SHALL BE GUARANTEED WIT TOLERANCE OF APPLICATION STANDARDS. 7 HYOSUNG STANDARD. ina HYOSUNG STD, | NO 1, ABOVE ALL DATA ARE CALCULATED AT 100% VOLTAGE, 2. CABLE GLAND :306X1EA [-* | Te: TOTALLY ENCLOSED DP: DRIP PROOF CHECKED | APPROVED EP: EXPLOSI \WPll: WERTHER PROTECTED I CKPARK | KSLEE ™ | SC: SELF COOLED FV: FORCED VENTILATED t | FC: FANCOOLED NV: NON VENTILATED AO: AIR OVER. ii SAI TE-25-0102-204 ‘AaQIOXOS7)uv¥e-0010-# 1-30 eS " KY} L LH8O0OMNSG ONNSOAH €3 wn oaoudar] conus | caro | nasaa | wea SNOISNAWIG SNALAO ayy Mg OSL VO8l°ON'Y4 YOLOW OV 30 dd NIVW LON YO4 TIOH ST8=7 “wd? LINN *(6%)Z8L : LHOISM “XONddY (¢ “06 40 SdLS G3LVLON 38 AVN XO LINGNOD SHL (Z IL SINVM Y3NOLSNO 41 BOIS 3LISOddO NO G31V901 38 NYO XOB LINGNOD 3HL (1 (s'gtexouddy)Brve-0010-F1—30WeS H8000MNSd DNNSOAH 68 fouowsar| onan | onoaro | woe | wwvec SNOISNSWIG SNIILAO Os31 108 l°ON'Y4 YOLOW OV au dWNd NIVAN Z’ON YO4 HIGH ST8=¥ mw: LINN “(8%)ZEL | AHOIBM “XOUddY (€ "06 40 SdALS O3LVLOY 3B AVN XOB LINGNOO 3HL (Z “LI SLN¥M ¥ANOISNO 4 ‘BQIS ALISOddO NO G3LV901 38 NVO XO8 LINGNOS BHA (1 <310N> (@'S12 x0uda¥) SEI are SEESPARE PARTS LIST FOR BOX NO. 38 SHIP NO. | 6126 STEERING GEAR ELEC. MOTOR (30kWx4P) SETS PER VESSEL QUANTITY NO.} NAME SKETCH REMARKS P, WEG] WORKING SPARE 9110 60 1 | BALL BEARING : 2 1 621222 T |) THES Tat St 9130 660 2 | BALL BEARING j 2 1 63122Z i 5} FLUTEK, LTD.SF) HYOSUNG INDUCTION MOTOR ane 39 | DATA SHEET Ma 1 | CUSTOMER: HYUNDAIMIPODOCKYARDCOLTD PROJECT # 20 HOE tere SOS CEH FR eR EER EM NO. i ‘SERVICE: a Sire Ee A QUANTITY z GENERAL DATA T PERFORMANCE DATA FRAME N Til ‘OUTPUT 104 KW (POLES [4 POLES __|ROTOR TYPE ‘SQUIRREL CAGE ‘COOLING METHOD T STARTING METHOD OL FREQUENCY ca PRIMARY. HHH INSULATION CLASS CLASS, VOLTAGE TEMP.RISEATFULLLOAD |__| NOLOAD CURRENT RES, METHOD % 0 a& 10SF FULLLOAD CURRENT THERMO. METHOD 5 ‘STARTING CURRENT TOCATION [INDOOR ‘SECONDARY ALTITUDE 100m VOLT (OPEN CIRCUIT) HUMIDITY 80 Sein CURRENT (LOAD) "AMBIENT TEMPERATURE “15-500 RES. (AT25°0 LINE) RATING | CONTINUOUS EFFICIENCY NEMA DESIGN 8 ‘AT A2 LOAD ‘MOUNTING LANGE ATSI4 LOAD BEARING TYPE BALL ‘AT FULLLOAD 'UNLOADILOAD BRG. NO. 6202276032 | POWER FACTOR. 'BRG. LUBRICATION | GREASE AT A2LOAD | PROTECTION GRADE Ht [ATS4LOAD [ATFULL LOAD ‘SERVICE FACTOR: a ‘SPEED (AT FULL LOAD) DRIVE TORQUE ‘SHAFT FULLLOAD 08 kgm EXTENSION — | LOCKED ROTOR 0.46 kgm VERTICAL BREAKDOWN 056 m EXTERNAL THRUST WAX UEAD GBe MOTOR OT 146 ign? fit zee MOTOR APPROX. WEIGHT i 16 ACCESSORIES (OPTIONAL) _[ PAINTING (MUNSELL NO.) RAL 6019 TEMPERATURE DETECTOR === SUBMITTAL DRAWINGS — WINDING NO. ‘OUTLINE DIMENSION SMKOI26 TYPE zi ‘CONDUIT BOX & COVER BEARING nl i { TYPE NO { ‘SPACE HEATER NO ine ao aa RATING NO SLIDE BASE NO. ‘ EXCEPT FOR STATEMENTS SPECIFIED ON THIS SHEET, SOLE PLATE ___ ANYTHING ELSE SHALL BE IN ACCORDANCE WITH TERMINAL BOX HYOSUNG STANDARD. MAIN HYOSUNG STD, | EREMARKS> AUX 1 CABLE GLAND: 208 ~___APPLIGATION STANDARDS: Iam i ! | TE:TOTALLY ENCLOSED ___OP:DRIPPROOF 1 DATE | PREPDBY | CHADBY | APPRVDBY EP: EXPLOSION PROOF (Exe-) EF: EXPLOSION PROOF (&xd~) | _O O7-Apr0_| Y.J.PARK | K.S.LEE | 8.S.PARK SC: SELF COOLED FV: FAN VENTILATED laa FC: FAN COOLED WC: WATER COOLED Tine i ca a if AT TE-25-0102-2A4 @® MROSING CORPORATION ‘AA(210x297)40 s ’ 9 Z LO WS | 2} nowdoayoo onnso SEpeem eck) feyst forso'66 an] S/n [moe] SERS [eee | wee ooo | Jaan 4-3L NLL “ON NOISN3WNIG ANMULNO NOLON OY aul wus uinn * (By LL a *xONdd¥ “(¢ .06 4O Sd31S GALVLOY 38 AVN XOB LINGNOD 3HL“(z “LL SLNWM Y3WOLSNO I 3QIS AUSOddO NO G3LV907 34 NV XOG LINGNOD SHL “(L <3LON> ‘tunvaa 22409 3 x09 LuNONOD (xoudav)srzAt File No| 00900666 TECHNICAL SPECIFICATION FOR ELECTRIC CIRCUIT (ELECTRICIC MOTOR FOR SERVO PUMP) Starter and alarm panel for electric motors for servo pump units shall be integrated in those for electric motors for main pump units provided by the FLUTEK. 1. General diagram Starter and alarm panels shall be connected as follows. Steering Gear Room (SGR) Engine Control Room (ECR) Wheel house (W/H) C63 No.l Control Box 440 V_ [7 for Auto-Pilot System at { Main Sots. No.1 No.1 Pum No.l ‘Alarm panel ‘Alarm panel : i 7 a foo oy { Servo S0He \Ponp/ Aces ' Nc 60Hz ( Servo }{ Be? DSU EEA CL Nel (sao \ sone (| er No2 No2 Main em Alarm panel Alarm panel ome No.2 Control Box: for AutoPilot System Note : 1. Electric motor for servo pump shall be arranged to start before electric motor for main pump (1~2 seconds). 2, Partial diagram for starter shall be referred to the drawings "ELECTRIC MOTOR DIAGRAM" 3. Starting signal of electric motor shall be given to the control box for auto—pilot system. 4, When specification of "Tanker" is applied to the steering gear, control panel for automatic isolation system shall bo provied. In this case, separate TECHNICAL SPECIFICATION FOR CONTROL PANEL (AUTOMATIC ISOLATION SYSTEM) is referred to. FLUTEK, LTD.42 2, Indication and alarms FOR REFERENCE, Following lamps shall be additionally provided in starter and alarm panels for main pump units. SGR ECR WH Running lamp ° ° 3° Overload lamp ° ° INo—voltage lamp ° ° Phase failure lamp ° ° Note: 1. Lamps to be provided according to the specification of those for main electric motor. 2. Other elements to be used for main electric motor. 3. Basic circuit diagram of electric motors control SOURCE FLUTEK, LTD.x 380 380 | _ FLUTEK-KAWASAKI TYPE ELECTRO-HYDRAULIC STEER: OPERATING INSTRUCTIONS ‘FORWARD No.2 Cy. Hot CYL u i T & NG GEARS ~ 4-95 HOLES thickness : 1.61 bol REMARKS «ARROWS IN (6/0 cour) CATE DIRECTION OF STARBOARD. MARK( -P€- ) SHOWS NORMALLY CLOSED VALVE, TYPE MAX. TORQUE Ton.m, MACHINE NO. [FSC 1. GANGE OVER OF THE MAN POWER UMTS SHOULD BE DONE BY OFERATWG ELEOTRE MOTER stor Sure. 12. WHOH Ae” SHEE FALLRE CCCURS THE APNE STON, THE OSFETIE SYTOM iY BOLAED OR STOPPED AND THE REQANIG SOINO SYSTEM CAN BE USED FOR 2. eta AOE BOUTON STON ACTUOED, GLY PUD MD LOST (Baume VLE 2000RONE TO TAS CPERATWG STRUCTION SENDA TE DEFECTIVE PART, THY SHTCH OFF THE AUTOMATIC ISOLATION SYSTEM ‘4 WHOL AL AA GNDK FOR PALURE STEERMG GEAR SYSTEL, MVESTGATE ME DUEETHE. PE 'W ORDER TO SOLE OPERATING THSTRUGTION eovomon | woe, Pour ope. on i woz airy a Ts al i SAFETY VALVE SET PRESSURE MPa 43 MPa (sco NAME PLATE fecrsnven] 1.5%360%80 MAX. WORKING PRESSURE NO.| PARTNO. | _ NAME OF PART DATE OF MANUFACTURE, MATERIAL|OTY| REMARKS FLUTEK, LTD. FLUTEK MARINE MACH, DESIGN | Tyee FE2|—*=*-T050 TYPE ‘SORE ONT, “Z| 30 | um “aA [ESSN EK] ee roxeron| LTD. INSTRUCTION, PLATE FOR OPERATING owe wo} 30950455E ‘seer NO. Rateooear)CONTENTS REVISION STEERING STEERING GEAR GEAR NO.2 oll TANK NO.1 OIL TANK phy 5k-25A FLANGE (SUPPLY BY FLUTEK) STORAGE TANK (255Lit.) + PAINT 1. TANK IN SIDE : VASO 2. TANK OUT SIDE : HEMPSLIN ENAMEL 5222(COLOR:WHITE) ; 1204 + REQUIRED QUANTITY OF OIL : 256 Lit. * ACTUAL CAPACITY OF TANK : 870 Lit. @ [Autexsurny [GLOBE VALVE 2 [5K=25A, 7 NAME PLATE: 1 [STORAGE TANK (19 é ‘AIR BREATHER FILTEA| 1_[uc-as=1168-40 5 RAIN PLUG 1 [Praia 4 1 3 1 2 1 1 o HAND PUNP 150 eaieev ‘SK-25A ANGLE VALVE LEVEL GAUGE, WITH SCALE BOARO Fuurex super | STORAGE TANK ssa e 150k9 NO.[ PARTNO. | NAME OF PART |warenaijaTy] REMARKS | WEIGHT MARINE MACH. DESIGN | TPE | ELEC.-HYD. STEERING GEAR SCALE [pnowecnon] UNIT | S| | OIL_COAMING © 10t PAD, Gt Steel Plate) / HSE 750 HEE] STORAGE TANK in 3RO MM oe (255 Lit.) DESIGN] CHEK [oman] sT-H61264 {SHEET FOoLUTEK, LID. "A2(594X420)45 9-e0057da owen] SNIANINA vMHava QD (INGA-dOL) HOAVD THATI AdAL LVI sut_[ > [rvs ‘Nowatios30 Tae 27 TT BY [erewonee wacusae Bou sawn | AL TRsaivit BNW vd ee SSS = ae [SRST SSS DNV WO 7 SVL SIVA | _NoUWORaa¥ foacimo Tension] 2no/Eie | SSaud oem o-s-00 [eaon Romvss05s o-9140SYMT parE. [areroveo| CONTENTS | REVISION [A\[i00104[omseo | BARS BaGmm— 2mm) _| EES] 46 TO OIL TANK STPG, Sch#40 fs 254 PIPE \\\ By SHIPYARD - 4 | SK=25A_ FLANGE STPG, Sch#40 Ld 25A PIPE ey _FLUTEK, NOTE 1, MAX. PRESSURE : kg/cm? 2. PUMP FLOW : 180cc/rev 3, OPERATE : MANUAL, HANO PUMP: 1 NO,| PART NO. NAME OF PART: |MATERIALIQ'TY) REMARKS WEIGHT MARINE MACH. DESIGN TYPE STEERING GEAR SCALE |PROJECTION) UNIT SSEMBLY OF FILLING PUMP FOR STORAGE TANK 3 RD MM DESIGN | CHECK ~T LOTTE k Ll pb At ioe47 HYDRAULIC OIL FOR STEERING GEAR wacen | SRY EQNS = SSANGYONG ISO VG 68 DAPHNE TURBINE OIL YUKONG TURBINE OIL TOTAL VISGA 68 ‘TOTAL EQUIVIS ZS 68 DTE 26 EXXON-MoBIL | ISO VG68 | DTE 16M DTE 10 EXCEL 68 SHELL TURBO OIL T 68 SHELL 180 VG 68 | SHELL TELLUS OIL T 68 SHELL TELLUS OIL 68 CALTEX REGAL OIL R & 0 68 CALTEX RANDO OIL 68 CALTEX ISO VG 68 CALTEX RANDO OIL HD 68 CALTEX RANDO OIL HDZ 68 BP ENERGOL THB 68, TH-HT 68, HLP 68 BP ENERGOL SHF 68 BP 1SO VG 68 BP BARTRAN 68 BP BARTRAN HV 68 VISGA 68 ELF ISO VG 68 TURBINE T 68 HYSPIN PERFECTO T 68 CASTROL. ISO VG 68 HYSPIN AWH-M 68 RANDO HDz 68 FAMM ISO VG 68 REGAL R&O 68 ‘TURBINE OIL 68 SK ISO VG 68 ZIC SUPERVIS X 68 FLUTEK,LTD.48 HYUNDAI MIPO DOCKYARD CO., LTD. SHIP No. : H6126 SER No NAME OF COMMODITY : 1.Motor Driven Grease Pump (Type : MSK-602-TSM) 2.Manual Grease Pump (Type : SK-224-T10M) 3.Filling Pump (Type : SJ-84H) 4,Control Panel (lype : YICB-2) 5.Sensor, Distributor (lype : YSA-1,SD-48) 3K INDUSTRY 91-3 Dangjeong-Dang Gunpo-Si Gyunggi-Do ‘Tel:02-2678-3303,Fax:03 1-452-3203,HP:019-550-1401 E-mailhoyounkang@hanmail.netDRAWING LIST SHIP No. 16126 No. NAME : DRAWING No. REMARK 1 | GREASE LUBE SYSTEM ASS'Y | GLSA-301 FOR RUDDER CARRIER 2 | LUBRICATION SYSTEM GLSA307 SCHEMATIC DIAGRAM. 3_ | MOTOR DRIVEN GREASE PUMP | GLSA-302 (TYPE: MSK-602-T5M) 4 _| MANUAL GREASE PUMP GLSA303 (TYPE: SK-224-TI0M) 3. | FILLING PUMP GLSA304 (TYPE: SI-84H) 6 | CONTROL PANEL GLSA-305 (TYPE: YTCB-2) 7 | SENSOR,DISTRIBUTING VALVE _ | GLSA-306 (TYPE: YSA-1,SD-4S) 8 | CONTROL PANEL DIAGRAM CPD-301 8-1 [JUNCTION BOX JBD-301 9 | PRESSURE GAUGE, GLSA-308 CHECK VALVE 10 | SPARE PARTS -THE END- 49OAT ae Tanne ap soy waisas 3am asvauo | 0 BN araavo wagany aod GSvRO INULIN S65 LHOTIA, sev 6109 Wa» ceuigaaTaD INIv 17 “D9 davioood oath IvaNNAH | sowaLsno Te a To Deron vo © ~| u-¥28-9 08 35035 “WI pa |e oer oe a we 7] rap eunemia | eewoews7a | BN ant RAISON 51 WWAOWIC SLLVW3HIS sorigo 1_eertce | "0ric0. i auf aa | ax | Cer WAvar| 31v9s G9 "09 @avanod BatW vena | seus! 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y g H] Ho a 0 Ue. oH € 13) S|= i g I POWER FAR & PLC FAULT s 5 a | so on we : eee il sissiueaie g | ie oan lee | we til 5 g || POWER FAL 5 = Is] MOTOR OVER CURRENT g 2 8 i {eles |. cova. poweR FAL E a2 [| oe % lelilsli 2 LI & 4 (| ar i | vet we E Hi 4m 1 |g i tee | i | oz Puwe AUN | [| aaa_[ at I anu BZN arues_far Wiio-85 W 3a ROU wow/DaNETS 35nd RO wna [ va OEE “OF moat oF 109) 27S AMON ‘ramen [Senora | ALD ‘ON 00H nousosa0 | ma ein ges eg ge eg gorge |r go gr meg NENT gp coe eTiz ut TO ONG O-GS2/e vt So.ATG Ue Wy-2 ANG we Lt frou 401 5/o sume v2 96 same eI |e ‘AG 18 220V 6OHZ(10OVA) AC 1B 220V GOHZ(100VA) a Ble 5|- g|2|° S) ola SB) 2\% o| 9|¢ & S| dla 8 4 a @je|2 5 8 a} | ol LE 8 vo vous Sl z}s AB Al8&3 7 m7 73 7 iw a | |B FRO OMG ON-c-S1/2 Ss |S |e y Ss un Ea =] S = & 3 Sly 3/8 a glzit wr | one Sola x B) e|7 ’ re wr = S 5 2 =| a|o wn 100 “OR LEVEL é a az J i le li fo ot 7 424 w fy (2, an wy 3/5) eee fern) LOK/LOW 6 va [102 OL LEVEL, Care tor worm | 3 6 @) ovine é owe arr oie eal to can} —+} («) g OL wet 5 LGi/.ow v4 [ott OL UEEL Slzlo von 3|3|& meee (NOT TANK 2/2] ow 05 a ee ze ale ae loa/.ai OL wet z ‘ofa wlélalé 6 ra ‘OL LEVEL, aia 5 sone 8 tf) ar ton nna ‘BUZIER STOP v Pe if cx ——t yh & a cas | __o E g vo = s wane a a wo x10] sone wt ef $$ tc re | seawe ed ‘7 ne 6 12 | seme ta CJ ga 15 €<1 NO LOAD TEST i i WeRe 440 V a 2122 a | OF 1380 w | PERCY 60 te 64.70 | 38.02 86.40 | “1768 30.66 “Noise Lovel (Mean Value} : 80 dB) *Nibration :0.30.8: mils * Over Load Test : 160 % 15 Seci - Good = + TENPERATURE RISE TEST -! * INSULATION & HIGH VOLTAGE TEST : OL TEST] A ier ce | srarbe [pron ey | EES ae a At | Dae | sanae SMG | 500 | .- 1880 “V | 009 Lom) 6780 ~e ae a, odo] + REMARKS * ae] ath 256 CONT 100% 1HaUR, Fy gk ese a LOCKED ROTOR TEST’ 60SEC. ‘at 200% % i TESTED BY Hi (2 i ae Gier) : +. =." QP HYOSUNG CORPORATION 3 ; : esa e Se AIS © 060-024-8282 0.A £F 065r268-9545 - FAX, 055-268-9234 ‘SAAS AAAAISYSTEMO O16} SHI ASLUCH. SH?90 TEST REPORT FOR THREE PHASE INDUCTION MOTOR Sa R= HSI NG Bal nc ov os mnie "°.__sazaeaszot 84 30 Kw | QUE" 4p 60 He [NSB ASS OF 540A RSE So | BERD “775 feu | PAINS $6.25% | FRAME No. 1801 + WEASURENENT OF WINDING RESISTANCE fat 15 0) way 7 ene7 a * NO LOAD TEST VERE “40 21.24 a | Oy 1370 w | PERCY 60. He * LOCKED ROTOR TEST : [are 541A] Oe 3420. w | FREQBIY "Go He Warne ay os = w | Fee = te ia Powel aSSitey | dle 47.73 = 1798; * 407 1789- 4 coon BAT. 79.72 1782, 8443 | 1776 86.57 1768 20.66 * Noise Level (Mean Value} : 79.7 dB: : ____ STS SBE 315.86. A. *Mibration :0.3.-0.7 mm/s, i * Over Speed Test : 125 % 2 Mi * Over Load Test : 160 % 16. Sec: » TEIPERATURE AISE: TEST b Te STATOR sROTOR Ae Danae .| sana Low] 67.8 0] oe RTING + 258 ODT, 00% HOUR, "Zoo ons, : oe i ESD othe ot, ea “ 0 acl «oe oe » Brean, CORPORATION tpg rae ees a IS # 060-024-6080. 0.A a 156-208-645 FAX. Geb, obe-00B4 2 dake Shans I wesaduT. Lb ee cs) =INSTRUCTIONS MANUAL FOR ELECTRO - HYDRAULIC STEERING GEAR ( RE & FE SERIES ) FLUTEK,LTD. ® HEAD OFFICE / MAIN PLANT 192-11, SHINCHON-DONG, CHANGWON, KYUNGNAM, REPUBLIC OF KOREA. 186-5551 FEX : 82-55~286-5557 + http://www.flutek.co.kr E-MAIL : flutek@fluek.co.kr @ MARINE MACHINERY FACTORY 79-2, SAMGA-RI, BONGSU-MYEON, UIRYEONG-GUN, KYUNGNAM, REPUBLIC OF KOREA TEL : 82-55-574-5744 FAX : 82-55-574-5714 ® SERVICE CENTER FLUTEK MARINE SERVICE CO., LTD. 880, 881 JINYOUNGRI, JINYOUNG, KIMHAE, KYUNGNAM, REPUBLIC OF KOREA TEL : 82-55-345-8951~2 FLUTEK,LTD.SAFETY PRECAUTIONS Before you use the product, you SHALL read this instruction manual and SHALL ful ly understand how to use the products. You SHALL also observe the related regulations and rules regarding safety. To use the product safely, you SHALL carefully read all Warnings and Cautions in this instruction manual PNooncer indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or serious accident. Brn indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or serious accident. lly hazardous situation which, if not avoided, may result [A[caution indicates a poten in minor or moderate injury. A NOTICE | signs used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property. C1] __Warnings and Cautions related to operation WARNING] This product(part) is designed and manufactured in accordance with the specifications of this ship, so it is impossible to change specification after delivered or to equip other ships. | Re WARNING! Never operate the product(part) after you have alcoholic drink or drug. EE WARNING| Operate the hydraulic pump and valves in accordance with the instruction plate, otherwise the ship can lose the steering capability causing serious accident. AA | caution | D0 not step on the Product(part), hit it, drop it, and give strong outside force to it, as one of these actions may cause the failure of work, damage, or oil | leakage. CAUTION | Use the safety equipment to avoid injury when you operate the product(part). bb CAUTION | Pay enough attention on handling method to avoid pinching hands or back problems that may be caused by heavy weight of the product(part) or handling posture.> CAUTION | Wipe the oil on the floor off completely, as the oil creates slippery conditions that may result in injuring. IA notice Keep the product(part) from dust and rust and pay the attention to the surrounding temperature and humidity when you transport or store the product(part). A\\yorice Replacing the seals may be required if you use the product(part) after long time storage. Warnings and Cautions related to installation and removal of the product (part) WING DANGER | Turn off the power before starting wiring or other works related to the electric power, otherwise you can be stuck by an electric shock. # WARNING| Instal jon, removal, piping and wiring shall be done by the certified person. WARNING| Make it sure that the power of the hydraulic power unit is turned off and that the electric motor has completely stopped before starting installation or | removal. You must also check the system pressure has dropped to zero. CAUTION | Use the specified bolts and keep the specified tightening torque when you install the product(part). Usage of unauthorized bolts, lack of torque, or excess of torque may create problems such as failure of work, damage and oil leakage. A caution | ciean the threads and mounting surface completely, otherwise you may experience damages or oil leakage caused by insufficient tightening torque, broken seal. Warnings and Cautions for operation ting or moving part such as electric m Kee, your or connecting rod, otherwise it may result in death or serious injury. WARNING| Investigate the cause immediately if you find something wrong such as unusual | noise, oil leakage and smoke, and fix it properly, otherwise you may encounter damage, fire, or injury. iiWARNING Use the proper working oil, and maintain the contamination, otherwise it may not work or be damaged. WARNING} Use the product under the specification mentioned in the drawings and the specification she A {caution Make it sure that piping and wiring are correct and all the connection is tightened correctly before start operating, especially if it is the first run. Otherwise you may experience injury. A [caution Keep your body off the product during the operations as it may become hot, in order to avoid a burn. [4] Warnings related to maintenance WARNING Make it sure that the ship is safety condition such as at anchoring or at dock before starting maintenance, check or repair. WARNING} | WARNING Never modify the product. Do not disassemble and assemble without approval by KPM. It may cause troubles and failure, or it may not work as specified. If it is necessary by all means to disassemble and assemble, it shall be done by an authorized person.1 2 3 4 General Detailed Description of Main Parts 2.1 Steering Gear 244 2.1.2 2.1.3 21.4 2.2 Hydraulic Pump 221 2.2.2 2.3 Continuous Control! System 2.3.1 2.3.2 Instructions for Installation Instructions for Adjustment 4.1 Preparation all 42 Contents Wc? “ouvv00doD0DO Ram and Hydraulic Cy! inder oe Oil Tank see tee eee Oil Block Valve + + ee eee Construction and Name of Parts + Principle of Operation Operation 9s se te ee eee Construction ++ seer rere Wiring seers Working Oi! and Filling 4.1.3 Application of Lubricating Oi! and Grease +++ +++ 4.1.4 Centering of Hydraulic Pump and Electric Motor 4.1.5 4.2. Adjustment 4.24 4.2.2 4.2.3 4.2.4 Inserting of Ram V-packing + + + Electric Motor Starting + + + + Adjustment of Servo Pump Pressure Air Release in Hydraulic Regulator Adjustment of Pump Neutral Position - cof RM HAMAD 20 21 24ey 8 4.2.5 Air Release in Hydraulic System 4.2.6 Adjustment of Control Box 4.2.7, Adjustment of Pump Control Unit 4.2.8 Adjustment of Rudder Angle Limiter 4.2.9 Measurement and Adjustment of Rudder Turning Speed 4.2.10 Adjusting Steer ing Method 5.1 Normal Steering 5.2 Local Steering Instructions for 6.1 General Notes 6.2 Check Items 6.3 Detail of Check Items 6.3.1 Normal Checks 6.3.2 Before Voyage Checks 6.3.3 Periodical Checks (at dock or basin) 6.3.4 Check of Working Oi! 6.4 Replacement of Ram V-Packings 6.5 Dismantling and Assembling of Line Filter 6.6 Dismantling and Assemb! ing of Hydraulic Pump Test of Safety Valve Naintenance +++ +e eee ee 6.7 Dismantling Procedures for Pintle Bearing Inspection Trouble Shooting 7.1 General Notes 7.2 Trouble Shooting of Steering Gear 7.3 Trouble Shooting of Valve, Pump and Electric Motor Service Net Work Guide sere eee eee ee 22 22 23 24 24 24 26 26 26 29 29 31 32 32 34 35 38 39 40 ay 46 48 48 49 53 55Fig. Fig, Fig, Fig, Fig, Fig. Fig, Fig. Fig. Fig, Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. 10. 12, 13, 14, 16. 16, 17. 18, 19. 20. a 22, 23. 24, 2B, st of Attached Drawings ASSEMBLY OF TILLER AND RAMs ttt tte eee ee eee HYDRAULIC CYLINDER ee er re SOIL TANK UNIT ee eee eee ee eee VALVE UNIT (RE SERIES) vt ttt eee eee eee VALVE UNIT (FE SERIES) + + est teen eee FUNCTION OF OB VALVE 0 tt tt ttt te eee ee eee + OB VALVE (OBIS) se ee ee te ee eee CMMI) = foc ooG0udoGGDODDD DUG OB VALVE (0830) tee etter ee eee ee eee SOLENOID VALVE AND MANUAL ISOLATING VALVE AXIAL PISTON PUMP eee te ee ee eee ee PRINCIPLE OF PUMP WORKING + + + + + bee EXPLODED VIEW OF AXIAL PISTON PUNP 0+ +t ee ee eee ‘STEERING SYSTEM BLOCK DIAGRAM tt tte eee PUMP CONTROL SYSTEM ttt tte eee eee eee PUMP CONTROL UNIT tt tee tee ee eee eee ee GONNECTING DIAGRAM OF PUMP CONTROL UNIT os ++ ss eae Vila ur) coosc0dauGgouDOODDSGG DIFFERENTIAL TRANSFORMER © + 2 eee eee eee ee ‘SERVO PUMP UNIT (REG-090) + ++ +e reer eee eee SERVO PUMP UNIT (REG-260/500) + +++ eeeeeeee oo RELIEF VALVE FOR SERVO PUMP LINE FILTER CENTERING OF HYDRAULIC PUMP AND ELECTRIC MOTOR AIR RELEASING METHOD tt etter eee eee ee ADJUSTING PROCEDURE OF SAFETY VALVE + +++ +s eee ASSEMBLY OF RAM V-PACKINGS + + +t tee eee eee DISMANTLING PROCEDURE FOR PINTLE BEARING INSPECTION TROUBLE SHOOTING FLOW CHART (STEERING GEAR) + + + + + + + 72 73 74 75 76 77 78 79 80 81 82 83 84 851. General Kawasaki Electrical Pump Control (Continuous Control) Steering Gear is of the “Repson Slide Type” construction and consists mainly of tiller, ram and ram pin, hydraulic cylinder, valves and pipings, Kawasaki axial piston pump and pump control ut The hydraulic pump is tilted and discharges the oil, through the control box and the Pump control unit according to the order rudder angle from the steering stand. The ram thrust produced by the pressure oi! is transmitted to the tiller arm through the ram pin and the roller bearings and converted to the torque of the tiller keyed to the rudder stock and then the rudder is moved. The signal of the actual rudder angle is directly feed-backed to the steering stand by means of the repeat back unit, and when it coincides with the signal of the order rudder angle, the rudder stops, Thus, in the contro! system of the Electrical Pump Control (Continuous Control) Steering Gear, the actual rudder angle is directly compared with the order rudder angle and the deviation signal between order and actual rudder angles controls directly the tilting angle of the hydraulic pump. Therefore the steer ing gear can obtain the very fast response and the accurate rudder angle, and the ship can keep her heading correctly with a less steering order This improves the propulsion efficiency remarkably and consequently can save fuel consumption of the main engine highly. One or two sets of the hydraulic pump and electric motor are provided and have enough capacity to operate the rudder within the time required by the classification society. For the specifications of the steering gear, refer to the PARTICULARS of the separate volume. For the general arrangement and the hydraulic circuit, refer to ti ARRANGEMENT and HYDRAULIC CIRCUIT of the separate volume.2 Detailed Description of Main Parts 2.1 Steering Gear rer 212 Tiller : (Fig. 1) The tiller made of cast steel, designed and manufactured according to the requirements of classification society is fixed to the rudder stock with the key. On the fork typed openings of the tiller, the hardened steel plates are bolted and they contact directly with the rol ler bearing of the ram. According as the roller bearing rotates on this surface, the linear movement of the ram is converted to the circular motion of the tiller. Ram and Hydraulic Cylinder : (Figs. 1 & 2) (1) The ram is made of carbon stee! for mechanical structural use, and the hydraulic cylinder of nodular cast iron. (2) The ram pin is incorporated into the center of the ram whose surface has been finished with high accuracy, and the rotatory roller bearings are fitted into the upper and lower parts of the ram pin and contact directly with the fork typed openings of the tiller arm. The ram thrust is transmitted to the tiller through the ram pin. Therefore, the ram pin is subjected to a strong force, but this can be dealt with by employing the material of high tensile strength. The oilless metal is fitted in the bore of the roller bearing and minimize the rotational friction between the ram pin and the roller bearing. And also lubrication with oi! on the bearing is unnecessary. (3) Four (or two) hydraulic cylinders that move the two (or one) sets of ram are securely installed on the bed plate of the hull. A pair of opposed hydraulic cylinders is connected with the ram guide bar and a pair of parallel! hydraulic cylinders (in case of four cylinders) is connected with the connecting bracket. The hydraulic pump unit and the electric motor are instal led on the hydraul io cylinders.Inside of the each hydraulic cylinder, neck bushing is provided, supports the ram and withstands the perpendicular component force of the ran, Five V-packings are also provided inside of the each hydraulic cylinder for preventing oi! leakage. The packings are tightened by the adapters and the packing gland, and have superior seal ing effect. The rudder movement is indicated by the rudder angle indicator plate fitted between opposed hydraulic cylinders. The max. turning angle is |imited by the rudder angle limiter at about 36.2 degrees although the max. working angle is 35 degrees. ‘And also the rudder movement is mechanical ly restricted by the stopper at the bottom of hydraulic cylinder (about 37 degrees) 2.1.3 Oil Tank : (Fig. 3) The oi! tank is made of cast iron and mounted on the hydraulic cylinder. Inside of the tank, the hydraul ic pump, | inkage necessary for tilting the pump cylinder and pipes are installed, and outside of the tank, pump contro! unit, Servo pump unit and valve unit are mounted. The oi! filler, filter, oi! level gauge, thermometer. drain plug ete. are also Provided on the tank. 2.1.4 Oil Block Valve : (Fig, 4, 5 & 6) (1) Function Starting up one pump only provided that two or more pumps are instal led and also piping connection is ready for paral le! running of the pumps, delivered Pressure oi! from the running pump will not actuate ram, but merely drive the idle pumos in their reverse direct ion. The oil block valve is a provision for preventing reverse driving of the idle pump. The oi block valve consists mainly of main spool, spring and valve casing having ports AV, BV, AC, BC.(2) Operation Right oi! block valve As the solenoid control valve is energized, pressure oil delivered from running pump reaches the right end of main spool through a hole of valve casing, moves the main spool! to the left against spring and pass AV/AC ‘and BV/BC are opened. Then the pressure oil from pump is distributed to the hydraulic cylinders and actuates on the ram, Left oi! block valve As the solenoid control valve is de-energized, no pressure oi! is supplied to the right end of main spoo! and valve is in the position where ports AV and BV are by-passed and AC and BC is closed as shown in the left figure, Sopressure oi! from running pump as well as hydraul ic cyl inders is stopped at the valve and no pressure oi! is applied on idling pump. Idling pump, therefore, will not be driven in its reverse direction, The solenoid control valve is energized after a few second later than the starting of electric motor (after the electric motor reaches the rated revolution) by means of timer. Therefore electric motor can be started under low load condition due to the pressure oil from cylinder being not applied on the pump. Also the solenoid control valve has the following functions in the Electrical Pump Control (Continuous Control) Steering Gear © At the operation of rudder |imiter, steering gear can be instantaneously stopped by being “OFF” condition. @ At the failure of control source, steering gear can be automatically stopped by being “OFF ” condition. As wel | as the main spool! and spring, the safety valve, the spring loaded check valve for replenishing the hydraulic cylinder are integrally mounted on the valve casing and the 0B valve is installed outside of oi! tank as a part of valve unit.22 Hydraulic Pump 2.21 Construction and Name of Parts : (Fig. 8) The hydraulic pump is a variable displacement axial piston type, available up to a high pressure of 39.2 MPa (400 kef/om’}, compact and light, and shows high volumetric and mechanical efficiencies without influenced by pressure range. The pump is installed inside of the oil tank by means of the bolted flange and direct-coupled through coup! ing to the electric motor outside of the oil tank. The pump consists mainly of the cylinder (151) fitted in the cylinder casing (202), the seven piston sub (NO. 123-piston, NO. 121-connecting rod, etc, ) being in reciprocating motion in seven bores of the cylinder, the driving shaft Sub-group which transmits power to the pump, the bearings which support the driving shaft, the bearing casing (201), the front cover (251) in which oil seal (103) is provided, the valve cover sub-group. The cylinder (151) is guided by the center rod (161) and rotated on the valve plate (171) fitted on the valve cover (253). As contact surfaces of the cylinder and the valve plate are of the spherical construction, self-center ing can be obtained when the cylinder is rotated. The driving shaft (101) is supported by the bearing casing (201) through the roller bearing (104) and tapered roller bearing (111). The cylinder casing (202) is supported by the two needle rol ler bear ings (205) . The cylinder casing (202) together with the cylinder (151), therefore, can be tilted around the axis of the needle roller bearings (205) by moving the pin of the cylinder casing by means of pump contro! unit, Rotating motion of the driving shaft (101) actuated by an electric motor is transmitted to the cylinder (151) through the connecting rod (121), the cylinder (151) is accordingly rotated around its center in the synchronous speed of the driving shaft (101)2.2.2 In the case the cylinder (151) is located in the obl ique position against the driving shaft centre, the piston (123) reciprocates in the cylinder bore relatively to the cylinder. The valve plate (171) having a suction-and a del ivery-port to change over oi! with the reciprocating motion of the piston is provided between the cylinder (151) and the valve cover (253). The valve plate (171) and the cylinder (151) are in optimum hydraul ic balance during pump running. Oil to be delivered from and sucked in the pump cylinder passes through the Passages in the valve cover (253), the cylinder casing (202) and the pipe flange (254), then it is transferred to the pipe outside of the pump. Suction valve unit (No. 280-suction valve cover, No. 281-poppet, No. 283-spr ing eto) serves for replenishing oil automatically from the oi! tank during pump running. Principle of Operation : (Fig. 9) The driving shaft (101) of the pump is driven by the electric motor through coup! ing. Rotating motion of the shaft is thereafter transmitted to the cyl inder through the piston sub as described in foregoing sub-section. Referring to the sectional views of the pump in Fig. 9, principle of pumping action is illustrated. Middle and bottom of the right figures are the sections perpendicular to the left figure, and direction of rotation is assumed as clockwise viewed from the shaft end, In the case that the tilting angle of the cylinder is equal to zero, i.e. the axis of the cylinder aligns with that of the driving shaft as shown in top and middle figures, any relative motion between the piston and the cylinder bore with pump rotation wil! not occur, no oi! will consequently delivered. No delivery from the pup with its rotation as described above is called as neutralIn the case that the cylinder is tilted around its tilting axis as shown in the bottom figure, the pistons below X-Y |ine are going to withdraw fron the bottom of the cy! inder bore with their clockwise rotation and suck oi! through the port “b” of the valve plate, and the pistons above X-Y line are going ‘to approach to the bottom of the cylinder bore and discharge oi! through the port “a” of the valve plate, Displacement per revolution depends on the tilting angle of the cylinder from its neutral position and reaches its maximum value at the tilting angle of 27 degrees (the maximum tilting angle is adjusted according to the type of steering gear). If the oylinder is tilted to the reverse direction of the bottom figure, the reverse action of the pistons relative to the cylinder bore will take place, accordingly the pistons below X-Y line wil! discharge oi! through the port “b” and the pistons above X-Y | ine will suck oi! through the port “a”. Such being the case, direction of flow can be changed without alter ing the direct ion of rotation of the driving shaft. Relation of direction between oi! flow and tilt of the cylinder is shown in the table. The valve plate (171) in Fig. 8 having two ports “a” “b” in ig. 9 is of importance for changing over oi! as well as preventing oi! leakage through the cylinder end, 2.3. Continuous Contro! System 2.3.1 Operation : (Fig. 11 & 12) The signal of order rudder angle is compared with the feed-back signal of actual rudder angle at the steering stand and its deviation signal is transformed into the pump contro! signal in the contro! box. By this signal, the torque motor is driven and the hydraulic pump is tilted ‘through the hydraulic regulator. The oi! is consequently discharged from the 10+hydraulic pump and appl ied to the hydraulic cylinder, and the tiller will be rotated through the ram and the ram pin. The torque motor is stopped when the pump tilting angle reaches that corresponding to the pump contro! signal because the electric signal of pump tilting angle is feed-backed to the contro! box by the differential transformer (LVDT) in the pump control unit. In proportion as the actual rudder angle nears to the order angle, the hydraulic pump returns to neutral position due to the reverse rotation of ‘torque motor and the tiller stops when the actual rudder angle coincides with order angle and oi! is not discharged from the hydraulic pump because the electric signal of actual rudder angle is feed-backed to the steering stand by the repeat back unit. 2.3.2. Construction (1) Control Box This box is supplied by the autopilot manufacturer in order to transform the deviation signal from the steering stand into the pump control signal and drive the torque motor. It also controls the solenoid contro! valve when the rudder angle limiter is operated. (2) Pump Control Unit : (Fig. 13) This unit consists of hydraulic regulator, torque motor and pump tilting angle indicator plate, differential transformer (LVDT) The pump contro! signal from control box drives the torque motor and the hydraul ic pump is continuously control led through the hydraul ic regulator. The differential transformer (LVDT) is also provided in order to feed-back the electric signal of the pup tilting angle to the control box. The pump control knob for local steering is usually mounted on the pump control unit and used when the autopilot system is failed or steering gear is adjusted, “ie(2.1) Hydraulic Regulator : (Fig. 13) The pilot spool (202) of the hydraul ic regulator is moved by the torque motor (101). The servo piston (403) connected to the cylinder casing of hydraulic pump is also moved by the help of pressure oi! generated from the servo pump and the oi! is discharged from the hydraulic pump. Operation of regulator is explained by referring to Fig. 12. The rotor shaft of torque motor is connected to the pilot spool! (202) and rotational movenent is converted to the stroke of spool The servo piston (403) is also connected to the tilting pin of pump and the movement of piston is transmitted to the pump. While, the servo piston (403) is connected to the feed-back sleeve (203) through feed-back lever (303) and the stroke of piston is feed-backed ‘to the feed-back sleeve. When the pilot spool (202) is controlled to “pushing in” direction (rightward in the figure), pressure oi! from servo pump is lead into the chamber A (oi! passage from a to b is closed) The chamber B is opened to the drain through oil passage b to Accordingly the servo piston (403) moves rightward and stops at the position where the feed-back sleeve (203) closes the oi! passage b to the drain, that is, the servo piston stops at the position corresponding to the stroke of pilot spool (202). Servo piston (403) tilts the pump in the same direction and by the same angle in accordance with the movement of pilot spoo! (202) When the pilot spool (202) is controlled to “pulling out” direction (leftward in the figure). pressure oil is lead into both chanber A and B. As pressure receiving area of chamber B is larger than that of A, servo piston (403) moves leftward and stops at the position where the pilot spool stops. At that position the oi! passage from to the drain opens to chamber B and the oil passage from a to b is closed “12+Servo piston (403) tilts the pump in the same direction and by the same angle in accordance with the movement of pilot spool Also the spring (655) is provided in order to keep the pump at neutral position (Tilting angle 0 degree) when no force is given to the pilot spool (202). This spring returns the pilot spool (202) to the neutral Position when the contro! source of torque motor is failed and the pump also returns to neutral position. Note : Neutral position has been adjusted and set the adjusting pin (302) before delivery. Do not attempt to adjust the regulator at field. (2.2) Torque Motor (Fig. 15) Torque motor is provided in order to contro! the pilot spool and consists mainly of the frame (1) where the stator (11) is mounted, the rotor with the spider (13) and magnet (12) fixed to the rotor shaft, the stopper with lever (3) and bolt (7), the name plate (5) with pump tilting angle indicator etc. and installed on the casing of hydraulic regulator. (2.3) Differential Transformer LVDT (Fig. 16) LVDT is provided in order to detect the movement of pilot spool and feed-back the electric signal of the pump tilting angle to the control box. LVDT consists of the case (2) with coil (9), the spindle (11) and core (10) connected to the pilot spool of regulator etc. and is mounted on the casing of regulator. (8) Servo Pump Unit (Fig. 17) Servo Pump Unit is provided in order to supply the pressure oi! to hydraul io regulator and 0B valve and mounted on the oi! tank. The servo pump is coupled to the electric motor through flexible coup! ing and started before main punp/motor. (4) Relief Valve for Servo Pump (Fig. 18) Relief valve is mounted on the manifold of valve unit in order to adjust ~13-the servo pressure. Adjusting pressure is 1.8 ~ 2.0 Pa (18-20kef/om!} and set before delivery. (S) Line filter (Fig. 19) The working oi! flowed from the inlet of the filter by the servo pum is filtered while passing through the filter element from inside to outside and reaches the outlet, then actuates the hydraulic regulator and OB valve. The filter consists of the cover (2) with an indicator, the tee (5) with a relief valve, the filter element (3), the drain plug (7), ete. (6.1) Indicator During the filtration, the filtering surface is contaminated by the accumulated dirt in the oi! and the differential pressure between the inlet and the outlet is increased, which causes a bad effect on the servo pump and hydraulic equipments. So the indicator is provided in order to know the degree of clogging condition (differential pressure) beforehand, When the indicator ring (red) is floated up to the white level in the column (highest position), the differential pressure is 0.2 MPa {2kgf/cn?]. In this case, the element (3) must be cleaned, However it will be desirable to clean when the ring reaches the middie position in height (the differential pressure is 0.1 MPa (1kef/om?}) since after then the ring will reach the top position comparatively in short time. (6.2) Relief Valve When the element is not cleaned although the indicator shows the clogging condition (highest position). the element may be damaged since the pressure on element is increased due to the less of al lowable flow. The relief valve is provided in order to prevent the damage of hydraulic equipments and valve is operated when the differential pressure is 0. 29 ~0.31 MPa (3.0~3. 2kef/cm?}, then a part of flow reaches the outlet -14-(6) Mm i through the element. directly without pas: Repeat Back Unit This unit is connected mechanical ly to the tiller in order to feed-back the electric signal of actual rudder angle to the steering stand. This unit is supplied by the autopi lot manufacturer. Rudder Angle Liniter Rudder angle limiter is provided in order to stop the movenent of steering gear instantaneously by cancel ling the electric signal to torque motor and de-energizing the solenoid valve consequently 0B valve is unloaded when the steering gear will be moved by any reason over than the max. working angle (35 degrees on each side) The limit switches are mounted between opposed hydraulic cylinders and operated by the movement of ram. -15-3. Instructions for Installation The steering gear will be shipped in sub-assembly groups. In this case, special care should be taken to keep safe from injuring every parts, in particular the sliding surfaces of tiller, ram, rampin, roller bearing and the gauges. The tiller is usually installed on the rudder stock before launching. The hydraulic cylinders are then installed on the bed plate of the hull. The installation of the important components such as cylinder etc. should require centering adjustment and facing-up with the liner put on the bed plate. For smooth operation and correct rudder angle, the installation should be strictly carried out in accordance with the relative positions and dimensions of each parts. For easy instal lation, the main component parts which go together are applied with match marks and knock-pin holes before being dismantled and despatched from our works. The hydraulic cylinder is securely bolted to the bed plate and each cylinder foot is provided with the thrust receiver (stopper and cotter) The hydraulic pipes are shipped after bending and cleaning (by pickling, flushing and corrosion preventing) of pipes are carried out and each flange is applied with blind Plugs at our works. Prior to filling with oil, check thoroughly the clean! iness inside the oi! tank, hydraulic cylinder etc. Until the basin trial of the steering gear, cover the surface of the ram with cloths for preventing the adhesion of slag and impurities. Since the steering gear room is especially subjected to hard vibration, each bolt is applied with stoppers for preventing looseness and the hydraulic pipe is secured to the steering gear bed plate by pipe bands. When the installed steering gear is painted aboard ship, care should be taken that machined sliding surfaces are not painted over but rather coated with lubricant or grease for preventing paint adhesion. ~16-4. Instruction for Adjustment When satisfied that the tiller, ram, hydraulic oylinder, oil tank, electric motor, valves, Pipes, repeat back unit etc. are correctly positioned, make operational Preparation and adjustment in the following manners. 4.1. Preparation at Wiring : Connect the electrical parts of contro! box, steering gear terminal box to which torque motor and LVDT are connected, solenoid controlled valve, rudder etc. in accordance with the instruction manual angle limiter, repeat back u of autopilot manufacturer. 4.1.2 Working Oil and Filling (1) Working Oi! The working oi! applicable should be pure mineral oil. Use of vegetable oil is strictly prohibited because the punp function is spoiled due to depos its, The highly viscous hydraul ic oi! which has additions of anti foaming agent, anticorrosive agent etc. is generally recommended for working oil The suitable range of viscosity is 10 cst - 1000 cst and the range of the operating temperature is limited to-20°C - 80 °C due to oil seal, O-ring etc. Further, as the deterioration of oi! becomes excessive beyond 65 °C, it is desirable not to exceed 60°C. “7Viscosity m/s {cst} High-viscosity limit High temperature Umit i i 3 Low viscosity mit The hydraulic oi! having the fol lowing properties has widely used for the steering gear and is recommendable for working oi! Grade Kinenatic viscosity | Viscosity] Flash | Pour Wiscosity grade) im?/s index | point | Point {oSt]_(at 40°C) cc fc 180 VG68 61.2 to 74.8 incl Min, Min Max. 180 VG56 _| Over 50. 6 to 61. 2 excl 95 200 720 Caution 1. The oi! must be dealt with carefully not to allow dust and other impurities to mix. 2. No oil mixture of different brands shall be allowed by any means. 3, The working oi! for the use especially in cold regions shal! be asked to the oi! maker and our works. Necessary quantity of the oil is indicated in the drawing of ARRANGEMENT. -18-(2) Filling Hydraulic System with Working Oil : When working oi! is filled in hydraulic system, a filter of 200 mesh or over should be applied for preventing foreign matters and dust. “Fill the hydraul ic cylinder with oil little by little through the oi! filler at the upper part of hydraulic cylinder. In this case, air vent valve and cylinder stop valve should be thoroughly opened. “Fill the oi! tank with oi! through the upper filler up to the red line of the oi! level gauge which shows the upper | imi 4.1.3 Application of Lubricating Oil and Grease 414 Since the roller bearing and each joint portion of the steering gear are provided with oil less bearing and oi |-impregnated metals respectively, it is not necessary to lubricate with oi! or grease in normal cases. However application of oi! or grease is required at installation for rust prevention. ‘Apply grease to the sliding parts of the lever. * Fully apply working oil to the ram surface. + Slightly apply grease for rust prevention to other machined surfaces (especial ly to the roller bearing, hardened steel! plate and ram guide bar) Centering of Hydraulic Pump and Electric Motor : (Fig. 20) Poor centering wil! cause over-heating, wear, noises and vibration of the bearing of hydraulic pump and electric motor, oi! leak from the oil seal, wear of the coupling etc. Correct centering should be checked in the fol lowing manners. (1) Parallel Error As shown in Fig. 20, keep a suitable clearance between the coupling faces, instal! a dial gauge on the coupling of the electric motor and let touch its pointer to the coupling of the pump. (2) Inclination Error : Measurement wil! be performed as mentioned above, however touch the dial -19-gauge pointer to the point near the outer face of the coupling of the pump. The permissible tolerances of the parallel error and incl ination error shal | be adjusted within the range shown in Fig. 20. 4.1.5. Inserting of Ram V-packing : (Fig. 23) The Ram V-packings are not inserted at delivery from our works. It is necessary therefore to insert them before the ram is moved, After the confirmation that the ram and packing gland involve no dust and impurities, fit the packings. The detailed inserting method is referred to Item 6.4. 4.2. Adjustment After the preparation of each part has been finished, operation and adjustment will take place by means of the pump control knob in the steering gear room. Clean each sliding surface carefully, open the stop valve and close the air vent valve. 4.2.1 Electric Motor Starting : In the first place disconnect the contro! box from electrical power. Before starting the electric motor, rotate the hydraulic pump by hand (5 ~10 turns) to circulate hydraulic oi! in each part of the hydraulic pump. After confirmation of the pump tilting angle being roughly in neutral by means of the tilting angle indicator plate of the pump contro! unit, start the electric motor. Confirm the rotating direction of hydraulic pump and check for oi! leakage from the front cover of pump and abnormal vibration. (The rotating direction is indicated in the drawing of ARRANGEMENT and on the bodies of hydraulic pump and electric motor. ) 4.2.2 Adjustment of Servo Pressure The servo pressure supplying to the hydraulic regulator should be adjusted to 1.8 - 2.0 NPa [18-20 kef/cm’] (the green-colored range on the dial plate -20-4.2.3 4.2.4 of the pressure gauge) by the relief valve mounted on the manifold of vaive unit. However it is unnecessary to re-adjust the servo pressure onboard, since it has been adjusted at our works, If the adjusted pressure should be the different value from the above at a daily check, adjust it according to the following procedure. Remove the cap nut (3-10), loosen the lock nut (3-6), and adjust the pressure by turning the adjusting screw (3-2). Turn the screw clockwise, and the pressure rises, and vice versa, After the adjustment, tighten the lock nut securely. (For the sectional arrangement of the relief valve, refer to Fig. 4 and 18) Air Release of Hydraulic Regulator Residual air in the servo piston cylinder of the hydraulic regulator should be released through the air vent plug (13) Open the air vent plug, and turn the pump control knob to the right and left alternately unti! the bubbles does not come out. Adjustment of Pump Neutral Position The pump neutral position is adjusted before delivery and it need not to be re-adjusted on board. However if necessary, the pump neutral position can be adjusted in accordance with the fol lowing procedure such as the pump, the regulator, the torque motor, the LVDT etc. are re-assembled by any reason. (1) Hydraulic Pump 1. Stroke ful ly the tilting lever (Fig. 3-1681) together with the pump to the direction of hydraulic regulator. 2. After installing the power lock (Fig. 3-1741) at the end of servo piston (Fig. 13-403), push the piston into the tilting lever. Then connect the piston and the lever by tightening the poner lock (Tightening force is listed in Fig. 13.) oe3. By measur ing the length between the end of piston and the casing of hydraul ic regulator, put the pump in neutral position. (The length is listed in Fig. 13.) (2) Hydraulic Regul ator 1, Disconnect the contro! box from electric power. Push the manual button of the solenoid control valve and lock it by means of lock nut, 2, Start the electric motor. 3. If the ram is moved large, grab the adjusting pin (Fig. 13-802) with large monkey spanner (ebéut 300 m), and turn to the right or left slightly to find where the ram stops. Adjust it inorder that the ram movement is less than about 0.5 degrees/nin, at the rudder angle of zero decree. Don't loosen set bolts (Fig. 13~ 316) of the adjusting pin before the adjustnent. 4. If set bolts of the adjusting pin are loosened, tighten the three set bolts to 6.9 N-m {70 kgf-om} uniformly by using torque wrench, then turn the adjusting pin to adjust to zero position. (ote) Set bolts (Fig. 13- 316) must NOT be tightened after the adjustment of adjusting pin. @) Torque Wotor 1. Insert the rotor (Fig. 15-12 and -13) into the rotor shaft (Fig. 13-103). 2. Install the flane without the name plate (Fig. 15-5) so that its receptacle becomes in the direction of port or starboard side, 3. Insert the clanp elenent (Fig. 15-2) and flange (Fig. 15-10) into the rotor. (irection of rotor is referred to Fig. 13.) 4, Put the stopper lever (Fig. 15-3) on the flange and lock it with flange by means of bolt (Fig. 15-4). 5. Fit the name plate and knob. (The direction is shown in Fig. 13.) (4) Differential Transformer (LVDT) 1, Adjust the length so that the distance between the end of pilot spool -2-4.2.5 42.6 4.2.7 (Fig. 13-202) and the edge of core (Fig. 15-10) is 89:0. 2mm. Air Release in Hydraulic System ; (Fig. 21) It is not enough to fil! the hydraulic system with hydraul ic oi! at preparation (When the pump is tilted after starting, its abnormal noises prove that a great amount of air is still left inthe system.) In order to expel air in the systen, push the manual button of the solenoid control valve and look it by lock nut and operate the steering gear slowly with the pump control knob to “Port” and “Starboard” sides alternately (up to near 30 degrees in both directions) and open the air vent valve on the upper part of the hydraulic cylinder of the pressure side (ram-drawing side). Keep on doing this work until the intermittent movement of ram is finished and smooth movement begins. In this case the hydraulic pump will be started one by one. Care should be taken to the oi! level of oj! tank and replenish the working oil if necessary. Note : 1. Don't open the air vent valve on the cylinder where ram is pressed. If it will be opened, the air that has tried to expel will be sucked in agai 2. Before expelling the air, don't run the hydraulic pump for hours. Adjustment of Contro! Box Since the contro! box is supplied by the auto-pilot manufacturer, refer to its instruction manual for its detail. The adjusting items are as follows. (1) Zero Adjustment. (2) Adjustment of Maximum Tilting Angle of Hydraulic Pump (3) Adjustment of Proportional Band (4) Adjustment of Rudder Angle Adjustment of Maximum Pump Stroke : (Fig. 13 & 15) Having finished adjustment of Item 4.2.6 “Adjustment of Control Box”, adjust the position of the mechanical tilting stopper of the pump control unit. -23-4.2.8 4.2.9 Loosen the lock nut, set the bolt (7) to the position 2~3 mn from the maximum tilting position of the lever (3), and then tighten the lock nut (68). This adjustment serves to limit the maximum tilting angle during the local steer ing. Note : In this adjustment, prevent the lever (3) from striking this bolt (7) during the normal steering without fai! Also, during the local steering, don’t strike the bolt (7) hardly with the lever. Adjustment of Rudder Angle Limiter : Set the limit switch position of the rudder angle limiter at 36.2°. Confirm that the 0B valve becomes unloaded (solenoid valve is de-energized), the hydraul ic pump returns to its neutral position and the steering gear stops, when the actual rudder angle reaches this limited angle. Then give an order of the opposite side to confirm that the 0B valve becomes again onloaded (Solenoid valve is energized), the hydraulic pump is tilted, and the steering gear is moved, ‘And also limit the max. order rudder angle of auto pilot so that the max. actual rudder angle is about 35. 5° Measurement and Adjustment of Rudder Turning Speed (1) Normal Steering © + The steer ing gear is tested to be capable of putting the rudder over from 35 degrees on either side to 30 degrees on the way to 35 degrees on the other side in 28seconds with the vessel! running ahead at max. speed. + Correct adjustment has been finished before delivery from our works. If something unsatisfied with the requirement of classification society Will be found, adjust the max. pump tilting angle again, “For special requirements, adjustment has been made to satisfy its specifications. (2) Emergency Steering (in case of two pumps parallel running) ~24-4.2.10 The steering gear is tested to be capable of putting the rudder over from 15 degrees on either side to 15 degrees on the other side in 60seconds with the vessel running ahead at half speed or 7 knots (or 8 knots), whichever is greater. One pump is used in emergency steering. Adjusting Test of Safety Valve : (Fig. 22) The safety valve |imits the max. pressure of the hydraul ic system and releases abnormal high pressure produced in the hydraulic system to protect the system against abnormal load acting on the rudder. The adjusting pressure has been set at the adjusting pressure shown in PARTICULARS before delivery from our works, Readjustment is not required accordingly. However, it is necessary to confirm the operation on board together with the Pressure test of the hydraulic pipes, gaskets etc., whose procedures are as fol lows (1) Preparation : The safety valve test wil! be carried out by means of the pump contro! knob (Local Steering) * Disconnect the contro! box from electrical power, * Push the manual button of the solenoid contro! valve and look it by means of lock nut. Depending on the safety valve subject to confirmation, the hydraulic pump and the stop valve shal! be operated as shown in Fig. 22 (2) Safety Valve Operation Start the electric motor and hydraul ic pump and operate the steer ing gear by the pump contro! knob. ‘When the rudder angle is over 35 degrees, move the rudder slowly. Since the ram reaches the stopper at the bottom of the cylinder, the pressure will rise. Turn the handle then until the pump tilting angle ~25-cones near 1/2 of the design max. pump tilting angle Under this condition, Confirm the adjusting pressure of the safety valve by observing the ‘movement of the pointer of the pressure gauge. (The adjusting pressure is marked with red on the dial plate of the pressure gauge. ) * The operation of the safety valve shal! not exceed 30 seconds at a time because the electric motor may cause burning. (3) Adjustment of Safety Valve : If the adjusting pressure of the safety valve is differed from the designed one, adjust it in the following manners ; The assembly section is shown in Fig. 6 + Remove the safety valve cap nut (3-10) and loosen the lock nut (3-6) * Adjust the pressure by turning the adjusting screw (3-2) Pressure will rise if screw is turned to right and pressure will drop if turned to left. “After the adjustment, fix the lock nut and put the cap nut as original. When confirming the safety valve, check for oil leakage and abnormal ity in each part of the steering gear. After the test is over, put the stop valve, isolating valve, solenoid contro! valve, pump contro! knob etc. to the original condition.5. Steering Method The steering gear can be operated by the following methods assuring correct and easy hand! ing and changing : (1) Automatic steering by remote contro! system in wheelhouse (2 Hand steering by renote contro! system in wheelhouse (Follow up control / Non-follow up control) (3) Local steering in steering gear room (by the pump contro! knob) 5.1. Normal Steer ing : The normal steer ing is made by the above-mentioned method, (1)Autonatic steering or (2)Hand steering (Follow up control). (Non-fol low up control is used when the automatic or hand steering (Fol low up control) cannot be used caused by failure eto. ) For details, refer to the Instruction Nenual of the autopilot maker because the contents are different depending upon the renote contro! system in the wheelhouse (bridge). The steering gear can be operated with all hydraulic cylinders and combinations of hydraulic pumps order to meet with the requirements of classification society. ‘Also changing-over of the hydraulic pump can be done by the remote control of electric motor. The rudder angle can be freely contro! led by the order signal of the renote control system from 35 degrees on either side to 35 degrees on the other side. Precautions : 1. Correctly operate the hydraulic punp and valves in accordance with the instruction plate. 5.2 Local Steering : In failure of the contro! system in the wheelhouse (bridge) or during the -21-adjustment operation of the steering gear, the steering goar can be operated by ‘the punp control knob of punp control unit mounted on the oi tank in the steering gear room, The steering gear is control led by the fol loving procedure. (1) Preparation (1.1) Disconnect the control box from electric power. (1.2) Push the manual button of the solenoid control valve and lock it by means of lock nut. 2) Operate the steering gear by turning the pump control knob by watching the pump tilting angle indicator plate and rudder angle indicator plate, (@) then the steering gear reaches the desired angle, release the pump control knob. The knob and the hydraul ic pump will return to the neutral position and steering r will stop automatical ly. Precautions : 1. Correctly operate the hydraulic pump and the valves in accordance with the instruction: plate. 2. Don’t operate the steering gear over max. working angle (35 degrees) because the rudder angle |i iter is not actuated in local steering. 3. Reduce the ship's speed to half of the max. service speed or 7 knots (or-8 knots) whichever is greater in case of the failure of pipings, and so on.6. Instructions for Maintenance In order to ensure good operation and long life of the steering gear, following maintenance and checks should be carried out. 6.1 General Notes : (1) Filling hydraulic system with working oi! : Apply good grade mineral hydraulic oi! or equivalent, and keep the working oi! fully supplied into the hydraulic cylinder, oi! tank, and piping system. Any air in the hydraulic system will produce abnormal noises from the hydraulic pump and cause not only unstable rudder angle but also other troubles. In case of replenishing the working oil, use the oi! of same brand. (2) Correct Operation of Stop Valve : Correctly open and close the stop valve and isolating valve in accordance with the instruction plate. + Air Vent Valve : Never open the valves during the steering gear is operated. If not, it will cause the failure of steer ing. * Safety Valve : Never touch the safety valve unreasonably because it has been correctly adjusted. (3) Lubrication and Rust Prevention of Each Part : Properly apply the lubricant on the ram surfaces and sliding levers. Apply the grease on the part where is afraid of rust due to the environment. (4) Pump Starting * Start the hydraulic pump in neutral position as far as possible Starting up under a big eccentricity will have the possibility of causing the excessive current of the electric motor. * Pay attention especially when the hydraul ic pump is started at low temperature such as winter season (below 10°C approx. ) -29-6) © M After ensuring the oi! temperature rises by keeping small eccentricity and steering smal! rudder angles, start the normal steering. Pump Stop Stop the hydraulic pump after ensuring that the rudder angle is in neutral (zero) position, Pump Operation at Zero Tilting Angle : Long-time operation of hydraulic pump at zero tilting angle at anchor should be avoided as far as possible. If unavoidable, it should be limited within 24 hours, because this will be undesirable for the lubrication between cy! inder and valve plate of the hydraulic pump. Check Items Checks shall be carried out surely by referring to Item 6.2 and 6.3. Special care should be taken to the oi! level and temperature of the oil tank, operating conditions of hydraulic pump and steering gear, tightness of bolts, oi! leakage etc.6.2 Check Items : Period Check Items Period Check Items Daily [AT Oi! quantity Before C)_‘OiT quantity Voyage A-2 Oi! temperature Check (2) Valve positions 4-3 Cylinder pressure (3) Oi temperature 4-4 Abnormal noises (4) Lubrication of sliding parts A-5 Oi! leakage (5) Ram surface 4-6 Current of electric motor (6) Pump neutral position A-T Servo pump pressure (7) Operating condition 4-8 Torque motor temperature (8) Air release Weekly [B-1 General operating condition FarTodioaT Ci) Safety valve Checks B-2 Lubrication of sliding parts | (at dock | (2) Rudder turning speed or basin) 8-3 Cleanliness of machined part: (3) Coupling WonthTy — | C- Ram V-packing (4) Clearance between tiller and roller C-2 Air vent valve (5) Pressure gauge and C-3 Stop valve and isolating valvel ‘thermoneter C-4 Oil seal of pump contro! unit] (6) Bolt, nut, pin and turnbuckle (7) Ram V-packing Quarterly| D-1 Bolt, nut, pin (8) Oil seal of pump control unit -2 Turnbuckle (9) O-ring of pipe joints 0-3 Coup! ing (10) Gasket packing D-4 Oil level switch (11) Cylinder bottom packing D-5 Line filter em arly] EL Side late of ram gulde bar (12) Pump contro! unit ear | E-2 Working oil-visual check (13) Electric motor (14) Working oi! Yearly | F=1 General function and (15) Tank cleaning appearance (16) Line filter cleaning F-2 Working oi |-property inspection (17) Hydraul ie pump (18) Air release -3t-6.3. Detail of Check Items 6.3.1 Normal Checks Carry out the fol lowing checks whenever the ship is navigating or anchoring and take proper measures if necessary A) Daily Checks AI Oi! Quantity in Oil Tank * Check the oi! level in oi! tank is within the range of the oi! level gauge. If not, examine the cause, repair if necessary and refill oi! tank with new clean oi! A-2 Oil Temperature in Oil Tank + Check the oj | temperature in the oi! tank by compar ing with the normal data. Normal ly oi! temperature wil! be within 30°C plus room temperature. If it exceeds 80°C, stop the hydraul ic pump and examine the cause. A-3 Hydraulic Cylinder Pressure : “Check the pressure of hydraulic cylinder by means of the pressure gauge by comparing with the normal data. If it is abnormally high, examine the cause. 4-4 Abnormal Noises. : “Check its origin in the steering gear and examine the cause A-8 Oi! Leakage “Check for oi! leakage from the oi! tank, hydraulic cylinder, valves and pipe joints. A-6 Current of Electric Motor : “Check for excessive current of the electric motor. A-T Servo Pump Pressure “Check the pressure of servo pump by means of the pressure gauge. Adjusting pressure is 1.8 ~ 2.0 MPa (18-20 kgf/cm’) 4-8 Torque motor temperature * Check the temperature of torque motor, by comparing with the normal data, -32-Normally temperature will be within 30°C plus room temperature. If it exceeds 80°C, stop the torque motor and examine the cause. B) Weekly Checks : B-1 General Operating Condition of Steering Gear + Check the st ring gear is in normal operation. Expel air in its circuit, if necessary, B-2 Lubrication of Sliding Parts * Lubricate the ram surface, tiller hardened steel! plate, roller bearing and levers. Apply the ram surface with working oi! and apply other surfaces with a light film of grease, B-3 Cleanliness of Machined Parts : “Wake periodical cleaning and try to prevent rust by applying grease. ©) Monthly Checks : +1 Ram V-Packing = + Check a light film of oi! is produced on the ram surface. Adjust the packing gland, if necessary. C-2 Air Vent Valve + Check the valves are securely closed. If not, tighten them hard up not to be loosened by vibration. G-3 Stop Valve and Isolating Valve : + Check the valves are opened or closed correctly in accordance with the instruction plate. Tighten them hard up by means of lock nuts not to be loosened by vibration. G-4 Oi! Seal of Pump Control Unit : * Check for oi! leakage from the drain inspection ports provided at the foot of torque motor. Renew oi! seal (109), if necessary. D) Quarterly Checks D-+1 Bolt, Nut and Pin : *Check the fixing condition of each bolt, nut, pin, pressure gauge and valves. -33-If loosen, tighten them evenly and hard up. 0-2 Turnbuckle * Check the nuts and lock washers for turnbuckle are tightened hard up. D-3 Coupling + Exchange the grease in the coupl ing. Turn off the power of electric motor and steer ing stand before starting the work, First exchange Within one month Second exchange or more : Every three months 0-4 Oi! Level Switch : * Confirm that the alarm is given by pushing down the float in the oi! tank, D-5 Line Filter * Check the clogging condition of filter by means of indicator. Wash the filter element, if necessary (Refer to Item 6.5) E) Semi-yearly Checks : E+1 Slide Plate of Ram Guide Bar (white resin) + Check for any abnormal wear. E-2 Working Oi!-Visual Check : * Sample the working oi! each from the hydraulic cylinder and oil tank. (Inspect it by visual check and if found abnormal, examine in detail.) F) Yearly Checks : F-1 General Function and Appearance + Make a precision inspection if necessary, and repair or renew defective parts. + Clean thoroughly. F-2 Working Oi!-Property Inspection “Make a periodical property inspection of the working oil Sample about 1.0 lit. of working oi! each from the hydraul ic cylinder and the oi! tank, ~3d-Renew the working oi, if necessary. Refer to Item 6.3.4 6.3.2. Before Voyage Checks Check the followings before leaving the port. (1) Oi! Quantity in Oi! Tank : “Check the oi! level in oi! tank is within the range of the oi! level gauge Q) Valve Positions * Check the valves are opened or closed correctly in accordance with the instruction plate. (8) Oi! Temperature in Oil Tank : * Check the thermometer is not danaged. * Check the oi! tenperature is within proper range. (about 10°C to 60°) (4) Lubrication of Sliding Parts + Check the lubricating condition of each sliding part. Check for any rust. (5) Ram Surface *Gheck for excessive leakage from the Ran V-packing, The ram surface wil! be cleaned thoroughly (6) Pump Neutral Position : + Start the hydraulic pump one by one and confirm that ram does not move large by Non-fol low up control. + If it moves 0.5 degrees/min. or more, adjust by referring to Item 4.2.4 (1) Operating Condition * Check the rudder moves correctly by the order signal from the whee! house (bridge) and the actual angle agrees with the order angle (8) Air Release in Hydraulic System + Expel air in the hydraulic system 6.3.3 Periodical Checks (at dock or basin) : While the ship is at dock, periodical checks should be carried out where cannot -35-be examined fully at normal checks. Check in detail where found imoropriety at normal check and repair if necessary. (1) Safety Valve : “Check the safety valves are set at adjusting pressure, (The adjusting Pressure is marked with red on the dial plate of the pressure gauge.) “If not set, re-adjust it (Refer to Item 4.2, 10) “When testing, check for oil leakage from the seal (2) Rudder Turning Speed + Examine the rudder turning speed at basin trial and confirm the rudder can be moves from 35 degrees on either side to 30 degrees on the other side within 28 seconds (except for special requirements). “Check there is no large difference between the above data and the trial deta (3) Coup! ing : + Check the errors of centering are within the standard value by measur ing the centering of couplings with the dial gauge (Refer to Fig. 20). If exceeding the standard value, re-adjust it by referring to Item 4.1.4 (4) Clearance between Tiller and Roller Bearing : + Check the clearance between hardened steel plate and roller bearing is within the permissible value. If not, adjust with the liner or replace the hardened stee! plate. The permissible value of clearance : 0.5 ma () Pressure Gauge and Thermoneter : + Check for normal ity. +Repair or replace if necessary. (6) Bolt, Nut, Pin and Turnbuckle : * Check the tightness of all bolts, nuts, turnbuckles and also check for wear of the pins, * Tighten additionally or repair if necessary. ~36-(7) Ram V-packing « Replacement of packing is not required when there is no oil leakage from the packing gland under the condition that packing gland can be tightened and there is @ light film on the ram surface, + Even if oil leakage is not observed, it is desirable to renew it about every five years. (8) Oil Seal of Pump Control Unit + If oi! leakage is observed from the drain inspection ports provided at the foot of torque motor, renew oi! seal. + Even if oi! leakage is not observed, it is desirable to renew oil seal about every five years. (9) O-ring of Pipe Joints + If off leakage is observed, renew it. + Even if oi! leakage is not observed, it is desirable to renew it about every five years. + If the back-up ring is not damaged, it can be further used as it is. (10) Gasket Packing + If oil leakage is observed, renew it. * If sufficient thickness is kept and damage is not observed, the packing may be used as it is by tightening additionally. (11) Cylinder-bottom Packing : (Fig. 2) + If oi! leakage is observed, tighten the packing additional ly. If oi! leakage is not stopped, tighten it again by touching the ram to the plug and raising the pressure up to the adjusting pressure of the safety valve. Caution This packing has been installed inside of the hydraulic cylinder. Therefore the packing cannot be renewed unless the ram is drawn out. (12) Pump Control Unit : -31-* Check that the stopper is adjusted to the position of the max. punp tilting angle plus 2 or 3 mm, Refer to Item 4.2.7. (13) Electric Motor sMeasure insulation resistance between stator coil and frane (nore than 10 MQ). If found faulty, repair or replace the electric motor. + It is desirable to renew the bearing of the electric motor for servo pump about every three years, (14) Working Oil : + Sample the oi | each from the oi! tank and the hydraulic cyl inder and meke @ property analysis. “Whenever the oil reaches the renewal standard, renew it with new one. (15) Tank Cleaning *Clean thoroughly the interior of the oil tank when the working oil is renewed or about every two years. (16) Line Filter Cleaning = + Even if the clogging condition is not observed by means of indicator, it is desirable to clean the filter when the working oi! is renewed or about ‘two years. (17) Hydraulic Pump : + Care should be taken especial ly to worn-out parts, cylinder, valve plate and’ all bearings. +For details, refer to Item 6.6, (18) Air Release : +Expel air after periodical checks. 6.3.4 Check of Working O11 : As it is used long period the working oi! wil! be mixed with foreign matters, deteriorated in the quality, and have the inconvenience to keep on the normal operation of the steering gear. To avoid this, the oi! should be subjected to the periodical inspection. -38-Sanple the oi] at least every half a year for visual check and every year for detailed property inspection and decide its suitability. If the result exceeds the renewal standard, renew the working oi During the visual check (spot judgment), carefully observe the following points compared with the new of a. Isn't the color turned from light yellow to dark brown ? b. Isn't the smell producing an irritative smell 2 ©. Isn't there any sign of foreign matter ? d. Isn't it emlsified 7 Working Oit Renewal Standards ~ Item Changes resulting from Cause Working timit deterioration and pol lution (changing rate) Specific gravity Increase Deterioration 0.05 Flash point Decrease Deterioration 60°C Color Darker’ Oxidation, mixture Union) of worn powder 2 Viscosity Increase (decrease) Deterioration +10 % Acid value Increase Oxidation 0.4 me KOH/e Humidity Increase 0.05 % 6.4 Replacement of Ram V-Packing : (Fig. 28) Dur ing the replacement work of the packing, care should be taken to avoid damaging the ram surface and seal surface of the cy! inder. Five packings are inserted in each hydraulic cylinder. To facilitate the work, oblique cut has previously been made in one portion, (1) Drawing out of Packing : : V-packings can be drawn out by making use of the friction with the ran. Loosen the nut and lock nut of the packing gland by about Omm, 5, Move the ram slonly by local steering. (The packing can be drawn out little by little along with the fan.)8 @ ©, 4 rf & The packing can be drawn out by repeating above works a and b. If packing cannot be drawn out by above work, prepare a suitable tool and draw ut the adapter and packing. (The screw holes has been machined on the fenale adapter for disassenbl ing.) Inserting of Packing : Before inserting new packings, thoroughly remove dirt and impurities stuck on the interior of the stuffing box and the ram surface. Insert the male adapter inward. Wind the new packing to the ran. At the moment, confirm that the section is correctly met. (If the packing is hard, make it soft by hand rubbing.) Insert the packing inward by fingers or a banboo spatula to support the packing. Fol low the same manner subsequent to the second one. At the monent, the splits in the packing should be staggered around so that no two splits come together. Insert the female adapter and tighten the packing gland. Care should be taken then not to allow one-side tightening. The suitable clearance between the oyl inder and the packing gland is shom in Fig. 23. Operate the steer ing gear by the pump control knob and ad just the packing gland to form a light film of oi! on the ran surface. Check for excessive oi! leakage by raising the pressure up to the adjusting pressure of safety valve. Cautions : 1, Assembly of wrong inserting direction of ram V-packing will lead to failure in sealing. 2. Gare should be taken to the packing since it tends to fall itself when inserting 3. New packing may occasional ly cause of! leakage in the first condition. Tighten them additionally if necessary.65 a) b) °) °) 66 Dismantling and Assembling of Line Filter : When the indicator of the filter shows the clogging condition (red indicator ring is Floated up to the white level in the column). the line filter willl be dismantled and the filter elenent cleaned in the fol lowing procedures (Fig. 19 is referred to). It will be desirable to clean when the ring reaches the middle position in height. Loosen the bolts (20) and renove the cover (2). Nut will be detected at the inlet side. After loosening the nut (6) thoroughly, shift the tee (5) by about 2 an to the inlet side (left side) and pull out it. The filter element (3) will come out together with the tee Loosen the nut (8) on the bottom of element and pull out the elenent (3). Wash the element (3) by shaking in the washing oil and clean its surface by using a soft cloth. It is desirable to blow from the outlet side with compressed air. Loosen the drain plug (7) and discharge the oi! in the casing of filter. After cleaning the interior of casing, tighten again the drain plug. The assembly of the filter will be performed in reverse order to that of disassenbly. “Tighten the nut (6) slightly by means of finger. When filter circuit is actuated, the packing (16) at the outlet side will be tightened automatically by the help of differential pressure. So there is no oil leakage from the packing. + Tighten the bolts (20) hard up in symmetrical order little by little. Dismantling and Assenbl ing of Hydraulic Pump : 2 The hydraulic pump will be dismantled and checked in the following procedures. However, special attention and skill in dismantling and assenbl ing of the punp are required, so it is recommendable that the work is performed by the special ist, if possible (Exploded view of axial piston pump in Fig. 10 is referred to). ~a1-(D Preparatory Items : a, Tools necessary for dismant! ing and assenbling of the pump (bar spanner M4 ~ W20, pliers, driver, hamer, monkey wrench, depth gauge) b. Glean waste cloths and wooden pieces for bed seat ¢. Washing oi! (ebout 10 liters) d. Chain block, 2 sets (0.5 - 1 ton capacity) e. Spare parts of pump (2) Procedures for Disassembly = . Discharge oi! contained in the oi! tank, disconnect the link mechanism, hydraulic pipe, each valve, electric motor and the pump coupling, remove the pump from the oi| tank and lift the pump by the chain block. Place the pump ‘on a proper wooden piece. Caution : Disassemble at a clean place. b. Remove the valve cover (253) from the cylinder casing (202). Caution : The copper packing (203) is used at the ports of valve cover. Replace the copper packing at assembly. ©. Remove the suction valve cover (280) and the poppet (281). d. Renove the valve plate (171) from the valve cover (253) Pull out the cylinder (151) and the center rod (161). Caution = 1) Care should be taken not to lose the cylinder spring (165) because it is come out together with cylinder. 2) Place the cylinder taking care not to danage the sliding surface (spherical part). ¥. Remove the both pipe flanges (254). Caution Shims (211) for adjustment (centering) of the cylinder casing (202) are -42-inserted together with the thrust pad (210). Keep the top and the bottom shins separately to prevent mistakes in assembly. &. Remove the both supporting axle (208) from the cylinder casing (202). h. Remove the cylinder casing (202) from the bearing casing (201) Caution : Remove the cylinder casing by means of the chain block since the weight of casing is larger according to the size of pump. i. Remove the key (102) and then the front cover (251). Caution : 1) Remove the cover by using the drawing bolt holes without graver and driver. 2) Renove the front cover taking care not to danage the lip of the oil seal (103). If it is damaged, replace at assenbly. Remove the stop ring (105), the inner shim 2 (106) and the inner spacer (109) ‘rom the. driving shaft (101). They will come out by striking the top of the shaft with a wooden henner (Remove the stop ring by using a pliers). Kk. Grip the piston sub (01) and pull out the driving shaft. Caution : 1) Check that there is nothing wrong with the rol ler bearing (104) and the tapered roller bearing (111). If nothing, don’t pull out then and leave inside of ‘the bearing casing (201). 2) Don't remove the piston, connecting rod ete. from the driving shaft. 1, With the above, the disassembly is finished. (@) Check and Repairs : After the disassenbly is finished, check and repair each part. @ Worn Components : Care should be taken especially to the wears between the piston sub and the cylinder, the piston and the smal! spherical end of connecting rod, the large spherical end of connecting rod and the set ring, the center rod and the oyl inder. If there is no abnormal increase in the clearance and renarkable visual damage, replacement of then will be unnecessary. ~49-Standards for Replacement of Worn Parts (Whit: mm) ne Far size | og | 060 | ox | 120 | 100 | 260 | soo Noninai_size 16 [20 | | | 8 | 32 [0 Piston and [Standard clearance | 0.024 | 0.030 | 0.038 | 0.037 | 0. 042 | 0. 048 | 0.060 Cylinder. | Recomended Replacenent 0.050 | 0.060 | 0.070 | 0,080 | 0.090 | 0. 100 | 0. 120 Clearance Standard clearance | 0.15 | 0.16 [01 | O15 | 020 | 020 | 025 Piston and | Recomended Con-rod | Replacerent 0.60 | 0.60 | 0.60 | 0.50 | 0.55 | 0.85 | 0.60 Clearance Standard clearance | 0.09 | 0.09 [O10 | On [om | On| O10 Con-red and | Recommended Set ring | Replacenent 0.20 | 0.20 | 0.20 | 0.25 | 0.30 | 0.35 | 0.40 Clearance | Nominal size 6 [0 | 2 [| me |e Center rod | Standard clearance [0.024 | 0.030 | 0.033 | 0.037 | 0. 042 | 0.048 | 0.060 and Cylinder | Recomended Replacenent 0.050 | 0.060 | 0.070 | 0.080 | 0.090 | 0. 100 | 0. 120 Clearance | ® Cylinder and Valve Plate If the sliding surfaces of the cylinder and the valve plate are roughened, replace them at the same time. And if the worn value of the valve plate is over although sliding surfaces are in normal condition, replace the cylinder and the valve plate at the same time. The correction standards are as follows Parts Item Standards for Correction Cylinder Surface roughness requiring 32a ete falve plate correction (approx. VV finish) Recommended replacement Hs 84 Valve hardness plate Working limit (rep|acement) His 82 and under Standard hardness Hs 90 and over Note 1) 3.2-a indicates a state of roughened sliding surface which makes you feel a considerable scratching when you apply your nail to the sliding surface, @ Bearing Check for flaws and peeling off on the surface of the bear ing, Caution : When replacing the roller bearing, the tapered roller bearing and the needle ~44-roller bearing, consult with us for essential information. (4) Procedures for Assembly : The assembly of the pump wi! | be performed in reverse order to that of disassenbly. However special attention should be paid on the followings : @® Genera! Cautions a Repair the parts if damaged at disassembly work. Prepare the packings before assembly. Wash each part thoroughly with the washing oi! and dry it by blowing with compressed air. Use of waste cloth shall be avoided. If waste cloth is used, take care that fiber scraps wil! never remain on the cleaned parts, Apply clean working oi! on the moving parts before assembly. Tighten the bolts in symmetrical order little by little by referring the table. Tightening Torque Material} Item | Unit Bolt size N4_| MS | M6 | we | Mio | wiz | mie | wiB | M20 SCN435 | Torque kgf-om | 35 70120 300 $80] 1, 000| 2, 4003, 400] 4, 400) Nem | 3.4 6.9 11.8 29.4 56.9] 98.1] 295.4) 333. 4 a3t. 5 @ Cautionary Instructions in Assembly : When installing the oi! seal (103) to the front cover (251), carry out the hamering-in after ssce yeana - (White) applying the liquid packing to the periphery of the oi! seal Fill the grease into the oi! seal lip space and carefully instal! the front cover to the bearing casing (201). When inserting the O-ring (260)and back-up ring (261 and 263) into the pipe flange (254), care should be taken in the direction of them, ©. When inserting the thrust pad PIPE FLANGE (210) and the shim (211), care should be taken not to be wrongly inserted. Hund As the thrust pad and the shim may ‘THRUST PAD be fallen, prevent falling by applying the grease etc, 4. When installing the valve plate (171) to the valve cover (253), apply the grease etc. for preventing falling of the valve plate. @ When installing the copper packing to the port of the valve cover (253) replace it for new one. ‘As the packing may be fallen at assenbly, prevent falling from the port by applying the grease etc. f. After the assembly is over, rotate the driving shaft (101) by hand and ensure there is no abnormal ity. Then, instal! the pump inside of the oi! tank and put it to the original condition 6.7 Dismantling Procedures for Pintle Bearing Inspection : When inspecting the pintle, the rudder plate must be jacked up 400 to 500 mn, However, it cannot be done as it is because the arms of fork-typed tiller have inserted the ram at upper and lower parts. Therefore, dismantle the steering gear in the fol lowing procedures by referring to Fig. 24a, Remove all connecting levers above the tiller. Remove the stop ring for ram pin with a pliers and take off the upper and lower roller bearings. Caution The lower roller bearing will drop if the stop ring is removed, so safety is especial ly given to the work. ©. Loosen the bolt and remove the guide bracket. d. Loosen the ram pin set screw by around 20 mn, @, Jack up the ram pin from the lower part and pull out it completely upwards. ¥. Carefully and slowly turn the tiller and rudder plate (rudder stock) by means of @ winch at the dock up to the 90° position as shown in Fig. 24. Caution For the rudder plate not allowing the 90° turn due to the hull construction, remove the key, jack up only the tiller and turn it up to the 90° position. 8. Jack up the rudder plate (rudder stock) and the tiller in such condition, and inspect the pintle portion. h. After the inspection, assemble the steering gear in reverse order to that of disassembly. At the moment, screw the set screw for ram pin without fail are7. Trouble Shooting Guide Kawasaki Type Electro-Hydraulic Steering Gear is surely of sufficient strength and durability. In the event of trouble, it is necessary to Jet us know exactly what has been observed and what measures have already been taken. 7.1 General Notes : (1) The Steer ing Gear System is considered to be classified into the auto-pilot system (including the repeat back unit and gyro compass) that outputs the rudder order angle in the wheel-house (bridge), the continuous contro! system such as the sontro! box, the pump control unit etc, that controls the pump tilting angle in ‘the steer ing gear room with the above order received, and the steering gear, such as the ram, the cylinders, the tiller etc. ‘Any poor rudder response from the whee!-house (bridge) should be always dealt with by separating the auto-pilot system and the continuous contro! system from the steering gear for earlier discovery of the cause. (2) When an alarm is given for failure in any power unit, stop the power unit concerned (and then start another power unit). Then, investigate the defective part. (3) When investigating the cause of the trouble, operate the steering gear by the Pump control knob in the steering gear room (i.e. local steering). If the trouble continues, the cause wil! be in the steering gear and the detailed check of the steering gear should be carried out. If the steering gear operates in order, the cause wil! be in the auto-pi lot system or the continuous contro! system. Then proper remedies should be taken by referring to the Instruction Manuals of their systems. (4) When carrying out investigation and remedy, take care to prevent the entry of dirt and dust, and handle the parts not to damage them. (5) Take smooth procedures in the transportation and disassembly of heavy weights, and pay attention to safety. (6) If the cause is not cleared ask our company. -48-

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