FINISHED PLAN FOR SHIPBUILDER : SHIP NO, 2830 RULE NK DRAWINGS ELECTRO-HYDRAULIC STEERING GEAR TYPE : FE22-126 MESSRS. SHIN KURUSHIMA DOCKYARD CO., LTD. BUM Ook Me Mes aa YAY EDS, IPANEMAg,-09-/9 ra. List NO, = 2F- A ‘SHIN KURUSHIMA DOCKYARD CO,, LTD. 3167 06 24, 1993 st fz fr JOATE Nov. KE s BOB ease ee AZ KAWASAKI HEAVY INDUSTRIES, LTD. ee PRECISION MACHINERY DIVISION SENIOR MANAGER. MANAGER ASSISTANT MANAGER 22 2 bevmeecet CHECKED__Z. Pnatsuin oe DRAWN. Z Paaccrdes” FILING NO- sum [7 DRAWING NO. WRG Ae ORE FD 009029644 (SHEETS INCL. COVER)i 11 12 1-3 1-4 1-5 1-6 1-7 1-8 Fig.1 Schematic diagram of control systen - 2 3. CONTENTS Specifications Particulars Rules:and regulations = ~~~ Yaterials for main parts Spare parts and tools Test and inspection Painting Drawings and documents Scope of supply Hydraulic circuit diagram Arrangement Installation Piping arrangenent Tiller Be SER HEE SE Detail of tiller inner dia, Key and keyway Installation for repeat back unit Installation for rudder angle transmitter Level switch Electric motor for servo pump ~~ Limit switch for rudder angle limiter - List of spare parts and tools Shop test records1, Specifications 1-1, Particulars Steering gear type: FE22-126 Construction 2-rams, 4-cylinders : Rapson-Slide type Power units 2 identical type (Parallel use ) Control system Refer to-Big.1). |_Blectrical -pump.control,systen (2 systems) Steering method 1) Renote control from the bridge by is : pilot system 2) Local control by pump contro! knob Steering gear torque at max. working 1236 KN«m { 126 t+) pressure at 35 deg. Rudder turning angle - Starboard = s i Port 2 35 deg Limit rudder angle Starboard : 37 deg Port 387 deg Rudder turning speed by two power units| 65 deg /28 s Nornal radius of tiller ara 580 mo Ram dianeter 212 um Max. working pressure 23.5 MPa { 240 kef/cu*} Safety valve set pressure 29.4 MPa { 800 kef/ca*) @esign pressure) Hydraulic pump (aain pump) Type LY-060-410R10 Gent axis type ta piston punp) Max. tilting angle (stroke) 18.9 deg (18.7 Max. outlet flow 60.32 /nin Main | Electric motor (Customer's supply) pump | Output 18.5 Source ACAAOV-6OH2-3. Synchronous speed 1800 win ~! Rating 25% : cont. 100% : 1h 2009 : 30s Overload at safety valve set | 1909 Pressure Starting torque Min, 200 %Hydraulic pump Type ‘TOP-203HAE (Trochoid pump) Servo + pump | Blectric motor ~ Output 0.4 KW Source AC440V-60H2-3. Synchronous speed 1800 nin ~' a Rating 10096 = cont. Torque motor i - Rated .torque- (current) 4.0 Ket + cm: (DC 416A) Pump Max. torque (current) 8.0 on em (DC 3, 2A) Rotative angle £80 de cont. | Cable connect ion Cor mnector with plug unit | LVDT (Linear variable differential transformer) 4 Cable connection Connector with plug Unloading device Source Rush current Holding current Cable connection ‘ACL00(110)V-60H2~ 16 4.8 (5, 28)A 0.44 (0.5)A Terminals with cable gland (JIS F 8801-A15b ) Level switch for low level alarm Switching direction Switch rating Cable connection Low OFF ACL25V, 250V, 480V-15A DC30V-0. SA Terminals with cable gland (JIS P 8801-A15b ) Working fluid to recommend Description Hydraulic fluid or Anti-wear type hydraulic fluid Grade 180 VG 68 or VG 56 Oil viscosity 50~75 mn*/s { cSt} at 40 °C Required oi! quantity of steering gear | 4302 ~ Required oil quantity of storage tank | 2152 Name plate Language English Operating instruction plate . - Language Bngl ish & Japanese1-2, Rules and regulations DK 2) JIS (Japanese Industria! Standard) 1-8. Materials for main parts ‘Name Material | smbot | -Tiller -n-f-=Carbon_steel casting ~-8C49 Key Carbon stee! forging SF590A | Rotter Carbon steel $556 | w pin Nickel chromium steel ‘SNCB15. Ram Carbon steel $55¢ cy! Nodular graphite casting ASTM A536 High press. pipe Carbon steel (Seamless) STS42 1-4, Spare parts and tools (Refer to the List of spare parts and tools) 1) Spare parts ‘Name Percentage of spare E to working quantity Y-packing for cylinder Spring for safety valve O-ring & oil seal 2) Tools Rubber ring for flexible coupling Solenoid for unloading device Filter for unloading device Besse RRRKX, Name Pliers for stop ring Spare parts bo: Quantity 1 set 1 set1-5. Test and inspection 1) The test of the hydraulic pumps shall be performed in accordance with KHI's standard based on the rule of JIS P 6721. 2) The shop test of the steering gear shall be performed in accordance with the tule of JIS F 6720 “Shop Test Method for Ship’s Hydraulic Steering Gears” in the presence of the surveyor of the Classification Society and/or the inspector of the shipomer and the shipbuilder, = 3) The test and inspection of the steering, gear components shall be performed in accordance with the Classification Society requirements. a 4) If abnormal condition is not noticed at 1) and/or 2), the overhaul of pump and/or steering gear shall be onitted. 1-6. Painting 2) Finish Colour : Munsell 758G7/2 2) Method : Under coating : Zinc chromate anticorrosive - paint: 2-coats(40 um x 2) Finish coating: Alkyd resin ename] “2 coats (354m x 2) 1-1, Drawings and documents 1) Language : English 2) Number of copies Bee Drawing and document for Approval | for Installation-| for Finished plan Specifications Hydraulic circuit diagram Arrangement Instal la! Piping arrangenert mt Tiller 8 8 4 Detail of tiller inner dia. ey List of spare parts & tools Shop test records Instruction manual“1-8. Scope of supply (per one ship) t Our Item Name Quantity | supply 1 | Steering gear 1 set Q 1) Tiller & key (set) | O (Refer to the drawing in detail) 2) Ram ram pin & rollers - (2 sets)| O 3) Cylinder G sets)| O 4) Oil tank with accessory (2 sets)| O 5) Level switch for low level alarm @ sets)| O 6 ) Main pump (2 sets)}| O T+) Pump contro! unit (2 sets)| O 8 ) Valve unit 2 sets)}| O 9) Servo pump unit 2 sets)| O Cincluding electric motor) 10 ) Plexible coupling and seat for @ sets)| O main electric motor 11 ) Pressure gauge © sets)| O 12) Air vent valve @ sets)| O 13 ) Piping and pipe bands (set) | OQ 4) a switch for rudder angle @ sets)| O initer 15) wulier angle indicator plate (set) | O 2 | Control box 2 sets 3 | Linkage between repeat-back unit and 2 sets fe) tiller and pole - 4 | Pole for rudder angle transnitter 1 set ° 5 | Operating instruction plate 2 pes QO 6 | Spare parts and tools 1 set 3 21 | Electric motor for nain puap 2 sets 22 | Control unit (Starter) of electric motors| 2 sets for main pump and servo pump 23 | Pilot system 1 set 24 | Rudder angle transmitter and indicators | 1 set 25 | Linkage between rudder angle transmitter | 1 set ° and tiller 26 | Storage tank and pipings 1 set 27 | Pilling pump for storage tank 1 set 28 | Grease pump for rudder carrier 1 set 29 | Stoppers and cotters for cylinders 1 set 30 | Foundation bolts, nuts and liners for 1 set cylinders 31 | Working fluid and lubricant 1 set 32 | Installation work 1 set 33 | Pipe supporting 1 set 34 | Test operation on board and sea trial 1 set - 35 | Wiring 1 set Shipbuilder’s supply 00 00 00000 C0000 NOTE : Other components excepting mentioned above should be supplied by Shipbuilder.‘ ‘ < . ‘ : ‘ . i iy [FOR REFERENCE] one me oma fe marea ait sh . 3 fos | [ro an, . {hecseasenewew SUPPLIED BY KHI Prov cc = fet sme [zea Heer | = t bear] [=anactaa Eie.t feet | ~sentuarie siacnan or raenne “FEE ate ror RE TPE STEERING coAR HELE : | ror vorocawa _['y""aessosis FEFss ‘TORQUE MOTOR BY SHIPBUILDER TYPE: ER2-C2ODK560 SURGE ABSORBER ( SUPPLIED BY KHI) MAKER: NATIONAL, 2SETS/SHIP maavERiac oe Semon taaNAGEA mA]s00 NO, Hw Se STANDARD - «| ASané lwrrRiInGe DIAGRAM [eal taco cise enact OF PUMP CONTROL a PROJECTION, Og Seat UN 1 1 (FOR LV030/060/090) oarenae Ra Corr owo.no ame [Gane 25,1991 os. 4| FOR YOKOGAWA | 50951355 > SURRCAG) HYD, MACHINERY DIV. KAWASAKI HEAVY IND. LTD. a i 7-2MIL SWITCHES FoR eiuse os |=Se ORD oe Fae RUDDER ANGLE NO. 1 No.2 DRAWN CYL BhIMITER <_BCVL. t prcccccccme = 7+ SOMETT Sm] tose s Ae No.4 i No.3 CYL. cYL. / ae Gere ee ereeeee eer — "N” POSITION nepositign iL NORMAL! "E” POSITION CEMERGENCY) i@ 1 “E” POSITION, EMERGENCY) UNLOADING DEVICE 1 4 $ 1 \ | 1 1 I I | I | ' STORAGE TANK : ai . INLOADING DEVICE 1 i faa oa a au e@4 NO.2 NO.1 OL IK a FLT NOt OlL TANK te wae NO.2 MAIN PUMP _/ ® Ezz] i + ARROWS INDICATE DIRECTION OF STARBOARD. |r +_D-@ SHOWS THE NORMALLY CLOSED VALVE. [axa] OPERATING INSTRUCTIONS | = POSITION OF ISOLATING VALVE areRac a enon wanacen malice No. wnee poems faa CONDITION WORK, PUMP]WORK, CYL, fa ee we : NORMAL : ween aR ManasenRR Fg 5 zl a AGH Bee 7 ve AM Lance] FE 22> ¥KR TYPE Es ONE PUMP USE Ho. ALL N N Scace RE Pp an MANAGER DRA re 5 jo. N N eZ EMERGENCY No.t Note2_| E W TRO ANGLE Gam [onecxeoima HYDRAULIC CIRCUIT DIAGRAM _ (ONE PUMP USE) | No.2 No.384 | N E PROJECTION) 1 Mienhar. ELECTRO-HYDRAUUC STEERING GEAR oaTenae ‘ORAWN wa PART NO REET ows no @mee = 4 NOV. 26, 1986, Y 40950568 Ht 43 MH (A 3) HYD. MACHINERY DIV. KAWASAKI HEAVY IND. LTD. basset7 ™ oo 7 —— 7 T + T Poe 7 : FORWARD he 7 pip veNT va t VATERILS FOR MAN PARTS fra] Nae MATERIAL : = QTULER [CARBON STEEL casTiNG — [Scesncrsceg) O|REY [CARBON STEEL FORGING | SFSGOA = ROLLER _[CAREGN STEEL = |sssc gee e @|RAM PIN [NICKEL GHROMUUM STEEL [SNCAIS| © [RAM [CAREON STEEL [S55¢ “fa: w © pee a er ee ASS \ @ [CARBON STEEL (SEAMLESS) |stsaonsTs42)] Strout : 7 _| (a) — - : aunt == = q a -MOTES_ ee ft LARROWS SHOW CIREGTION OF MOTION TO PUT FLDOER TO STARBOARD, Ss o = BUT ROTATIONAL DIRECTION OF MOTOR IS CONSTANT IN ANY CASE. ze ae 2.SHADED PIPES INDICATE PRESSURE LINES WHEN RUDDER S BEINS [89,2 on | MOVED TO STARBOARD, ERAN Puna @) a : | a Pi STE < le : eCSN UES & 5 ANELIES, Is Uf ] im TEs * FOSHAN AME Pace STEFRNG GEAR FLAT VL \ \ Stef “TPE “DIMENSIONS (mim foi QUANTITY (FY | HASS ATeTeio elf e Hej [Hsia WORTE Oe ast w . 5% cm CDa Feira testacq oss Seo eie iors roisiel feet hisitio: 7180{580] 316 230) z < r 22-207 (2615 7] ne7io8st_ 1906851 316. 240 {13000 22 24: 1115] 265 12001 S29] 1133] "90 | ~295_| 18800 = 22 205 1840] 12001 28013601 980/260] 621 free 10 [ 760] 334 620_|—310_| "18000 == Se roa Ir 22— f63011510] 300/1S6S!1060 300] f1240 80. 390 | 23000, = 4 STANDARD __ oo 22-4 331 S655) 345) Ea Seah2S0) 230/850 386) 20-_| 410} 25500. seal wee a ojacd as/iessi60 338] —}713] haoai37s} Be0is05 1414 11.20~]Ses—t san | == ARRANGEMENT {lame eee W TOTAL Mase’ (EXCLUDING HOTGRS ) : pees [y20ss0081 Foo TOR DAGIRERY GN AREA PEAVY POLLO7 T z 7 T = 7 7 ee FORWARD 7 TF anow THCness oF SEAT KAN 9B AAT OETA GF LENE FOR CTUNOER, STOPPERS «COTTER Wen Dass UaRe BEY Abarth Hh a al Pe El ext sors {LSTEERNG GEAR SELLD BE STALLED M ACCORDANCE. WETH THE BSTALCTONS ‘HOWE M THE CRANNGS OF ARUAGEVENT AND THES OISTALLATON. 2-THCMESS OF ALL UNERS SHOAD BE MADE THICKER THAN TAT OF TS DRAWNG MO OECOED BY FITTING TOGETHER. SSMARE EACH SEAT RD AGAINST SHOCK. “APERFORM INSTALLATION CAREFULLY GECAISE THE DMENSON Bt [—) 15 IMPORTANT FOR REEPING CORRECT MELM ANGLE. STHE OMENSION (7 SHOWS THE THOWESS OF FOOT. - ‘GALL SEATS, LINERS, COTTERS. STOPPERS, BOLTS. AND MUTS ARE PROVED BY SHPBLALOER me \eotkE nthiar$ 2 ORES CARINE, oF EOE OE 2aRBoB sae ATAIIA LIE LAG Oe aE LOSE SBSH AMR G THOR ATL IED HE GRR TICE ema FE EMTEE) MERE LTE BF mo SRT OPK EE DCE T CADE TC TEDME HT ELSA TS RET Dame oF pant paral ‘ LneR For crunoee | ssaoofnd CD JuNER FoR CHNGER | ssac0fer2 i \\ lar erarer af \ Gee ete si (6) |HEXAGON HEAD BOLT | S30C | 32 : actenneneeta @) HEXAGON NUT Sac | 32 z t nm He ty TizTts Tis tts] te] tr | te Tis To! MINTPTQ(R]R (6) HEXAGON NUT sesciy 2 z ras tiea Leectee TESS, 122. : i 960] 1601401 s00/s28[1 1011 1s 70 [5801 788) 7 a hovs} pectesresteet pref retaert 35 : Te [Th [1 eels [ei [ee ue eee el [ett pole eieyeyelt [= [ei SRT - 055. Saat se- + As paso 2a = SAREE - = aah = ew [= " 102,126] 35 38 [reofi9a1 | 36 | 707 75, 425] 53 | 22 1130/45, 16 115 | 39 [M36/M201"75 [125]63.5] SS 2123 598 (61) a : eet FEge-tkK TPE ezz207 Ta ae aglae ies f Tots per iesieet erpaespes tse penta (4 INSTALLATION : Ee “Fi:RAM THRUST ——_ CAT 29.4¢PS [300kgt/En#l) [ELECTRO -HYORAULIC STEERING GEAR FeiRAM SIDE THRUST (AT. 23.44 (300%) a Tysbssoe79 : SoD WAERRERT DW RUST HEA #6 70ES PIBNG LIST FISBBNG SHOULD BE CARRIED QUT IN ACCORDANCE ST 2 AU PRES Ake GALIVERED IN PRE-SET STYLE. REE} Name LOCATION BIT 9 Noves RADIUS OF PIPE BEND IS AS FOLLOWS. ° ca ; Sm ey Fn Ne iA OF PR aaa P= [man PPE Nowe UNeiCHI 2721 47 Bho] sd | 42,7 130m q P= 2 [MAIN PIPE Do Wi 34-000 105mm = 3 MAIN PIPE NET VALVE U=RBZOT| y = 85mm CAN Bee, By TERS ASE NOT TO BETES B-S [MAIN PIPE: HORVALVE U “R030 VI" stsaio| a. kYDROSTATIC_TESTS FOR MANN PIPES ARE CARRIED IP-6 [MAIN PIPE, < “Noa Hi QUTATTER BENDING OF PIPES ANO WELDING OF FLANGES [P= 7 |MAIN PIPE [No.1 VALVE U-NO2VALYE Li | | Cepia ys ry 4.RYOROSTATIG TEST PRESSURE 1S_AS FOLLOWS. p= EoreONCaTION PPENOITANR-NoD TANK fa2.7) 5.5.1a27)3.5 IO[AIR VENT PIPE NoICYL. -No.1 TANK [10.5] 2.0 fio. 41 BO" BANDS SHOULD BE DELIVERED BY KHi = TH[AIRVENT PIPE No2OYL. ~No2 TANK i ‘IPE SUPPORTS SHOULD. BE DELIVERED BY SHPEULOR, o| PHaamvent pipe ; t [P=I3|AIR VENT PIPE NoACYL, -No2TANK. ae G.ALL PIPES ARE DELIVERED WITH BLIND PLUGS BY Kil [Pc1aiSERVO PIPE a senvo euse-suree 117.515.2043] 312 p-15|SeAvO PIPE |na2semvo puye-FiteR i thea Racrytere: J-16[SERVO PIPE. [rureA = no. valve UNIT il stesso AMT Es Te TKR CEL: P=t7|5eRVO PIPE eines \ Gitar Sis Heese Pa[SERVO PIPE. ie Ay Bos eT er ee [P=IS[SERVO PIPE “LTER= No 2 REGU Al i t 42.710 130mm, 7 34.0mm | 205mm 7.2mm J 85mm. 7 TenGoe TY iba EAE 0 SETS) 3. PeAKT nag gg ete wT 79T SRA 4. Bran I Fee RLF Fratehtanagarvidee x15 le " S.yaguceP le RMI Omer ys, SOPUED Br KAY aaah Sara TAT. a, eSancne 6. te Pam AHF THe LEAT INSTALLEO AT REAR PONT INDICATED IN fans ORANING, 2,REQUIRED NUMBERS OF PIPE BANDS. PIPE OUT. DIA. T Na. Perey, e272 12. (reze-aorl 9340 [12 USE THE ANGLE BAR(LSOx50x6 OR ABOVE) FOR PIPE SUPPORT, AND INSTALL IT ON THE STEERING GEAR SEAT AS MUCH AS POSSIBLE. PIPE SUPPORT SHOULD BE ARRANGED AS SHOWN IN FOLLOWING FIGURE. Mearns FEA ene H oUt Beer East [ins TOMB 927.2 imeanl 9340-112 Bega ba 7770 (LSOXSOX6 he) SAM Va He TK) BraRS teeter TTI! 4a aot g cere T te TE nee Te eee [Az [Aa K | [Ws [H7 [Halas] R 7 Serum [FEa2-O83 USaTToaGt S26 119 17 sz est 7 Pie RAND STEERING GEAR SEAT 4 Qe Tiof160]3: Cs : |FE 22-102, 12epas0)i6ssfi255) 4111110] 170]}083[e16] 110, 110] 580) : . 4 eee IT Of 17¢ 7 z ss tan fa Eze= 20/7 fr29b420) L ’ ae ce = rr FE22-% % % TYPE he PING. ARRANGEMENT acronis sTesIng en eer Wyeossoese EH4-n- “59. (FOR RYE BT) AL RR baat RE tab ILL BAT. __ Zamna enero Lee ae Ba RonRNEsODTC Ee eP ALG S--BoMIN HD Hee. © a pane rk se eet, ASSITIFATION SOCET.. — BAHATERVA, TEST AND. NSPECTION FOR TULER ASS JOBE COMRUCTED INTHE >REEEHCE OF THE SURVEYOR, Brecrmacine De BFE. A TULLERLUs Jo B¢_suBsecteo “HONDESTBUCTIWE TESTING. a — F-126 ~ K12 TELLER Ce t mactan|‘= FORWARD REMARKS, 1. TILLER WITH CONICAL BoRe WOULD BE DELIVERED LEAVING THE HAGHINING ALLOWANCE 14 MAY OF THE RuDDER Stock. 2, MACEINING AND SPOTTING OF TILLER SORE, TEYWAY AND KEY ARE OP SiI1PBUILOeR’S RESPONSIBILITY. ae 1 MERGERS —ALL, MIREMLTMATS. BATS. - 2eenes, 4—aac+-omreammR Revs, i ! zal 1 “Rule Gog tsh8 feat aa "a3 72H04 5/6/7 Es - —fe-[i2s] twee ff co AHEM a RRR oa poet FINAL CONDITION ar SHIPBUILDER [=~ OST ___| DETAIL OF TILLER INNER DIA, Hl JJUNE 12, 1990 -re |S 30951268 cFRE Wa) HYD. MACHINERY DIV. KAWASAKI HEAVY IND, LTO.2, SR oOREREOUTMAT ECE, 8. BDLURT48vbe4—-COUTRAT SCE, 1, QUANTITY OF KEY ¢ 1 ‘2, REY 1S 10 DELIVERED LEAVING fon FINISHING ALICE, ‘3, MEE 1S 70 DELIVERED WITH EVE BOLT FOR LIFTING. aa) ree oF | svox bia, erat fre eat wer oe fame OER. axa | vr] y |teles| cle-eves| siz |» |e» [ut minto = 30] x ee x6) 35 AE oe =. TA FAG = 418 105 x10 sa tmo-2uas fesmo lie [es | 90 1 ss sss ~ aig [121 » 75 [100 0 ~ o64 [117 x_Te]13 | 48 | x 100 [eo yas ss = st figs [58 L321 Jas [me reo | 7017.8 [105 = 48 [rio x74 f106 [a4 |2s |. 5-0 [105 [7.5] = 5 129 1s at [0-225 [ex-mo fr2a | @2 [10 = @ Jolt [a [no-ns [emo [46 [7% fio [175] 5] = xg sat | 2 tsa] 7 fas mio aes fea mio far | ee [ia 79 | 75 sa fag ahh a = 50 [165 Tio tea [eo [37] 8 [53] mo-217 [eso |62 [10s [160 a5]i0 =Sr ~ a] 1G iM emo ies fiz fo | | 8 = Sea i960] iz-zs7ea [ean [152 [18 | = X10 [206 | 8 1110 Tae" = 6 [2c x 1e2| 207 | ww 130] 11 i = To [72s x 154222 jeenig | 22 [150 [isso = rns [nig-29735 [eens [232 [1s [0s 1105 | 27S [i818 ]24¢ [10k Ten 13 [79 [nie 294 Het 1215 To | as 1, #4801 STANDARD Key & KEYWAY (GI B-HEBAD) 40950618 __| HYD. MACHINERY DIV. KAWASAKI HEAVY IND. LTD. ~~ ###8co.FE21.22-053~207) 2 RAR eee F£21,22-053,064) |Fe2n22=-ore-oser sro | ATS Fr2uz2~ 02,126 | s80 | s10 15 [oss 370 | 40 | 115 [1144 | e320] 1140 | 100_| 144 aco} 1220 | 115, 11224 | e3so|. 1220 2a 2s 255, reanz3= wa.sre| 640 | s40_| 20 | 316 | 576 zee Fee1z2-207__| 688 reco | veo | 15 _| 1284, 1280 | 10 _| 1204 Frevze— 24s | 718 | eos | 3028 5 reenz2-268 | 760 | 655 _| 32 75 | 3135, 400 | rsap-t-15~ [1344 | raso} 1340 | 100_| i304 y10_| 115_|1414 | paso} 410 | 100} 4 Fe2122-360__| ors | 695 Seas | 653.5 aso | 1520 | T4523 | rs00|_1520 | 100 _| 1523 anso | seo | 115 [1563 60 | 100 _| 1563, FE2%22~ 400, Tes | 3628 | 4ogs| sees a eZ 485 905 _| 775 __| 367.5 | 433.5 | 6935} R500} 1610 | 115 [1613 f Reso} 1610 | 100 [1613 TI AND aA bee * vie zo a (2 TRANSMITTER, a ; FoR vorosawa wavirec [Sal ct 7 STANDARD "ceria | * Pt Sem!) retype fat Wes pe ee q hth ,! Teaaee lesa 2 SALTO OF <2" TRANSMITTER nee, PRET! 9: Maweda| AND TRANSMITTER DETAIL_OF “8” CB'SBBESG) [San'05,1989 |" fo YN 30950724 _[# KANASAKI HYDRALLIC COLT. 38 ECIA2) 15a DOTTED LINE:ZONE OF DRAKE CONTACT (0) X:DIFPERDETIAL OF THE O¥~OFFUBOUTSO) 28 = FLANGE 5*- 654 fe ISA 125¥, 250V, 4000 a oC OSA 300 | 2 1 a 1 20] 1 bt) bt 1 | RUpBER 18] a/R nen [4e 2 " a|[SeEe" | exeoor 16 SOS TRG a[seteyt _ [eveeee asda a7 A nnass 14 EREAYER 1 ETE [nce 13 ATE RSS sfieor [sx ow 12] HY CRO SwizcH 1peearak® [ana 1a [ SE BEATE [afsren [are 10 bea ge sre | sre 9 [ARIRE 2 | SEAL, BEATE psa oer [sraiwcess [sus 900 i 1 pane 1 sep iran [ror ae 6 [S98 aise [own sear 1 [etainesa [ror 200 no 1[evaimane [so ie +] fear 1[reaens [aor oe + BEF ROUDER ———T [ovarmene [aor ae ne ee te ef ierrece wane — op me [oem3R0_ANGLE METHOD] INOUCTION: MOTOR - FOR SERVO PUMP. ROTATION. : _— ‘SHAFT EXTENSIOM DIMENSIONS IN amFOR REFERENCE (00800666. ‘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 shipbuilder. 1.General diagran a Starter and alarm panels shall be connected as follows. Steering Gear Room (SCR) Engine Control Room ( ECR) theelhouse ( W/H ) No.1 Control Box Mig Lfor Auto-Pilot Systes 60k Wo. : a : No.1 Alara Panel ic 93 uo y | Starter Oz No.2 ‘Mara Panel No.2 Control Box for Auto-Pilot System Note : 1.Blectric wotor 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 eleatric motor shall be given to the control box for auto-pilot systen.FOR REFERENCE 2. Indication and alaras a Following lamps shall be additionally provided in starter and alare panels for main pump units. t q ————— - Over toad: tamp No-vol tage lamp : Note + l.Lamps to be provided according to the specification of those for sain electric motor. 2.0ther elesents to be used for main electric motor. 3. Basic circuit diagram of electric sotors control SOURCE, 19°DIMENSIONS (mm ) ARRANGEMENT OF LIMIT SWITCH 11,1966 |" "ya0ss134¢4 cow RA aD YO. MACHINERY O1V. KAWASAKI HEAVY IND. LTO. coorLIST OF SPARE PARTS & TOOLS ELECTRO-HYDRAULIC STEERING GEAR FE22 ~.126 TYPE sno.2826/2827/ 2828/2630 [ cory [JOB NO. 4272H04/5/6/7 EIU ecaaven KAWASAKI NOTE HEAVY INDUSTRIES, LTD. 2 AL eer eR Re suaeeT “90-08-20 PRECISION MACHINERY DIVISION 2. pense, ogi oot ‘SRHUT AG EEO - oy CIS SHEETS INL. COVER)‘SPARE PARTS OF STEERING GEAR “—FEai=102, 726 eee FE22-102,125 TYPE” (“FOR ONE VESSEL ) \V-PACKING, FOR HYDRAULIC CYLINDER RUBBER RING 10 | PF 29 | FLEXIBLE SHAFT ‘COUPLING KAWASAKI HEAVY INDUSTRIES LTD. NISHKOEE WORKS, -hazre WAZETANLCHO. DuG.No.c0900856B _. Fw aE ae semu—A RERPOARER 22°DwG.NO.009008568 PAGE I a SPARE BaP NO, PARE oe BOKNO.- FE22-102,126,140,172__TYPE_(_FOR ONE VESSEL ) yRanes f DRAWING No. NAME skeren (MATERIAL Ram | RAMS a a 8% % No. a 4 ease |# 20] oem f- | 8 x ow 120 }o = RING -1 | FoR 28.4 x 3.2 " 25004C) 1236 ponneaa CYLINDER PLUG 20 Jo - Rina -2 |For 9.8 x 1.9 . * Sree) srepeeot ‘AIR VENT VALVE~ 0.0002 20 Jo = RING -3 | FOR 29.4% 3.1 ” Same Peetent OIL TANK PLUG 9.001 20 Por RING 7 » — |aesd 22882402 24x 3.2 4 Vor tank min ooRBG30 0-001 © = RING 821] 20 |For 24.99.x 3.53 . 1829 AS568 5 | PIPE FLANGE No.214 0.001 20 Jo ~ RING 32.92 x 3.53 « sed ASS6B -S |For NO.219 PIPE FLANGE 0.0015 20 | Pon JISB2401 FOR . na! -7 | PRESS. GAUGE 19-8 x, [4013] ooRBP2O IVALVE - pon : 31882401 20 {FoR * . . J-s |vauve unrt piu | 25-8 x 2-4 °9°7! oonsris * #7 (0.0003 MFRS RAKE WAWASAK! HEAVY INDUSTRIES LTO. NISHIKOBS WORKS. — © AbonEss NARI RASA DHPC SD HAZETANLGHO WISHI-KU KOBE JAPAN Rigs. Fw GP RESNOkI368 H ‘akeeil—a RRRTRORR eee ; 23DUG.NO. 09008: SPARE ‘i 7 jun ‘SP NO. —SPARE PARTS OF OIL BLOCK VALVE 0 ~ oe BOK NO. 0B15-V1.0/231-310 TYPE _( FOR ONE VESSEL ) eaanss SURELY a xo. Nae seeTcH marouan | PRS | E's | means 2a 2 8 s A PTR wane | no. [RET] 20] YNTHET srs ated i, RUBBER '5004C| B2401 | 0a x ow ANDRA] |... | 30} 20.8 x 2.4 " 1 -1| 0 -"RING i * ata " — l162 | OORBP2: [0.0008 30 -2] 9 - rine 24.4 x 3.2 ” 4 | 4 |] © [162 Joorsc2s [0.0008 30 ~3] 0 - RING 244x392 _* 6 | 6 | © 163 joorscas ~ 0.0009, ft. nk : - 30 . . 4] 0 - RING 11.8 x 2.4 ~f4]4 164 |oorsP12 (0.0002 i 30 « -s| 0 - RING | 18.8% 2.4 0 - ale S61 | ooRBP16 0.0003 | - = 7 : 30 0 - RING ” ae 9.8x 1.9 aja I3-s [CORBP1O (0.0002 30] 0 - RING ‘fon «| £600) 20.8 x 2.4 a|¢ j-e |OORBP21 (0.0008, - : 7 aa : © ~ RING “ = |(600) “8 25.7% 3.5 7 ala 7 JOORBP26 (0009 ~. |. 7 SPRI 55 <4 : 30) Sonne ¢ z 3 [prs | 4 | (600) 54 -s10K 8) sarery vALVE eee : feat 01 wl L.--| --- fb - | AERS NAME KAWASAKI HEAVY INDUSTRIES LTD. NISHIXOBE WORKS, © ADDRESS : NARI RAatet BHP TS : WAZETANECHO NISHI-KU KOSS JAPAN = RBKSRLORER SFw Beesmexzese - ee ekscniA RRR 245SPARE PARTS OF SOLENOID CONTROLLED VALVE . 4WE10D TvPE (FOR ONE VESSEL ) JISB2401, DORBP22 ‘SOLENOID lKewL71 |-oc/wi00 NERS NAME & ADDRESS maestomER (GAARA RETPROREE KAWASAKI HEAVY INDUSTRIES LTD. NISHIKOBE WORKS. NARIRAS ee DORIS WAZETANLCHO NISHISKU KOBE JAPAN BFY 6 Rueme e236 5 8 25 feeDIRECTIONAL CONTROL VALVE TYPE on SKETCH 15.8 x 2.4 NOK AGLLI9E0 KAWASAKI HEAVY INDUSTRIES LTD. NISHIKOSE WORKS, HARI RRL et DAP TS AZETANI-CHO NISHI-KU KOBE JAPAN ara Sowsmerk23¢5 2 (Ok CMA RELPRERTE 2631.2% 3.5 19.0013 15.8 x 2.4 BACK-UP RING BACK-UP RING KAWASAKI MEAVY INDUSTRIES LTD. NISHIKOBE WORKS. HARIRR tet HHP TS WAZETANLCHO NISHI-KU KOOS JAPAN QF Bees e e2345 6SPARE PARTS OF SERVO PUMP UNIT SPUOST TYPE ( FOR ONE VESSEL) skeTcM 17.8 x 2.4 28.7 x 3.5 J1sB2401 OORBP18 J1sB2401 OORBP29 J1SB2401 OORBP46, JISB2401 ooRBG2S 0003 | 19.8 x 2.4 003, 0008 JISB2401 OORBP14 JTsB2401 OORBF20 MARS NAME ‘A ADDRESS. eAeeLOREn 88 cont-a RRETHARIE, feaealeces KAWASAKI HEAVY INDUSTRIES LTD, NIGWKOBE WORKS. ig Rx mist aot TB WASETAN-CHO, NISH-KU, KOBE, JAPAN. SPRBRASNEsTIe 28DwG. NO. 009008563 SPARE PARTS OF SERVO PUMP UNIT TYPE ( FOR ONE VESSEL ) (AES MAME : ao > uantezuman sFRnmusNEHOES &K *O0UHA REET! 33TOOLS F21,22 - #¢* TYPE ‘Of MEWS NAME KAWASAKI HEAVY INDUSTRIES LTD, NISHIKOBE WORKS. & ADORESS M@RZIRRSSE BNET S HAZETANLCHO NISHI-KU KOBE JAPAN aissichen aFe SEaSTHe23468 o woe BLst ‘SHIP OWNER SHIPBUILDER :_ Shin Kurushima Dockyard Co.,Ltd. SHIP NO. 2830 NO.1b 2 POHER PUMP CYLINDER PRESSURE kef/cn® WACHINE NO. = sazno7 NO. 48305973 PUMP NO. t 5 15375, 1686926 JOB NO. : ‘TYPE 4272H07 WOTOR NO. or = 35° 35°S-30°P 36°P—30°S 35°S—0 EMERGENCY ( USED NO.1 20.6 |18*P—15°S 20.4 | 1SS—15°P EMERGENCY ( USED 15°P—15°S ae fe 20.7 | 18°S—15°P MMBTRARS BRAD KAWASAKI HEAVY INDUSTRIES,LTD. NISHI KOBE WORKSx-31- Ww : THD a WAY FEAR “OM fo oP "1 onal auaotp TEST RECORDS we 1 -oP-2 man: maton: pour Seni x0, 42306 372 ast STAND Xo ESF off. 150 vose nas ee ace Sh Gh le She SIE E ey Oe A és > fe te ties Rey SSC Se © SLE ST e L Ks ~ SE we Y teem J Chain / wid / wid 7 kane . e c * * tS tn notte — —| 5 = oF LZ Ea IL 2 7 Ld. | z 2 OPT. [728 E | z a aE oe | = z 2 Pm sa] —s FPS S| [STF | 2 (fe DO : Lae oz @| Tar i DE 22.8 | : lar 7] oe. 27.2 * -BIEY. 7 tS : ae |— * £2 5.6 | 2 za = = OF, WLUSSTECINT Tey waan @ KAWASAKI HEAVY INDUSTRIES LTD. mT 7 + NISHT-RORE WORKS PRECICINN WAcIINEDY nivicins PP GA"wae wires: x-s1- mana custowen * awe py pbo-wippmnp-T 2% WY TERRA 7 sven 7 TEST RECORDS 408. no. 42) 2aH0 7rd 8 Sent vo. pP30f3. 75° at zi Waa 8 winner ae Tere 7a a eric a SAGAS SL SA SZ Sn LEC SY BSCS OS oad CO SIS ee hash dt SOP g tae J Wht wrk 7 Ca ee Ye ca & = acaorarcent [=22-| |Z %alz Pop | 2799) | eS 2 [7780 | 2572 | luo. & | ZL 12274 |200 ob. | 27.7 | ae0 | SEE ZL a 227 [ase | Fs. iF. g fl ~ [2 0 $7. 7 ro j2ze9l F | BE eS | 22 | 0. 5 | 27-2 [765 PEF | oP. 3 27.5 Go lF 2 azo | 5 =| Zs [22PF |-2k0] SF laz- Z| P27 |27eFlz2 D| F2.2 | ga. 7 | z n a ERS h Lon KAWASAKI HEAYY INDUSTRIES Lr NISIIT KORR WORKS PPreicins!96-10 -8-611 ‘SHIP NO, NK _NO, 7985096 ie & 4108641 YT Serat No” mt, NOt SERVO PUNP Service yazess7 1 Ge NOV, 1996 NL ANDO aoa indo Rniice Lae & "oH: RAKM 5 O MeweET Loud Characteristics 1 Phase: (Actua Load Test) ‘3 Phase i (Circle Diagram Method) en ee nel. Resistance ose) mma tata: by SO0V Marre) Sm tae eae Tespection of Oster View Dade Steph Construction & Dimension: ace ss Good TEMP.RISE TEST (TEMP,RISE BY THERMOMETER METHOD-K) (AMB,TEMP, 14,9 °C) LOAD HoURS STATOR FRAME ROTOR SLIp BEARING 42 voLT (x) RUN (RMD (R,M) RING DRIVE ANTI-D, POLE 24 60 440 1000S 30.9 25 7 4 160% LOAD FOR 15SEC 125% SPEED FOR 2MIN 611 504603 02 ZOGSAz ~4051551INSPECTION REPORT OF INDUCTION MOTOR monte STOR OE Pee uw, 96940 =8-611 5 Cenoner_* Foto? ann, SHIP NO, wan, Va2ss? 1 Gatetn | NK NO. 79BSO9E Wort Ra me &, M4108617 Ve ua v, bs NOV, 1996 Serta to * ean dnte_* mot, NO.2 SERVO PUMP Bo a, NVANDO Sernee Beaedy ? wf Rk ® man Free a ao a oe ARR ® WW eneere Load Characteristics 1 Phone (Actual Land Test 3 Phase! (Cirely Diagram Method ao, Dye, wD. o, ™, SRY] as | se | 7s | soo | a2 | 28 | so | 1s | 100 | aa fea ,| 0-72 [0.78 | 0.86 [0.97 | 1.17 ere 32.8 73.9 | 76.6 | 7.5 67.8 | 70.5 [76.4 179 | F.48 [3.25 Baty Max Outre WAR? 31% BretoesTorgee enh Ines Resisanes rw) Det Sree Teapectn of Outer View Consrattion & Dinennen Gand ancieto TEMP.RISE TEST CTEMP,RISE BY THERMOMETER METHOD/K) (AMB,TEMP. 14,0 °C) LOAD HoURS STATOR FRAME ROTOR SLIP BEARING HZ VOLT (4) RUN CRM) CRAM) RING ORIVE ANTI-D, POLE 60 = 440 100s 8 $0.6 26 - - 8 = 4 160% LOAD FOR 15SEC : 6000 125% SPEED FOR 2MIN : GOOD . 405155100903167 Instruction Manual for Kawasaki Type Electro-Hydraulic Steering ‘Gear CRE&FE Series) SNo, 2530 KAWASAKI HEAVY INDUSTRIES, LTD. KOBE JAPANGeneral Contents 2. Detailed Description of Main Parts 3 4, 21 Steering Gear - 2a 212 21.3 214 Tiller Ram and Hydraulic Cylinder Oil Tank ~ Oil Block Valve 2.2 Hydraulic Pump 221 2.2.2 Construction and Name of Parts Principle of Operation 23 Continuous Controt System 23.1 232 Operation --- Construction Instructions for Installation Instructions for Adjustment 4.1 Preparation 41d 42 413 ad 415 Wiring Working Oi! and Filling - Application of Lubricating Oil and Grease - Centering of Hydraulic Pump and Electric Motor Inserting of Ram V-packing 4.2. Adjustment AQ 4.2.2 4.2.3 4.24 425 4.2.6 Electric Motor Starting Adjustment of Servo Pump Pressure Air Release in Hydraulic Regulator Adjustment of Punp Neutral Position Air Release in Hydraulic System Adjustment of Contro! Box -- 20 20 24 21 21 “22 22 22 23 24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 Test of Safety Valve ng Method <-s-ss-ssssstseeseseesceeessesenseessen sete edohtattes asta 5. St 5.1 Normal Steering ~ “28 5.2 Local Steering 28 6 Instructions for Maintenance sroreeesesssegreecntnartannnnnnasses cesserenes os 3D 6.1 General Notes o> sss se eeeoeuateacodt 30 8.2 Check Items --e--+ oonsossrsceesesceseeeeeeseeeeesesnnssncannennee ceentines sseen “32 6.3 Detail of Check Items ---- 6.3.1 Normal Checks 33 6.3.2 Before Voyage Checks 36 6.3.3 Periodical Checks (at dock of basin) <------ T 6.3.4 Check of Working Oi! is Pt PEE a Bt 6.4 Replacement of Ram V-Packings ~~~ BEEP EP r 41 6.5 Dismantling and Assembling of Line Filter -~-~- 42 6.6 Dismantling and Assembling of Hydraulic Pump 43 6.1 Dismantling Procedures for Pintle Bearing Inspection ------- 48 1. Trouble Shooting Guide ooee a 50 T.1 General Notes seer es soennrenees serene 50 7.2 Trouble Shooting of Steering Gear ss sere ee BT 1.3 Trouble Shooting of Valve. Pump and Electric Motor veo 5 5 & Overseas Service Net Work coe cress seeee cereeee BBFig. 18. 19, 20. a. 22. 23. 24. 2. List of Attached Drawings ASSEMBLY OF TILLER AND RAM ==> HYDRAULIC CYLINDER -- OIL TANK UNIT - VALVE UNIT (RE SERIES) VALVE UNIT (FE SERIES) FUNCTION OF OB VALVE -- OB VALVE (OBI5) ~~ 0B VALVE (0820) ovse:ssssserstsssistestsnisetsiiseis onssasannes nee § 08 VALVE (0830) coe 68 SOLENOID VALVE AND MANUAL ISOLATING VALVE - 69 AXIAL PISTON PUMP PRINCIPLE OF PUMP WORKING “14 . EXPLODED VIEW OF AXIAL PISTON PUMP: 12 |. STEERING SYSTEM BLOCK DIAGRAM --- 13 PUMP CONTROL. SYSTEM ---- 14 PUHP CONTROL UNIT -----ssse+ 18 J. CONNECTING DIAGRAM OF PUMP CONTROL UNIT - - 16 TORQUE MOTOR 11 DIFFERENTIAL TRANSFORMER 18 7. SERVO PUMP UNIT (REG-090) ------~ “19 ‘SERVO PUMP UNIT (REG-260/500) <-o-----eevoreoeeeestes eossereteentees ee BO) RELIEF VALVE FOR SERVO PUMP -------. “BA ‘LINE FILTER CENTERING OF HYDRAULIC PUMP AND ELECTRIC MOTOR Pe bbe ‘AIR RELEASING METHOD ----------- se B4 ADJUSTING PROCEDURE OF SAFETY VALVE <=: 00 0 co : 85 ‘ASSEMBLY OF RAM V-PACKINGS “86 DISHANTLING PROCEDURE FOR PINTLE BEARING INSPECTION --- aT ‘TROUBLE SHOOTING FLOW CHART (STEERING GEAR) -~--- crreseeeeee coe BB1 General Kawasaki Electrical Pump Control (Continuous Control) Steering Gear is of the “Rapson Slide Type” construction and consists mainly of tiller, ram and ram pin, hydraulic cylinder, valves and pipings. Kawasaki axial piston pump and pump control unit, The hydraul ic 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 control system of the Electrical Pump Control (Continuous Cont- rol) Steering Gear. the actual rudder angle is directly compared with the order rudder angle and the devia’ n signal between order and actual rudder angles controls directly the tilting angle of the hydraulic pump. Therefore the steering 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 class: ‘cation 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 the drawings of ARRANGEMENT and HYDRAULIC CIRCUIT of the separate volume.2 Detailed Description of Main Parts 21° Steering Gear : 244 Tiller : (Fig. 1) The tiller made of cast steel, designed and manufactured according to the requirements of classi ion society is fixed to the rudder stock with the key. On the fork typed openings of the tiller, the hardened stee! plates are bolted and they contact directly with the roller 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, 2.1.2 Ram and Hydraulic Cylinder : (Figs, 1 & 2) (1) The ram is made of carbon steel 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24.3 214 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 installed on the hydraulic cylinders, Inside of the each hydraulic cylinder, neck bushing is provided, Supports the ram and withstands the perpendicular component force of the ram 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 sealing effect. The rudder movement is indicated by the rudder angle indicator plate fitted between opposed hydraulic cylinders. The max, turning angle is limited by the rudder angle limiter at about 36,6 degrees although the max. working angle is 35 degrees. And also the rudder movement is mechanically restricted by the Stopper at the bottom of hydraulic cylinder (about 37 degrees). Oil Tank : (Fig. 3) The oi! tank is made of cast iron and mounted on the hydraulic cy! inder, Inside of the tank, the hydraulic 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 oil filler. filter. orf level gauge, thermometer. drain plug etc. are also provided on the tank. Oil Block Valve : (Fig. 4. § 8 6) (1) Function Starting up one pump only provided that two or more pumps are in- stalled and also piping connection is ready for parailel running of the pumps, delivered pressure oi! from the running pump wil! notactuate ran, but merely drive the idle pumps in their reverse di- rection. The oi! 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 contro! valve is energized, pressure oi! delivered fron 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 oi! from pump is distributed to the hydraulic cylinders and actuates on the ran, Left o1l block valve : As the solenoid control.valve is de-energized. no pressure oil is supplied to the right end of main spool and valve is in the posi- tion where ports AV and BV are by-passed and AC and BC is closed as shown in the left figure. So pressure oi! from running punp as well as hydraulic cylinders 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 e!- ectric motor can be started under low load condition due to the pressure oi! from cylinder being not applied on the pump. ‘Also the solenoid contro! valve has the following functions in theElectrical Pump Control (Continuous Control!) Steering Gear : @ At the operation of rudder limiter. steering gear can be instantaneously stopped by being “OFF” condition, @ At the failure of control source, ste ing gear can be auto- matically stopped by being “OFF * condition, ‘As well 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 in stalled outside of oi! tank as a part of valve unit. 2.2 Hydraulic Pump 2.2.1 Construction and Nane of Parts : (Fig. 8) The hydraulic pump manufactured by Kawasaki Heavy Industries Ltd, 1s of a variable displacement axial piston type. available up to a high pressure of 400 kaf/exl. compact and light. and shons high volumetric and mechanical efficiencies without influenced by pressure range, The punp is installed inside of the oil tank by means of the bolted flange and direct-coupled through the flexible coupling 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 oi! 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-centering 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 roller 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). In the case the cylinder (151) is located in the oblique 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 delivery-port to change over oil with the reciprocating motion of the piston is provided be- ‘tween the cylinder (151) and the valve cover (253), The valve plate (ITI) and the cylinder (151) are in optimum hydraulic balance during pump running, O11 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,222 Suction valve unit(No, 280-suction valve cover, No, 2B1-poppet. No 283-spring etc) serves for replenishing oi! automatically from ‘the oi tank during punp running. Principle of Operation : (Fig. 9) The driving shaft (101) of the pump is driven by the electric motor through the flexible coup! ing. Rotating motion of the shaft is thereafter transmitted to the cylinder ‘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 iflustrated, : Middle and bottom of the right figures are the sections perpendicular to the left figure, and direction of rotation is assumed as clockwise viewed fron 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 will not occur. no oi! ' consequently delivered. No delivery from the pump with its rotation as described above is cailed as neutral, In the case that the cylinder is tilted around its tilting axis as shown in the bottom figure, the pistons below X-Y line are going to withdraw from the bottom of the cylinder bore with their clockwise rotation and suck 01! 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 i adjusted -10-according to the type of steering gear). \f the cylinder 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 will dis- charge 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 altering the direction 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 Fig. 9 is of importance for changing over oi! as well as preventing oi! kage through the cylinder end, 2.3 Continuous Control System : 231 Operation : (Fig. 11.8 12) . The signal of order rudder angle 1s 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 1s driven and the hydraulic pump is tilted through the hydraulic regulator, The oi! is consequently dis- charged from the hydraulic pump and applied to the hydraulic cyl tnder. 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 control signal because the electric signal of pump tilting angle is feed-backed to the control box by the differential transformer (LVDT) in the pump contro! unit, In proportion as the actual rudder angle nears to the order angle, the hydraulic pump returns to neutral position due to the reverse -1ierotation of torque motor and the tiller stops when the actual rudder angle coincides with order angle and oil 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. 232 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 pum control signal and drive the torque motor, It also controls the solenoid control valve when the rudder angle limiter 1s operated. (2) Purp Control Unit : (Fig. 13) This unit consists of hydraulic regulator. torque motor and purp tilting angle indicator plate, differential transformer (LVDT). The pump contro! signal from contro! box drives the torque motor and the hydraulic pump is continuously control led through the hydraulic regulator. ; The differential transformer (LVDT) 1s also provided in order to feed-back the electric signal of the pump 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. (2.1) Hydraulic Regulator : (Fig, 13) The pilot spool (202) of the hydraulic regulator is moved by the torque motor (101), The servo piston (403) connected to the cylinder casing of hydraulic pup is also moved by the help of pressure oi! generated from the servo pump and the oil is dis~ charged from the hydraulic pump, Operation of regulator is explained by referring to Fin, 12, -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 punp. 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” direct- ion (rightward in the figure), pressure oil from servo pump 1s lead into the chanber A (oi! passage fron a to b is closed). The chanber B is opened to the drain through oil passage b to c. Accordingly the servo piston (403) moves rightward and stops at the position where the feed-back sieeve (203) closes the oil passa b to the drain, that is, the servo piston stops at the position corresponding to the stroke of pilot spoo! (202). Servo piston (403) tilts the pump in the same direction and by the same angle in accordance with the movement of pilot spool (202). When the pilot spool (202) is controlled to “pulling out” direct- ion (leftward in the figure), pressure oi! 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 posi jon 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, 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 -13-to the pilot spool (202). This spring returns the pilot spool (202) to the neutral position when the control 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 control the pilot spool and consists mainly of the frame (1) where the stator (11) 1s 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. (3) Servo Pump Unit (Fig, 17) Servo Pump Unit is provided in order to supply the pressure oi! to hydraulic regulator and 0B valve and mounted on the oi! tank, The servo pump is coupled to the electric motor through flexible coupling and started before main pump/motor, (4) Relief Valve for Servo Pump (Fig, 18) Relief valve is mounted on the manifold of valve unit in order to adjust the servo pressure, é Adjusting pressure is 18-20 kgf/ed and set before delivery. a(5) Line filter (Fig. 19) The working oi! flowed from the inlet of the filter by the servo pump is filtered while passing through the filter element from inside to outside and reaches the outlet, then actuates the hydraulic regulator and 0B valve, The filter consists of the cover (2) with an indicator, the tee (5) with a relief valve, the filter elenent (3), the drain plug (7). etc. (5.1) Indicator During the filtration, the filtering surface is contaminated by the accumulated dirt in the oil 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) 1s floated up to the white level in the column(highest position), the differential pressure is 2 kef/ed, In this case, the element (3) must be cleaned, However it will be desirable to clean when the ring reaches the middle position in height (the differential pressure 1s 1 kgt/cd) since after then the ring will reach the top position comparatively in short time, (5.2) Relief Valve When the elenent is not cleaned although the indicator shows the clogging condition (highest position), the element may be danaged since the pressure on elenent is increased due to the less of allowable flow, The relief valve is provided in order to prevent the danage of hydraulic equipments and valve is operated when the differential pressure is 3.0~2.2 kef/ed. then a part of flow reaches the outlet directly without passing through the element, ~15-(6) a) Repeat Back Unit This unit is connected mechanically 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 autopilot manufacturer. Rudder Angle Limiter Rudder angle limiter 1s provided in ordér to stop the movement of steering gear instantaneously by cancelling the electric signal to torque motor and de-energizing the solenoid valve consequently 0B valve is unloaded when the steering gear wil! 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, = Len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, ram pin. roller bearing and the gauges, ‘The tiller is usually installed on the rudder stock before launching, The_ hydraul cylinders are then installed on the bed plate of the hull. The installation of the important components such as cylinder etc, should re- quire 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 installation, the main component parts which go together are applied with match marks and knock-pin holes before being dis- mantled and despatched from our works, The hydraul ic 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 pick! ing. 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 throughly the cleanliness inside the o1! tank, hydraulic cylinder etc, Until the basin trial of the steering gear. cover the surface of the ran 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 1s secured to the sti ring 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, -1T-4 Instruction for Adjustment When satisfied that the tiller, ram, hydraulic cylinder, oi! tank, electric motor, valves, pipes, repeat back unit etc, are correctly positioned. make operational preparation and adjustment in the following manners, 4.1 Preparation : 4A Wiring : Connect the electrical parts of control box, steering gear terminal box to which torque motor and LVDT are connected, solenoid cont- rolled valve, rudder angie limiter. repeat back unit etc, in accor~ dance with the instruction manual of autopilot manufacturer. 4.1.2 Working Oil and Filling : (1) Working Oi : The working oil applicable should be pure mineral oil, Use of vegetable oi! is strictly prohibited because the pump function is spoiled due to deposits, The highly viscous hydraulic oi! which has additions of antifroth- ing 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. Q-ring etc, Further, as the deterioration of oi! becomes excessive beyond 65 C. it is desirable not to exceed 60°C. =18-! =. The hydraulic oil having the following properties has widely used for the steering gear and is recomendable for working oi. Grade | Kinematic viscosity {Viscosity | Flash Pour Viscosity , | { point grade) | cSt (at 40°C) —|_index c c i | [ i 180 v668 | 61,2 to 74.8 ine i 1 | in, 95 | min, 200 | max, -20 180 vGS6 | over 60,6 to 612 excl, | PASE EH | point | | | Caution : 1, The oi! must be dealt with carefully not to allow dust and other impurities to mix, 2. No oi! mixture of different brands shall be allowed by any means, 3, The working oil for the use especially in cold regions shall be asked to the oi! maker and our works, Necessary quantity of the oi! is indicated in the drawing of ARRANGENENT, (2) Filling Hydrautic System with Working Oil : hen working oil. is filled in hydraulic system. a filter of 200 mesh ‘or over should be applied for preventing foreign matters and dust. -19-o Fill the hydraulic 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 oil through the upper filler up to the red line of the oi! level gauge which shows the upper limit, 4.1.3 Application of Lubricating Oil and Grease : 4a. Since the roller bearing and each joint portion of the steering gear are provided with oilless bearing and oil-impregnated metals res- pectively. it is not necessary to lubricate with o1! or grease in normal cases, However appl ication of oi! or grease is required at installation for rust prevention, ‘© Apply grease to the sliding parts of the lever, © Fully apply working o1! to the ram surface, ‘© Slightly apply grease for rust prevention to other machined sur- faces(especially to the roller bearing, hardened stee! plate and ram guide bar), 4 Centering of Hydraulic Pump and Electric Motor : (Fig, 20) Poor centering will cause over-heating, wear, noises and vibration ‘of the bearing of hydraulic pump and electric motor. oi! leak from the oi! seal. wear of the coupling rubber etc. Correct centering should be checked in the following manners, (1) Parallel Error : ‘As shown in Fig, 20. keep a suitable clearance between the coupl ing faces. install 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 will be performed as mentioned above, however touch ‘the dial 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 shall be adjusted within the rangé show in Fig. 20. 4.1.5 Inserting of Ram V-packing : (Fig. 23) 4.2 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 end packing gland involve no dust and impurities, fit the packings, The detailed inserting method is referred to Item 6. 4. Adjustment : After the preparation of each part has been finished. operation and ad- justment wil! 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 purip control unit, start the electric motor. Confirm the rotating direction of hydraulic pump and check for oil leakage from the front cover of pump and abnormal vibration, -21-(The rotating direction is indicated in the drawing of ARRANGEMENT and on the bodies of hydraulic pump and electric motor, ) 4,22 Adjustment of Servo Pressure : The servo pressure supplying to the hydraulic regulator should be adjusted to 18-20 kgf/ca! (the green-colored range on the dial plate of the pressure gauge) by the relief valve mounted on the manifold of valve unit, However it is unnecessary to re-adjust the servo pressure onboard, since it has been adjusted at our works, \f 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 section al arrangement of the relief valve. refer to Fig. 4 and 18) 4.2.3 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 until the bubbles does not come out. 4.2.4 Adjustment of Pump Neutral Position : The pump neutral position is adjusted before delivery and it need not to be re-adjusted on board, However when the pump. the regu- lator, the torque motor. the LVDT etc, are re-assembled by any reason, the pump neutral position is adjusted in accordance with the fol lowing procedure, (1) Hydraulic Pump 1. Stroke fully the tilting lever (Fig, 3-1681) together with the pump ~29-to the direction of hydraulic regulator. 2After 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 tighter ‘the power lock (Tightening force is listed in Fig. 13.) 3.By measuring the length between the erid of piston and the casing of hydraulic regulator. put the pump in neutral position, (The length is listed in Fig. 13.) (2) Hydraulic Regulator 1.Disconnect the control box from electric poner, Push the manual button ‘of the solenoid contro! valve and lock it by means of lock nut. ZStart the electric motor. If the ram is moved, loosen the bolt(Fig, 13- 316) a little and turn the adjusting pin (Fig, 13-302) until the ram: is ~ ‘stopped, (If loosen too, the adjusting work will be difficult. ) 3.Then sot the adjusting pin by ‘tightening the bolt (Fig, 13-316). (3) Torque Motor 7 J. Insert the rotor (Fig. 15-12 and -13) into the rotor shaft (Fig. 13- 103), 2 Install the flame without the name plate (Fig. 15-5) so that its receptacle becomes in the direction of port or starboard side, 3 Insert the clanp element (Fig. 15-2) and flange (Fig, 15-10) into the rotor. (Direction 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) |.Adjust the length so that the distance between the end of pilot spool (Figt3-202) and the edge of core (Fig. 16-10) 1s 89 0.2m. 4.25 Air Release in Hydraulic System; (Fig. 21) -23-It is not enough to fill the hydraulic system with hydraulic oi! at preparation (When the pump is tilted after starting. its abnormal noises prove that @ great amount of air is still left in the system) In order to expel'air in the system, push the manual button of the solenoid contro! valve and lock 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 degr sin 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 movenent of ram 1s finished and smooth movenent begins. In this case the hydraulic pump will be started one by one. Care should be taken to the oi! level of oi! tank and replenish the working oil if necessary, Note : 1. Don't open the air vent valve on the cylinder where ram 1s pressed, If it will be opened, the air that has tried to expel will be sucked in again, 2. Before expelling the air. don’t run the hydraulic pump for hours, 4.2.6 Adjustment of Control Box : Since the control box is supplied by the auto-pilot manufacturer. tefer to its instruction manual for its detail. The adjusting items are as fol lows, (1) Zero Adjustment (2) Adjustaent of Maximum Tilting Angie of Hydraulic Pump (3) Adjustment of Proportional Band (4) Adjustment of Rudder Angle -24-4.2.7 Adjustment of Maximum Pump Stroke : 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, Loosen the lock nut, set the bolt (7) to the position 2~3 nm 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 steering, Note : In this adjustment. prevent the lever (3) from striking this bolt (7) during the normal steering without fail, Also, during the local steering. don't strike the bolt (7) hardly with the lever. 4.2.8 Adjustment of Rudder Angle Limiter : Set the limit switch position of the rudder angle limiter at 362° . Confirm that the 0B valve becones unloaded (solenoid valve is de~ energized), the hydraulic 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° . 4.2.9 Measurement and Adjustment of Rudder Turning Speed : (1) Normal Steering : © The stee 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 28 seconds with the vessel running ahead at max, speed. © Correct adjustment has been finished before delivery from our works, -25-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 paralle! running) : 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 60 seconds with the vessel running ahead at half speed or 7 knots (or 8 knots). whichever is greater. One pump is used in emergency steering. 4.2.10 Adjusting Test of Safety Valve : (Fig, 22) The safety valve limits the max. pressure of the hydraulic 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, Re-adjustment is not re- quired 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 follows : (1) Preparation : The safety valve test will be carried out by means of the pump control knob (Local Steering). © Disconnect the contro! box from electrical poner. (© Push the manual button of the solenoid control valve and lock 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 hydraulic pump and operate the steer- -26-ing gear by the pump control 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 comes near % 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 shall 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 assenbly 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 1s 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 oi! leakage and ab- normality in each part of the steering gear. After the test is over. put the stop valve. isolating valve. solenoid contro! valve, pump control knob etc, to the original condition,& Steering Method The steering gear can be operated by the following methods assuring correct and easy handl ing and changing : (1) Automatic steering by remote control system in wheelhouse (2) Hand steering by renote control system in wheelhouse (Follow up control / Non-fol low up control) (3) Local steering in steering gear room (by the pump contro! knob) 5.1 Normal Steering = The normal steering is made by the above~nent ioned method. (1) or (2). For details. refer to the Instruction Manual of the autopilot maker because the contents are different depending upon the remote contro! system in the wheelhouse (bridge). The steering gear can be operated with all hydraulic cylinders and conbi- nations of hydraulic pumps in order to meet with the requirerents of classification society. : Also changing-over of the hydraulic pump can be done by the renote control of electric motor. The rudder angle can be freely controlled by the order signal of the remote control system from 35 degrees on either side to 35 degrees on the other side, Precautions : 1. Correctly operate the hydraulic pump and valves in accordance with the instruction plate, 5.2 Local Steering : In failure of the contro! system in the whee! house (bridge) or during ‘the adjustment operation of the steering gear. the steering gear can be ‘operated by the purp control knob of pump contro! unit mounted on the -28-oil tank in the steering gear room, ‘The steering gear is controlled by the following 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 contro! knob by watch- ing the pump tilting angle indicator plate and rudder angle indicator plate, (3) When the steering gear reaches the desired angle, release the pump contro! knob, The knob and the hydraulic pump will return to the neutral position and steering gear will stop automatically. 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 limiter 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, -29-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 hydraul ic pump and cause not only unstable rudder angle but also other troubles, In case of replenishing the working oil. use the oi! of sane brand, (2) Correct Operation of Stop Valve : Correctly open and close the stop valve and isolating valve in accord- ance with the instruction plate. so Aur Vent Valve : Never open the valves during the steering gear is operated, If not. it will cause the failure of steering, © Safety Valve : Never touch the safety valve unreasonably because it has been co- trectly 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 environ- nent. (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 ~30-(5) (6) (1) causing the excessive current of the electric motor. ‘© Pay attention especially when the hydraulic pump is started at low ‘temperature such as winter season (below 10°C approx. ). After ensuring the oil temperature rises by keeping small eccentricity and steering small 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 punp 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 cylinder and valve plate of the hydraulic pump, Check Itens : Checks shal! be carried out surely by referring to Item 6.2 and 6,3, Special care should be taken to the oil level and temperature of the orl tank, operating conditions of hydraulic pump and steering gear, tightness of bolts. oi! teakage etc, =31-6.2 Check Items : Period | Check items | Period | Check items Daily A-1 Oi! quantity Before | (1) Oil quantity voyage A-2 Oil temperature check | (2). Valve positions A-3 Cylinder pressure (3) Oi! temperature A-4 Abnormal noises (47 Lubrication of sliding parts A5 Oil leakage (5) Ram surface A-6 Gurrent of electric motor (6) Operating condition ! A-T Servo pump pressure (7) Air release | A-8 Torque motor temperature j Weekly B-1 General operating Periodi-| (1) Safety valve condition cal checks | (2) Pump neutral adjustment. 8-2 Lubrication of sliding | (at dock parts ‘or basin) (3) Rudder turning speed | 8-3 Cleanliness of machined (4) Coupling | parts 6) Clearance between tiller Monthly | C-1 Ram V-packing and roller C-2 Coup! ing (6) Pressure gauge and ‘thermometer C-3 Air vent valve (7) Bolt. nut. pin and ‘tunbuck le 1 C-4 Stop valve and isolating t valve | (8) Ran V-packing i €-5 Oil seal of pump contro! | ji! seal of pump control i unit [nit ; Quar- hi 0-1 Bolt. nut. pin (9 O-ring of pipe joints terly D-2 Turnbuckle (i) Gasket packing D-3 Oil level switch 2 Cylinder bottom packing | 0-4 Line filter (3 Pump contro! unit \ Semi- E-1 Slide plate of ram guide 40 Electric motor yearly bar 9 Working o1! E-2 Working oi!-visual check {1 Tank cleaning Yearly F-1 General function and 1 Line filter cleaning appearance 7 1® Hydraulic pump F-2 Working oi!-property inspection 09 Air release -32-6.3 Detail of Check Items : 6.3.1 Normal Checks : Carry out the following checks whenever the ship..is navigating or anchoring and take proper measures if necessary, A) Daily Checks : At A? Ag And AG AT Oi! Quantity in Oil Tank : © Check the oi! level in oil tank is within the range of the oi! | gauge, If not, exanine the cause, repair if necessary and refill oi! tank with new clean oil. Oil Temperature in Oi! Tank : (© Check the oil temperature in the oil tank by comparing with the normal data, Nornally oil temperature will be within 30°C plus room temperature, If it exceeds 80°C. stop the hydraulic punp and examine the cause, Hydraulic Cylinder Pressure : (© Check the pressure of hydraulic cylinder by means of the pres- sure gauge by comparing with the normal data, {f it is abnormally high. examine the cause, Abnormal Noises : © Check its origin in the steering gear and examine the cause, Oi! Leakage : © Check for oi! leakage from the oi! tank, hydraulic cy! inder, valves and pipe joints. Current of Electric Motor : © Check for excessive current of the electric motor. Servo Pump Pressure © Check the pressure of servo punp by means of the pressure gauge. Adjusting pressure is 18-20 kef/cr. -33-A-8 Torque motor temperature ‘© Check the temperature of torque motor, by comparing with the normal date, 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 steering gear is in normal operation, Expel air in its circuit. if necessary, 8-2 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 : © Make periodical cleaning and try to prevent rust by applying grease, €) Monthly Checks : C-1 Ram V-Packing : © Check a light film of o1! is produced on the ram surface. Adjust the packing gland. if necessary, C-2 Coupling : © Check much rubber powder caused by wear of rubber ring is not found under and around the coupling. If found, stop the pump and adjust the centering, Renew rubber rings, if necessary, C-3 Air Vent Valve : © Check the valves are securely closed If not, tighten them hard up not to be loosened by vibration, C-4 Stop Valve and Isolating Valve : © Check the valves are opened or closed correctly in accordance -34-with the instruction plate. Tighten them hard up by means of lock nuts not to be loosened by vibration, C-5 Oi! Seal of Pump Contro! Unit : © Check for oi! leakage from the drain inspection ports provided at the foot of torque motor, Renew oil seal (109). if necessary. 1D) Quarterly Checks = D-1 Bolt, Nut and Pin : © Check the fixing condition of each bolt, nut, pin, pressure ‘gauge and valves, If loosen, tighten then evenly.and hard up, D-2 Turnbuckle = © Check the nuts and lock washers for turnbuckle are tightened hard up. D-3. Oi! Level Switch : ; © Confirm that the alarm is given by pushing down the float in the oi! tank, D-4 Line Filter © Check the clogging condition of filter by means of indicator. Wash the filter element. if necessary (Refer to Item 6.5). €) Semi-yearly Checks : E-1 Slide Plate of Ram Guide Bar (white resin) : © Check for any abnormal wear, E-2 Working Oil-Visua! Check : © Sample the working oi! each from the hydraulic cylinder and oi! tank, (Inspect it by visual check and if found abnormal, ex- amine in detail, ) F) Yearly Checks : F-1 General Function and Appearance : © Make a precision inspection if necessary. and repair or renew =35-defective parts, © Clean throughly, F-2 Working Oil-Property Inspection : © Make a periodical property inspection of the working oil, Sample about 1.0 lit. of working oi! each from the hydraulic cylinder and the oi! tank, Renew the working oil, if necessary. Refer to Iten 6.3.4, 6.3.2 Before Voyage Checks = Check the followings before leaving the port. (1) Oi! Quantity in O11 Tank : © Check the oil level in oil tank is within the range of the oil level gauge. (2) Valve Positions : © Check the valves are opened or closed correctly in accordance with the instruction plate, (3) Oi! Temperature in Oil Tank : © Check the thermometer is not damaged, © Check the o1! temperature is within proper range, (about 10°C to 60°C), (4) Lubrication of Sliding Parts : © Check the lubricating condition of each sliding part, Check for any rust. (5) Ram Surface : © Check for excessive leakage from the Ran V-packing, The ram surface will be cleaned throughly. (6) Operating Condition (© Check the rudder moves correctly by the order signal from the whee! house (bridge) and the actual angle agrees with the order ~36-angle. (7) 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 can not be examined fully at normal checks. Check in detail where found impropriety at normal check and repair if necessary, (1) Safety Valve © Check the safety valves are set at adjusting pressure. (The ad- justing 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 oi! leakage from the seal. (2) Pump Neutral Adjustment : © Start the hydraulic pump one by one and confirm that ram does not move, © If it moves large. adjust by referring to Item 4,2. 4, (3) 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 re- quirenents), © Check there is no large difference between the above data and the trial data, (4) Coupling © Check the errors of centering are within the standard value by measuring the centering of couplings with the dial gauge (Refer to Fig, 20). -37-If exceeding the standard value, re-adjust it by referring to Item 4.1.4. © Check for wear on the globe surface of the rubber ring, Replace it with the spare if necessary. (5) 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 an (6) Pressure Gauge and Thermoneter : © Check for normal ity, © Repair or replace if necessary. (7) 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. (8) Ram V-packing : (© Replacenent of packing is not required when there is no oi! leakage from the packing gland under the condition that packing gland can be tightened more than 2nn and there is a light film ‘on the ran surface, © Even if oi! leakage is not observed. it is desirable to renew it about every four years. (9) Oil Seal of Pump Control Unit = © If oi! leakage is observed from the drain inspection ports provid- ed 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 four years. -38-(10) O-ring of Pipe Joints : © If oil leakage is observed, renew it, o Even if oi! leakage is not observed, it is desirable to renew it about every four years, © If the back-up ri can be further used as it is not damaged, is, (11) Gasket Packing : © If oil leakage is observed, renew it. © If sufficient thickness 1s kept and danage is not observed. the packing may be used as it is by tightening additional ly. (12) Cylinder-bottom Packing : (Fig, 2) © If oil 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 can not be renewed unless the ram is drawn out. (13) Pump Control Unit : © Check that the stopper is adjusted to the position of the max. pump tilting angle plus 2 or 3 mn. (14) Electric Motor : © Measure insulation resistance between stator coi! and frame (more than 10 MQ), If found faulty, repair or replace the electric motor. (15) Working Oi! = © Sample the oi! each from the oi! tank and the hydraulic cylinder and make a property analysis. ~39-(© Whenever the oil reaches the renewal standard, renew it with new one. (16) Tank Cleaning : © Clean thoroughly the interior of the oil tank when the working oi! is renewed or about every two years, (17) 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 il is renewed or about two years. (18) Hydraulic Pump : : : © Care should be taken especially to worn-out parts. cylinder, valve plate and al! bearings. © For details, refer to Iten 6.6. (19) Air Release : © Expel air after periodical checks : 6.3.4 Check of Horking Oil : As it is used long period the working oil will be mixed with foreion matters. deteriorated in the qual ity. and have the inconvenience to keep on the normal operation of the steermg gear. To avoid this. the oi! should be subjected to the periodical inspection. Sample the o11 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 oil : a. Isn't the color turned from light yellow to dark brown ? b. Isn't the smel! producing an irritative smell ? c. Isn't there any sign of foreign matter 7 d. tsn't it emulsified ? =40-Working Oi! Renewal Standards Item Changes resulting | Cause Working limit from deterioration (changing rate) and pollution Specific gravity increase deterioration 0.05 Flash point [decrease deterioration 60°C Color oxidation, (Union) darken mixture of 2 worn powder Viscosity | increase (decrease) | deterioration | +1096 Acid value | increase oxidation 0.4 mg KOH/g Humidity increase 0.0596 ' 6.4 Replacement of Ram V-Packing : (Fig. 23) During the replacenent work of the packing. care should be taken to avoid damaging the ram surface and seal surface of the cylinder, 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 ram, 2, Loosen the nut and lock nut of the packing gland by about 2an, b. love the ran slowly by local steering, (The packing can be drawn out little by little along with the ran.) ¢. The packing can be drawn out by repeating above works a and b, If packing can not be drawn out by above work, prepare a suitable tool and draw out the adapter and packing. (The screw holes has been machined on the female adapter for disassembling. ) (2) Inserting of Packing : a, Before inserting new packings. tharoughly remove dirt and im- purities stuck on the interior of the stuffing box and the ran surface, aged65 b. Insert the male adapter inward, c, Wind the new packing to the ram At the moment, confirm that the section is correctly met, (If the packing is hard, make it soft by hand rubbing. ) d, Insert the packing inward by fingers or a bamboo spatula to support the packing, @. Follow the same manner subsequent to the second one, At the moment, the splits in the packing should be staggered around so that no two splits come together. 4, 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 cylinder and the packing gland ig. 23. 8. Operate the steering gear by the pump control knob and adjust the is shown in packing gland to form a light film of oi! on the ram surface, h, 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 Care should be taken to the packing since it tends to fall itself when inserting, Dismantling and Assenbl ing of Line Filter : When the ii jicator of the filter shows the clogging condition (red indicator ring is floated up to the white level in the column). the line filter will be dismantled and the filter element cleaned in the following procedures (Fig. 19 is referred to). It will be desirable to clean when the ring reaches the middle posi jon in height. -42-a) Loosen the bolts (20) and remove the cover (2), b) Nut will be detected at the inlet side. After loosening the nut (6) thoroughly, shift the tee (5) by about 2 mn to the inlet side (left side) and pull out it, The filter element (3) will come out together with the tee, ¢) Loosen the nut (9) on the bottom of element and pull out the element 3). 4) 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. 2) 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 disassembly. © Tighten the nut (6) slightly by means of finger. When filter circuit is actuated, the packing (15) at the outlet side will be tightened automatically by the help of differential pressure, So there is no oi! leakage from the packing. © Tighten the bolts (20) hard up in symmetrical order little by little. 6.6 Dismantling and Assenbling of Hydraulic Pump : The hydraulic pump wil! be dismantled and checked in the fol lowing procedures, However, special attention and skill in dismantling and assenbl ing of ‘the pump are required. so it is recomendable that the work is performed by the specialist. if possible (Exploded view of axial piston pump in Fig. 10 is referred to ). (1) Preparatory Items : a, Tools necessary for dismantling and assembling of the pump (bar -43-