Installation Manual Steeringgear Shipkits B.V. Hull No SK120

Technical specification
Steering Gear
Type Rolls-Royce steering gear

SR722 FCP
Date : 21.08.2012
Id : 10-12-00938
Rev : 00
Customer : Shipkits B.V.

Customer reference : CON-01331, 4200 dwt Heavy Lift Vessel
Shipyard : Shipkits B.V.
Hull no. : SK120
Type of vessel : Construction - Heavy Lift Ship

Class : BV
Contract manager : Marie Kristine Longvastrand,
marie.longvastrand@rolls-royce.com
Order : 12S000638
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

Page 1 of 9
Table of contents
01.00 System description ........................................................................................................... 3
02.00 Scope of supply/technical description ............................................................................... 4
02.01 General ....................................................................................................................... 4
02.02 Steering gear .............................................................................................................. 6
02.03 Start/stop and control system ...................................................................................... 7
02.04 Alarm system .............................................................................................................. 8
02.05 Rudder angle indicator system .................................................................................... 8
02.06 Spare parts and special tools pr. ship set. ................................................................... 9

Page 2 of 9
01.00 System description
Rolls-Royce steering gear

Type: SR722 FCP
Rudder actuator
Effective torque : 275 kNm
Max working pressure : 125 bar
Allowable axial load : 370 kN
Allowable radial load : 855 kN
Rudder stock diameter : 320 mm
Max. mechanical rudder angle : 2x72°
Max. electrical rudder angle : 2x65°
Additional rudder angle limitation (class requirement) : 2x35°
Steering time at 30° - 0° - 35° : 28 s with one pump unit in line
Steering time at 30° - 0° - 35° : 14 s with two pump units in line
Electric motor
Power : 15.0 kW (S1)
Current : I N = 30 A
Rotational speed : 1450 rpm
Voltage : 3x380-400 V
Frequency : 50 Hz
Type : M3AA 160 MLB-4
Protection : IP 55
Design : B35
Insulation class :F
Heating : Yes, (through the windings)
Start/stop and control system

Control panels for console mounting in the bridge
Control system unit for bulkhead mounting with interface to analogue autopilot.
Panel for run/stop indication
Motor controllers for bulkhead mounting in the steering gear room
The system is powered internally from motor controllers
Limit switches and potentiometers for the follow-up system are mounted in feed back units
Alarm system
Panels for console mounting.
Interface to Voyage Data Recorder (VDR) and ship’s main alarm system
Interface to alarm sensor
24VDC external power supply (100W)
Rudder angle indicator system

Panorama type for ceiling mounting
Console mounting types
Rudder angle indicator amplifiers
Feed back potentiometers in feed back unit
Interface to VDR
Accuracy according to class 1.5
Type approved by MED (Marine Equipment Directive)
24VDC external power supply (50W)

Page 3 of 9
Classification requirements
Society-notation: BV (Notation according to project requirement).
The equipment is dimensioned in accordance with the above classification society rules valid on
the date of this specification.
Painting and colours:

According to RRCM standards if not other specified.
Panels : RAL 9011
Cabinets : RAL 7035
Electric motor : RAL 5014
Mechanical components : primer
02.00 Scope of supply/technical description
02.01 General
Equipment not supplied

Scope of supply is defined in the technical specification.
Not included in scope of supply are:

- Foundation and fastening bolts for equipment supplied.
- Autopilot, DP and joystick
- Piping
- Wiring
Technical information - Drawings
Dimension drawings, hydraulic diagram, electrical diagram and technical data for the steering
gear system will be delivered. All according to documentation list issued for each order.
Steering gear design
The steering gear design is based on well-proved technology as well as long experience.
Workshop testing
The steering gear system is workshop tested according to the class requirement and RRM
standard.
Corrosion protection and surface treatment
The steering gear actuator is provided with corrosion preventing coat, which is intended for
protection under normal transport conditions. The rotor is finish treated according to RRM
standard.
Shipment
Depending on transport methods and delivery times components may be shipped separately.
Installation into the ship and mounting of components are customer's responsibility if not
otherwise is stated.

Page 4 of 9
Safe storage
All equipment are prepared for storage in dry and dust free environments up to 6 months from
delivery.
Piping and cabling
Connections between components supplied by RRM are the customer's responsibility. However,
type of pipes and cables are given in the diagrams and mounting instructions.
Installation, inspection, starting up and sea trial
Installation of the steering gear system in the ship and mounting of components are the
customer's responsibility if not otherwise stated.
Instruction manuals – Language
1 CD with English user/installation manuals

2 pcs. Installation manuals covering the mechanical/hydraulic parts in English language
2 pcs. Installation manuals covering the electrical parts in English language
2 pcs. Users manuals covering the mechanical/hydraulic parts in English language
2 pcs. Users manuals covering the electrical parts in English language
All drawings, documents and sign plates on the equipment will also be delivered in English
language. All drawings will be delivered in PDF-format.

Page 5 of 9
02.02 Steering gear
0010 1 pc. Rudder actuator (rotary vane) type SR722 FCP

Complete with spherical self-aligning rudder carrier; pressure pumps; non-return
valves; load control valves; valve block with sensors for hydraulic lock alarm; filter
units and mechanical rudder angle indicator; feed back units with limit switches,
transmitters for the steering control system and the rudder angle indicating system.
Oil included.
Drawing numbers: A-9909, A-9161, W-1601-00-06, 0002-1515, 0002-5397
0020 1 pc. Sleeve for hydraulic coupling

Complete with mounting piston. Rudder stock diameter: 320 mm.
Drawing number: A-9295
0030 1 pc. Expansion tank

60 litres without oil, with gauge glasses, low oil level switches, cocks and fittings.
0040 1 pc. Storage tank

Storage tank, volume 120 litres with hand pump, level indicator and necessary
connections.

Page 6 of 9
02.03 Start/stop and control system
0050 2 pcs. Motor controllers (FCP) (IP44)

For bulkhead mounting in the steering gear room. Vibration dampers included. Plastic
cable glands included.
Motor controller is numbered from the port side.
Drawing numbers: 0002-1731, L-1799-00-16
0060 2 pcs. Frequency converters (IP44)

For bulkhead mounting in the steering gear room with ammeter, hour counter
indication and power supply for heating of electrical motor through the windings.
Drawing numbers: 0000-0319, 0000-0322
0070 1 pc. Control system unit (IP44)

For bulkhead mounting in the bridge with interface to analogue autopilot. Plastic cable
glands included.
Drawing numbers: W-1221-01-00, L-1299-00-01
0080 1 pc. Control panel (IP22)

For desk mounting in the forward bridge console with start/stop push buttons, dimmer,
steering mode selections, non-follow-up push buttons for emergency steering and
follow-up controller.
Drawing numbers: 0002-0626, L-1320-01-05
0090 2 pcs. Indoor follow-up controller (IP22)

For desk mounting in the bridge wing console with in command push button and
dimmer.
Drawing numbers: 0002-1028, 0002-1247
0100 1 pc. Indication panel (IP22)

For run/stop/autostart indication and for desk mounting in the engine control room
console.
Drawing numbers: 0002-1030, 0002-1251

Page 7 of 9
02.04 Alarm system
0110 1 pc. Alarm panel (IP22)

For desk mounting in engine control room with alarm lights for overload, phase failure,
low oil level, power failure and hydraulic lock and push buttons for alarm test, alarm
acknowledge, alarm buzzer and with one common steering gear failure alarm contact
(voltage free) to ship’s main alarm system.
Drawing number: W-1802-00-01
0120 1 pc. Alarm panel (IP22)

For desk mounting in bridge console with alarm light and push buttons for alarm test,
alarm acknowledge, alarm buzzer and with interface to VDR on RS422 NMEA.
02.05 Rudder angle indicator system
0130 1 pc. Rudder angle indicator amplifier

For mounting inside the console.
0140 1 pc. Rudder angle indicator, 144x144 (IP22)

For desk mounting in forward bridge console.
0150 1 pc. Panorama rudder angle indicator, Ø370 (3-face) (IP22)

With dimmer for overhead mounting in the wheelhouse.
0160 2 pcs. Indoor rudder angle indicator, 144x144 (IP22)

For desk mounting in bridge wing console.

Page 8 of 9
02.06 Spare parts and special tools pr. ship set.
0170 1 set Standard spare parts

Set of Standard Spare parts.
0190 1 pc. Mounting tools

Complete set of hydraulic mounting tools, including hydraulic pump, two (2) injector
pumps, hose, fittings, gauge and wrench for the hydraulic coupling.
1 set Manuals
- 2 Printed mechanical user manuals in English language.
- 2 Printed electrical user manuals in English language.
- 2 Printed mechanical installation manuals in English language.
- 2 Printed electrical installation manuals in English language.
- 1 CD with English user/installation manuals.
Piping diagram: A-8798
Cable diagram: 0003-2550

Page 9 of 9
APPENDIX A - TECHNICAL DATA SPECIFICATION
Revision A
Rolls-Royce Steering Gear

TYPE SR722 FCP
Steering gear
Type SR722 FCP
Shipyard Shipkits B.V.
Hull No. SK120
Rudder Actuator:
Type SR722
Max. working pressure 125 bar
Design pressure 156 bar
Max. torque 275 kNm
Test pressure 234 bar
Rudder stock diameter 320 mm
Rudder angle electrical 2x35 / 2x65° electrical stop
(Rudder angle limitation included)
Rudder angle mechanical 2x72° (approx.)
Manoeuvring time one/two pumps 28/14 seconds (30°- 0 - 35°)
Setting of relief valves 156 bar
Hydraulic Oil Shrink Coupling:

Rudder stock diameter Ø 320 g7
Sleeve diameter Ø 320 E8
Pull-up lenght 28 mm
Max allowed injection pressure 1305 bar
Max allowed mounting pressure 417 bar
Pump unit:
Make Rolls-Royce
Type FCP-44
Pressure pump type Sauer Danfoss SNM3-44
Setting of relief valves 125 bar
Testing pressure 188 bar
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-
Royce. Failure to do so is a violation of copyright laws.
0003-2421 (Master rev. 02.2011-07-02) generated: 11.07.2012

Page 1 of 2
Electric motor:
Type NORM IEC 160MLB - 4
Speed 1465 r.p.m.
Rating output 15,00 kW (S1)
Voltage 3x380 V, 50Hz
Protection class IP55
Insolation class F
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-
Royce. Failure to do so is a violation of copyright laws.
0003-2421 (Master rev. 02.2011-07-02) generated: 11.07.2012

Page 2 of 2
INSTALLATION MANUAL
Rolls-Royce Steering Gear SR
Mechanical and hydraulic system
Type:
Yard and hull no. :Shipkits B.V. : SK120

Project no. :12S000638
Date 24. August 2012
Page 2 of 55 Installation Manual Rolls-Royce Steering Gear
TABLE OF CONTENTS
1 INTRODUCTION ...................................................................................... 5
1.1 Purpose .............................................................................................................................5
1.2 Warranty ............................................................................................................................5
1.3 Structure of this manual ....................................................................................................5
1.4 Abbreviations .....................................................................................................................6
2 SAFETY ................................................................................................... 7
2.1 General statement .............................................................................................................7
2.2 Safety Annotations ............................................................................................................8
2.3 Declaration of conformity...................................................................................................8
3 SYSTEM DESCRIPTION ......................................................................... 9

3.1 System overview ...............................................................................................................9
3.2 Design .............................................................................................................................11
3.2.1 Rudder actuator ...............................................................................................................12
3.2.2 Pump unit ........................................................................................................................13
3.2.3 Cylindrical rudderstock connection..................................................................................13
3.2.4 Valve block ......................................................................................................................14
3.2.5 Rudder stock ...................................................................................................................15
3.2.6 Feed back units ...............................................................................................................15
3.2.7 Exspansion tank ..............................................................................................................16
3.3 Function ...........................................................................................................................17
4 DELIVERY SPECIFICATIONS............................................................... 18
5 TECHNICAL DATA ................................................................................ 19

5.1 Steering gear, SR-series .................................................................................................19
5.2 Oil recommendations ......................................................................................................20
5.2.1 System oil volume ...........................................................................................................21
5.3 Standard painting specifications......................................................................................22
6 HANDLING AND PRESERVATION ....................................................... 23

6.1 Delivery check .................................................................................................................23
6.2 Storage ............................................................................................................................23
7 INSTALLATION ..................................................................................... 24

7.1 Installation overview ........................................................................................................25
7.2 Lifting ...............................................................................................................................26
7.3 Installation of Steering gear.............................................................................................27
7.3.1 Filling of oil / “Pulling up” .................................................................................................30
7.4 Installation of expansion tank ..........................................................................................34
7.5 Piping instructions ...........................................................................................................35
7.6 De-airing ..........................................................................................................................37
7.7 Dismantling and re-installation (hydraulic coupling) ........................................................38
8 COMMISSIONING .................................................................................. 41

8.1 Precautions before start-up .............................................................................................41
8.2 Activities performed by the shipyard personnel ..............................................................42
Rolls-Royce Steering Gear Installation Manual Page 3 of 55

9 CONTACT LIST .....................................................................................43
10 FINAL INSPECTION AND TEST PROCEDURE....................................47

10.1 Function test.................................................................................................................... 47
10.2 Harbor acceptance test ................................................................................................... 47
10.3 Sea acceptance test ....................................................................................................... 52
11 TOOLS ...................................................................................................53
12 DESIGN DRAWINGS .............................................................................54

12.1 Mechanical ...................................................................................................................... 54
12.2 Hydraulic ......................................................................................................................... 54
13 REVISION ..............................................................................................55

1 INTRODUCTION
1.1 Purpose
The Installation manual provides the information necessary to plan and install the delivered
system safely and correctly. It also enables you to verify the functionality of the equipment.
Also included are instructions for handling of the goods after they have been received at the yard.
It is important that the instructions be followed carefully to avoid problems during outfitting and
commissioning. This manual also provides instructions for all activities essential for
commissioning.
1.2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is
misused or not handled in accordance to prescribed standards, for example dismantling the
equipment to a level greater than described.
1.3 Structure of this manual

The first part of this manual describes the Rolls-Royce Steering gear. This helps in understanding
the maintenance procedures in the subsequent chapters.
Chapter 3 and 4 provide project specific information.
Chapter 5 provides technical data.
Chapter 7 includes all installation procedures.
Chapter 8 and 10 provide all information related to commissioning and sea trial.
Note!
A separate user manual is available, and may be ordered specifically from Rolls-Royce Marine as
required.
Note!
All pictures used in this manual are for illustration only.

1.4 Abbreviations
Abbreviation Description
ºC Centigrade
cSt Centistokes (oil viscosity)
CCW Counter Clock Wise
CW Clockwise
DP Dynamic Position
E0 General alarm
EP-additives Extreme Pressure additives
FCP Frequency Controlled Pumps
Follow-Up. Rudder moves to the rudder angel set by
FU
the operator,(Analog steering signal)
Hz Hertz (frequency)
Kg Kilogram (weight)
kW Kilowatt (power)
l/min Liters per minute (flow)
mm Millimeters (lengths and diameters)
Non-Follow-Up. Time dependent steering. Rudder
NFU moves as long as the operator activates the steering
lever. (on/off steering signal).
RPM Revolutions Per Minute (rotation speed)
SV Spherical Vane
V Volt (voltage)
WSC Welding Sequence Chart

2 SAFETY
Please take the time to read this chapter carefully, as it concerns your safety.
2.1 General statement

"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR
INDIRECTLY CREATES RISKS TO:
[1] THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR,
[2] THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING
UNDERTAKEN.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK
ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL
AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE
PERSONS UNDERTAKING THE WORK.
IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED
BY THIS DOCUMENT TO PROTECT AGAINST RISKS TO THE ROLLS-ROYCE STEERING
GEAR AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM
THEIR RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTION
REFERRED TO ABOVE ARE IMPLEMENTED.
IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME
AWARE OF ANY ROLLS-ROYCE MARINE PRODUCT DESIGN RELATED FEATURE WHICH
COULD CREATE RISK TO A PERSON UNDERTAKING WORK OR TO THE PRODUCT
AND/OR ITS COMPONENTS PLEASE CONTACT THE RESPECTIVE TECHNICAL PRODUCT
MANAGER AT ROLLS-ROYCE MARINE AS IMMEDIATELY."

2.2 Safety Annotations
All safety directions must be respected in order to avoid damage to personnel, environment and
equipment. In this user manual the following annotations are used with belonging signification:
Warning
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal
or severe personnel injuries or substantial product or property damage, if the
required precautions are not taken.
CAUTION!
CAUTION indicates possibilities for hazards or unsafe practices, which COULD result in minor
personnel injuries and/or property damage, if the required precautions are not taken.
Note!
Note draws attention to specific information of technical significance which might not be obvious
to specialist personnel, or points at important remarks in the procedures to follow.
2.3 Declaration of conformity

Rolls-Royce Steering Gears are designed and built as per the following standards according
existing requirements from:
 IMO
 SOLAS
The Steering gears are also designed according to requirements by the following classification
societies:
 Det Norske Veritas (DNV).
 American Bureau of Shipping (ABS).
 Lloyds Register (LR).
 Germanisher Lloyds (GL).
 Bureau Veritas (BV).
 RINA
 ClassNK (Nippon Kaiji Kyokai)
 China Classification Society (CCS)
 Russian Maritime Register of Shipping (RS)
 Korean Register of Shipping (KR)
A Class Certificate is issued for each Steering gear in accordance with the Class of the vessel.

3 SYSTEM DESCRIPTION
The purpose of this section is to give a better understanding of the different parts of the Steering
gear and to ensure safe and efficient operations.
3.1 System overview
The Rolls Royce Steering gear, SR- FCP; is a slow running hydraulic motor with high torque.

The complete Steering gear is normally integrated with two frequency controlled reversible pump
units, valve block and electrical feed back units. The Steering gear has a very compact design,
which minimizes the pipe work during installation at yard.
Compared with a conventional steering gear system where the pump is continuously running and
oil is controlled by a maneuvering valve, the FCP-system works quite different. The normal
situation for FCP is that pump/electric motor not is running. This means that the pump/electric
motor starts when a rudder command signal is given and stops when the rudder has reached the
desired position. The advantages will be lower running time, less energy consumption, less noise,
lower temperature, less wear, a cleaner system and a longer lifetime.
The motor controller (frequency converter) for the electric motor

on each pump unit has separate and independent supply from
the switch boards. The two systems are therefore both
hydraulically and electrically separate and independent. A fault in
one system will therefore not interfere with the operation of the
other unit. As illustrated in the picture.
The steering gear is also equipped with a unique vane sealing

design. The sealings are arranged in a manner that allows them
to absorb spherical movement. The Steering gear absorbs all
radial and axial forces from the rudder.

3.2 Design
The Rolls-Royce Steering Gear SR - FCP design is based on long experience. The unique
spherical design with cylindrical rudderstock is patented in most of the world.
The Steering gear consists of five main parts; rudder actuator [1] pump unit [2], cylindrical
rudderstock connection [3], valve block [4], and rudder stock [5]. Additionally the system consists
of feed back units and expansion tank, if installed, emergency wheel pump.
Pos. Component Chapter

1 Rudder actuator 3.2.1
2 Pump unit 3.2.2
3 Cylindrical rudderstock connection 3.2.3
4 Valve block 3.2.4
5 Rudder stock 3.2.5
(6) Feed back units 3.2.6
(7) Expansion tank 3.2.7
(8) Emergency wheel pump 3.2.8

3.2.1 Rudder actuator
The Rudder actuator consists mainly of:
[1] = Rotor,
[2] = Ring shaped cylinder with vanes and dividing walls

fastened to the rotor,
[3] = Housing (upper and lower),
[5] = ”U” seal on each piston,
[6] = Spherical bearings situated on the rotor.
The vanes work in a ring shaped cylinder with the rudder

stock as the centre. The pistons [2] are fastened to the
rotor in a manner; witch allows them to absorb and adjust
to the spherical deflection of the rotor due to misalignment
in installation or deflection of the rudder stock.
The housing [3] is a cast cylinder with oil channels [4] leading the oil to the different
chambers. The upper and lower housing parts are connected with several bolts.
The synthetic bearing pads maintain 100% surface contact

at all times even as the rudder stock flexes. It will also
absorb and suppress vibrations and shock pulses. The
bearing surface is continuously lubricated by the hydraulic
oil, which ensures long lifetime of the bearings.
The rudder actuator can be delivered with two or three

pistons, which give different rudder angles and developed
torque. The unit develops a constant torque over the full
rudder angle.

3.2.2 Pump unit
The motor [2] for each pump unit starts when a rudder
command signal is given and stops when the rudder has
reached the desired position. The power for operating
control and steering systems are both hydraulically and
electrically separated and independent.
The power pump units consist of four main parts:
[1] = Reversible pump,
[2] = Electric motor,
[3] = Bell house,
[4] = Flexible coupling.
When both pump units are running the ship will achieve 100% speed condition in proportion to
the size of the pump units. The most common pump is the gear wheel pump. Some pump models
have extra accessories.
3.2.3 Cylindrical rudderstock connection

The rudder stock connection is based on hydraulic sleeve coupling by use of an intermediate
sleeve between the steering gear rotor and the rudder stock.
The design provides the obvious advantage that the rudder stock is cylindrical, parallel,
through the coupling without keyway, threads or taper complicating the production. The main
advantage with this principle is that there is only one producer of the two conical parts; rotor
bore and sleeve outer surface.
The coupling consists of the following main components:
[1] = Mounting piston,
[2] = Seal ring,
[3] = Rotor,
[4] = Tapered sleeve,
[5] = Rudderstock,
[6] = O-ring.
3.2.4 Valve block

The integrated valve block with filter units has fewer and less complex valves due to the
reversible pumps.The distributing valve housing is flanged to the housing of the Steering gear
and contains:
 Non-return valves,
 Load sense valves,
 Solenoid operated isolating valves,
 Relief valves,
 Return filters unit.
The relief valves are adjusted at the factory to the design pressure stated in the technical
information.

3.2.5 Rudder stock
The cylindrical rudder stock simplifies the manufacturing
and eliminates the blue fit tests and allows for rudder stock
height adjustment.
Accurate length of rudder stock is not required.
3.2.6 Feed back units

The Steering gear is equipped with two separate feed
back units, one for each system. The feed back unit
contains:
 Transmitter for the rudder indicating system
 Switches for limitation of the rudder travel
 Transmitter for the control system.
The unit is factory fitted to a bracket flanged to the top of

the actuator. The drive for the feedback unit is provided as
a chain/belt drive to the rotor. The chain/belt is pre-
tensioned by a spring to eliminate play.
The drive shaft follows the turning of the rudder stock and
transfer the movement to the potentiometers and the
tripping releaser for the limit switches.
The potentiometers can be single, double or triple

depending on the installation. The tripping cams are
adjusted to interrupt the steering signal about 2 degrees
before the rotor reaches mechanical stop.

3.2.7 Exspansion tank
The expansion tank must be installed according to
specifications by Rolls-Royce Marine.
The expansion tank contains gauge glasses indicating

minimum and maximum level during normal operation of
the Steering gear, and two electrical level switches
monitoring the oil level.
The expansion tank comes in three different sizes, 25, 60

or 120 liters. The 60 and 120 liters expansions tanks are
equipped with two extra plugs for use if the pump unit is
fitted with accessories.
The lower section of the expansion tank is divided internally into two separate sections by a
dividing wall. This is to prevent both pump units from losing oil, in case there is a leakage
from the unit or corresponding piping. The volume of the upper section is common for the
total hydraulic system. In case of leakage from one of the pump units the other pump can
continue operating without interruption.
Apart from the cocks for connecting the expansion pipes, the expansion tank also contains
connections for storage tank, drain plug, inspection cover with filler cap, strainer and air filter.

3.3 Function
The ring shaped cylinder is divided into chambers by dividing walls. The rudder command signal
controls the maneuvering pump and directs the oil flow to the chambers of the rotor. The rotor
will then turn in the direction corresponding to the control signal. When the ordered position is
reached, the maneuvering pump will stop and a hydraulic blocking valve will lock the position of
the rudder.
The built-in blocking spools in the maneuvering valve and the wheel pump automatically lock
the rudder in any desired position. They also prevent outside forces from being transferred to
the wheel pump.
If follow-up steering (analogue steering) is installed, the steering lever is turned to the desired
rudder angle; the rudder will then travel until the selected angle is reached. The steering system
can be supplied to accept either analogue or on/off command signal from the autopilot, joysticks
or dynamic positioning system.

4 DELIVERY SPECIFICATIONS
Please refer to Technical Specification.

5 TECHNICAL DATA
This chapter contains technical data, and similar relevant information.
5.1 Steering gear, SR-series
Model Number of Max working Max mechanical Weight approx

Vanes torque [kNm] rudder angel [kg]
SR 562 2 40 2 x 61 o 450
o
SR 622 2 70 2 x 72 800
SR 642 2 110 2 x 72 o 1200
o
SR 662 2 170 2 x 72 1800
SR 722 2 275 2 x 72 o 2750
o
SR 723 3 412 2 x 44 2800
o
SR 742 2 433 2 x 74 3700
o
SR 743 3 650 2 x 44 3800

5.2 Oil recommendations
. Warning
 Using oil other than specified by Rolls-Royce Marine may cause

malfunctions when manoeuvring the vessel. This may cause personal
injury and equipment damage.
 Before using other brands, please contact Rolls-Royce Marine.
Note!
The oil is one of the main components in a hydraulic steering gear, and must therefore be
selected and handled with this in mind. The performance of the unit is highly depended on the
viscosity of the oil. The surrounding temperatures of the hydraulic components when operating at
extreme temperature conditions, tropic or arctic waters, shall be taken into account when
selecting type of oil.
General requirement to the hydraulic fluids used on Rolls Royce Steering Gear should meet DIN
51524.
 The viscosity index improve must not be broken down and effect flow and lubrication
properties
 Pour point should be below -30o centigrade.
 The oil must contain the following additives.
 Performance qualities:
a. Anti-wear properties
b. Water and foaming resistance
The following hydraulic oils are approved and recommended by Rolls Royce marine
Manufacturer Type
AGIP AGIP ARNICA 32
BEVEROL HV-ISO32
BP BARTRAN HV32
CALTEX RANDO HDZ32
CASTROL HYSPIN AWH-M 32
CENTURY NEVIS 7
CEPSA CEPSA HV 32
CHEVRON RANDO HDZ32
SHELL TELLUS T32
STATOIL HYDRAWAY HVXA 32
TEXACO RANDO HD Z32

Manufacturer Type
YUKONG ZIC SUPERVIS X32
EXXON MOBIL DTE10 EXCEL 32
NYNÄS HYDOL 32
ESSO (Exxon) UNIVIS N 32
HISPANO
HYDRO DRIVE HP150
QUIMICA, S.A
LUB MARINE
VISGA 32
(TOTAL)
MOBIL SYNTHETIC MOBIL SHC 524
CAUTION!
Do not mix hydraulic oil with other types of oil. Even very small amounts of other oil in the
hydraulic oil, will considerably lower the quality of these oils.
Change the oil when laboratory tests show:
 High neutralizing number
 Low remaining amount of EP-additives
 High amounts of insoluble particles in the oil
 Oil cleanliness no longer is within 17/14 or better according to ISO standard 4406, class 8 or
better according to NAS 1638
 If components of the hydraulic system have been broken down.
5.2.1 System oil volume
Model Oil volume

SR 562 Approx 35 litre

5.3 Standard painting specifications
 The paint coating offers protection against corrosion under normal transportation, storage,
and outfitting periods.
 The yard carries out the final treatment according to the total painting system for the ship.
 Paint and color according to RRCM standard, if not other specified.
Preparation before coating must adhere to the following specifications:
Specification Applies to
ISO 8501-1 Surface preparation.
ISO-8503—1 Steel roughness. (Medium (G) Ry 50-80 micron.)
ISO 8502-3 Dust-free testing before painting
ISO 8502-4 Climatic conditions during painting

6 HANDLING AND PRESERVATION
6.1 Delivery check

Immediately upon arrival, the equipment must be unpacked and inspected. If there are any
complaints, you must inform Rolls-Royce Marine as soon as possible.
During the testing before delivery, the unit has been filled with hydraulic oil.
The oil should meet the requirements stated in chapter 5.1. In chapter 5 you can also find the
volume of oil.
6.2 Storage
The equipment is packed and conserved for shipment and storage for 6 months - unless
otherwise agreed in writing. Storage days are counted as delivery date to first start-up.
During storage, it is important to protect the equipment against corrosion as well as moisture and
dust.
At the shipyard, store all goods indoors. Temporary built shelters with good ventilation can be
used for some heavy components. Dust free environment is necessary for storing electrical
equipment. However, assembled machinery and electric motors must be stored in an area
without ground excitation.
Immediately after installation, the hydraulic system and Steering gear has to be filled with oil.
All openings and pipes are to be sealed off at all times. Fill the pipes with oil to inhibit rust.
Preferably use oil specified by Rolls-Royce Marine.
The Steering gear must be rotated at intervals if installed or stored in an area close to working
machinery which causes ground excitations.
Electronic equipment should be protected from excessive dust and humidity.

7 INSTALLATION
Note!
Note!
It is highly recommended to read this entire chapter before starting any installation work.
Warning
 Never work alone when installing heavy components, even when using
secure lifting equipment such as lockable block and tackle. Most lifting
devices require two people, one to operate the lifting device and another
to ensure that the components do not get caught and damaged.
 Using hydraulic oil other than that specified in this manual may cause
malfunctions when manoeuvring the Steering gear. This may cause
injuries to the personnel and damage to equipment.
 Always wear protective goggles if there is a risk of splinters, grinding

sparks and splashes from acids or other chemicals. Eyes are extremely
sensitive and an injury to them can result in loss of sight.
CAUTION!
 Each Steering gear has its own serial number stamped on; the sign is fastened to the upper
housing. The hydraulic coupling; sleeve and mounting piston, corresponding to the actual
Steering gear are stamped with the same serial number.
 For twin installations it is important that the correct hydraulic coupling is connected to the
correct Steering gear. (The sleeve has its serial no. in the lower end, and the mounting piston
on top).
 The upper cylindrical part of the rudderstock has to be checked for correct diameter and
tolerance G7. The hydraulic coupling; sleeve and mounting piston, is supplied in a separate
box during consignment. The covers covering the Steering gear rotor bore must be removed.
 The parts have to be handled with great care to avoid any damage. All scores and marks
have to be removed carefully by polishing. Without being able to maintain a sufficient oil film,
the sleeve and rotor will come in contact when the sleeve is driven up by the mounting pump.
This may cause scuffing of the surfaces and the coupling will get stuck before the prescribed
pull up length is obtained.
Note!

7.1 Installation overview
Component Seq. Procedure Tools Reference Cha.
1 Lifting Lifting equipment 7.2
2 Installation of Mounting piston “Dimension drawing” 7.3
Steering gear Wrench “Appendix A”
with locking ring
Measuring clock “Foundation drawing”
assemblies (if
applicable)
3 Installation of Chain tackles. “Dimension drawing” 7.3
Steering gear Mounting piston “Appendix A”
with hydraulic Wrench “Foundation drawing”
coupling (if
Support wedges
applicable)
4 Filling of oil / Mounting pump 7.3.1
“pulling – up” Injector pump
Wrench
5 Installation of “Dimension drawing” 7.4
Steering exspansion tank “Piping diagram”
Gear
6 Piping Bending machine “Piping diagram” 7.5
instructions Wrench
7 De-airing “Assembly drawing” 7.6
“Piping diagram”
8 Dismantling and Chain tackles “Dimension drawing” 7.7
re-installation of Mounting pump “Appendix A”
Steering gear Injector pump “Foundation drawing”
with locking ring
Wrench
assemblies (if
applicable)
9 Dismantling and Chain tackles “Dimension drawing” 7.7
re-installation of Mounting piston “Appendix A”
Steering gear
Wrench “Foundation drawing”
with hydraulic
coupling (if Measuring clock
applicable)

7.2 Lifting
Spare parts Ref. no Special tools and test Qty
equipment
Lifting equipment
Reference documents Consumables Qty
The actual Steering gear unit is delivered in one part. The mounting piston and sleeve coupling
are delivered as separate parts. For weights see Chapter 5.1.
Use the three lifting eyebolts [1] on top of the mounting piston,
as illustrated in the picture to the right.
Use the four lifting eyebolts[2] fitted on the Steering gear

housing as shown in the picture to the right
Note!
Lifting equipment is the ship yard`s responsibility.

7.3 Installation of Steering gear
equipment
Mounting piston tool 1
Support wedges As req.

“Dimension drawing”
“Appendix A“
Pos Description
1 Mounting piston (nut)
2 Sleeve coupling
3 Support wedge

Pos Description
4 O-ring
(5) Spacer
(6) Adjusting screws
(7) Bolts
Note!
The rudderstock has to be locked and secured by chain tackles outside the hull at the correct
level and alignment.
1. The sleeve, mounting piston, rotor bore and rudderstock has to be thoroughly cleaned,
de-greased and inspected carefully.
2. The rudder stock can be wetted by marine diesel oil to simplify lowering of the sleeve.
CAUTION!
Do never use any lubricant other than marine diesel oil between the sleeve and rudderstock,
as this may cause the coupling to slip
3. After thoroughly inspection, lubricate the outside of the sleeve with oil.
4. Fit the mounting piston [1] to the sleeve [2] and lift the
assembly by the eyebolts in the bores provided in the
mounting piston.
5. Enter the sleeve [2] over the rudderstock. Lower it

carefully until the lower end of the sleeve is approx
150 mm below top of foundation.

6. Support the sleeve [2] by using support wedges [3] to
the rudderstock
7. Remove the mounting piston
8. Lubricate rotor bore with oil.
9. Centre the actuator, hanging in chain tackles over the

rudderstock, as accurate as possible. Check that
alignments of rudderstock and rotor centre line is as
close as possible
10. Lower the actuator carefully over the rudderstock until

it sits lightly on the sleeve`s cone. Do not allow the
actuator to sit on the sleeve by its full weight.
11. The seal between the mounting piston [1] and sleeve
[2] is provided by an o-ring [4] in the groove on top of
the sleeve.
12. Ensure that the o-ring [4] is in good condition prior to

installation.
13. Lubricate threads on sleeve [2] and mounting piston

[1] by Moly Coat (MoS2).
14. Fit the o-ring [4] into the groove in sleeve [2] upper end.
15. Lower the mounting piston [1] and turn it carefully tight against the sleeve, using the
wrench provided for the purpose, and knock it tight lightly using a hammer.
The steering gear must remain hanging in the tackles during the further procedure.
16. Lift the Steering gear just a little to remove the supporting wedges.
17. Check that the level of the rudderstock is correct and adjust level of actuator in order to
obtain clearance between foundation and bedplate equal to height of spacers plus “pull-
up” length.

7.3.1 Filling of oil / “Pulling up”

equipment
High pressure pipe 2
Injector pump 2
Mounting pump 1
Adapter block 2
Note!
 The mounting pump and the injector pump shall use the same oil. The oil provides lubrication
of the outside of the sleeve during pull-up and lowering.
Recommended viscosity is about 300 cst at 20°C at normal tempered conditions. Working at
lower temperatures, the oil should be tempered or use thinner oil (100 cst at 50°C). Low
viscosity oil will spread easier over the contact surfaces between rotor and sleeve. This is of
vital importance both during assembly and dismantling of the coupling.The oil type and
viscosity used must follow the Rolls-Royce Marine instructions.
1. Fill the injector pump [1] and the mounting pump [2] with
the prescribed oil.
Note!
 The oil type and viscosity used must follow the Rolls-Royce
Marine instructions.
2. Connect the injectors to the Steering gear. Connect the injector pump [1] to the rotor, and
mounting pump [2] to the mounting piston, by the extension high-pressure pipe/hoses [3].
The rotor is locked mechanically in zero-position by transport brackets consignment and

assembly. This is to keep the rotor in place until the hydraulic coupling is fitted.
3. Build up the oil film between the sleeve and rotor by operating the injectors [1] and [2]. Start
to operate the mounting pump and injector simultaneously and slowly.

4. Find and mark the reference height, “zero-point”, when the
sleeve is tight against the rudderstock.
5. Move / rotate the Steering gear forward and backward a

little during the pulling.
Correct “zero-point” is when the actuator is tight (fixed) and the

injector pressure is drained.
6. At this point the distance between base of the Steering

gear (base of eye bolt foundation) and top of foundation
should be the actual “pull-up” plus the thickness of chock
fast / spacer. As illustrated in the picture.
7. Start to operate the mounting pump and injector pump

simultaneously and slowly. The chain must be lowered
simultaneously during “pull up”.
CAUTION!
If the sleeve enters in steps, i.e. jumping, when the mounting pump is operated, this indicates
that the oil film between the sleeve and rotor is not sufficient. This may cause scuffing of the
surface. Stop operating the mounting pump while operating the injector to restore the oil film
before continuing operating the mounting pump. The travel of the sleeve must be smooth and
even.
Note!
 An increase of pressures will be noticed on both pumps during the “pulling” and is monitored
by the pressure gauges equipped.
 When the actual “pull-up” length is reached, the operation has to be stopped and injection
pressure must be drained.
8. Mark the position of mounting piston below the zero point for further reference. The drive-
up/pull-up length will differ from one coupling to another depending on the rudder stock
diameter and classification requirement.
CAUTION!

Do not exceed the required drive-up/pull-up as this may deform the coupling.
9. Remove the pipe / hoses and plug all connecting points not in use.
10. Remove transport brackets [5] and adjust level and

alignment of actuator by the adjusting screws [6] on the
foundation brackets - according to tolerances as described
in step 10 below.
11. Fit a ruler [4] on top of the rotor. Use a micrometer to

monitor relative vertical movement between the top edge of
the rotor and the mounting piston, as illustrated on the
picture. Maximum divergence should be within +/- 0, 25.
12. Monitor movement to front, sides and rear as illustrated in

the picture.
13. Check alignment of rudder stock lower bearings and neck bearing, to centre the actuator on
the foundation.
Note!
Do not apply turning force on housing, as this may disturb the zero angel position of the rotor.
14. Use a rag over the by-pass screw for protection. Remain the mounting pressure for half an
hour and re-check the “pull-up” distance. Bleed the pressure and re-check the distance

15. Re-check alignment of housing and weld side stoppers to foundation and fit wedges. Spot-
weld.
16. Adjust steel spacers if steel are intended.
17. Disconnect pressure pipes between the hydraulic pump and valve block, and plug all
connections by blend plugs.
18. Loosen and remove the electric motor.
19. Drill and ream for foundation bolts.
20. Fit foundation bolts [8], and nuts [7] to correct torque. Nuts
to be locked by counter nuts.
Note!
If epoxy resin is intended follow producers/manufacturers
procedure.
CAUTION!
Neither load nor torque should be applied to the coupling within 24 hours after assembly. The
bores for the injector pump and mounting pump have to remain open in order to evacuate the oil
film and thus obtain the required friction between the surfaces.
21. After the installation of Steering gear is completed, some classification authorities
recommend that two alignment marks should be stamped, one on the rudderstock and one
on the rotor eventually on the housing. This to easier observe if the connection should slide
a bit. (If the rudder for instance has touched the sea floor).
22. Refit the electric motors and connect all pipes correctly.
23. Perform the de-airing procedure as described in chapter 7.7.

7.4 Installation of expansion tank
Spare parts Ref. no Special tools and test equipment Qty
Reference documents Page Consumables Qty
”Dimension drawing”
1. The expansion tank is to be fitted on a vertical bulkhead

as close to the Steering gear as practically possible.
2. Install the expansion tank 0-2m above the top of the

Steering gear.
3. Connect the expansion tank by separate pipes to each

pump unit and one to the Steering gear.
4. The filter [1] and filler cap [1] situated on top of the
expansion tank must be easy accessible for oil filling.
5. Connect the fixed storage tank [5] for hydraulic oil to the
connection [2] provided on the side wall of the
expansion tank. The expansion tank is always to be
connected to a storage tank, normally located below the
expansion tank. On the pipe line between the two tanks
there is a manual pump [6].
6. Test the oil level alarm [3] by removing the two fixing
bolts and lifting it out of the oil.
CAUTION!
The cocks [4] flanged to the bottom of the tank must be easy
accessible for operation in case of emergency.

7.5 Piping instructions
Bending machine 1
”Piping diagram”
Note!
The components have nut and cone ring fittings according to DIN 2353 or welding flanges.
If welded pipes are to be used, the following procedure is to be followed:
1. Thoroughly clean and pickle the welded pipes in 20% sulpheric acid for at least 4 hours.
2. Flush thoroughly with water, and then fill with hot solution of sodium carbonate. Leave the
solution for 1 hour.
3. Flush the pipes once more with hot water, and then dry the inside of the pipes.
4. Cover inside surface pipe surface with oil
When laying pipes, the following guidelines are to be followed:
5. Clean pipe ends well after the pipe has been cut at right angles.
6. Remove any burrs
7. Lubricate the fitting with oil before the nut and cone ring is pushed on to the pipe.
8. Press the end of the pipe hard into the fitting to get the pipe into the right position.
9. Tighten the nut so that the cone ring cuts into the correct position.
10. Tighten the nut so that the cone ring cuts into the pipe, and tighten a further 1-1, 5 turns.
11. Undo the nut and check that the cone ring has cut properly into the pipe. Re-tighten the nut.

Note!
 Cleanliness during installation is essential.
 All pipes must be thoroughly cleaned for swarf, dust, welding slag etc. before fitting to ensure
safe and trouble free operation of the unit.
 All pipes must be well shaped and installed with only the minimum of bends.
 To adjust pipe dimensions to national standards, it may be necessary to use caliper pipes to
enter the pipe couplings provided on the components.
 Approved welding flanges are recommended for large pipe diameters.
 All pipes should be laid with an incline to ease de-airing of the system.
 Avoid air pockets, where this is not possible; install de-airing plugs at the highest points.
 Do not use filler material and heat when bending pipes, but bend in cold condition using
suitable tube bending equipment.

7.6 De-airing
Wrench
”Assembly drawing”
”Piping diagram”
Warning
 Never operate the Steering gear too hard over position, or against
mechanical stop when de-airing the unit.
 Running against mechanical stop will give full pressure in the system
depending on the setting of the relief valves.
 If air is left in the system this may be heard as increasing noise from the
pumps. They must then be stopped to avoid damage.
1. All FCP Steering gears are delivered from factory filled with oil. However, due to piping and
assembling work the pumps and pressure pipes have to be refilled and de-aired after the
installation of the Steering gear is completed.
2. Loosen all pipe connections on the pumps and turn the corresponding cocks on the
expansion tank to open position.
3. When clean oil appears tighten the connection correctly.
4. Check that the power supply from the main switchboard to each motor controller is correct
and each electric motor is connected for the correct supply.
5. Turn the switch on the motor controller to position 3 “local control”. Check that the direction of
the Steering gear is correct by operating the manual emergency push buttons in front of the
motor controller.
6. Start one pump, unscrew starboard de-airing plugs on the Steering gear 2-3 turns and make a
brief manoeuvres to port by operating the emergency push buttons.

7.7 Dismantling and re-installation (hydraulic coupling)
equipment
High pressure pipe/hose 2
Injector pump 2
Mounting pump 1
Mounting piston tool/ wrench 1
Adapter block 2

“Dimension drawing”
“Appendix A”
“Foundation drawing”
The principles for dismantling are that the oil injection pump will expand the rotor and build up
an oil film between the rotor bore and the sleeve. When the parts are separated the coupling
sleeve will shut down, driven by the tension and taper until arrested by the mounting piston.
1. Provide arrangement for carrying the weight of the rudderstock and to perform controlled
lowering.
2. Ensure all connecting oil pipes are disconnected.
3. Check that the mounting piston [1] can be loosened on

the sleeve with the wrench [2] provided for the
purpose. If the mounting piston should be found stuck
on the sleeve, it must be checked while the sleeve is
still locked to the shaft. Re - tighten the nut by hand
only.
4. Operate the Steering gear to mid position.
5. Fill up the mounting pump [5] with clean oil
6. Connect the hoses [4] to the bore leading to the

cylinder formed by the mounting piston and the rotor.
7. Fill the mounting piston with oil by using the mounting

pump [5]. This in order to hold the sleeve when free.
Breathing of cylinder can be performed by inserting a
thin feeler gauge pass the seal.

8. Fill up the injector pump [3] with oil and air bleed.
9. Connect the injectors via the enclosed extension high-

pressure houses to the bores on the rotor, leading to
the surface between the sleeve and the rotor. As
illustrated in the picture [6].
10. Further air bleed the injector pump by taking a few

pump strokes, with the by-pass screw open, until air
free oil is flowing from the screw.
11. Build up a pressure of 30 - 40 bars at the mounting pump, and maintain this pressure by
compensating for possible leaks.
12. Operate the injector slowly to spread an oil film between the sleeve and the inside of rotor
surface. If the pump shaft has a spring action, breathe further.
CAUTION!
It takes a certain amount of time to spread the oil film, and a too rapid and inpatient pumping
at this step might damage the coupling. It should be possible to notice a gradually increase of
the required force when operating the injector.
When the oil film is spread, and the rotor is loose, the pressure at the mounting pump might
have a sudden increase from the pre-set pressure of 30 - 40 bars to 150 - 200 bars.
13. Continue to maintain the film by working the injector pump slowly.
14. Lower the coupling sleeve and rudderstock by throttling the by-pass and cock on the
mounting pump.
Note!
 The rudderstock will drop free when the sleeve is lowered the original pull up length.
Suitable arrangement has to be provided to avoid damage.
 During lowering of the sleeve, the injector has to be worked rapidly as it takes all the
delivery of oil they can give to maintain the oil film when the coupling slides down.
CAUTION!
It is extremely important to maintain the oil film at this stage as contact between the sleeve
and rotor bore may score the surfaces.
15. Operate the injector until the sleeve can be turned on the shaft.

Warning
 Do never attempt to remove the coupling without the mounting piston

. properly fitted and 30 to 40 bars on the mounting pump. If this is
omitted the sleeve and shaft will shoot off by an acceleration force in
way of 400kN. (Approx. value for rudderstock diameter of 360 mm).
16. Dismantle all piping connected.
17. Dismantle the foundation bolts and welded side chocks.
18. Lift the Steering gear free from the foundation by the
eye bolts.
19. Lift the sleeve of the rudder stock by the eye bolts
provided on the mounting piston.
20. The sleeve, mounting piston, rotor bore and rudderstock has to be thoroughly cleaned,
de-greased and inspected carefully after each dismantling.
Note!
It may be possible to enter the rudder stock while the Steering gear remains on the
foundation, but the sleeve can easily be damaged when attempting to enter the rudderstock.
To re-install the Steering gear and hydraulic coupling, follow the installation and oil filling/
“pulling-up” procedures.

8 COMMISSIONING
8.1 Precautions before start-up
Warning
In the event of a malfunction during the test program for the control system and
the hydraulic system, investigate and remedy the malfunction immediately.
Operating a vessel with a malfunction in the control system or in the hydraulic
system may cause personal injury and equipment damage.
Caution!
CAUTION!
 Check that all mechanic and hydraulic components are mounted as specified (in case of
any alterations since the installation period) and that nothing is missing.
 Check that all electrical connections are completed.
 Check that all cabinet earthing are made properly.
 Check that electric power is available (but do not power up!).
 Ensure that the work will not be disturbed by testing of other machinery or painting.
 Keep the appropriate type of oil available for topping up.
 If services of other companies are used to run the prime mover, make necessary
arrangement to organize this.

8.2 Activities performed by the shipyard personnel
Items to be checked off before startup Checked Sign.

Is the Steering gear installed on foundation/rudderstock
Are the Steering gear and rudder blade both installed on leading line for
mid-ship position
Are transport bracket removed
Is the Steering gear aligned to makers specification
Have fitted foundation bolts been used
Are proper side chocks welded in place
Are all hydraulic pipelines installed and flushed
Is correct hydraulic oil filled to whole system
All electric cables installed in steering gear room
Correct electrical supply available in steering gear room
All cables/wiring connected in ECR
Correct electrical supply available in ECR
All equipment / wiring installed on bridge
Correct el supply available on bridge
Any breakages/defects noted on any equipment
Can the rudder be turned freely during commissioning
Please list any damaged items here with probable cause of damage:
Date:
Stamp/Sign:

9 CONTACT LIST
Country Address Telephone Fax
Rolls-Royce Marine AS +47 815 20 070* +47 70 20 86 00
Deck Machinery & Steering gear
Brattvaag
Serviceboks 1522
Norway
N-6025 ÅLESUND, NORWAY
Deck.machinery.brattvaag@rolls-
royce.com
* 24 hr emergency
North America
Rolls-Royce Canada Ltd +1 902 468 2883 +1 902 468 2759
(GSN Commercial Marine)
196 Joseph Zatzman Drive, Unit 9
Canada
Dartmouth, Nova Scotia B3B 1N4
Canada B3B 1N4
UMLH@rolls-royce.com
Rolls-Royce Marine Inc. New Orleans +1 504 464 4561 +1 504 464 4565
200 James Drive West
St. Rose, LA 70087 USA
marianne.leine@rolls-royce.com
Rolls-Royce Commercial Marine +1 954 436 7100 +1 954 436 7101
10125 USA Today Way
Miramar, Fort Lauderdale
Florida 33025 USA
USA marianne.leine@rolls-royce.com
Rolls-Royce Marine Inc +1 508 668 9610 +1 508 668 2497
110 Norfolk Street
Walpole, MA 02081 USA
marineinfo@rolls-royce.com
Rolls-Royce Marine Seattle +1 206 782 9190 +1 206 782 0176
1731 – 13th Avenue SW
Seattle, WA 98134-1009
seattle.marine@rolls-royce.com
South America
Rolls-Royce Marine Ltda +55 21 3860 8787 +55 21 3860 4410
Rua General Jose Cristino 31
20921—400 São Cristovão
Brazil
RIO DE JANEIRO RJ, Brazil

Asia
Rolls-Royce Marine Shanghai +86 21 5818 8899 +86 21 5818 9388
No. 1 Xuan Zhong Road - Nan Hui
Industrial
China
Zone
201300 SHANGHAI
Merchant.marine@rolls-royce.com
Rolls-Royce Maine Hong Kong Ltd +852 2526 6937 +852 2868 5344
Rm. 4103 41st Floor, Hopewell Centre
Hong Kong 183 Queen`s Rd East,
Wanchai, HONG KONG SAR
service.hongkong@rolls-royce.com
Rolls-Royce Mumbai, +91 22 6640 38 38 +91 22 6640 38 18
103, Windsor, Kalina, Santacruz
India (East)
Mumbai-400 098
marine.india@rolls-royce.com
Rolls-Royce Marine Japan K.K +81 3 3237 6861 +81 3 3237 6846
Tobunsha Bldg. 4F
2-5-1, Kudan-Minami
Japan
Chiyoda-ku
TOKYO 102-0074 JAPAN
tokyo@rolls-royce.com
Rolls-Royce Marine Korea Ltd +8 251 831 4100 +8 251 831 4101
Noksan Industrial Complex 18B-2L
1578-1, Songjeong-dong,
Korea
Gangseo-gu
BUSAN 618-270 Korea
jane.park@rolls-royce.com
Rolls-Royce Marine +7 4232 495 484 +7 4232 495 484
Vladivostok Rep Office
Russia 5F, 3-B, Streinikova Str.
Vladivostok 690065, Russia
ulstein@mail.primorye.ru
Rolls-Royce Marine Singapore Pte Ltd +65 686 21 901 +65 686 32 165
No 6 Tuas Drive 1,
Singapore
SINGAPORE 638673
Europe
Rolls-Royce Marine Benelux B.V. +31 10 40 90 920 +31 10 40 90 921
Werfdijk 2 (Port 2828)
Benelux
3195 HV Pernis Netherlands
benelux.service@rolls-royce.com

Rolls-Royce Marine AS +45 9930 3600 +45 9930 3601
Vaerftsvej 23
Denmark
DK-9000 AALBORG Denmark
denmark.marin@rolls-royce.com
Rolls-Royce Marine Oy Ab +358 2 83791 +358 2 8379 4808
PO Box 220 (Suojantie 5)
Finland
FIN-26100 RAUMA Finland +358 4 006 66678
rolls-royce.finlanf@rolls-royce.com
Rolls-Royce Marine France +33 1 468 62811 +33 1 468 79398
Immeuble de Monaco
France 4 Place des Etas-Unis, Silic 261
F-94578 RUNGIS Cedex France
mariann.leine@rolls-royce.com
Rolls-Royce Marine Deutschland +49 40 381 277 +49 40 389 2177
Stettiner Strasse 3
Germany
D-22850 Norderstedt
sales.hamburg@rolls-royce.com
Kaminco Overseas Inc +30 1 45 28 240 +30 1 42 94 887
Presented by KAMINIS Co Ltd
Greece
57 Akti Miaouil PO Box 80115 +30 1 42 93 355
GR-PIRAEUS 18510 Greece
Rolls-Royce Marine Italia s.r.l. +39 010 749 391 +39 010 749 3950
Via Castel Morrone, 13
Italy
16161 Genova
genova.marine@rolls-royce.com
Rolls-Royce Marine Poland +48 58 782 06 55 +48 58 782 06 56
Alfa Plaza Building
Poland
28-32 Batorego Street
81 366 GDYNIA Poland
agnieszka.werra@rolls-royce.com
Rolls-Royce Espana SA +34 977 296 444 +39 977 296 450
Poligono Industrial de Constanti
Spain c/Dinamarca
E-43120 Tarragona
rrme.spain@rolls-royce.com
Rolls-Royce AB +46 550 84000 +46 550 18190
Box 1010
Sweden
S-681 29 Kristinehamn Sweden 46 70 528 6566*
rrab.Sweden@rolls-royce.com
Rolls-Royce Commercial Marine Ltd +44 1322 312028 +44 1322 212054
UK Nucleus, London Science and
Business Park
Brunel Way, Dartford, Kent DA1 5GA

sales.Dartford@Rolls-Royce.com
Australia
Perth Office +61 8 9336 7910 +61 8 9336 7920
Unit 2, 8 Wallace Way
Fremantle, WA 6160, Perth +61 418 567 523*
doug.brice@rolls-royce.com
Australia
Melbourne Office +61 3 9873 0988 +61 3 9873 0866
Unit 1, 87 Heatherdale Road
Ringwood, Victoria 3134, Melbourne +61 417 323 077*

10 FINAL INSPECTION AND TEST PROCEDURE
10.1 Function test
Test Checked
Make sure that the “Installation checklist”, chapter 8, has been thoroughly run
through.
Browse through the installation and verify that everything is according to the
instructions and specifications. Check the oil filling, the electrical connections, the
shaft alignments and the piping.
Power up the hydraulic units and verify that all set points on pressure switches,
transmitters, indicators and sensors are according to specifications/drawings.
Check remote start/stop, alarms and shut down signals.
Test the different systems applicable to this particular installation and preliminary
tune to best behavior.
10.2 Harbor acceptance test

This form is to be properly filled in and returned to the Rolls Royce Marine, if any problems should
occur to the Steering gear or the belonging system.
Harbor acceptance test is to be found on the following pages.

Make: Rolls-Royce Marine AS
Steering gear type:
HARBOUR
Yard:
ACCEPTANCE TEST
Hull no:
Rolls-Royce Marine AS Our order no:
Date:
dept. Deck Machinery &
Steering gear
Responsible: Rolls-Royce Marine AS

Yard:
Purpose of functional test:

The unit was tested to ensure that all system functioned satisfactory.
Following system shall be tested:
1. Hydraulic test
2. Emergency steering from steering gear room
3. Alarm system
4. Main steering position.
5. Aft steering position
6. Port wing steering position.
7. Stbd steering position.
8. External connection.
How to fill in the form:
Not applicable
Test accepted V
Test not accepted FAILED
Hydraulic test
Hydraulic test Pump 1. Pump 2. Pump 3. Pump 4.

o
Maneuvering time (65 <28sec) [Sec]
Safety valves on pump unit [Bar]
Safety valves on rudder motor [Bar]
Emergency steering from the steering gear room

1. Turn the selector switch in front of each motor controller to position 3. “Local control”.
2. Alarm for “power failure control system” will occur.

3. Operate the emergency push buttons in front of the motor controllers:
Emergency Pump 1. Pump 2. Pump 3. Pump 4.

steering
Operate
emergency push
buttons
Alarm system
Main alarm panel (engine control room):
1. Push the “system test” button on the alarm panel for more than 5 seconds.
All alarm lights and buzzers both on the slave alarm panel and on the main alarm panel will now
be tested. All Steering gear control system will be turned on through the auto-start feature (if
delivered). In this way the complete alarm system will be tested.
2. Push the aud./ack.-button once
The buzzer in the main alarm panel will stop if an alarm has occurred.
3. Push the button once more and the auto start loop opening and if the alarm condition is still
present, the alarm lights goes from flashing to steady light, otherwise it is turned off.
Slave alarm panel (bridge):
4. Push the “panel-test” button in the control panel for more than 5 seconds.
All lights and the buzzer shall be activated as long as the button is pushed.
The “audible” button in the control panel stops the buzzer if an alarm has occurred. The alarm
light can only be acknowledged from the engine room.
Alarms to be tested Pump 1. Pump 2. Pump 3. Pump 4.

Overload pump
Phase failure pump
Power failure pump
Power failure control
Power failure aux. steering
Low oil level
Hydraulic lock pump
Clogged filter pump
High oil temp pump
Earth failure pump

General alarm, E0
Main steering position
Function to be tested Pump 1. Pump 2. Pump 3. Pump 4.

Start/stop
Limit switches
NFU emergency steering
NFU steering (aux. steering)
FU steering (aux steering)
Rudder angle indication
Aft Steering position

Start/stop
FU steering (aux. steering)
Port wing steering position

Start/stop
Stbd wing steering position

Start/stop

External connection

Autopilot
Joystick
Dynamic position
Rolls-Royce Marine AS Yard representative
Date: Date:
Sign: Sign:

10.3 Sea acceptance test
Test Checked
When at sea, gradually and gently increase the load according to the illustrated
procedure, following this table.
Oil pressure shall be watched continuously. Observe vibration and noise level on
all equipment.
Note!
Engineer on duty must be informed to react on any alarm!
Perform maneuvering test as specified from classification society.
Ensure that all interfaces towards DP, Joystick and other systems are working
according to specification and customer’s satisfaction.

11 TOOLS
The tools found in the table below, are delivered with the Rolls-Royce Steering Gear.
Art. no. Description Qty. Inst. Comment

MT-7962 Mounting piston wrench 1 SR 722 / 723
MT-8428 Mounting piston wrench 1 SR 742 / 743

12 DESIGN DRAWINGS
The listed drawings are general drawings only. See Technical specifications for complete drawing
set.
12.1 Mechanical
Drawing/ document Document number

Rudder actuator, Dimension drwg. See Tech.Specification
Rudder actuator, Foundation design drwg. See Tech.Specification
Expansion tank, Dimension drwg. See Tech.Specification
12.2 Hydraulic

Piping diagram See Tech.Specification
Hydraulic circuit diagram See Tech.Specification

13 REVISION
Revision Reason for revision Date Signature
- Release 11.02.2010 Stine Ødegaard Urke

INSTALLATION MANUAL
Rolls-Royce Steering Gear
Electrical system
Art.No:
Ser.No:
Yard and hull no. :Shipkits B.V. : SK120

Project no. :12S000638
Date 24. August 2012
TABLE OF CONTENTS
1 INTRODUCTION ...................................................................................... 5
1.1 Purpose .............................................................................................................................5
1.2 Warranty ............................................................................................................................5
1.3 Structure of this manual ....................................................................................................5
1.4 Abbreviations .....................................................................................................................6
2 SAFETY ................................................................................................... 7
2.1 General statement .............................................................................................................7
2.2 Safety Annotations ............................................................................................................8
2.3 Declaration of conformity...................................................................................................8
3 SYSTEM DESCRIPTION ......................................................................... 9

3.1 System overview and design .............................................................................................9
3.2 Control system.................................................................................................................11
3.2.1 Control panels without steering controls .........................................................................11
3.2.2 Alarm system ...................................................................................................................11
3.2.3 Auto start .........................................................................................................................12
3.2.4 Rudder indication systems ..............................................................................................12
3.2.5 Motor controller................................................................................................................13
3.2.6 General power unit ..........................................................................................................13
3.2.7 Feed back unit .................................................................................................................13
3.3 Function ...........................................................................................................................14
4 PROJECT SPECIFICATIONS................................................................ 16
5 TECHNICAL DATA ................................................................................ 17

5.1 Standard painting specifications......................................................................................18
6 HANDLING AND PRESERVATION ....................................................... 19

6.1 Delivery check .................................................................................................................19
6.2 Storage ............................................................................................................................19
6.3 Storage for more than 6 months......................................................................................19
7 INSTALLATION ..................................................................................... 20

7.1 Installation overview ........................................................................................................20
7.2 Component location ........................................................................................................22
7.3 Externals cables ..............................................................................................................23
7.4 Main supply .....................................................................................................................24
7.5 Electric motor...................................................................................................................25
7.6 Adjustment of limit switches in feed back unit .................................................................26
7.7 Adjustment of transmitter of the rudder indicator system ................................................27
7.8 Adjustment of dimmer .....................................................................................................28
7.9 Renew pump control card ...............................................................................................29
7.10 Renew start relay.............................................................................................................30
7.11 Renew alarm system cards .............................................................................................31
7.12 Renew bulb on control panel ...........................................................................................32
8 COMMISSIONING .................................................................................. 34

8.1 Precaution before start-up ...............................................................................................34

8.2 Installation check list and testing .................................................................................... 35
8.2.1 Motor controller ............................................................................................................... 35
8.2.2 Control equipment .......................................................................................................... 35
8.2.3 Dimmer test .................................................................................................................... 35
8.2.4 Alarm System test .......................................................................................................... 36
8.2.5 Function test alarm inputs .............................................................................................. 36
8.3 Harbour acceptance test (HAT) ...................................................................................... 37
9 CONTACT LIST .................................................................................... 41
10 FINAL INSPECTION AND TEST PROCEDURE ................................... 45
11 TOOLS .................................................................................................. 46

11.1 Light bulb dismounting tool ............................................................................................. 46
12 DOCUMENTS, DRAWINGS AND DATASHEETS ................................ 47

12.1 Electric ............................................................................................................................ 47
13 REVISION.............................................................................................. 48

1 INTRODUCTION
1.1 Purpose
The Installation manual provides the information necessary to plan and install the delivered system
safely and correctly. It also enables you to verify the functionality of the equipment.
Also included are instructions for handling of the goods after they have been received at the yard. It
is important that the instructions be followed carefully to avoid problems during outfitting and
commissioning. This manual also provides instructions for all activities essential for commissioning.
1.2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is
misused or not handled in accordance to prescribed standards, for example dismantling the
equipment to a level greater than described.
1.3 Structure of this manual

The first part of this manual describes the Rolls-Royce Steering gear electrical system. This helps
in understanding the maintenance procedures in the subsequent chapters.
Chapter 4 provides project specific information.
Chapter 5 provides technical data.
Chapter 7 includes all installation procedures.
Chapter 8 and 10 provide all information related to commissioning and sea trial.
Note!
A separate user manual is available, and may be ordered specifically from Rolls-Royce Marine as
required.
Note!
All pictures used in this manual are for illustration only.

1.4 Abbreviations
Abbreviation Description
DP Dynamic positioning
DOL Direct Online start
E0 General alarm
NFU or FU steering signal from external equipment as
External steering
joystick, autopilot or DP.
Frequency Conventional: speed signals are controlled

FCON
by frequency converter and direction by solenoid valve
Frequency Controlled Pumps: speed and direction

FCP
signals are controlled by frequency converter
Frequency Emergency: frequency converter reduce

FEMG
speed and power in "emergency mode"
Follow-Up: Rudder moves to the rudder angle set by

FU
operator(Analog steering signal)
In-Command Steering mode/stand take over push button
LED Light Emitting Diode
Non-Follow-Up: Time dependent steering. Rudder

NFU moves as long as the operator activates the steering
lever. (on/off steering signal)
Steering mode Example: autopilot, joystick, DP, NFU, FU etc.

2 SAFETY
Please take the time to read this chapter carefully, as it concerns your safety.
2.1 General statement

"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR
INDIRECTLY CREATES RISKS TO:
[1] THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR,
[2] THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK
ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL
AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE
PERSONS UNDERTAKING THE WORK.
IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED
BY THIS DOCUMENT TO PROTECT AGAINST RISKS TO THE ROLLS-ROYCE STEERING
GEAR AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR
RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTION REFERRED TO
ABOVE ARE IMPLEMENTED.
IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME
AWARE OF ANY ROLLS-ROYCE MARINE PRODUCT DESIGN RELATED FEATURE WHICH
COULD CREATE RISK TO A PERSON UNDERTAKING WORK OR TO THE PRODUCT AND/OR
ITS COMPONENTS PLEASE CONTACT THE RESPECTIVE TECHNICAL PRODUCT MANAGER
AT ROLLS-ROYCE MARINE AS IMMEDIATELY."

2.2 Safety Annotations
All safety directions must be respected in order to avoid damage to personnel, environment and
equipment. In this user manual the following annotations are used with belonging signification:
Warning
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal
or severe personnel injuries or substantial product or property damage, if the
required precautions are not taken.
CAUTION!
Indicates possibilities for hazards or unsafe practices, which COULD result in minor personnel
injuries and/or property damage, if the required precautions are not taken.
Note
Draws attention to specific information of technical significance which might not be obvious to
specialist personnel, or points at important remarks in the procedures to follow.
2.3 Declaration of conformity

Rolls-Royce Steering Gears are designed and built as per the following standards according
existing requirements from:
 IMO
 SOLAS
The Steering gears are also designed according to requirements by the following classification
societies:
 Det Norske Veritas (DNV).
 American Bureau of Shipping (ABS).
 Lloyds Register (LR).
 Germanisher Lloyds (GL).
 Bureau Veritas (BV).
 RINA
 ClassNK (Nippon Kaiji Kyokai)
 China Classification Society (CCS)
 Russian Maritime Register of Shipping (RS)
 Korean Register of Shipping (KR)
A Class Certificate is issued for each Steering gear in accordance with the Class of the vessel.

3 SYSTEM DESCRIPTION
This section provides detailed information about the system to ensure safe and efficient operations.
3.1 System overview and design

The system illustrated is an example of what a Steering gear system with a single rudder
installation can consisting of.
If the installation contains two Steering gears, the systems will include two separated and
independent systems with both independent and synchronized steering of the rudders.
Note
The Steering gear control system can be delivered with different control stations and alarm system.

3.2 Control system
3.2.1 Control panels without steering controls

Each control panel can contain different functions depending on the required installation for the
vessel.
The control panels consist of:
 Panel front with overlay (color: black RAL 9011).
 Operating components connected to printed circuit board.
 Terminal plate wired to control panel.
In chapter 6. Operation you can find an overview of control

panels.
3.2.2 Alarm system

The AS02 alarm system is designed to meet the regulations of the classification societies,
SOLAS and IMO for a ships steering gear system. One alarm system AS02 can monitor two
pumps.
The AS02 alarm system main modules are:
 Alarm panels
 Alarm interface cards
 CAN bus

The main components of the alarm
system are the alarm interface card,
bridge alarm panel [1] and the ECR
alarm panel [2].
The alarm interface cards are

equipped with terminals for sensors
and are located in the motor
controller for each pump. Output
signals to the ships general alarm
system (E0) is also provided in both
alarm panels.
There are normally two alarm panels

for each rudder connected to the
system. One acts as the main alarm
panel (bridge) [1]. If the main alarm
panel fails the slave [2] automatically
takes over.
One system can monitor 2 pumps,

having from 7 to 20 alarms. Each
alarm system has its own network
CAN bus solution with PRDIO 15
CPU cards. The alarm sensor
signals are connected to the
interface cards, one card in each
alarm panel and motor controller.
3.2.3 Auto start

Definition of the auto start [1] function: automatic start of
the other pump unit upon failure of the running pump.
All start / stop panels are equipped with auto start

indication lamps [1]. These lamps will be lit upon an alarm
or by pushing the “TEST” button to the bridge alarm panel.
Note!
The auto start signal is a 3 sec. pulse only.
3.2.4 Rudder indication systems

Each Steering gear has two separate indication system. The rudder indication system can be a 3
wire indication system

3.2.5 Motor controller
3.2.6 General power unit
3.2.7 Feed back unit

3.3 Function
Each Steering gear are supplied with two independent pump units each driven by an electric motor.
The motor controller for the electric motor on each pump unit has separate and independent supply
from the switch boards. The installation can contain one or two Steering gears.
The supply for the control system is powered from corresponding motor controller. The two
systems are therefore both hydraulically and electrically separate and independent.
The pump control card can be used as a separate control system or together with Aux. steering
unit. The pump control card can be interfaced to different steering modes and external equipment.
The functions of the different components can maintain:
Component Function(s)
Control panels without steering controls  Start/stop/auto-start for each pump unit
 Rudder angle selection
 Steering mode selection
 Non-follow-up push buttons with override
 Non-follow-up steering lever
 Follow-up controller
 By-pass and separating system
 Dimmer module
Control panels with steering controls  Non-follow-up steering lever
 Follow-up steering controller
 Rudder indication
Alarm system  Overload
 Phase failure
 Power failure
 Power failure control
 Low oil level
 Hydraulic lock alarm
 Power failure aux steering
 Clogged filter.
 High oil temp
 Earth failure alarm (optional)

Component Function(s)
 Rudder sync failure (optional)
Rudder indication system  Provides continuous indication of the

steering gear actual rudder position.
 According to SOLAS and IMO requirements

two fully redundant separate systems for
each rudder are required.
Motor controller  Interface card for the alarm unit
 Start/stop of pump motor
 Power supply to steering system
 Alarm transmitter (contact/circuit) to alarm

system
 Direction and speed control of the pump
 Power supply to steering system
 Emergency NFU steering
General power unit  Different starting methods
 Frequency converter
Feedback unit  Transmitter for the rudder indication system
 Feed back card

4 PROJECT SPECIFICATIONS
Please refer to technical specifications.

5 TECHNICAL DATA
For project specific technical data not found on this page, please refer to technical specifications.
Solenoid driver Electrical specification

Supply voltage 18-31 VDC
Current consuption Max = 4A
Normal (one solenoid energised) = 0.9 A
Stand-by = 25 mA
Max. input voltage Equal to supply voltage
Max. continuous output current 2A
Alarm relay contact ratings Max. current = 2 A
Max. voltage = 24V AC / DC
Max. power = 30W / 50VS
Dimensions / weight Width = 60mm
Depth = 70 mm
Alarm system AS02

Alarm panels Bridge and ECR
Alarm interface cards One for each motor controller
CAN bus solution RRDIO15 CUP cards

5.1 Standard painting specifications
The components are delivered according to the following specification:
Component Paint Color Amount µm

Panels RAL 9011 Manufacturer`s
standard
Cabinets bridge RAL 7035 Manufacturer`s
standard
Cabinets other RAL 7035 Manufacturer`s
standard
Purchased equipment:
Component Paint Color Amount µm

Frequency converter Manufacturer`s Eloxated aluminium Manufacturer`s
standard standard

6 HANDLING AND PRESERVATION
6.1 Delivery check

Immediately upon arrival, the equipment must be unpacked and inspected. If there are any
complaints, you must inform Rolls-Royce Marine as soon as possible.
Each unit is type approved only when they are located inside the original cabinet.
6.2 Storage
The equipment is packed and conserved for shipment and storage for 6 months - unless otherwise
agreed in writing. Storage days are counted as delivery date to first start-up.
During storage, it is important to protect the equipment against corrosion as well as moisture and
dust.
At the shipyard, store all goods indoors. Temporary built shelters with good ventilation can be used
for some heavy components. Dust free environment is necessary for storing electrical equipment.
However, assembled machinery and electric motors must be stored in an area without ground
excitation.
Immediately after installation, the hydraulic system and Steering gear has to be filled with oil.
All openings and pipes are to be sealed off at all times. Fill the pipes with oil to inhibit rust.
Preferably use oil specified by Rolls-Royce Marine.
The Steering gear must be rotated at intervals if installed or stored in an area close to working
machinery which causes ground excitations.
Electronic equipment should be protected from excessive dust and humidity.
6.3 Storage for more than 6 months

The eelectric parts must be protected from excessive dust and humidity, and be stored under
general dry, clean and healthy temperature and under environmental conditions.
The electronic parts (including electronic circuit cards), must be protected from ESD, and packed in
Electronic Static Discharge bags. The parts must be stored under general dry, clean and healthy
temperature and under environmental conditions.
Note!
The electronic parts must be inspected every month.

7 INSTALLATION
This chapter describes all relevant maintenance procedures and activities to be carried out by the
ship’s crew.
Warning
 Qualified personnel must carry out all electrical installations, and all work must
be executed in accordance with the rules or the classification society.
 Always wear protective goggles if there is a risk of splinters, grinding sparks

and splashes from acid or other chemicals. Eyes are extremely sensitive and
an injury to them can result in loss of sight.
 Do not use components not made by RR-Marine in any of the Rolls-Royce

cabinets. If other product are used the guaranty will be abolished.
7.1 Installation overview

1 Component location Cable diagram 7.2
2 Eksternal cables Cable diagram 7.3
3 Main supply Cable diagram 7.4
Technical data
sheet.
4 Electric motor Cable diagram 7.5
Technical data
sheet.
5 Adjustment of limit Screw driver Technical data 7.6
switches in feed Hexigonal key
back unit
6 Adjustment of Screw driver Feed back unit 7.7
transmitter for the Ohm-meter drawing
Electric rudder indication
equipment system
7 Adjustment of Screw driver Rudder angle 7.8
rudder indicator indicator amplifier
amplifier (3 wire drawing
system if
applicable)
rudder feed back drawing
card (CAN bus if
applicable)
transmitter of the Ohm-meter drawing
control system
10 Adjustment of Screw driver Drawing of amplifier 7.11
control system card

amplifier card
11 Adjust 0-point on Screw driver Cable diagram 7.12

FU-controller
12 Adjustment of Screw driver Technical data 7.13
dimmer
Note!
If components must be renewed during installation the procedures below are to be followed.

1 Renew pump Screw driver Control system unit 7.14
control card drawing
2 Renew the micro Screw driver Drawing of the lever 7.15
switch on steering
lever/ push button
3 Renew limit switch Screw driver Feed back unit 7.16
in feed back unit Soldering tool drawing
4 Renew amplifier Screw driver Control system unit 7.17

card drawing
5 Renew selector Screw driver Control system unit 7.18
card drawing
6 Renew start relay Screw driver Drawing of motor 7.19
Electric controller
equipment
7 Renew solenoid Screw driver Drawing of motor 7.20
driver (only for controller
conventional
system if
applicable)
8 Renew alarm Screw driver Drawing of alarm 7.21
system cards panel
9 Renew bulb on Light bulb Cable diagram 7.22
control panel dismounting tool
10 Repair the Instruction Instruction manual 7.23
frequency converter manual for for frequency
( if applicable) frequency converters
converters

7.2 Component location
Cable diagram
Warning
 The units are type approved only when they are located inside the original
cabinet.
 The components must remain inside the cabinets, and never be pleased
outside its original cabinet.
 The control system CS – is made for bulkhead mounting and is normally mounted on the
bridge or room adjacent to the bridge.
 The cable length from the control system to the bridge equipment must not be more than 100
m.
 The motor controller type MC - is made for bulkhead mounting and is normally mounted in
the steering gear room. The controller must be mounted in a position from where the
mechanical rudder on the Steering Gear can be clearly viewed.
 The control panel type CU – and CM – must be placed easily visible and accessible on the
bridge.

7.3 Externals cables
Cable diagram
 All cables must be approved of the classification society
 The cross-section of the cables for the control and rudder indication system must be
according to the cable diagram.
 The cross-section of the main supply cables to the electric motors must be selected
according to the rules of the classification society. Confer pertaining list of cables for the
installation.

7.4 Main supply
Cable diagram
Technical data sheet
Note!
Special requirements are applicable for selection of the main circuit breaker.
 Power supply to the motor controller must be connected with separate cables directly
from the main switch board.
 The supply of 24V DC for the rudder indicator system and alarm system must be supplied
from a battery with constant supply.

7.5 Electric motor
Cable diagram
Thecnical data sheet
 The electric motor is selected for duty type S6-40% (continuous operating periodic duty).

7.6 Adjustment of limit switches in feed back unit
Spare parts Ref. Special tools and test equipment Qty
no
Screw driver 1
Hexagonal key 1

Technical data chap. 5
1. Remove cover on the feed back unit.
2. Switch off power supply for the Feed back unit.
3. Open the locking screws [1] using a hexagonal key.
4. Move the Steering gear to the limit switch position.
The tripping cams are adjusted to interrupt the steering

signal about 1-2 degrees before the Steering gear reach
mechanical stop.
5. Adjust the position of each ring [2].
6. Tighten the locking screws [1] using a hexagonal key.

7.7 Adjustment of transmitter of the rudder indicator system
no
Screw driver 1
Ohm-meter 1

Feed back unit drawing
1. Check that the rudder and mechanical rudder

indicator on the Steering gear [1] is in zero position.
2. Switch off power supply to the rudder
3. Disconnect the red wire 5 [2] to the centre point of the

feedback potentiometer and the end points (green
and yellow wires).
4. Measure the resistance between one end point and

the midpoint, red-green [3], red – yellow [4]. The
resistance should be approx 2,5 kΩ. The resistance
between each end point and midpoint shall be equal.
If necessary:
5. Loosen the locking screw [5] and turn the

potentiometer [6] until resistance between the end
points and midpoint to each side is equal.

7.8 Adjustment of dimmer
no
Screw driver 1

Technical data chap. 5
1. Locate the PC1024 card located on the terminal list

/plate for the main control panel.
2. Adjust the potentiometer P20 [1] using a screw driver.

7.9 Renew pump control card
no
Pump control card 1 Screw driver 1

Control system unit drawing
1. Switch off power supply for the control system
2. Check that the wiring connection between the control system and motor controller are ok.
3. Loosen all connected wires [1].
4. Loosen the screws [2].
5. Replace the faulty pump control card.
6. Refit all wires and screws.

7.10 Renew start relay
no
Start relay 1 Screw driver 1

Drawing of motor controller
1. Check wiring connection.
2. Check pump control card.
If the above mentioned items are checked and found in order, the start relay must be
renewed.
3. Ensure power supply to the motor controller is

switched off.
4. Locate the defect relay.
5. Loosen all connecting wires [1].
6. Loosen screws [2] on start rely.
7. Renew relay.
8. Refit wires and screws.
9. Turn on power supply.

7.11 Renew alarm system cards
no
Screw driver 1

Drawing alarm panels
If the trouble shooting has concluded that alarm cards

must be replaced, following procedure must be used:
1. Ensure that power supply to the alarm system is

switched off.
2. Loosen the actual card / cards connection.
3. Renew the actual card / cards.
4. Turn on power supply.

7.12 Renew bulb on control panel
no
Bulb Dismantling tools 2

Cable diagram
1. Remove the cover protecting the bulb using the

dismounting tool, as illustrated in the picture.
2. Use tool from the spare parts to remove the bulb.
3. Renew the bulb using the tool.
4. Replace the cover.

8 COMMISSIONING
8.1 Precaution before start-up

Warning
 In the event of a malfunction during the test program for the control system
and the hydraulic system, investigate and remedy the malfunction
immediately. Operating a vessel with a malfunction in the control system or in
the hydraulic system may cause personal injury and equipment damage.
CAUTION!
 Check that all mechanic and hydraulic components are mounted as specified (in case of
any alterations since the installation period) and that nothing is missing.
 Check that all electrical connections are completed.
 Check that all cabinet earthing are made properly.
 Check that electric power is available (but do not power up!).
 Ensure that the work will not be disturbed by testing of other machinery or painting.
 Keep the appropriate type of oil available for topping up.
 If services of other companies are used to run the prime mover, make necessary
arrangement to organize this.

8.2 Installation check list and testing
8.2.1 Motor controller
Motor controller Checked Signed

Power supply from the main switchboard to each motor controller is
correct.
Each electric motor is connected for the correct supply.
Maneuvering pump rotates in the right direction stbd. and port.
Emergency steering is possible, when the selector switch on the motor
controller is set to “local” position.
Remote start from the bridge is possible, when the selector switch on the
motor controller is set to “remote control” position.
It is not possible to use remote start from the bridge, when the selector
switch on the motor controller is set to “stop” position.
8.2.2 Control equipment

Test that the rudder corresponds correctly when given rudder command by the different control
equipment listed below.
Control equipement Checked Signed

Non-follow -up main steering push buttons for each pump unit.
Non-follow -up steering levers for each pump unit.

Follow-up-steering levers for each pump unit.
8.2.3 Dimmer test
Dimmer Checked Signed

The lamps on the bridge Steering gears panel are dimmed when turning
the dimmer knob.

8.2.4 Alarm System test
Function test alarm panel Checked Signed

Activate the buzzer and all visual alarms on the panel by pushing the
“test” button.
Reset the buzzer by pushing the “Ack” button.
Stop visual alarm flashing by a second push on the “Ack” button.
Activate the general alarm system (E0) by pushing the “test” button.
Activate alarms on the corresponding motor controller to test the auto
start.
Overload alarm output from the frequency converter is adjusted to the full
load current of the electric motor. Factory setting.
8.2.5 Function test alarm inputs
Alarm Action Pump Pump Punp Pump Signed

no1 no 2 no 3 no 4
Phase Remove one of the fuses to the phase
failure failure relay.
Power Remove one of the fuses for the
failure start/stop circuit.
Low oil Disconnect the level switch on the
level expansion tank.
Clogged Disconnect the wire connected to the
filter clogged filter sensor.
High oil Disconnect the wire connected to
temperature temperature sensor, normally located
on the pump. (Steering gear with oil
cooler).
Earth failure Disconnect the wire connected to earth
failure relay in the motor controller.
Power failure aux. steering/feed back unit Checked Signed

Remove the fuses for the aux. steering in the motor controllers.
Disconnect one of the wires connected to the feed back unit
Hydraulic lock alarm Checked Signed

Maintain the test of the hydraulic lock alarm as described below

8.3 Harbour acceptance test (HAT)
Make: Rolls-Royce Marine AS

Steering gear type:
HARBOUR
Yard:
ACCEPTANCE TEST
Hull no:
Rolls-Royce Marine AS Our order no:
Date:
dept. Steering gear
Responsible: Rolls-Royce Marine AS

Yard:
Purpose of functional test:
 The unit was tested to ensure that all system functioned satisfactory.
 Following system must be tested:
1. Hydraulic test
2. Emergency steering from steering gear room
3. Alarm system
4. Main steering position
5. Aft steering position
6. Port wing steering position
7. Stbd steering position
8. External connection.
How to fill in the form:
Not applicable
Test accepted V
Test not accepted FAILED

Hydraulic test
Hydraulic test Pump 1. Pump 2. Pump 3. Pump 4.

o
Maneuvering time (65 <28sec) [Sec]
Safety valves on pump unit [Bar]
Safety valves on rudder motor [Bar]
Emergency steering from the steering gear room
Alarm system
1. Push the “test” button on the alarm panel for more than 5 seconds.
All alarm lights and buzzers both on the slave alarm panel and on the main alarm panel will now be
tested. All Steering gear control system will be turned on through the auto-start feature (if
delivered). In this way the complete alarm system will be tested.
2. Push the aud./ack.-button once
The buzzer in the main alarm panel will stop if an alarm has occurred.
3. Push the button once, and if the alarm condition is still present, the alarm lights goes from
flashing to steady light, otherwise it is turned off.
Alarms to be tested Pump 1. Pump 2. Pump 3. Pump 4.

Overload pump
Phase failure pump
Power failure pump
Power failure control
Power failure aux. steering
Low oil level
Hydraulic lock pump
Clogged filter pump
High oil temp pump
Earth failure pump
General alarm, E0
Main steering position

Start/stop
Limit switches

Aft Steering position

Start/stop
FU steering (aux. steering)

Port wing steering position

Start/stop
Stbd wing steering position

Start/stop
External connection

Autopilot
Joystick
Dynamic position
Rolls-Royce Marine AS Yard representative
Date: Date:
Sign: Sign:

9 CONTACT LIST
Country Address Telephone Fax
Rolls-Royce Marine AS +47 815 20 070* +47 70 20 86 00
Deck Machinery & Steering gear
Brattvaag
Serviceboks 1522
Norway
N-6025 ÅLESUND, NORWAY
Deck.machinery.brattvaag@rolls-
royce.com
* 24 hr emergency
North America
Rolls-Royce Canada Ltd +1 902 468 2883 +1 902 468 2759
(GSN Commercial Marine)
196 Joseph Zatzman Drive, Unit 9
Canada
Dartmouth, Nova Scotia B3B 1N4
Canada B3B 1N4
UMLH@rolls-royce.com
Rolls-Royce Marine Inc. New Orleans +1 504 464 4561 +1 504 464 4565
200 James Drive West
St. Rose, LA 70087 USA
marianne.leine@rolls-royce.com
Rolls-Royce Commercial Marine +1 954 436 7100 +1 954 436 7101
10125 USA Today Way
Miramar, Fort Lauderdale
Florida 33025 USA
USA
Rolls-Royce Marine Inc +1 508 668 9610 +1 508 668 2497
110 Norfolk Street
Walpole, MA 02081 USA
Rolls-Royce Marine Seattle +1 206 782 9190 +1 206 782 0176
1731 – 13th Avenue SW
Seattle, WA 98134-1009
seattle.marine@rolls-royce.com
South America
Rolls-Royce Marine Ltda +55 21 3860 8787 +55 21 3860 4410
Rua General Jose Cristino 31
Brazil
20921—400 São Cristovão
RIO DE JANEIRO RJ, Brazil

Asia
Rolls-Royce Marine Shanghai +86 21 5818 8899 +86 21 5818 9388
No. 1 Xuan Zhong Road - Nan Hui
Industrial
China
Zone
201300 SHANGHAI
Merchant.marine@rolls-royce.com
Rolls-Royce Maine Hong Kong Ltd +852 2526 6937 +852 2868 5344
st
Rm. 4103 41 Floor, Hopewell Centre
Hong Kong 183 Queen`s Rd East,
Wanchai, HONG KONG SAR
service.hongkong@rolls-royce.com
Rolls-Royce Mumbai, +91 22 6640 38 38 +91 22 6640 38 18
103, Windsor, Kalina, Santacruz
India (East)
Mumbai-400 098
marine.india@rolls-royce.com
Rolls-Royce Marine Japan K.K +81 3 3237 6861 +81 3 3237 6846
Tobunsha Bldg. 4F
2-5-1, Kudan-Minami
Japan
Chiyoda-ku
TOKYO 102-0074 JAPAN
tokyo@rolls-royce.com
Rolls-Royce Marine Korea Ltd +8 251 831 4100 +8 251 831 4101
Noksan Industrial Complex 18B-2L
1578-1, Songjeong-dong,
Korea
Gangseo-gu
BUSAN 618-270 Korea
jane.park@rolls-royce.com
Rolls-Royce Marine +7 4232 495 484 +7 4232 495 484
Vladivostok Rep Office
Russia 5F, 3-B, Streinikova Str.
Vladivostok 690065, Russia
ulstein@mail.primorye.ru
Rolls-Royce Marine Singapore Pte Ltd +65 686 21 901 +65 686 32 165
No 6 Tuas Drive 1,
Singapore
SINGAPORE 638673
Europe
Rolls-Royce Marine Benelux B.V. +31 10 40 90 920 +31 10 40 90 921
Benelux Werfdijk 2 (Port 2828)
3195 HV Pernis Netherlands

Benelux.service@rolls-royce.com
Rolls-Royce Marine AS +45 9930 3600 +45 9930 3601

Vaerftsvej 23
Denmark
DK-9000 AALBORG Denmark
denmark.marin@rolls-royce.com
Rolls-Royce Marine Oy Ab +358 2 83791 +358 2 8379 4808
PO Box 220 (Suojantie 5) Mob:
Finland
FIN-26100 RAUMA Finland +358 4 006 66678
rolls-royce.finlanf@rolls-royce.com
Rolls-Royce Marine France +33 1 468 62811 +33 1 468 79398
Immeuble de Monaco
France 4 Place des Etas-Unis, Silic 261
F-94578 RUNGIS Cedex France
mariann.leine@rolls-royce.com
Rolls-Royce Marine Deutschland +49 40 381 277 +49 40 389 2177
Stettiner Strasse 3
Germany
D-22850 Norderstedt
sales.hamburg@rolls-royce.com
Kaminco Overseas Inc +30 1 45 28 240 +30 1 42 94 887
Presented by KAMINIS Co Ltd Mob:
Greece
57 Akti Miaouil PO Box 80115 +30 1 42 93 355
GR-PIRAEUS 18510 Greece
Rolls-Royce Marine Italia s.r.l. +39 010 749 391 +39 010 749 3950
Via Castel Morrone, 13
Italy
16161 Genova
genova.marine@rolls-royce.com
Rolls-Royce Marine Poland +48 58 782 06 55 +48 58 782 06 56
Alfa Plaza Building
Poland
28-32 Batorego Street
81 366 GDYNIA Poland
agnieszka.werra@rolls-royce.com
Rolls-Royce Espana SA +34 977 296 444 +39 977 296 450
Poligono Industrial de Constanti
Spain c/Dinamarca
E-43120 Tarragona
rrme.spain@rolls-royce.com
Rolls-Royce AB +46 550 84000 +46 550 18190
Box 1010 Mob:
S-681 29 Kristinehamn Sweden 46 70 528 6566*
Sweden rrab.Sweden@rolls-royce.com

Rolls-Royce Commercial Marine Ltd +44 1322 312028 +44 1322 212054
Nucleus, London Science and
UK
Business Park
Brunel Way, Dartford, Kent DA1 5GA
Sales.Dartford@Rolls-Royce.com
Australia
Perth Office +61 8 9336 7910 +61 8 9336 7920
Unit 2, 8 Wallace Way Mob:
Fremantle, WA 6160, Perth +61 418 567 523*
Australia
Melbourne Office +61 3 9873 0988 +61 3 9873 0866
Unit 1, 87 Heatherdale Road Mob:
Ringwood, Victoria 3134, Melbourne +61 417 323 077*

10 FINAL INSPECTION AND TEST PROCEDURE
There are no final inspection and test procedure required for the ship yard personal.

11 TOOLS
The tools found in the table below, are delivered with the Rolls-Royce Steering gear electrical
system.
Art. no. Description Qty. Spare. Comment

5309-61-9730.0 Light bulb dismounting tool 1 See picture below 11.1
5309-61-9740.0 Light bulb dismounting tool 1 See picture below 11.1
11.1 Light bulb dismounting tool

12 DOCUMENTS, DRAWINGS AND DATASHEETS
The following documents should be used as reference.
12.1 Electric

13 REVISION
Revision Reason for revision Date Signature
- Release 11.02.2010 Stine Ødegaard Urke

Installation Manual Steeringgear Shipkits B.V. Hull No SK120

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Installation Manual Steeringgear Shipkits B.V. Hull No SK120

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Technical specification

Type Rolls-Royce steering gear

Customer : Shipkits B.V.

Type of vessel : Construction - Heavy Lift Ship

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

01.00 System description ........................................................................................................... 3

02.00 Scope of supply/technical description ............................................................................... 4

02.01 General ....................................................................................................................... 4

02.02 Steering gear .............................................................................................................. 6

02.03 Start/stop and control system ...................................................................................... 7

02.04 Alarm system .............................................................................................................. 8

02.05 Rudder angle indicator system .................................................................................... 8

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

Rolls-Royce steering gear

Start/stop and control system

Rudder angle indicator system

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

Painting and colours:

02.00 Scope of supply/technical description

Equipment not supplied

Not included in scope of supply are:

Technical information - Drawings

Steering gear design

Corrosion protection and surface treatment

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

Piping and cabling

Installation, inspection, starting up and sea trial

Instruction manuals – Language

1 CD with English user/installation manuals

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

0010 1 pc. Rudder actuator (rotary vane) type SR722 FCP

Drawing numbers: A-9909, A-9161, W-1601-00-06, 0002-1515, 0002-5397

0020 1 pc. Sleeve for hydraulic coupling

Drawing number: A-9295

0030 1 pc. Expansion tank

Drawing number: A-9417

0040 1 pc. Storage tank

Drawing number: A-9807

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

0050 2 pcs. Motor controllers (FCP) (IP44)

Motor controller is numbered from the port side.

Drawing numbers: 0002-1731, L-1799-00-16

0060 2 pcs. Frequency converters (IP44)

Drawing numbers: 0000-0319, 0000-0322

0070 1 pc. Control system unit (IP44)

Drawing numbers: W-1221-01-00, L-1299-00-01

0080 1 pc. Control panel (IP22)

Drawing numbers: 0002-0626, L-1320-01-05

0090 2 pcs. Indoor follow-up controller (IP22)

Drawing numbers: 0002-1028, 0002-1247

0100 1 pc. Indication panel (IP22)

Drawing numbers: 0002-1030, 0002-1251

Tech.spec. 12S000638 (Master rev. 03.2010-03-17) generated: 23/05/2012

0110 1 pc. Alarm panel (IP22)

Drawing number: W-1802-00-01

0120 1 pc. Alarm panel (IP22)

Drawing number: W-1802-00-01

02.05 Rudder angle indicator system

0130 1 pc. Rudder angle indicator amplifier

Drawing number: W-2010-00-01

0140 1 pc. Rudder angle indicator, 144x144 (IP22)

Drawing number: W-1430-00-07

0150 1 pc. Panorama rudder angle indicator, Ø370 (3-face) (IP22)