User Manual Steeringgear Shipkits B.V Hull No SK120 SR722 FCP

USER MANUAL
Rolls-Royce Steering Gear SR

Mechanical and hydraulic system
Type:
Yard and hull no. :Shipkits B.V. : SK120

Project no. :12S000638
Date 8. January 2013
Page 2 of 60 User 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 Expansion 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 OPERATION .......................................................................................... 23

6.1 Before start ......................................................................................................................23
6.2 Start. ................................................................................................................................23
6.3 Normal operation .............................................................................................................24
6.4 Stop .................................................................................................................................24
6.5 Emergency operation ......................................................................................................25
6.5.1 Local operation of the Steering gear ...............................................................................25
6.5.2 Non-follow-up main steering............................................................................................25
7 MAINTENANCE ..................................................................................... 26

7.1 Maintenance overview .....................................................................................................27
7.2 Routine maintenance ......................................................................................................28
7.3 Oil sampling .....................................................................................................................30
7.4 Refilling of oil ...................................................................................................................32
7.5 Filter insert replacement ..................................................................................................33
7.6 Adjustments of valves .....................................................................................................36
7.6.1 Adjustment of relief valves ..............................................................................................37
7.6.2 Adjustment of working pressure load control valves .......................................................40
7.7 Replacement of solenoid .................................................................................................42
Rolls-Royce Steering Gear User Manual Page 3 of 60

7.8 Replacement of solenoid valve ...................................................................................... 43
7.9 Replacement of pump unit.............................................................................................. 44
7.10 Replacement of flexible element .................................................................................... 46
8 TROUBLE SHOOTING ......................................................................... 48

8.1 Pump unit........................................................................................................................ 48
8.2 Steering gear .................................................................................................................. 48
8.3 Expansion tank ............................................................................................................... 51
8.4 Wheel pump (if installed) ................................................................................................ 51
8.5 Lamp control panel ......................................................................................................... 51
8.6 Alarm list ......................................................................................................................... 51
9 CONTACT LIST .................................................................................... 52
10 SPARE PARTS ..................................................................................... 56

10.1 Ordering spare parts....................................................................................................... 56
10.2 Spare parts list ................................................................................................................ 56
10.3 Preservation ................................................................................................................... 56
11 TOOLS .................................................................................................. 57
12 DESIGN DRAWINGS ............................................................................ 58

12.1 Mechanical...................................................................................................................... 58
12.2 Hydraulic ......................................................................................................................... 58
13 REVISION.............................................................................................. 60

1 INTRODUCTION
1.1 Purpose
This manual describes operation and maintenance procedures required on board for the Rolls-
Royce Steering Gear. Always make the manual available to the technical staff.
The manual includes general information about the Rolls-Royce Steering Gear product line, as well
as project specific information and technical data.
The user manual provides the information necessary to operate and maintain the Rolls-Royce
Steering Gear system safely and correctly
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 describes the Rolls-Royce Steering Gear.
Chapters 6, 7 and 8 describe the relevant operation and maintenance procedures.
Chapters 4, 5 and 12 provide project specific information.
Note!
A separate manual for installation 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 Clock Wise
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)
SR Spherical Rotor
V Volt (voltage)

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 six main parts; rudder actuator [1] pump unit [2], cylindrical
rudderstock connection [3], valve block [4], cylindrical rudder stock [5], and feed back units.
Additionally the system consists of an expansion tank and 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; which 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 Expansion 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 Appendix.

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 61o 450
o
SR 622 2 70 2 x 72 800
SR 642 2 110 2 x 72o 1200
o
SR 662 2 170 2 x 72 1800
SR 722 2 275 2 x 72o 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 that specified by Rolls-Royce Marine may cause
malfunctions when maneuvering 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
YUKONG ZIC SUPERVIS X32

Manufacturer Type
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 OPERATION
Warning
 If any malfunction is detected when operating the Rolls-Royce Steering Gear,

the malfunction must be investigated and remedied. Operating a Rolls-Royce
Steering Gear with a malfunction in the control system or hydraulic system
may cause personal injury or equipment damage. Similarly, any malfunction
that might occur in the systems when the Rolls-Royce Steering Gear is in
operation must be remedied or the Steering gear taken out of service.
CAUTION!
Before operating the equipment, please refer to chapter 2 for the “General Statement, Safety and
Warnings instructions”.
Ensure that:
 Nobody is working with the equipment before operating it.
 The maintenance instructions (chapter 7 & 8) are strictly followed.
6.1 Before start

1. Ensure that power is available.
2. Check that there are no alarms.
3. Ensure that the rudder and mechanical rudder indicator on the Steering gear is in zero position.
6.2 Start.
1. Turn the selector switch on the motor controller to position 3. “Local control”.
2. Start one pump at the time.
3. Push the button marked “run pump 1”
The lamp indicates the power supply. The electric motor on the Steering gear will start when a
command to the rudder is given.

6.3 Normal operation
Remote control with the ship’s automation system is possible only when the selector switch on the
motor controller is set to the remote control position.
One or both pump units simultaneously, can without any manual change of valves drive the
actuator. By stopping one of the electric motors, the corresponding pumps will automatic isolate the
system not in use. A mechanical fault in one of the pump units, pipes or electrical fault in one of the
systems will therefore not interfere with the operation of the other unit. The control system is
designed to restart the running pump, in case of power failure or black out.
Please refer to the electric system user manual, for details regarding the operation of the steering
gear from the bridge.
6.4 Stop
1. Stop the power supply to the Steering gear.
2. Stop one pump at the time.
3. Turn the selector switch on the motor controller to position 2 “stop”.

6.5 Emergency operation
Warning
When performing emergency operation, always be in radio contact with the

bridge.
6.5.1 Local operation of the Steering gear
1. Locate the motor controller.
2. Turn the selector switch [1] to position 3. “Local control”
3. The "Run pump"light [2] is lit as long as the selector switch [1]
is in "Local control".
4. Use the maneuvering push buttons [3] on the front of the

motor controller to move the rudder.
6.5.2 Non-follow-up main steering

1. Start one pump at the time from the bridge.
2. Use the non-follow-up push buttons [3] on the override panel to control the rudder.

7 MAINTENANCE
This chapter describes all relevant maintenance procedures and activities to be carried out by the
ship’s crew.
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 oversee to the lifting device and the other to ensure
that the components do not get caught and damaged.
 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.
 Using hydraulic oil other than the one specified in this manual may cause
malfunctions when maneuvering the vessel. This may cause personal injury
and equipment damage.
CAUTION!
 Most chemicals intended for the product (engine and gearbox oils, glycol,
gasoline and diesel), or the workshop (degreasing agent, paints and solvents)
are harmful to your health. Read the instructions on packaging carefully! Always
follow protective measures such as using a protective mask, goggles, gloves etc.
Ensure that other personnel are not unknowingly exposed to harmful substances
in the air that they breathe; ensure adequate ventilation. Dispose used and
excess chemicals according to instructions.
 Ensure that the warning or information decals on the product are always visible.
Replace decals that are damaged or painted over.
 Take care of the hydraulic oil when replacing parts in the hydraulic system. Any
oil spillage, even a small one, will cause environmental damage. Used filter
elements and worn out hydraulic oil should be disposed safely.
 If hydraulic oil disappears from the system and there is a risk that this oil is
polluting the seawater, the system must be immediately shut down and
inspected.
 Do not use the Rolls-Royce Steering Gear if local rules do not permit this.
Note!
 Use spare parts produced by Rolls-Royce Marine, or by a manufacturer
approved or licensed by them. Use of other than approved spare parts will void
the warranty and may result in system failure or reduced lifetime.

7.1 Maintenance overview
Rolls-Royce Steering Gears are designed to maintain safe operation with a minimum of
maintenance. However, to avoid unexpected stops, we will emphasize the importance to maintain
the installation on regular basis.
In connection with scheduled class survey, general overhaul or repair we advise to use engineers
from our factory or factory trained engineers from our service representatives in different countries.
This will limit the time of repair to a minimum and ensure continuous safe operation.
The following table lists the maintenance procedures.
Procedures Condition Chapter
Routine maintenance. See separate table for routine maintenance 7.2

activities.
Oil sampling. At regular intervals. 7.3
Refilling of oil. Is only necessary if there is an oil leak in the 7.4

system.
Filters insert replacement. Filter indicator. 7.5
Adjustments of load control The Steering gear movement stops when the 7.6
valves and distributing rudder pressure increases.
valves.
Replacement of solenoid. Rudder movement problems. 7.7
Replacement of solenoid Rudder movement problems. 7.8

valve.
Replacement of flexible Pump not running, while motor is. 7.9

coupling.
Replacement of pump unit. Pump not running. 7.10

7.2 Routine maintenance
The table lists maintenance activities to be carried out by the ship’s crew at regular intervals.
Activity: How often:
D W M 6M 12M 24M
1 Check oil level in expansion tank. X

2 Visual check of pump units/filters. X
3 Visual check of actuator. X
4 Sample of hydraulic oil. X
5 Visual check of coupling and seal on pump shaft. X

7.3 Oil sampling
Spare parts Ref. no Special tools and test equipment Qty
Sample bottle 1
Sampling hose 1
Container/bucket 1
Reference documents Consumables Qty

Technical data chap. 5 Linen rag
Oil, as recommended in chapter 5
Note!
The hydraulic system must be running for a while before the oil sampling procedure is carried out.
The oil sampling points are located on the upper rear

valve block port and stbd.
1. Locate the oil sampling plug
2. Remove the protecting cap [1].

3. Connect the pressure measuring hose [2] to the
measuring point while the Steering gear is
manoeuvred.
4. Flush the hose by letting some of the oil run through

the hose and in to a bucket.
5. Fill a clean sample bottle [4] with oil.
CAUTION!
It is extremely important that oil bottle used for oil
sampling is chemically pure, and that the procedure is
performed with a high degree of cleanliness.
6. Close the sample bottle.
7. Attach label to sample bottle indicating AQM type and

number.
 Oil type
 Date
 Sampel taken by
 Used for how long
8. Compare sample with new oil by visual examination

and smelling.
9. If oil colour or smell has clearly changed or there are

impurities in the oil, change the oil.
10. Send the oil sample to be examined immediately
Note!
 Use only recommended type of oil according to chapter 5.1
 The oil must at all times meet the specification for actual type of oil used in the system. Take oil
samples regularly.
 Follow the instructions regarding oil change intervals or the recommendations based on an oil
sample test.

7.4 Refilling of oil
Spare parts Ref. no Special tools and test equipment Qty

Technical data chap. 5 Oil, as recommended in chapter 5.1 As req.
1. Locate the storage tank.
2. Make sure essential cocks are in open position.
3. Pump oil into the system by using the handle on the

pump [1] mounted on the storage tank.
4. Refill oil according to the recommendations and oil

volume.

7.5 Filter insert replacement
Spare parts Ref. Special tools and test equipment Qty
no
Bucket 1

Linen rag As req.
A clogged filter will be indicated either by an alarm, or

locally by an indicator [1] on the Steering gear filter, as
Note!
Normal system temperature important.
1. Turn the selector switch [2] on the current motor

controller to position 2 “stop”.
2. Turn the connecting oil chocks [3] on the expansion

tank to closed position.
3. Place a bucket underneath the filter bowl.

4. Unscrew the filter bowl [4], as illustrated in the picture
5. Refit a new filter bowl.
6. Open the connecting oil chocks on the expansion tank.
7. De-air by drain the top of distributing valve.
8. Turn the selector switch on the motor controller to position 1 “remote control”.

7.6 Adjustments of valves
The pressure pipes between pump and valve block inclusive pump is tested from factory according
class requirement to 1.5 x working pressure, normally 188 bar.
The type of the valve block mounted on the Steering gear is depending on the Steering gear size
and the required oil flow needed throughout the hydraulic system. The location of the relief and
load control valves on the valve block is illustrated in the table below.
Valve block FV 4 (4)

Relief valves Load control valves pump 1.
1 Port relief valve 3 Port load control valve

2 Stbd relief valve 4 Stbd load control valve

7.6.1 Adjustment of relief valves

no
Hexagonal key 1
Adjustable spanner 1
Screw driver 1

Appendix
Note!
The adjustments must be done separate both for port and starboard side. The procedure below
describes the adjustment of the valves by running pump 1.
1. Turn the selector switch [1] on the motor controller

connecting pump 1 to position 3 “local control”
2. Disconnect pump 2 by turning the selector switch [2]

on the motor controller connecting pump 2, to position
2 “Stop”.
3. Locate the load control valves [3] connecting pump 1,

as illustrated in the picture.

4. Loosen the nut [4] on both valves as illustrated on the
picture.
5. Tighten both valves to max pressure by bottom turning

the adjustment screw [5].
6. Open pressure gauge chocks [6].
7. Operate the Steering gear carefully to mechanical stop

by the port push buttons [7] in front of the motor
controller connecting pump 1.
8. Maintain the manoeuvre until the pressure on port

pressure gauge [8] is read.
9. Release the pressure by maneuver a few degrees the opposite way.
If the pressure is correct proceed to point 13 - if not, continue to step 10.
10. Locate the relief valves [9], as illustrated in the picture.

11. Unscrew the cap nut on the port relief valve [10].
12. Adjust the pressure [11] by a screw driver, as

13. Replace the cap nut and check pressure.
When port pressure is correct, operate the Steering gear in opposite direction and accomplish
the same procedure to stbd.
When both valves are correct adjusted by pump 1, they are also correct for pump 2.

7.6.2 Adjustment of working pressure load control valves

no
Hexagonal key 1
Adjustable spanner 1

Appendix
1. Mace sure the selector switch [1] on the motor

controller connecting pump 2 is set to position 2
“Stop”.
2. Turn the selector switch [2] on the motor controller

connecting pump 1, to position 3 “local control”.
3. Locate the load control valves [3] connecting pump

1 and adjust the screws on both load control
valves [3] a few turns out.
4. Operate the Steering gear carefully to mechanical

stop port, by the port push button [4] in front of the
motor controller.

5. Read the pressure on port pressure gauge [5], and
adjust if necessary.
6. Tighten the lock nut [6], as illustrated in the

picture.
7. Operate the Steering gear carefully to mechanically stop stbd. by the stbd push button [4]
in front of the motor controller.
8. Read the pressure on stbd. pressure gauge [5], and adjust if necessary.
9. Tighten the lock nut [7], as illustrated in the

picture.
10. Adjustment of “working pressure” both port and stbd. are now finished for pump 1.
Accomplish the same procedure for pump 2.
11. Turn the selector switch on the motor controller connecting pump 1, to position 2 “Stop”,
and the selector switch on the motor controller connecting pump 2, to position 3 “local
control”. Follow the same procedure above using the push buttons in front of the motor
controller connecting pump 2.

7.7 Replacement of solenoid
no
Solenoid 1 Adjustable spanner 1
Screw driver 1

controller to position 2 “stop”, as illustrated in the
picture.
2. Unscrew the solenoid nut [2].
3. Remove the solenoid [3].
4. Unscrew the cable plug [4] from the solenoid by using

a screw driver.
5. Remove the cable plug [4].
6. Fit the cable plug [4] on a new solenoid, and tighten the screw.
7. Replace the solenoid on the valve.
8. Tighten the nut [2] carefully by a torque 4 Nm.
9. Turn the selector switch [1] on the motor controller to position 3 “Local control”
10. Make a brief test manoeuvre by pushing the

emergency push buttons [5] in front of the motor
controller.
11. If the test is ok, turn the selector switch [1] on the motor controller to position 1 “Remote
control”.

7.8 Replacement of solenoid valve
no
Solenoid valve 1 Adjustable spanner 1
Screw driver 1

controller to position 2 “Stop”.
2. Unscrew the solenoid nut [2].
3. Remove the solenoid [3] while the cable plug is

connected.
4. Unscrew the solenoid valve [4].
5. Refit a new solenoid valve.
6. Tighten the valve carefully to 108 Nm.
7. Replace the solenoid [3] on the valve.
8. Tighten the nut [2] carefully by a torque 4 Nm.
9. Turn the selector switch on the motor controller to position 3 “Local control”
10. Make a brief test manoeuvre by pushing the

emergency push buttons [5] in front of the motor
controller.
11. If the test is ok, turn the selector switch [1] on the motor controller to position 1 “Remote
control”.

7.9 Replacement of pump unit
no
Pump 1 Adjustable spanner 1
Screw driver 1
1. Turn the selector switch on the current motor controller

to position 2 “stop”, as illustrated in the picture.
2. Turn the connecting oil chocks [2) on the expansion

3. Loosen all connecting pipes; an example [3] is


4. Unscrew the nuts [4] connecting the bell house to the
electric motor.
5. Remove the bell house with pump.
6. Unscrew the nuts [5] connecting the pump to the bell

house.
7. Carefully remove the pump [6] with flexible coupling

from the bell house.
8. Remove the original coupling from the original pump

over to the new pump.
9. Mount the pump with flexible coupling to the bell

house.
10. Make sure the pump and flexible coupling is correct fitted inside the bell house.
11. Remount the complete unit on to the electric motor.
12. Refit all connecting pipes.
13. Open chocks on the expansion tank, and release air from the circuit.
14. Make a brief start locally and repeat de-airing.
15. Turn the selector switch on the motor controller to position 1 “Remote control”.

7.10 Replacement of flexible element
no
Flexible coupling Adjustable spanner 1
element
1. Turn the selector switch [1] on the motor controller to

position 2 “Stop”.
2. Turn the connecting oil chocks [2) on the expansion

3. Loosen all connecting pipes; an example [3] is


4. Unscrew all nuts [4] connecting the bell house to the
motor.
5. Carefully remove the bell house [5] and pump [6].
6. Replace the flexible element [8], as illustrated in the

picture.
7. Carefully refit the bell house and pump.
8. Refit all connecting nuts between bell house and motor, and tighten.
9. Refit all connecting pipes.
10. Open chocks on the expansion tank, and release air from the circuit.
11. Make a brief start locally and repeat de-airing.
12. Turn the selector switch on the motor controller to position 1 “Remote control”.

8 TROUBLE SHOOTING
Please refer to the tables in this chapter for trouble shooting and corrective actions.
8.1 Pump unit

Symptoms Possible faults Components Corrective
actions
Check that the
cock connecting
Air in the pump the oil reservoir
Noise from the pump Pump system
system is open. If
necessary de-air
the system
8.2 Steering gear

actions
Repair the
Broken el. power Frequency
frequency
to el. motor converter
converter
Renew the limit
Defective micro switch in feed
switches in the back unit
limit switch box Limit switch
FB or in the Renew the limit
The Steering steering lever switch in the
gear can only be steering lever
operated to one
Locate the defect
side Failure in the
Wiring wiring
wiring
connections connection(s)
connections
and renew.
Rudder
movement
problems Defective Repair the
Frequency
frequency frequency
converter
converter in the converter
motor controller
Defect micro
The steering Renew the micro
switch in the Micro switch
gear goes to switch
steering lever
hard over
position without Defect on the Repair the
Frequency
rudder command power pump unit frequency
converter
driver signal converter
The rudder is not The relief Renew the return

stationary when valve(s) in the Relief valve
spring
acted on by distributor valve

actions
external force is blocked in
open position
due to impurities Change the
in the oil or hydraulic oil
defective return
spring
The relief valves
in the distributor
Test and adjust
valve opens due Relief valves
the safety valve
to faulty
adjustment
Test piston seals
Worn piston
Piston seals and if necessary
seals
renew seals
Rudder The Steering
movement gear moves
Air in the Repeat de-airing
problems uneven, when Hydraulic system
hydraulic system of system
given rudder
command
Defect on the
power pump unit
frequency Frequency Test and repair
converter, converter driver
overload
The Steering protection
gear movement
Faulty
stops when the
adjustments of Test and adjust
rudder pressure Relief valve
relief valve in relief valves
(force) increases
distributor valve
Test and if
Worn piston oil necessary renew
Piston oil seals
seals the piston oil
seals
The rudder
cannot be
Defect micro
brought from Renew the micro
switch in the feed Micro switch
hard over switch
back unit
position to mid-
ship
The Steering
gear works Defect on the
slower than pump unit Frequency Test and repair
normal, when frequency converter driver
given rudder converter
command
Noise generated
by the steering Air in the De-air the
Hydraulic system
gear when given hydraulic system system
rudder command

actions
Defect amplifier Renew amplifier
Amplifier card
card card
Defect selector Renew selector
Selector card
The Steering card card
gear fails to Defect pump Renew control
respond when Control card
control card card
given rudder
command Defect wiring
Locate the defect
connections
Wiring wiring
between control
Rudder system and
and renew.
movement motor controller
problems Defect amplifier Renew amplify
Amplifier card
card card
Rudder cannot Defect wiring

be moved out of connections Locate the defect
center position between control Wiring wiring
system and connections connection(s)
feedback /control and renew.
panel
Feed back
The rudder potentiometer not Locate and
movement is not correct adjusted adjust the
Potentiometer
equal to each FU controller incorrect
side (port/stbd) potentiometer not potentiometer
correct adjusted

8.3 Expansion tank
actions
De-air the
Air in the system Expansion tank
system
The expansion tank overflows

Locate the
Damaged seals Seals damaged seal
and renew
8.4 Wheel pump (if installed)

actions
The wheel on the
hand pump
Leaking blocking
rotates when the Repair the
valve in the Blocking valve
electrical steering leakages
wheel pump
system is
Malfunctioning operated
wheel pump
The wheel pump
works Sticking suction
Correct valves
inefficiently in valves in the Valves
problems
one or both wheel pump
directions
8.5 Lamp control panel

actions
Lamp in control panel will not light Defect bulb Bulb Renew bulb
Problems with the Steering gear may also appear as a combination of one or more of the above
mentioned sections. The conditions can also be related to the electrical system please refer to the
user manual for the electrical system.
8.6 Alarm list

Please refer to the Rolls-Royce Steering Gear electrical system user manual.

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 SPARE PARTS
Note!
 Information regarding the Steering gear type and
installation number is found on a sign mounted on the
mid rear upper housing as illustrated in the picture.
(On the SR 562, SR 622, SR 642 and SR 662 the sign
is mounted on the front of the mid upper housing).
 The information is also found on the front page of this

manual.
10.1 Ordering spare parts

When ordering spare parts, the following information must be given:
 Installation No. (T- Followed by a number), vessel’s name and owner’s name.
 Shipping address and invoicing address.
 Drawing Number, Position Number, Article Number (Art.no.) and Quantity.
10.2 Spare parts list

Refer to Appendix.
10.3 Preservation
Spare parts should be kept in a dry and dust free environment.

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 Appendix for complete drawing set.
12.1 Mechanical
Drawing/ document Document number

See Appendix
Rudder actuator, Dimension drwg.
See Appendix
Rudder actuator, Foundation design drwg.
See Appendix
Rudder actuator, Ass. drwg. w/part list
See Appendix
Distributing valve, Ass. drwg. w/part list
See Appendix
Safety valve, Ass. drwg. w/part list
See Appendix
Pump unit, Ass. drwg. w/part list
See Appendix
Feed back unit, Ass. drwg. w/part list
See Appendix
Power take off, Ass. drwg. w/part list
See Appendix
Expansion tank, Ass. drwg. w/part list
See Appendix
Spare part list mechanical
12.2 Hydraulic

See Appendix
Piping diagram
See Appendix
Hydraulic circuit diagram

13 REVISION
Revision Reason for revision Date Signature
- Release 29.06.2009

INSTRUCTION MANUAL
TENFJORD
STEERING GEAR
Shipkits B.V.
Hull No.: SK120
WHEN ORDERING SPARE PARTS, PLEASE STATE THIS NUMBER:
ORDER NO.: 12S000638
Rolls-Royce Marine AS,

dept. Steering Gear – Tenfjord, N-6264 Tennfjord, Norway
E-mail: tenfjord@rolls-royce.com www.rolls-royce.com
INSTRUCTION MANUAL
APPENDIX B
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 300 mm
Rudder angle electrical 2x35 / 2x65° electrical stop
(Rudder angle limitation included)
Rudder angle mechanical 2x67° (approx.)
Manoeuvring time one/two pumps 27/14 seconds (30°- 0 - 35°)
Setting of relief valves 156 bar
Hydraulic Oil Shrink Coupling:

Rudder stock diameter Ø 300 g7
Sleeve diameter Ø 300 E8
Pull-up lenght 27 mm
Max allowed injection pressure 1380 bar
Max allowed mounting pressure 280 bar
Pump unit:
Make Rolls-Royce
Type FCP-48
Pressure pump type Sauer Danfoss SNM3-48
Setting of relief valves 125 bar
Testing pressure 188 bar
INSTRUCTION MANUAL
APPENDIX B
Electric motor:
Type NORM IEC 160MLB - 4
Speed 1450 r.p.m.
Rating output 15,00 kW (S1)
Voltage 3x380 V, 50Hz
Protection class IP55
Insolation class F

INSTRUCTION MANUAL
APPENDIX B
APPENDIX B – DRAWINGS/PART LIST
 FOLLOWING DRAWINGS ARE ENCLOSED:
Rudder actuator Dimension drwg. A-9909d

Rudder actuator Foundation design A-9161e
Rudder actuator Ass. drwg. w/part list 0003-2013a
Hydraulic coupling Ass. drwg. w/part list A-9295
Mounting tool Ass. drwg. w/part list A-9803
Distributing valve Ass. drwg. w/part list A-10117c

Safety valve Ass. drwg. w/part list H-5713c
Pump unit Ass. drwg. w/part list A9075-44
Feed back unit Ass. drwg. w/part list A-10046c

Power take off Arr. drwg. w/part list A-9869f-70
Expansion tank Arr. drwg. w/part list A-9565g
Piping diagram A-8798c

Hydraulic circuit diagram A-8242n
Spare part list mechanical

Part List
Item ID 000099134 Revision A

Description Rudder Actuator Status RELEASED
Effective Date 07.01.2013 Levels 1
Level Pos Qty Unit Item ID Rev Description Size Extra information El-reference
0 piece 000099134 A Rudder Actuator SR722B,Ø320,2X65°,HC,FCP
1 0002 1 piece 60105-8792 B Lower Actuator Housing SR722B 01
1 0004 1 piece 60205-7931 A Rotor SR722B, Ø320 02
1 0006 1 piece 60305-9203 A Upper Actuator Housing SR722B 03
1 0008 4 piece 331-M20X045 # Socket Screw M20X45 04
1 0010 8 piece 331-M20X100 # Socket Screw M20x100 05
1 0014 0 piece 212-1774-35 # O-Ring 177,40x3,53 07
1 0016 4 piece 374-M20 # Lock Washer M20 Ø21,0/Ø30,7X3,4 08
1 0018 2 piece 60405-10386 # Piston SR722, 2X65 09
1 0020 0 piece SR720-07 B Bracket SR720, PL4 10
1 0022 2 piece 60505-9950 # Dividing Wall SR720 KOMPL. 11
1 0024 0 piece SR720-06 # Piston Seal 12
1 0026 0 piece SR720B-12 # Support Segment SR720B, 9x8x267 13
1 0028 2 piece 336-T1.2 # Plug BSP1/2 " 14
1 0030 2 piece 213-PP45-D A Seal Washer BSP1/2 15
1 0032 4 piece 321-M16X100 # Hexagon Head Screw M16x100 16
1 0034 2 piece 415-10X14 # Needle Ø10x14 17
1 0036 2 piece SR720B-18 B Key 205x35x24 18
1 0038 4 piece 070049 A Plug 1/4" BSP 19
1 0040 4 piece 213-PP45-B A Seal Washer BSP 1/4, Ø13,74/ø20,57x2 20
1 0042 1 piece 212-10200-40 # O-Ring 1020,00x4,00 21
1 0044 1 piece 212-10950-40 # O-Ring 1095,00x4,00 22
1 0046 1 piece 212-11500-40 # O-Ring 1150,00x4,00 23
1 0048 1 piece 212-12000-40 # O-Ring 1200,00x4,00 24
1 0052 3 piece 343-M24 # Eye Bolt M24 26
1 0054 0 piece 333-M08X016 # Countersunk Screw M8X16 27
Page 1 of 3 Print Date: 07.01.2013

1 0056 2 meter 211-040 # Packing Cord Ø4 28
1 0058 2 piece 000071069 A Cylinder Seal SR722, segment 29
1 0060 19 piece SR720-31 A Bearing Shell SR720 69
1 0062 19 piece SR720-32 C Bearing Shell SR720 30
1 0064 1 piece 63205-8803 A Distance Ring Ø450/Ø420X3 31
1 0070 2 piece 218-400X450X22 # Seal Ring 400-450-22 UN 34
1 0072 2 piece 000071069 A Cylinder Seal SR722, segment 35
1 0076 1 piece 213-PP45-F A Seal Washer BSP3/4 37
1 0078 1 piece 241-GE28L-3.4 # Standpipe Adapter Ø28-3/4 38
1 0084 2 piece 63205-8800 A Distance Ring Ø500/Ø465X3 41
1 0088 2 piece 218-450X500X22 # Seal Ring 450-500-22 UN 43
1 0090 15 piece 60705-8820 A Bearing Shell SR722/723 44
1 0100 4 piece SR720-13 A Adapter Sleeve SR720 49
1 0106 4 piece 61505-9348 # Sealing Retainer SR722 52
1 0108 0 piece 63305-8837 B Support Segment SR720 53
1 0114 2 meter 211-040 # Packing Cord Ø4 56
1 0116 3 piece 63705-8813 B Transport Bracket SR720, 120X75X5 57
1 0120 6 piece 63705-9266 A Distance Piece Ø16X1,5X54 64
1 0138 1 piece 191-485X445X3 # Flange Seal 485X445X3 70
1 0140 1 piece 69999-8068 C Nameplate 105x74x1 for steering gear 71
1 0150 1 piece 60805-8802 # Plate SR720, LOWER, Ø508/Ø410x12 33
1 0160 4 piece 69905-9070 # Spacer SR720, 310X75X15 45
1 0170 16 piece 333-M10X030 # Countersunk Screw M10x30 46
1 0180 2 piece 63819-9133 B Pipe Section Ø35X3, 90DEG., 600X340 47
1 0190 2 piece 63819-9134 A Pipe Section Ø35X3, 90DEG., 350X330 48
1 0200 1 piece 60805-9290 A Plate SR720, 30x3, L=715 42
1 0210 1 piece 69805-8758 E Adapter Plate SR720 72

1 0220 3 piece 321-M16X080 # Hexagon Head Screw M16x80 63
1 0240 2 piece 241-EVGE22 A Standpipe Adapter Ø22 73
1 0250 4 piece 213-PP45-F A Seal Washer BSP3/4 74
1 0260 2 piece 290-000 # Filter SPIN ON 75
1 0270 2 piece 241-EVW22L # Elbow Ø22 76
1 0280 2 piece 63899-8316 # Pipe Section Ø22X2, 90DEG, 130X90 77
1 0300 0 piece 290-001-TF # Filter Cartridge SPIN ON 79
1 0310 2 piece 451-102 # Hose FCP 80
1 0320 2 piece 289-000 # Gauge Valve 1/4-1/4 , straight stream w/wheel 61
1 0330 2 piece 292-000 # Pressure Gauge BSP1/4", 0-250bar 62
1 0350 4 piece 375-12 # Spring Washer M12 59
1 0360 2 piece 212-0329-35 # O-Ring 32,93x3,53 60
1 0370 8 piece 341-M12X040 # Stud M12X040 81
1 0390 8 piece 371-12 # Plain Washer M12 83
1 0400 8 piece 351-M12 # Hexagon Nut M12 84
1 0430 1 piece 62005-8830 B Scale SR720, 0-70 degree 87
1 0440 8 piece 336-T1.4 # Plug BSP1/4 " 88
End of Report

Part List
Item ID HC-9295-320 Revision A

Description Hydraulic Coupling Status RELEASED
0 piece HC-9295-320 A Hydraulic Coupling HC, Ø320
1 0002 1 piece SR720-02-4-320 E Mounting Piston SR720, Ø320 03
1 0003 1 piece 221-S55044-3900 # Piston Seal Ø390 04
1 0004 1 piece 336-R1.4 # Plug BSP1/4 01
1 0005 1 piece SR720-02-2-320 H Coupling Sleeve SR720, Ø320 05
1 0010 1 piece 212-3250-24 # O-Ring 325,00X2,40 02
1 0015 1 piece 792-HYLSEK.SR72 # Packaging SR720, HYLSEKASSE 50 X 50 X 080 CM.
End of Report

Part List
Item ID FV4-10117 Revision C

Description Distributing Valve Status RELEASED
0 piece FV4-10117 C Distributing Valve FV4, HYDR.LOCK, SR662, SR722
1 0020 2 piece 61255-8913 L Valve Housing FV4 03
1 0030 2 piece 336-T3.4 # Plug BSP3/4 " 04
1 0040 2 piece 241-RI3.4X1.4 A Reducing Nipple BSP3/4/ED/BSP1/4 05
1 0050 2 piece MV20-5713 C Safety Valve MV20 06
1 0060 4 piece 336-T1 # Plug BSP1 07
1 0070 4 piece 295-0001 # Non Return Valve 0,2 bar 08
1 0080 4 piece 381-I029 # Locking Ring Ø29x1.2 09
1 0090 4 piece 212-0521-26 # O-Ring 52,07 X 2,62 10
1 0100 6 piece 335-M06X1 # Plug M6X1 11
1 0110 4 piece 295-0003 # Balance Valve 120L/MIN, 1:8 12
1 0120 4 piece 295-0002 A Solenoid Valve 190 l/min 13
1 0130 4 piece 336-T3.8 # Plug BSP3/8 " 14
1 0140 4 piece 212-0282-26 # O-Ring 28,25 X 2,62 15
1 0180 4 piece 64755-8982 B Non Return Valve ø50MM 21
1 0190 2 piece 61255-10113 C Valve Housing FV4 22
1 0250 1 piece 61204-8149 M Valve Housing FV4 30
1 0260 2 piece 241-EVL28L # Pipe Coupling Ø28 32
1 0270 2 piece 241-EVGE22 A Standpipe Adapter Ø22 33
1 0280 2 piece 335-R3.4 # Plug BSP3/4" 34
1 0290 4 piece 415-10X14 # Needle Ø10x14 35
1 0300 4 piece 5700-002 B Magnet Coil CCS240D, 240VAC, 50/60HZ, 14W 36
1 0350 4 piece 241-FM35L # Pipe Coupling FM35L, Ø35, EO2-Functional nut 41
1 0360 2 piece 241-GE12L-3.8 # Standpipe Adapter Ø12 42

Item ID FV4-10117 Revision C
Description Distributing Valve Status RELEASED
1 0380 4 piece 63199-8378 A Valve Washer Ø29/Ø23.5X2 44
1 0400 4 piece 336-M08X1 # Plug M8X1 46
1 0410 4 piece 220-08 # Seal Ring Ø8/Ø12X1 47
1 0420 4 piece 241-GE35L # Standpipe Adapter Ø35 02
1 0440 2 piece 241-KOR28.22L # Reducing Nipple Ø28/Ø22 48
1 0450 4 piece 5422-AP6/S212 # Proximity Switch AP6/S212 49
1 0470 6 piece 336-T1.2 # Plug BSP1/2 " 51
1 0480 0 piece 212-0124-18 # O-Ring 12,42 X 1,78 52
1 0481 2 piece 241-GE28L-11.4 # Standpipe Adapter Ø28-1 1/4 53
1 0490 2 piece 295-EMA3-R1.4 A Measuring Nipple EMA3, BSP1/4" 56
End of Report

Part List
Item ID PU-9075-44 Revision F

Description Pump Unit Status RELEASED
0 piece PU-9075-44 F Pump Unit FCP, M160, SAUER SNM3/44, 44CCM
1 0010 1 piece 298-R44-001 A Gear Pump 44CCM, SNM3, reversible 01
1 0030 4 piece 376-10 # Spring Washer B10 03
1 0040 1 piece 421-003 # Coupling Flange BOSCH G/160 04
1 0050 1 piece 432-1003 # Flexible Clutch 05
1 0230 4 piece 323-M16X065 # Hexagon Head Screw M16X65 07
1 0260 1 piece 433-1003 # Flexible Coupling Element Spidex 38, X38KR 10
1 0270 1 piece 432-2010 # Flexible Clutch 11
1 0280 2 piece 298-35MM A Adapter Ø35-Ø55 12
1 0300 1 piece 241-GE10PLM # Standpipe Adapter M14x1.5, Ø10 13
1 0310 1 piece 213-PP45-10 A Seal Washer Ø9/16" 14
1 0330 4 piece 371-RF-16 # Plain Washer M16 15
1 0350 1 piece 241-GZ35 # Pipe Coupling Ø35 17
1 0370 1 piece 241-W35L # Elbow Ø35 19
End of Report

Part List
Item ID FB40-10046 Revision D

Description Feedback Unit Status RELEASED
0 piece FB40-10046 D Feedback Unit FB40
1 0006 1 piece 61350-10032 E Shaft FB40, M25X1,5/Ø25X122 02
1 0008 1 piece 63750-8759 C Bracket FB40, 3XØ12 03
1 0010 2 piece 63150-10108 A Plain Washer Ø40/Ø22X1 04
1 0014 1 piece 60750-8754 M Bush FB40, Lead in bushing 05
1 0020 1 piece 334-M03X10 # Socket Set Screw M3x10 06
1 0050 2 piece 344-M03X45 # Slotted Roundhead Screw M03X45 09
1 0070 1 piece 218-022X035X06 # Seal Ring 22-35-6 WASY 11
1 0080 1 piece 63150-8900 A Plain Washer Ø40/Ø22X2 12
1 0090 1 piece 381-A022 # Locking Ring A22 13
1 0100 2 piece 411-2215-MF41 # Slide Bearing ø22/ø25X15 14
1 0110 1 piece 212-0489-26 # O-Ring 48,90x2,62 15
1 0120 1 piece 344-M04X10 # Slotted Roundhead Screw M4x10 16
1 0140 2 piece 366-KM09 # Lock Nut M45X1,5 18
1 0180 5 piece 5400-V3-9119M # Micro Switch V3-9119M, FOR FB-UNIT 19
1 0190 6 piece 5401-JV-9005 # Micro Switch JV-9005C 20
1 0200 6 piece 5401-MS-001 A Micro Switch MS-001, SEAL PREME 21
1 0210 3 piece 5593-DR8 # Gasket DR8 22
1 0220 3 piece FB30.20 A Distance Piece FB30.20, 30X18X6 23
1 0230 1 piece 381-A025 # Locking Ring A25 10
1 0240 1 piece 366-KM05 # Lock Nut M25x1,5 24
1 0250 2 piece 344-M03X40 # Slotted Roundhead Screw M03X40 25
End of Report

Part List
Item ID PT-9869-70 Revision F

Description Power Take Off Status RELEASED
0 piece PT-9869-70 F Power Take Off SR720, 2x70
1 0010 1 piece 000065757 A Purchase Kit PT, fastening equipement for chain 01
1 0090 2 piece 69990-10138-10 A Chain Arrangement SR720,2x70 / SV430,2x65 09
1 0100 2 piece 000063332 A Chain Wheel FB40, Z=80 10
1 0120 2 piece 334-M06X16 # Socket Set Screw M6x16 12
1 0140 1 piece 69905-9250 C Support Ring PT SR720, Ø450 14
1 0150 2 piece 63750-9181 C Bracket FB40 15
1 0170 2 piece 63750-9865-01 # Bracket FB40 17
1 0180 1 piece 62050-9041 B Pointer SR720/SR740, 2 FB 18
1 0220 1 piece 69905-9972 A Chain Case SR720, FB40 22
1 0230 1 piece 69905-9974 # Chain Case SR722/723, BACK, FB40 23
1 0240 2 piece 69999-9528-66 # Distance Piece M8x66 24
1 0250 2 piece 354-M08 # Lock Nut M8 25
1 0290 6 piece 354-M06 # Lock Nut M6 29
End of Report

Part List
Item ID 000096208 Revision B

Description Spare Part Kit Status RELEASED
0 piece 000096208 B Spare Part Kit SR6.., SR722, FCP
1 0002 1 piece SP-34014 B Spare Part Kit ELECTR., CS, 2 YEARS
2 0004 5 piece 000103689 A Fuse FUSE 5X25, 4A, 450V, TIME-LAG MC
2 0006 5 piece 10498 B Fuse FUSE 5X20MM 4A, SLOW MC
2 0008 5 piece 10499 A Fuse 5X20MM 6.3A, SLOW MC
2 0010 10 piece 000079851 A Lamp 031-963.5 SERIES 31, 36V-30mA CM,CU
2 0012 5 piece 56075 A Fuse 5X20MM 2,0A SLOW AS
2 0030 1 piece 000079850 A Mounting Tool MOUNTING TOOL FOR EAO, 61-9730.0
2 0040 1 piece 11127 # Tool Kit LAMP REMOVER FOR SERIES 06
1 0003 1 piece 000096196 B Spare Part Kit SR6.. FCP, SR722 FCP, mechanical
2 0002 2 piece 5700-002 B Magnet Coil CCS240D, 240VAC, 50/60HZ, 14W
2 0010 4 piece 290-001-TF # Filter Cartridge SPIN ON
End of Report

USER MANUAL
Electrical system
Art.No:
Ser.No:
Yard and hull no. :Shipkits B.V. : SK120

Project no. :12S000638
Date 8. January 2013
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 Control system.................................................................................................................10
3.2.1 Control panels without steering controls .........................................................................10
3.2.2 Control panels with steering controls ..............................................................................10
3.2.3 Alarm system ...................................................................................................................10
3.2.4 Auto start .........................................................................................................................11
3.2.5 Rudder indication systems ..............................................................................................11
3.2.6 Motor controller................................................................................................................12
3.2.7 General power unit ..........................................................................................................12
3.2.8 Feed back unit .................................................................................................................12
3.3 Function ...........................................................................................................................12
4 PROJECT SPECIFICATIONS................................................................ 14
5 TECHNICAL DATA ................................................................................ 15

5.1 Standard painting specifications......................................................................................16
6 OPERATION .......................................................................................... 17

6.1 Operator facilities.............................................................................................................18
6.1.1 Main operating facilities ...................................................................................................18
6.1.2 Wing and auxiliary operation facilities .............................................................................19
6.1.3 Rudder indicators ............................................................................................................20
6.1.4 Alarm panels....................................................................................................................21
6.1.4.1 Main alarm system AS02 ................................................................................................21
6.2 Before start ......................................................................................................................25
6.3 Start .................................................................................................................................25
6.4 Remote operation from the bridge...................................................................................26
6.4.1 Non –follow up push buttons ...........................................................................................26
6.4.2 Non – follow - up steering lever .......................................................................................26
6.4.3 Follow - up steering lever ................................................................................................28
6.5 Stop .................................................................................................................................28
6.6 Dimmer unit .....................................................................................................................28
6.7 Rudder angle indicators ..................................................................................................29
6.8 When an alarm occur ......................................................................................................29
6.9 Emergency operation ......................................................................................................29
6.9.1 From bridge .....................................................................................................................29
6.9.2 Local operation of the Steering gear (FCP) ....................................................................31
6.9.3 Local operation of the Steering gear (Conventional pumps RV / IRV)............................32

7 MAINTENANCE .................................................................................... 34
7.1 Maintenance overview .................................................................................................... 35
7.2 Routine maintenance...................................................................................................... 36
7.3 Renew pump control card............................................................................................... 37
7.4 Adjustment of transmitter of the rudder indicator system ............................................... 38
7.5 39
7.6 Adjust the 0-point for the FU-controller .......................................................................... 39
7.7 Renew the micro switch on steering lever ...................................................................... 40
7.8 41
7.9 Renew start relay ............................................................................................................ 41
7.10 Renew bulb on control panel .......................................................................................... 42
7.11 Adjustment of dimmer..................................................................................................... 43
7.12 Renew alarm system cards ............................................................................................ 44
8 TROUBLE SHOOTING ......................................................................... 45

8.1 Trouble shooting when an alarm is present ................................................................... 45
8.1.1 Electrical system ............................................................................................................. 45
8.2 Trouble shooting when no alarms present ..................................................................... 46
8.2.1 Electrical system ............................................................................................................. 46
8.2.2 Alarm system .................................................................................................................. 48
8.2.3 Lamp control panel ......................................................................................................... 49
8.2.4 Frequency controllers ..................................................................................................... 49
9 CONTACT LIST .................................................................................... 50
10 SPARE PARTS ..................................................................................... 54

10.1 Ordering spare parts....................................................................................................... 54
10.2 Spare parts list ................................................................................................................ 54
10.3 Preservation ................................................................................................................... 54
11 TOOLS .................................................................................................. 55

11.1 Light bulb dismounting tool ............................................................................................. 55
12 DOCUMENTS, DRAWINGS AND DATASHEETS ................................ 56

12.1 Electric ............................................................................................................................ 56
13 REVISION.............................................................................................. 57

1 INTRODUCTION
1.1 Purpose
This manual describes operation and maintenance procedures required on board for the Rolls-
Royce Steering Gear Electrical system. Always make the manual available to the technical
staff.
The manual includes general information about the Rolls-Royce Steering Gear Electrical system
product line, as well as project specific information and technical data.
The User manual provides the information necessary to operate and maintain the Rolls-Royce
Steering Gear Electrical system safely and correctly
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 3 describes the Rolls-Royce Steering Gear electrical systems main components.
Chapters 6, 7 and 8 describe the relevant operation and maintenance procedures.
Chapters 4, 5 and 12 provide project specific information.
Note!
A separate manual for installation 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 CREATE 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

The system illustrated is an example of what a Steering gear system with a single rudder
installation can contain.
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 installation required for the
installation.
The control panels consist of:
 Panel front with overlay (colour: 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 Control panels with steering controls

The control equipment is components for selecting rudder
angle.
Control equipment consists of non-follow-up steering lever,

non-follow-up push buttons, follow-up steering controller,
and push buttons on motor controller module.
3.2.3 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.
3.2.4 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 on the bridge alarm
panel.
Note!
The auto start signal is a 3 sec. pulse only.
3.2.5 Rudder indication systems

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

3.2.6 Motor controller
3.2.7 General power unit
3.2.8 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

Component Function(s)
 Low oil level
 Hydraulic lock alarm
 Power failure aux steering
 Clogged filter.
 High oil temp
 Earth failure alarm (optional)
 Rudder sync failure (optional)
Rudder indication system  Provide 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 (if applicable)
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 energized) = 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 electrical components are delivered according to the following specification:
Component Paint Colour 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 Colour Amount µm

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

6 OPERATION
Warning
 If any malfunction is detected when operating the Rolls-Royce Steering gear,

the malfunction must be investigated and remedied. Operating a Rolls-Royce
Steering gear with a malfunction in the control system or hydraulic system
may cause personal injury or equipment damage. Similarly, any malfunction
that might occur in the systems when the Rolls-Royce Steering gear is in
operation, must be remedied or the Product taken out of service.
CAUTION!
Before operating the equipment, please refer to Chapter 2 for the General Statement, Safety and
Warnings instructions.
Ensure that:
 Nobody is working with the equipment before operating it.
 The maintenance instructions (Chapter 7 & 8) are strictly followed.
 The power is available.

6.1 Operator facilities
6.1.1 Main operating facilities
Start and stop

2 pumps 4 pumps
 Start/stop
 Rudder angle selection
Non-follow-up
1 pump 2 pumps
 Start/stop  Start/stop
 Steering mode selector  NFU override steering push buttons

(emergency steering)
 NFU override steering lever
 NFU override steering lever
 In command

Follow-up
2 pump 4 pumps Wheel
 Start/stop  FU Steering wheel
 NFU override steering push buttons (emergency steering)  in command push

button.
 FU controllers
 In command
6.1.2 Wing and auxiliary operation facilities
Non-follow-up Follow-up
2 pump 2 pumps 4 pumps
 NFU lever
 FU controller
 In command

6.1.3 Rudder indicators
The rudder angle indication system is an independent indication system that provides continuous
indication of the Steering gear actual rudder position. The pointer is manually zero adjusted without
power supply connected.
Overview rudder indicators on bridge/wing:

6.1.4 Alarm panels
6.1.4.1 Main alarm system AS02
Main alarm panel on bridge and engine control room
 Terminals for E0, Auto start pumps, external buzzer, power supply
 Terminals for connecting to the CAN bus
 Alarm led`s and buzzer
 Backlight with dimming push buttons. Only bridge panels.
 NMEA card for alarm text transmission to the vessels VDR. (Normally only bridge panels).
 Lamps for indication of each alarm.
 Acoustic alarm (Buzzer).
 Button for test. This activates all alarm lamps, buzzer and NEMA text transmission.
Note!
When an alarm is present a complete system test is not possible.
 Button for acknowledges alarms.
Description lamps / push buttons:

The alarm buttons have two functions depending on whether it is pressed once or twice:
 First push: Turns off the local buzzer.

 Second push: Stops the local blinking alarm light. The lamps will show a permanent light
if the alarm condition is still present. If not, the alarms will be turned off. Buttons for
backlight adjustment. (Alarm panel in ECR is normally without backlight).
Standard alarm functions Reason for alarm / used when

Overload pump Electric motor overload
Phase failure pump Phase failure to electric motor
Power failure pump Power failure to electric motor
Power failure control Power failure steering control system
Low oil level pump Level switch mounted in the oil tank
Hydraulic lock alarm pump Proximity switch on valves
Power failure aux. steering Common for two pump units
Optional alarm functions Reason for alarm / used when

Clogged filter pump (Class/RRM Sensor on the filter unit
requirement)
High oil temp pump (Class/RRM Used for steering gear with oil cooler
requirement)
Earth failure alarm pump (Customer Only activated when the motor is not running
requirement)
Rudder synch failure alarm (Customer Only used on vessels with two rudders
requirement)
Alarm interface cards

Terminals for sensors, power supply
Main functions of the alarm interface cards
(one for each motor controller) Terminals for connection to the CAN bus
Description of rudder synch failure alarm

Measure the deviation between the two
rudders when the system is operating in
Purpose of a “Rudder synch failure alarm” synchronized mode. If the deviations is
greater than +-2.5°, this shall be indicated
with an audible and visual alarm
The technical solution for this alarm is to

mount a potentiometer in the feed-back unit
for each steering gear. The two signals are
How the alarm system detects the “ Rudder then connected to an analogue comparator
synch failure alarm” relay, which can be adjusted to give a
galvanic isolated alarm signal. This alarm
signal is further connected to an alarm input
on the alarm interface cards.

Description of hydraulic lock alarm
Hydraulic lock may occur where the hydraulic
system is arranged such that malfunctions
(for example, in directional valves) can cause
power units to work in closed circuit with each
other rather than in parallel delivering fluid to
Purpose of a “Hydraulic lock alarm”
the rudder actuator. Where a single failure
can lead to hydraulic lock and loss of
steering, an audible and visual alarm, which
identifies the failed system, is to be provided
on the navigation bridge.
Our technical solution for this alarm is to
mount one inductive sensor at each end of
the manoeuvring valve in order to detect
How the alarm system detects the “Hydraulic whether the spool is going to port or starboard
lock alarm” side. This kind of arrangement has been
provided for each of the two pump units. The
order signal is generated from the control
system.
If a pump is running in remote control and a
command signal is given to the steering gear
and the proximity switch sense that the valve
When will the “Hydraulic lock alarm” occur? is locked, a "Hydraulic lock alarm" will be
monitored both on the bridge and in the
control room after approx. 3 seconds for the
given pump.
Alarm panel back plane circuit board
Description for terminals and jumpers

X1 Power supply input / output
X2 CAN bus input / output and RS 422 Output for NMEA-0183 text transmission
X3 External alarm E0 / External buzzer
X4 Auto start outputs
JP20 Strapping for auto-start pump A/C
JP21 Strapping for auto-start pump B/D

NMEA 0183 VDR interface
RRC 485 “Piggyback card”
The “VDR” text transmission from the steering gear AS02 alarm system is designed in accordance
with IMO performance standard A. 861(20) and IEC 61996.

6.2 Before start
1. Check that there are no alarms.
2. Ensure that the selector switch on the motor controller is in “Remote control” position.
6.3 Start
Note!
For technical reasons the pump units should be running for approximate the same number of
working hours.
2. Push the button [1] “start”.
The green lamp will then be lit.
3. Select the steering mode by pressing the in command

push button [2].
The lamp will then be lit.
This function can be configured in different modes

depending on the installation:
Activate the steering mode by pressing the in command

push button for the desired steering mode, the steering
mode will be activated immediately. Only for FU-steering
and single rudder installation:
If the in command push button is activated, the system required that the order signal is equal
to the position of the Steering gear, before the actual steering mode is activated. If not, the in
command light will start flashing to indicate that the ordered signal must be changed. The
order must be changed inside a period of 6-7 sec. When the actual steering stand is activated
the in command light goes from flashing to steady.

4. If needed select rudder angle (normally automatically
controlled from the Ships speed (LOG).
 Low angel
 High/low angle
Override the LOG by select high rudder angle.
6.4 Remote operation from the bridge
6.4.1 Non –follow up push buttons

Non-follow-up push buttons with override switch is the main steering mode and is often connected
with priority.
1. Turn the override switch [4] to “override” position.

(Not necessary for system with instantaneous
override function).
The override light for each pump will then lit. An audible
alarm will be activated (if required).
2. Reset the alarm by pushing the “buzzer release” [5]

button.
3. Use the non-follow-up push buttons marked stbd.

[7] and port. [6] to move the rudder.
4. To exit this situation turn the override switch [4] to

the “release” position”.
6.4.2 Non – follow - up steering lever

Non- follow-up steering lever is a time dependent control of the rudder. The rudder moves for as
long as the lever is activated.

1. Operate the rudder by moving the steering lever to
stbd. /port.
The position of the steering gear will be stored in

memory and used as order signal when the NFU
steering lever is not used.
This function can be checked by operating the NFU

main steering.

6.4.3 Follow - up steering lever
Follow-up controller moves the rudder angle set by the operator. For two rudder system the follow
up function can be supplied for independent and/or synchronized steering. The controller has the
possibility of gain adjustments.
1. Use the follow-up controller [8/9] by turning the

steering controller.
The follow-up functions can be supplied for independent

and/or synchronised steering.
2. For synchronized steering: Push the in command

sync button [10].
3. Use the controller [8] for synchronized manoeuvring.
4. For independent steering: Push the in command

“indp” button [11].
6.5 Stop
1. Stop one pump at the time from the bridge,
2. Push the button [15] “stop”, the corresponding red

lamp will light.
If an alarm occurs the stand-by pump unit will be started

automatically. The auto start indication light is lit for about
3 seconds.
6.6 Dimmer unit

Each control panel normally has one electronic dimmer
unit. All control lamps except the alarm lamps have the
dimmer function.
1. To dim the control lamps, turn the button [16], as

The dimmer level can be adjusted, please refer to chapter

7 Maintenance, procedure 7.19.

6.7 Rudder angle indicators
Read the rudders actual position on the rudder indicators.
Red –Port
Green – Stbd
There are two indicator system installed per Steering gear

in accordance with the Class requirements.
6.8 When an alarm occur

In case an alarm condition is present for more than 3 second the buzzers are turned on and
the alarm lamp start to flash on both alarm panels independently.
1. Push the “ACK” button once.
 The local buzzer is turned off, but the alarm lamps are still flashing.
2. Push the “ACK” button once more.
 The flashing alarm lamp will be disabled.
 The local alarm lamps go from flashing to steady light, if the alarm condition is still
present.
 If not, it is turned off.
6.9 Emergency operation
6.9.1 From bridge

The main control panel is normally supplied with non-follow-up push buttons for emergency
steering.
When the non-follow-up push buttons are supplied with priority:
2. Push the button [1] “Start”.

3. Use the non-follow-up push buttons marked port. [19]
and stbd. [20] to operate the rudder.
4. An audible alarm will be activated.
5. Reset the alarm by pushing the “buzzer release”

button [18].
6. To regain normal steering turn the override switch [17]

to “release” position.
When NFU – emergency steering is NOT supplied with priority:
1. Activate the emergency steering by turning the override switch [17] to “override” position.
2. Use the non-follow-up push buttons marked port. [19] and stbd. [20] to operate the
rudder.
3. To regain normal steering turn the override switch [17] to “release” position.

6.9.2 Local operation of the Steering gear (FCP)
Warning

bridge.
1. Locate the motor controller.
2. Turn the selector switch [1] to position 3. “Local

control”
Note!
 The power failure control will be monitored.
 The “run pump” [2] indication lamp will be lit.
3. Use the maneuvering push buttons [3] in front of the

motor controller to maneuver the rudder.

6.9.3 Local operation of the Steering gear (Conventional pumps RV / IRV)
Warning

bridge.
Emergency operation valves (control valves) are on the

IRV- and some RV- Steering gears located on the Power
pack unit as illustrated.
Emergency operation valves (control / lock valves) are on

the latest RV-Steering gears mounted on the housing, as
illustrated.
When 1 pump is running:
1. Start stand-by pump
2. Stop the running pump

position 3 “Local control”
Note!

4. Locate the valve connected to the running pump.
5. Use the red and green handles to push the buttons [3]
to manually maneuver the rudder.
Note!
Only one of the pumps to be running.
When 2 pumps are running:
1. Stop the faulty pump
If the alarm occurs on both pumps:
2. Stop pump 1.
3. If no response start pump 1.
4. Stop pump 2.

position 3 “Local control”
Note!
6. Locate the valve connected to the running pump.
7. Use the red and green handles to push the buttons [3]
to manually maneuver the rudder.
Note!
Only one of the pumps to be running.

7 MAINTENANCE
This chapter describes all relevant maintenance procedures and activities to be carried out by the
crew.
Warning
Changes or modifications to the system not expressly approved by Rolls-Royce

Marine could void the warranty or the user's ability to operate the equipment.
The following warnings and cautions are for your safety, for the prevention of injury from electric
shock and for a safe operation of the equipment. Also see chapter 2.
 While performing maintenance tasks, always position the equipment (and yourself) on a stable
and safe surface.
 Ensure that all accessible cables cannot be walked on, tripped over or damaged by
transportable items.
 If a device is damaged or fails to function correctly, disconnect it from the power source. Refer
to the system drawings to locate the nearest fuse/circuit breaker, see chapter 12 Design
Drawings.
 Do not attempt to repair any sub-component yourself – consult a qualified Rolls-Royce service
technician.
 A serious electrical shock hazard exists within the covers of some components (i.e. displays)
and on marked locations inside the cabinets (marked with 220 VAC or 24 VDC).
Electrostatic Discharge
CAUTION!
It is very important that you are connected to ground before touching any electronic components or
printed circuit boards.
The life span of electronics can be affected by damage caused by electrostatic discharge. This can
happen if a charged tool or person touches a component.
Therefore it is very important that all tools and personnel are discharged by touching a grounded
point before the printed circuit board or any of the components are touched. It is equally important
to discharge the package with the new component before opening it.
A person walking on a carpet can be charged with up to fifteen thousand volt (15000 V). In worst
case, some sensitive components can be destroyed when discharged with about 100 V.

7.1 Maintenance overview
Rolls-Royce Steering Gears are designed to maintain safe operation with a minimum of
maintenance. However, to avoid unexpected stops, we will emphasize the importance to maintain
the installation on regular basis.
In connection with scheduled class survey, general overhaul or repair we advise to use engineers
from our factory or factory trained engineers from our service representatives in different countries.
This will limit the time of repair to a minimum and ensure continuous safe operation.
The following table lists the maintenance procedures:
Procedures Condition Chapter
Routine maintenance See separate table for routine maintenance 7.2

activities.
Renew the pump control No starting 7.3

card
Rudder movement problems
Adjustment of limit switches The rudder cannot be moved from hard over 7.4
in feed back unit position to mid-ship
Adjustment of transmitter for Rudder movement problems 7.5

the rudder indication system
Adjust 0-point on FU- Rudder movement problems 7.9

controller.
Goes to hard over when starting up
Renew limit switch in feed Rudder can only be operated to one side 7.12
back unit
Steering gear cannot be brought from hard over
to mid ship
Rudder cannot be moved out of centre position
Renew start relay No starting 7.15
Renew bulb on control panel Defect bulb 7.18
Adjustment of dimmer Dimmer not correct adjusted 7.19
Renew alarm cards Fault in alarm system 7.20

7.2 Routine maintenance
The table lists maintenance activities to be carried out by the ship’s crew at regular intervals.
Activity: How often:
M Y
1 Functional test of steering modes from all steering stations, normal

and emergency mode.
X
2 Test alarm system by pushing the “test” button X

3 Visual check of all components included in the alarm, control and
steering system.
X
4 Test operation of switches, cable connections, and the insulation

properties of the motor.
X
5 Local start of pump units directly from each starter cabinet. X

6 Visual check of control station X
7 Check communication system between Steering gear room and
bridge
X

7.3 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
4. Check that the wiring connection between the control system and motor controller are ok.
2. Loosen all connected wires [1].
3. Loosen the screws [2].
4. Replace the faulty pump control card.
5. Refit all wires and screws.

7.4 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.

7.5
7.6 Adjust the 0-point for the FU-controller

no
Screw driver 1

Cable diagram
1. Select the steering mode by activating the in-

command push button [1].
The in-command function can be configured in two

modes
 If the operator activates the in-command button, the

steering mode will be activated immediately.
 If the in-command push button is activated the system require that the order signal is
equal to the position of the Steering gear before the actual steering mode is activated. If
not the in-command light will start flashing to indicate that the operator must change the
ordered signal. The order must be changed within 6-7 sec. When the steering mode is
selected the in-command light goes from flashing to steady. This function is only available
for vessels with one steering gear.
2. Adjust the 0-point for the FU-controller by turning the

nut [2].
o
3. Adjust ordered signal from FU-controller to 8V (50 ,
o
FU-controller) or 10V (70 FU-controller)
4. When the position of the controller is max. order

(mechanical stop), J2-2 (0V) to J2-6 (order signal)
equal respectively 8V.

7.7 Renew the micro switch on steering lever
no
Screw driver 1

Drawing of the lever
If it is concluded that the rudder will not move two one

direction due to faulty micro switches, these must be
replaced.

7.8
7.9 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.

7.10 Renew bulb on control panel
no
Bulb 1 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.

7.11 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.

7.12 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.

8 TROUBLE SHOOTING
8.1 Trouble shooting when an alarm is present
8.1.1 Electrical system

One alarm system monitors two pumps.
Alarms Reason Corrective

action
Stop the faulty pump and start
The electric motor is
Overload the other pump if not already
overloaded.
running.
Stop the faulty pump and start
Phase failure to
the other pump if not already
electric motor.
Phase failure running.
Main power supply Start the other pump if not
out of range. already running.
Set the selector switch on the
motor controller to “remote”
position.
Power failure steering
Power failure control Renew broken fuses in the
control system.
motor controller.
Repair solenoid driver in the
motor controller.
Main power supply
from switch board is Use emergency steering.
lost.
Turn the selector switch on
Main switch in motor
Power failure electric motor the motor controller to position
controller is off.
1 “remote control”.
Broken fuses internal Stop the faulty pump and start
in the motor the other pump if not already
controller. running.
Refill oil from storage
Low oil level in the
Low oil level tank.(See procedure in
hydraulic system.
mechanical User Manual)
Fault on the solenoid
driver in the motor Repair solenoid driver in the
controller. (Only motor controller.
conventional systems)
Defect solenoid on
Hydraulic lock
the manoeuvring Renew solenoid on the
valve. (Only manoeuvring valve.
conventional systems)
Locked manoeuvre Stop the faulty pump and start
valve. the other pump if not already

Alarms Reason Corrective
action
running.
Defect sensor. Renew sensor
Change the hydraulic oil. (See
Dirty oil. procedure in mechanical
Clogged filter installation manual)
Renew filter. (See procedure
Clogged oil filter
in mechanical User Manual)
Power failure steering
Use emergency steering
control system
Faulty amplifier card,
Adjust amplifier card.
aux. steering.
Aux. Steering Broken fuses internal
Repair/renew the broken
in the motor
fuses.
controller.
Faulty feed back Replace feed back
potentiometer. potentiometer.
8.2 Trouble shooting when no alarms present
8.2.1 Electrical system

actions
Defect pump Renew the

Control card
control card. control card
Renew the start

Defect start relay Relay
relay
Not starting
Defect wiring
Locate the defect
connections
Wiring wiring
between control
connection connection(s)
system and
and renew.
motor controller
Renew the limit

Defective micro switch in feed
The Steering
switches in the back unit
gear can only be
limit switch box Limit switch
operated to one
FB or in the
side Renew the limit
steering lever
switch in the
steering lever

actions
Locate the defect

Failure in the
Wiring wiring
wiring
connections
and renew.
Defective Repair the

Frequency
frequency frequency
converter
converter converter
Defect solenoid
driver Solenoid driver in
Renew driver
(conventional motor controller
pumps)
The steering Defect micro
gear goes to Renew the micro
switch in the Not starting
hard over switch
steering lever
position without
Rudder rudder command
movement when one of the Defect solenoid
problems pump units is driver Solenoid driver in Renew solenoid
started, without (conventional motor controller driver
giving rudder pumps)
command
The rudder
cannot be
Defect micro
brought from Renew the micro
switch in the feed Micro switch
hard over switch
back unit
position to mid-
ship
Defect amplifier Renew amplifier
Amplifier card
card card
Defect selector Renew selector
Selector card
card card
Defect pump Renew control
Control card
The Steering control card card
gear fails to
Defect wiring
respond when Locate the defect
given rudder connections
Wiring wiring
command between control
system and
and renew.
motor controller
Defect solenoid
driver Solenoid driver in Renew solenoid
(conventional motor controller driver
pumps)
Defect amplifier Renew amplify
Amplifier card
Rudder cannot card card
be moved out of Defect wiring Locate the defect
centre position Wiring
connections connections wiring
between control connection(s)
actions
system and and renew.
feedback /control
panel
Defect solenoid
driver Solenoid driver in Renew solenoid
(conventional motor controller driver
pumps)
Rudder Rudder cannot
movement be moved from Adjustment of
Wrong adjusted
problems hard over Limit switches limit switches in
limit switch
position to mid- feed back unit
ship
Feed back
The rudder potentiometer not Locate and
movement is not correct adjusted adjust the
Potentiometer
equal to each FU controller incorrect
side (port/stbd) potentiometer not potentiometer
correct adjusted
8.2.2 Alarm system

actions
Defect fuse Back plane card Renew fuse
Defect back
Back plane card Renew card
plane card
Missing power Loose internal
supply Cables Reconnect
cables
Change placing
Wrong placing of
Alarm ponds of panels (ECR /
Alarm system panels
bridge)
problems
Change placing
Wrong placing of
Alarm ponds of panels (ECR /
Missing signals panels
bridge)
to VDR
Defect piggy
Piggy back card Renew card
back card
All alarm lights Fault on CAN CAN bus and
Check and repair
are lit bus cables

8.2.3 Lamp control panel

actions
Lamp in control panel will not lit Defect bulb Bulb Renew bulb
Problems with the Steering gear may also appear as a combination of one or more of the above
mentioned sections.
8.2.4 Frequency controllers

For system equipped with frequency converter, see own instruction manual from the manufacturer.
Every motor controller has a parameter list inside the motor controller door.
Note!
It is important that only these parameters are used.
If program is lost for some reason please contact the Rolls-Royce Marine Steering Gear service
apartment.

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 SPARE PARTS
Note!
 Information regarding the Steering gear electrical
system is found on a sticker inside the door on every
electrical cabinet.
 The information is also found on the front page of this

manual.
10.1 Ordering spare parts

When ordering spare parts, the following information must be given:
 Installation No. (T- followed by a number), vessel’s name and owner’s name.
 Shipping address and invoicing address.
 Drawing Number, Position Number, Article Number (Art. no.) and Quantity.
10.2 Spare parts list

Refer to chapter 12. Design drawings.
10.3 Preservation
Spare parts should be kept in a dry and dust free environment.

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

Technical specification
Steering Gear
Type Rolls-Royce steering gear

SR722 FCP
Date : 22.10.2012
Id : 10-12-00938
Rev : 10
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 rev. 10 (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 : IN = 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
Electrical installation: DMN227-061
Interface description: 0002-4810
Configuration steering gear: 0003-2555
Terminal diagram: 0003-2552
Cable list: 0003-2551
Power comsumption list: 0003-2553
Emergency steering procedure: 0002-2971

Page 9 of 9
Rauma Brattvaag™
227-061
GUIDELINES
FOR
ELECTRICAL INSTALLATION
Table of contents:
1. GUIDELINES FOR INSTALLATION ACCORDING TO EMC ................................................................................. 2
2. DOCUMENT REVISIONS ............................................................................................................................................ 3
3. INTRODUCTION .......................................................................................................................................................... 4
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or
4. POWER CABLES .......................................................................................................................................................... 4

4.1 General................................................................................................................................................................... 4
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.
4.2 Redundant power supply........................................................................................................................................ 4

4.3 Frequency converter cables.................................................................................................................................... 4
5. CONTROL CABLES ..................................................................................................................................................... 4
5.1 Control of solenoid valves ..................................................................................................................................... 4
6. SIGNAL CABLES ......................................................................................................................................................... 4
6.1 Dig. feedback signal (from valves / starters) ......................................................................................................... 4
6.2 Analog signal (from valves / transmitters) ............................................................................................................. 5
7. BUS CABLES ................................................................................................................................................................ 5
7.1 Ethernet COAXIAL ............................................................................................................................................... 5
7.2 Ethernet TWISTED PAIR ..................................................................................................................................... 5
7.3 ProfiBus ................................................................................................................................................................. 5
7.4 Can Bus.................................................................................................................................................................. 6
7.5 RS-422/485 Transmissions .................................................................................................................................... 6
7.6 FIBRE OPTICAL .................................................................................................................................................. 6
8. INSTALLATION ........................................................................................................................................................... 7
8.1 General................................................................................................................................................................... 7
8.2 Cabinets ................................................................................................................................................................. 7
8.3 Motors .................................................................................................................................................................... 7
8.4 Encoders ................................................................................................................................................................ 7
8.5 Power cables .......................................................................................................................................................... 7
8.6 Control cables ........................................................................................................................................................ 7
8.7 Signal cables .......................................................................................................................................................... 7
8.8 Bus cables .............................................................................................................................................................. 8
8.9 Connecting load cells ............................................................................................................................................. 8
8.10 Installation of frequency converters....................................................................................................................... 8
9 REFERENCES ............................................................................................................................................................... 8
Prep. by/date: RHj/28.11.05 227-061, rev. J KRAV Page 1 of 8

® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
1. GUIDELINES FOR INSTALLATION ACCORDING TO EMC
The following 10 rules are the basics for designing systems in compliance with EMC. Rules 1 to 7 are generally valid.
Rules 8 to 10 are especially important to limit noise emission.
Rule 1 All metal parts of the switch cabinet should be connected with one another through the largest possible
surface area so that the best electrical connection is established (no paint on paint!). If necessary, use contact
or scraper discs. The cabinet door should be connected to the cabinet using the shortest possible grounding
straps.
Rule 2 Signal, line supply, motor and power cables should be routed away from another (this eliminates mutual
interference!). The minimum clearance is 20 cm. Barriers should be provided between power and signal
cables. These barriers should be grounded at several locations.
Rule 3 Contactors, relays, solenoid valves, electromechanical operating hour counters etc. in the cabinet must be
provided with noise suppression devices, e.g. using RC elements, diodes, varistors. These devices must be
connected directly at the coil.
Rule 4 Non-shielded cables belonging to the same circuit (feeder and return cables) should be twisted with the
smallest possible distance between them. Wires, which are not used must be grounded at minimum one end.
Rule 5 Generally, noise which is coupled in, can be reduced by routing cables as closely as possible to g rounded
steel panels. For this reason, cables and wires should not be routed freely in the cabinet, but as closely as
possible to the cabinet itself and the mounting panels. This is also true for reserve cables. Connect the
reserve cables/conductors to ground at both ends to achieve an additional shielding effect.
Rule 6 Incremental encoders must be connected using shielded cables. The shield must be connected at the
incremental encoder and at the AC drive converter through the largest possible surface area. The shield may
not be interrupted, e.g. using intermediate terminals.
Rule 7 The shields of signal cables must be connected to ground at one end only, through the largest possible
surface area to establish a good electrical connection (transmitter and receiver). If the potential bonding
between the screen connections is poor, an additional potential bonding conductor with a cross-section of at
least 10 mm² should be connected in parallel with the shield to reduce the shield current. The shields can be
connected to ground at several locations, e.g. on the cabinet housing and on cable trays. Foil shields are not
recommended. Braided screens provide a better shielding effect (factor of 5).
Rule 8 Always place a radio interference suppression filter close to the noise source. The filter is to be connected
flush with the cabinet housing, mounting plate, etc. The best solution is a bare metal mounting panel (e.g.
stainless steel, galvanized steel), because the complete mounting surface can be used to establish good
electrical contact. The incoming and outgoing cables of the radio interference suppression filter should be
separated.
Rule 9 All variable-speed motors should be connected using shielded cables, whereby the shield is connected at
both ends to the housings through the largest possible surface area to minimize the inductance. The motor
feeder cables should also be shielded outside the cabinet, or at least screened using barriers. Cables with steel
shields are not suitable.
To connect the shield at the motor, a suitable cable gland with shield connection can be used. It should be
ensured that the connection between the motor terminal box and the motor housing has low impedance.
Otherwise, use an additional grounding strap between them. Never use Plastic motor terminal boxes!
Rule 10 Installing components such as output reactors, sinusoidal filters, motor filters, fuses, contactors, etc may not
interrupt the shield between the motor and the frequency converter. The components must be mounted on
mounting panels, which also simultaneously serve as the shield connection for the incoming and outgoing
motor cables. Metal barriers may be required to shield the components.

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
2. DOCUMENT REVISIONS
Change Date Sign Description

D 28.11.05 RHj Update of document.
Added information regarding selection of “fire resistance” or “flame
retardant” cable type. (Ch. 3)
E 12.01.07 RHj
Added new requirements regarding cables for frequency converter
duty. (Ch. 4.2)
F 12.03.05 bten Corrected outdated IEC norms with new norms
Added information regarding recommendation og “Halogen free
G 29.06.07 RHj cable” (Ch. 3) and specified insulation level on power cables for
frequency converter duty. (Ch. 4.2)
H 14.01.09 RHj Updated reference to project specific cable list.
I 08.06.11 RHj Adjusted to include steering gear. (Info from TS)

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
3. INTRODUCTION
This instruction gives requirements and guidelines regarding the electric installation of the winch control system and
the Steering Gear system.
The instruction also gives guidelines for the selection of cables between different communication network node points
within winch control system. Cable type and requirements are listed up below.
This instruction refers in most cases to cables of type “fire resistance”, however cables of type “flame retardant” can
be selected if similar specification.
This instruction refers to cables of type “Halogen Free”, if other cables are used this could lead to damage on
equipment.
NOTE!
All project specific requirements, such as dimension are described in the project specific cable list.
General requirements:
Twisted pair cables to comply with: IEC 60092-376, 60332-3-22, 60754-1/60754-2, 61034-1/61034-2
Power cables to comply with: IEC 60092-353, 60092-350, 60332-3-22, 60754-1/60754-2, 61034-1/61034-2
4. POWER CABLES
4.1 General
For power cables, it is required using a shielded cable with braided screens (0-1000V).
All phases are to be represented in each cable.
Cable dimension: According to documentation.

4.2 Redundant power supply

Where redundant supply is required, the supply must be in separate feeders from the main switchboard.
If required by the class, one of the supplies must be taken from the emergency source of power.
4.3 Frequency converter cables

For power cables, it is required using a shielded cable with braided screens of type
BFOU (VFD) or similar. All phases are to be represented in each cable.
Cable dimension: According to documentation.
Recommended insulation requirement:

General: 2 x nominal DC voltage
(Nominal DC voltage at 690 VAC supply approximately 950 VDC)
Note!
This include supply cables to frequency system, and cables from frequency system to electrical motor
5. CONTROL CABLES
5.1 Control of solenoid valves
For control of solenoid valves, it is required using a shielded cable.
(Coil voltage. 24V / 110V / 230V)
Cable Data: Pair, shielded, 1,5 mm² min. (60 or 250V)
(for cable length >100m 2,5mm²)
For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type, BFOU(C) type or similar.
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and 24 pair. (Acc. to data sheet)
6. SIGNAL CABLES
6.1 Dig. feedback signal (from valves / starters)
For dig. feedback signal, it is required using a shielded pair cable. (24V DC)
Cable Data: Pair, shielded, 0,75 mm² min. (60V)

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
PWM signal must have separate cables (for each consumer).
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and 24 pair. (Acc. to data sheet)
6.2 Analog signal (from valves / transmitters)

For analogue signal, it is required using a shielded pair cable. (0-24V)
Cable Data: Pair, shielded, 0,75 mm² min. (60V)
We recommend not mixing digital and analog signals in the same cable.
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and (24) pair. (Acc. to data sheet)
7. BUS CABLES
7.1 Ethernet COAXIAL
For coaxial Ethernet it is recommended to use a ”Thinnet” or ”Cheapernet” cable for LAN 10 base 2. Cable shield
must be connected to ground at the computer end (UN 900), and terminators must be used at both ends.
Cable Data:
Type: LAN 10 base 2 DEC Coaxial
Cable outer diam.: 4.65 mm
Impedance: 50 Ω
Capacity (nom): 88 pF/m
7.2 Ethernet TWISTED PAIR

For Ethernet with twisted pair it is recommended to use a 10BASE-T of S-FTP (Braid and foil screened Twisted Pair)
cable of category 5 or higher.

Cable Data:
Type: 2x2x0.5mm²
Impedance: 100 ± 15 Ω (1-100MHz)
Range: Max. 90 m.
A recommended category 6 cable is LANmark-6 F2TP Cat.6 LSZH from Nexans:

Type: Twisted pair, shielded, 4x2x0.55 mm (cable diameter)
Cable outer diam.: 6.5 mm
Impedance: 100 Ω ± 15 Ω (1-100MHz)
7.3 ProfiBus
End- terminators must be used in both ends.
External – Yard installed cable

Siemens brand – DNV approved cable.
Cable Data SIENOPYR-FR PROFIBUS M-02Y(ST)CHX:
Type: Twisted pair, shielded, 1x2x0.325 mm² (22 AWG)
Cable inner sheath: ø 8.0 mm
Cable outer diam.: ø 10.0 mm
Impedance: 150 ± 15 Ω
Capacitance: max. 30 pF/m
Internal – In cabinets / cabins only

Lapp Muller SAS
Cable Data : M-02Y(ST)CHX L2/FIP-DP
Type: Twisted pair, shielded, 1x2x0.34mm²
Cable outer diam.: ø 8,65mm
Impedance: 150 ± 15 Ω
Capacitance: max. 32 pF/m

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
7.4 Can Bus
For the CAN bus, it is required using a shielded twisted pair cable. According to the ISO 11898-2 standard, cables to
be chosen for CAN bus lines should have a nominal impedance of 120 Ohm, and a specific line delay of nominal 5
ns/m. Line termination is provided with 120 Ohm resistors terminated at both ends of the line. The length related
resistance should have 70 mOhm/m. All these mentioned AC and DC parameters are suitable for a 1 Mbit/s
transmission rate at 40 m segment length. With increasing segment length, a higher cable cross-section must be used
(see recommended values of ISO 11898).
Can-H and Can-L connected to one pair, Can-GND to the other pair.
This type of bus do not require any special type of cable, so most common twisted pair cables available can be used.
Cable Data:
Type: Twisted pair, shielded, low capacity, 0,75 mm² min.
Cable outer diam.: max 14 mm (when connector is used).
Impedance: 120 Ω (min. 108 Ω, max. 132 Ω)

Capacitance: max. 60 pF/m.
Resistance: max 40 Ω/km.
Range: Max 300m.
A recommended cable is :
Manufacture : Lapp Muller - France
Description : MARINEBus M-O2Y(st)CHX2Y 1x2x0.75mm+0.75mm.
Conductor : 1 x 2 x 0.75q + 0.75q
Cable outer diam. : 11.1 mm.
Impedance : 120 Ω.
Capacitance (800 Hz) : max. 40 pF/m.

Approved by : DNV certificate E-9274

Part No. manufacture : 67106
Maximum cable length : 300m
Supplier worldwide : Miltronic AS - Norway
Part No. Supplier : 1111646
7.5 RS-422/485 Transmissions

For wiring of RS-422/485 signals, it is recommend using a shielded twisted pair cable. RS-422/485 signals do not
require any special type of cable; so most twisted pair cables can be used. On the other hand, the transmission range
will increase if a cable with lower capacitance and larger diameter is used.
Sign-A and Sign-B connected to one pair, Sign-GND to the other pair.
Cable Data:
Type: Twisted pair, shielded, low capacity, 0,75 mm² min.
Cable outer diam.: max 14 mm (when connector is used).
Resistance: Max 100 Ohm totally on bus.
Capacity: 42pF/m maximum.
Range: Max 1200m.
For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type or similar.
Note! Special for Steering gear delivery
Screened twisted pair (0.5 mm2 minimum).

Impedance 120 ohm min 108 maks 132.
Termination at the end of the line at the receiver.
7.6 FIBRE OPTICAL

The fibre optical cables must be of multimode type with a core diameter of 50 or 62.5 µm, and cladding diameter 125
µm. ST connectors (also known as BFOC) are to be used in both ends of the cable. Each fibre optical link requires a
duplex connection, i.e. a total of four single fibres for each connection box.
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Cable Data:
Type: Multimode.
Cable Core Diameter 50 or 62.5 μm.
Cladding Diameter: 125 μm.
Recommended cables:
Nexans Gx-62,5 QIQI-ø3.7-R1.0 or Gx-62,5 QIQG-ø3.7-R1.0,
Draka Gx-50/125 AXXI-I/O-W or Gx-62.5/125 AXXI-I/O-W
Optronics OM1LST08UBK
8. INSTALLATION
8.1 General
According to classification requirements.
The following precautions must be taken in regards to cabling:
 Ensure that there is sufficient space for the cables and cable-ducts used.
 Ensure that there are no cable bends that reduce cable performance,
 special attention to optical cables.
 Ensure that power and signal cables are separated.
 As a general rule, the minimum distance between power cables and signal cables is 0.3 meter.
 Avoid routing of cables near power generator cables.

 Ensure that cables are secured inside cabinet.
 Cabinet to be grounded.
 Ensure that cable screens are terminated correct according to the system drawings
All cables are to be according to requirement by the classification society and relevant directives.
For installations with DNV classification please check against the DNV document “Classification Notes No. 45.1”
(December 1995), tables 4.1 and 4.2.
8.2 Cabinets
The steel cabinets must be properly earthed (Bonded). Cabinet doors and flanges are connected electrically with the
cabinet. Do not remove flanges or cable glands from el. cabinets; this to maintain the electromagnetic screen.
8.3 Motors
The motors must be properly earthed (Bonded). Junction boxes and flanges are connected electrically with the motor.
Do not remove flanges or cable glands from el. motor; this to maintain the electromagnetic screen.
8.4 Encoders
The cable screen is connected to the earth-bar in the cabinet, and to the screen in the encoder cable in the other end.
It must not be connected to earth in any other places (Earth terminals in junction boxes not to be used).
Each wire pair must be connected according to documentation. Unused wires must be connected to earth.
8.5 Power cables

Power cable shield grounded in both ends.
8.6 Control cables

Signal cable shield grounded in one end only (see documentation for shield grounding).
8.7 Signal cables

Signal cable shield grounded in one end only (see documentation for shield grounding).

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
8.8 Bus cables
Communication cable shield grounded according to documentation.
Each wire pair must be connected according to documentation.
8.9 Connecting load cells

All cables connecting load cells has to be connected to terminals in special terminal boxes placed on winch. This
work has to be carried out under supervision by Roll Royce Marine.
Signal cable shielded connected to terminals (see documentation for shield grounding).
8.10 Installation of frequency converters

Regarding installation of frequency converters, see instruction manual under section for installation.
9 REFERENCES
IEC 60092-353
IEC 60092-376
IEC 60092-350
IEC 60332-3-22
IEC 60754-1/60754-2
IEC 61034-1/61034-2

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Steering Gear Brattvaag™
0002-4810
Interface for Steering Gear

Signals from Steering Gear control system
Run indication, pump xn (x=A-B, n=1-2)
Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-Un-X2: 17 18 19
Potential free contact NO +CSx-Un-X2: 23 24
Potential free contact NO +MCxn-X2: 9 10
x=A-B, n=1-2
Power indication, pump xn (x=A-B, n=1-2)

x=A-B, n=1-2
Autostart indication, pump xn (x=A-B, n=1-2)

x=A-B, n=1-2
Port order, pump xn (x=A-B, n=1-2)

x=A-B, n=1-2
Stbd order, pump xn (x=A-B, n=1-2)

x=A-B, n=1-2
Follow up selected, pump xn (x=A-B, n=1-2)

Potential free contact NO +CSx-Un-X2: 34 35 36
x=A-B, n=1-2
Follow up selected, rudder x (x=A-B)

Potential free switching contact CO +CSx-U10: 20 21 22
x=A-B
Override signal, rudder x (x=A-B)

x=A-B
Sign.: TS : 22.03.11 Appr.TS : 22.03.11 0002-4810, rev. D Page 1 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Order signal output, rudder x (x=A-B)
Signal type Terminal Group name 0V +/-10V
Analog +/- 10V +CSx-U10: 7 8
x=A-B
Note: Order signal +/-10V is available to VDR system.
Ready signal steering modes, rudder x (x=A-B)

Mode Signal type Terminal Group name Common NO NC
1 Potential free switching contact CO +CSx-U11: 7 8 9
x=A-B
Pulse signal, leaving DP

Signal type Terminal Group name Common NO
Potential free switching contact CO +CSA-K2: 15 18
Pulse signal, leaving Joystick

Potential free switching contact CO +CSA-K3: 15 18
Remote/Stop/Local indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Grp. name Common Remote Stop Local
Potential free contact +MCxn-X2: 14 11 12 13
x=A-B, n=1-2
Motor voltage supply, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name L1 L2
Motor voltage Supply 1 +MCxn-X1: 1 2
Motor voltage Supply 2 +MCxn-X1: 3 4
x=A-B, n=1-2
High/Low Rudder angle indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common Low High
Potential free switching contact CO +MCxn-X4: 15 16 17
x=A-B, n=1-2
NMEA-signal from alarmpanel APxn (x=A-B, n=1-2)

Signal type Terminal Group name TD+ TD- GND
NMEA-0183 signal (RS422) +APxn-X2: 7 8 9
x=A-B, n=1-2
Note: NMEA-0183 only activated when 5801-RRC485 card is installed in the alarm panel
NMEA-0183 signal from bridge alarm panel is provided to VDR system.
E0-Alarm from alarmpanel APxn (x=A-B, n=1-2)

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Potential free contact NO +APxn-X3: 1 2
x=A-B, n=1-2
Autostart signal from alarmpanel APxn (x=A-B, n=1-2)

Potential free contact NO, to pump x1 +APxn-X4: 1 2
Potential free contact NO, to pump x2 +APxn-X4: 3 4
x=A-B, n=1-2
External buzzer alarmpanel APxn (x=A-B, n=1-2)

Signal type Terminal Group name (+) (-)
24VDC 50mA +APxn-X3: 3 4
x=A-B, n=1-2
Rudder angle indication from RAI-amplifier RAIxn (x=A-B, n=1-6)

Signal type Terminal Group name (0V) (+/-10V)
+/- 10V +RAIxn+U10-X4 1 2
x=A-B, n=1-6
Note: One of these signals are available to VDR system.
Rudder angle indication from Feedback-unit FBxn (x=A-B, n=1-2)

Signal type Terminal Group name Clockw. Wiper Counter Clockw Mid.point
5kohm potmeter 2 +FBxn 4 5 6 7
5kohm potmeter 3 +FBxn 8 9 10 11
x=A-B, n=1-2
Note: Only for use as rudder indication to DP
Only one of the potentiometers are available for external use.

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Signals to Steering Gear control system from external equipment
In command pulse for modes CSx (x=A-B)
Potential free contact, pulse NO +CSx-U11: 1 2
x=A-B
Eneable request from DP/Joystick CSx (x=A-B)

From Signal type Terminal Group name Common NO
DP Potential free contact, pulse NO +CSx-X10: 9 10
Joystick Potential free contact, pulse NO +CSx-X10: 13 14
x=A-B
Request from DP/Joystick CSx (x=A-B)

From Signal type Terminal Group name Common NO
DP Potential free contact, pulse NO +CSx-X10: 11 12
Joystick Potential free contact, pulse NO +CSx-X10: 15 16
x=A-B
Analog steering signal, +/-10V CSx (x=A-B)

Mode Signal type Common Signal in Adjusted signal To mode in CS
1 Analog +/- 10V +CSx-U11:13 -X10:n -X10:n +CSx-U11:11
x=A-B n=1-4 n=5-8
Note: The signal is routed through a potentiometer for individual adjustment.
There are 4 available potentiometers, hence only 4 analog inputs can be used.
Connect the signal to terminal –X10:1-4
Connect terminal –X10:5-8 to the correct mode

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Digital steering signal for pump xn (x=A-B, n=1-2)
Signal type Terminal Group name Port Common Stbd
Potential free switching contact CO +CSx-+Un-X5: 7 8 9
x=A-B, n=1-2
From speed log to select low rudder angle, to panel i (i=1-4)

Pump no Signal type Terminal Group name Terminal
A1 Potential free switching closed when high speed +CPi-X130: 1 2
A2 Potential free switching closed when high speed +CPi-X130: 7 8
B1 Potential free switching closed when high speed +CPi-X131: 1 2
B2 Potential free switching closed when high speed +CPi-X131: 7 8
i=1-4
Only to be used when Start/Stop panel is not includedd in RR scope of supply:

Digital Start/Stop signal for pump xn (x=A-B, n=1-2)
Start +CSx-+Un-X3: 1 2
Stop +CSx-+Un-X3: 1 3

Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Doc. ID: 0003-2555 Rev: A

Instruction, Manufacturing
Configuration Of Steering Gear
Circuit diagram alarm system W-1006-00-02

Classification drawing control system W-1007-00-01
Classification dwg. Rudder ind. System W-1005-00-01
Classification drawing Deviation alarm
Class. drawing bypass & Separation system
Power consumption pump unit 15kW
Voltage pump unit 380V
Connection type
Frequency pump unit 50Hz
Current pump unit 30A
Yard Shipkits B.V.
Hull no. SK 120
Rolls Royce Marine order no. 10-12-00938
Software alarm panel 5250-W18020001-1

Software motor controller 5250-W18020001-2
Classing company: BV
One man bridge operation? No
Emergency steering procedure Doc. No. 0002-2971
Originator: T.Hel Verifier: T.Sel Page 1 of 8

Doc. ID: 0003-2555 Rev: A
Alarm List Steering Gir

Alarm List Steering Gear
Description Al.Nr Light Al.Nr Descrition
Overload 10 ⃝ 20 Overload
Phase Failure 11 ⃝ ⃝ 21 Phase Failure
PW/Freq Failure 12 ⃝ ⃝ 22 PW/Freq Failure
Power Failure Control 13 ⃝ ⃝ 23 Power Failure Control
Low Oil Level 14 ⃝ ⃝ 24 Low Oil Level
Hydraulic Lock 15 ⃝ ⃝ 25 Hydraulic Lock
Not used 16 ⃝ ⃝ 26 Not used
Aux. Steering 19 ⃝ ⃝ 29 Aux. Steering
Note: The alarms are indicated on bridge and in machinery space area

Doc. ID: 0003-2555 Rev: A
Lamp Text For Control Panel

Main Control Panel:
Reference Lamp text
Pump A1 Pump 1
Pump A2 Pump 2
In Command No. 1 In Command Autopilot

In Command No. 2 In Command Main FU

Doc. ID: 0003-2555 Rev: A
Bridge wing control panel:

Reference Lamp text
In Command No. 1 In Command Wing FU

Doc. ID: 0003-2555 Rev: A
Jumper setting for control system

Jumper setting for Pump Control Card:
Jumper Description Setting
JP1 (+U1) St. Signal Common +/- + (Tennfjord)

JP2 (+U1) St. Signal Common +/- + (Tennfjord)
JP3 (+U1) NFU Main St. Override YES (Note 1)
JP4 (+U1) NFU St. Override (Note 0) YES (Note 1)
Gain Adjustment External Equipment:

Steering
Description Internal Conection
mode
(-X10:1) Not used -X10:5 To -U11:11

(-X10:2) Not used -X10:6 to -U11:24
(-X10:1) Autopilot -X10:7 to -U11:37
(-X10:2) Not used -X10:8 to

Doc. ID: 0003-2555 Rev: A
Jumper Setting for AUX Steering:

Steering Description Jumper Setting CS1 CS2
(-U10) Feed back connected JP20 = Yes
(-U41) Feed back connected JP60 = Yes
1 (-U42) Not used JP50 = FU EXT, JP51 = Master Slave

2 (-U42) Not used JP60 = FU EXT, JP61 = Master Slave
3 (-U42) Autopilot JP70 = FU EXT, JP71 = Master Slave
4 (-U43) Main FU JP50 = FU EXT, JP51 = Master Slave

5 (-U43) Port Wing FU JP60 = FU EXT, JP61 = Master Slave
6 (-U43) Stbd Wing FU JP70 = FU EXT, JP71 = Master Slave
Note: For Jumper setting on backplane, see drawing for control system
Note 0: If NFU Steering is not used apply internal connection X6:3 to X6:6
Note 1: Setting for JP3 and JP4 should be "NO" for classification societies GL and ABS, except when
notation for "One man bridge operation". See also jumper setting for control panel
Note 3: For vessels with frequency controlled pumps, delivered with NFU and FU steering an internal
connection -X7:6 to -X7:7 must be applied

Doc. ID: 0003-2555 Rev: A
Jumper setting for alarm system

Jumper setting alarm panels:
Interface card type: RRDIO15
Jumper Description Setting bridge Setting E.C.R.
X3 Can Bus1 Termination Yes No
X4 Can Bus2 Termination No No
X5 Can-Gnd Connected to Rf-Gnd No No
X7 Jumper for programming Operating Operating
X8 Node number (Number *10exp.1) [8] [9]
Back plane type: 5801-AS02-BPL-00

Autostart Setting Bridge Autostart Setting E.C.R
Jumper: JP21 Jumper: JP20 Jumper: JP21 Jumper: JP20
Al. 10 On Al. 20 On Al. 10 On Al. 20 On
Al. 16 Off Al. 26 Off Al. 16 Off Al. 26 Off
Jumper Setting Motor Controller:

Interface card type: RRDIO15
Jumper Description Setting MC. A1 Setting MC. A2
X3 Can Bus1 Termination No Yes
X4 Can Bus2 Termination No No
X5 Can-Gnd Connected to Rf-Gnd No No
X7 Jumper for programming Operating Operating

Doc. ID: 0003-2555 Rev: A
Jumper Setting For Control Panel

Main Control Panel:
Jumper setting for override modules:
JP1 External override YES

JP2 Override light dimmed NO
JP3 Buzzer Connected YES (Note 0)
Jumper setting for dimmer module:

JP30-Ch.9 Supply to channel External


JP30-Ch.13 Supply to channel Internal
JP30-Ch.14 Supply to channel Internal
Note 0: Must be set to "NO" if jumper setting for control system (pump control card, JP3 and JP4) is
"NO"

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
FREQ. CONTR. STEERING GEAR Originator: T.Hel 16.12.10 EMERGENCY STEERING PROCEDURE =SGCS
FOR STEERING GEAR
NO EXTRA ALARMS Verified: MSK +
CONTROL SYSTEM
C 17.08.12 tab Original: Replaced for: Replaced by: Reference: Draw. Rev. Inst.
B 14.10.11 Removed "Mode Selection" instructions T.Hel Rolls-Royce Marine AS

Dept. Steering Gear - Tenfjord
no.
0002-2971 C
Rev. Date Description Eng. Tel. +47 70 20 85 00 Fax. +47 70 20 86 00 Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party,
or used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.
Part List
Item ID 000096208 Revision B

Description Spare Part Kit Status RELEASED
0 piece 000096208 B Spare Part Kit SR6.., SR722, FCP
1 0002 1 piece SP-34014 B Spare Part Kit ELECTR., CS, 2 YEARS
2 0004 5 piece 000103689 A Fuse FUSE 5X25, 4A, 450V, TIME-LAG MC
2 0006 5 piece 10498 B Fuse FUSE 5X20MM 4A, SLOW MC
2 0008 5 piece 10499 A Fuse 5X20MM 6.3A, SLOW MC
2 0010 10 piece 000079851 A Lamp 031-963.5 SERIES 31, 36V-30mA CM,CU
2 0012 5 piece 56075 A Fuse 5X20MM 2,0A SLOW AS
2 0030 1 piece 000079850 A Mounting Tool MOUNTING TOOL FOR EAO, 61-9730.0
2 0040 1 piece 11127 # Tool Kit LAMP REMOVER FOR SERIES 06
1 0003 1 piece 000096196 B Spare Part Kit SR6.. FCP, SR722 FCP, mechanical
2 0002 2 piece 5700-002 B Magnet Coil CCS240D, 240VAC, 50/60HZ, 14W
2 0010 4 piece 290-001-TF # Filter Cartridge SPIN ON
End of Report

User Manual Steeringgear Shipkits B.V Hull No SK120 SR722 FCP

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User Manual Steeringgear Shipkits B.V Hull No SK120 SR722 FCP

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USER MANUAL

Rolls-Royce Steering Gear SR

Yard and hull no. :Shipkits B.V. : SK120

3 SYSTEM DESCRIPTION ......................................................................... 9

4 DELIVERY SPECIFICATIONS............................................................... 18

5 TECHNICAL DATA ................................................................................ 19

6 OPERATION .......................................................................................... 23

7 MAINTENANCE ..................................................................................... 26

Rolls-Royce Steering Gear User Manual Page 3 of 60

8 TROUBLE SHOOTING ......................................................................... 48

9 CONTACT LIST .................................................................................... 52

10 SPARE PARTS ..................................................................................... 56

11 TOOLS .................................................................................................. 57

12 DESIGN DRAWINGS ............................................................................ 58

13 REVISION.............................................................................................. 60

Page 4 of 60 User Manual Rolls-Royce Steering Gear

1.3 Structure of this manual

Chapter 3 describes the Rolls-Royce Steering Gear.

Chapters 6, 7 and 8 describe the relevant operation and maintenance procedures.

Chapters 4, 5 and 12 provide project specific information.

Rolls-Royce Steering Gear User Manual Page 5 of 60

Page 6 of 60 User Manual Rolls-Royce Steering Gear

2.1 General statement

IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS

IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

Rolls-Royce Steering Gear User Manual Page 7 of 60

2.3 Declaration of conformity

 Det Norske Veritas (DNV).

 American Bureau of Shipping (ABS).

 Lloyds Register (LR).

 Germanisher Lloyds (GL).

 Bureau Veritas (BV).

 ClassNK (Nippon Kaiji Kyokai)

 China Classification Society (CCS)

 Russian Maritime Register of Shipping (RS)

 Korean Register of Shipping (KR)

Page 8 of 60 User Manual Rolls-Royce Steering Gear

3.1 System overview

Rolls-Royce Steering Gear User Manual Page 9 of 60

The motor controller (frequency converter) for the electric motor on

The steering gear is also equipped with a unique vane sealing

Page 10 of 60 User Manual Rolls-Royce Steering Gear

Pos. Component Chapter

Rolls-Royce Steering Gear User Manual Page 11 of 60

[2] = Ring shaped cylinder with vanes and dividing walls

[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

The synthetic bearing pads maintain 100% surface contact

The rudder actuator can be delivered with two or three

Page 12 of 60 User Manual Rolls-Royce Steering Gear

The power pump units consist of four main parts:

[1] = Reversible pump,

[2] = Electric motor,

[3] = Bell house,

[4] = Flexible coupling.

3.2.3 Cylindrical rudderstock connection

The coupling consists of the following main components:

[1] = Mounting piston,

[2] = Seal ring,

[4] = Tapered sleeve,

Rolls-Royce Steering Gear User Manual Page 13 of 60