Owner's Manual For Porsgrunn Rotary Vane Steering Gear S-1995

OWNER’S MANUAL
FOR
PORSGRUNN ROTARY
VANE STEERING GEAR
S-1995
Jiangsu Hantong Shipyard

HT57-126
Aker Porsgrunn AS
Dokkveien 8
3920 PORSGRUNN
NORWAY
Tlf.: (+47) 35 93 12 00
Fax.: (+47) 35 93 12 01 / (+47) 35 93 12 02
E-mail: porsgrunn@akersolutions.com
www.akersolutions.com
INDEX
1 INTRODUCTION .......................................................................................................... 3
2 SYSTEM DESCRIPTION ............................................................................................. 4
2.1 General .................................................................................................................4
2.2 Steering gear actuator .........................................................................................6
2.3 Hydraulic System .................................................................................................7
2.3.1 Hydraulic power units ........................................................................................................ 7
2.3.2 Directional Valve Block ..................................................................................................... 8
2.3.3 Relief Valve Block ............................................................................................................. 8
2.4 Electrical System .................................................................................................9
2.4.1 Motors ............................................................................................................................... 9
2.4.2 Starter cabinets ................................................................................................................. 9
2.4.3 Control and indication panels ........................................................................................... 9
3 FUNCTIONAL DESCRIPTION ....................................................................................10
3.1 General ...............................................................................................................10
3.2 Rudder fall-off, Follow-up/Autopilot (FU) and non-Follow-up (NFU) modes .. 10
3.3 Operation from bridge .......................................................................................10
3.3.1 Normal operation ............................................................................................................ 12
3.3.2 Alarms ............................................................................................................................. 13
3.4 Surveillance from engine control room ............................................................15
3.5 Operation from steering gear room ..................................................................15
3.5.1 Operation from the starter cabinet .................................................................................. 16
3.5.2 Emergency steering from steering gear room ................................................................ 17
4 MAINTENANCE ..........................................................................................................18
4.1 General ...............................................................................................................18
4.2 Inspection and maintenance during normal operation ...................................18
4.2.1 Maintenance after start-up .............................................................................................. 18
4.2.2 Preventive maintenance during operation ...................................................................... 18
4.3 Recommended main inspection and maintenance intervals ..........................20
4.3.1 Main Inspection intervals ................................................................................................ 20
4.4 Test, adjustment, repair and disassembly/assembly instructions ................. 21
4.4.1 Functional test of steering gear ...................................................................................... 21
4.4.2 Adjustment of electrical limit switches ............................................................................ 21
4.4.3 Functional test of alarm system ...................................................................................... 22
4.4.4 Re-packing of lower packing gland ................................................................................. 22
4.4.5 Alignment of motor and pump ......................................................................................... 24
4.4.6 Check adjustment of relief valve setting ......................................................................... 25
4.5 Hydraulic oil maintenance.................................................................................26
4.5.1 Oil sampling and maintenance ....................................................................................... 26
4.5.2 Fluid change procedure .................................................................................................. 27
4.5.3 Recommended oil type ................................................................................................... 29
4.6 Spare parts .........................................................................................................30
4.7 Troubleshooting.................................................................................................31
4.7.1 General procedure when rudder does not follow order .................................................. 31
4.7.2 Alarms ............................................................................................................................. 31
4.7.3 Other failure modes ........................................................................................................ 33
ANNEX A – TECHNICAL SPECIFICATION

ANNEX B – SYSTEM, MECHANICAL AND HYDRAULIC DRAWINGS
ANNEX C – ELECTRICAL DRAWINGS
ANNEX D - CERTIFICATES
ANNEX E – SPARE PART LIST
Owners’ Manual July 2012 2

1 INTRODUCTION
Porsgrund Mekaniske Værksted introduced the world’s first rotary vane steering gear for
ships in 1933. Today Aker Porsgrunn supplies steering gears for torque requirements up to
5850 kNm and an upper part rudder stock diameter up to 800 mm.
This manual gives the vessel owner, manager and crew information required to safely
operate the Porsgrunn Rotary Vane Steering Gear and recommendations for maintenance
of the steering gear unit.
Please take time to read this manual to get a thorough understanding of the steering gear
components and its operations and maintenance.
The Owner’s Manual consists of three main parts which are general for all steering gear.
Specific information for the steering gear can be found in the drawings and specification in
the annexes.
• The first part consists of a general system description of the steering gear and
components.
• The second part gives a functional description of the system, including operation and
alarms
• The third part consists of maintenance routines, recommendations for service and
spare parts and troubleshooting tables.
The following symbols are used throughout the manual in order to indicate important parts.
Please read these parts carefully and pay special attention to the remarks:

2 SYSTEM DESCRIPTION
2.1 General
The Porsgrunn Rotary Vane Steering Gear system consists of the main actuator, the
hydraulic power units, the starter cabinets and the control and alarm panels. Depending on
the configuration, the power units can be installed as an integrated part of the main actuator
or they can be separate units. The standard type of steering gears is always delivered with
at least two independent hydraulic power units.
All Porsgrunn Rotary Vane Steering Gears comply with the latest SOLAS regulations and
classification requirements.
The control valves for operation of the steering gear are installed directly on the main
actuator.
Steering control system is a part of the delivery for some steering gear systems. The
steering control system is documented in a separate manual.
Some systems are delivered with frequency controlled electrical motors. These functions are
described in a separate manual.
The steering gear system components are installed in both the steering gear compartment,
in the engine control room and on the bridge. See Figure 2.1 for a general overview of the
Porsgrunn Rotary Vane Steering Gear System.
The following section gives a brief description of each component, with its main function.

Wheelhouse
O
P RUDDER ANGLE
T RUDDER ANGLE INDICATOR RUDDER ANGLE
I INDICATOR PORT PANORAMA 3-WAY INDICATOR STARBOARD
O
N
A
L
CONTROL AND INDICATION

PANEL START / STOP /
ALARM
P
O
R
S
G
INDICATION PANEL Engine Control
R
SIGNAL / ALARM Room
U
N
N
S
U
P
P
L
Y
Steering Gear Room
PORT VALVE BLOCKS STARBOARD

STARTER HYDRAULIC STARTER
POWER UNIT
HPU
HYDRAULIC
POWER UNIT
VALVE BLOCKS
Figure 2.1 Porsgrunn Rotary Vane Steering Gear System

2.2 Steering gear actuator
The steering gear actuator is the main component transferring the hydraulic pressure in the
system into rudder torque. The rudder stock is connected to the steering gear actuator by a
keyless conical connection. The actuator itself is supported by the steering gear foundation,
to which all torque is transformed through a bolted connection. In addition, the weight of the
actuator and the vertical load from the rudder is carried by the foundation. The actuator
consists of the following main parts: Rotor, housing, mechanical stoppers, cover and
expansion tank. See Figure 2.2 for actuator assembly details.
Indicator shaft
Tab washer Mechanical rudder angle indicator
Level switch Expansion tank
Oil filling cap Limit switches
Manometer
Stay bolt
Pilot valve Rudder stock nut
Valve block Hydraulic ring piston
Foundation bolt Upper bearing
Adjustment screw
Sealing ring
By-pass valve Rotor
Foundation
Relief valve Lower bearing

Ball valve block
Lower packing gland Packing Rudder carrier
Figure 2.2 Steering Gear Actuator
The Rotor (tiller) is made of nodular cast iron, and it is the moving part within the actuator. It
is connected to the rudder stock with a keyless conical connection. The oil injection method
is used for press-fitting of the rotor to the rudder stock. The rotor is enclosed by the housing
and the cover. The rotor has two or three vanes, and together with the stoppers, the vanes
divide the inside of the actuator into four or six chambers. Different pressure on each side of
the rotor vanes makes the rotor move.
The Housing is made of nodular cast iron, and it is the part of the actuator that is connected
to the vessel’s structure. Normally it is placed on a foundation. The connection is provided
by foundation bolts. In the lower part of the housing there is a floating rudder carrier and a
lower radial bearing. They are made of a brass alloy. The rudder carrier takes the full vertical

load of the rotor, rudderstock and rudder. The lower bearing is shrunk into the housing and
takes the radial forces from the lower side of the rotor. In the lower part of the housing, there
is an integrated packing gland where the rudderstock enters the actuator.
The mechanical stoppers are made of nodular cast iron and limit the maximum rudder angle.
The stoppers are fixed in the housing by means of stay bolts. The stay bolts go through the
bottom of the housing, the stoppers and the cover.
The Cover is made of nodular cast iron. The upper bearing is made of a brass alloy. It is
shrunk into the cover and takes the radial forces from the upper side of the rotor. The cover
is fastened to the housing by means of bolts and the stay bolts.
The Expansion tank is mounted on top of the cover. The tank allows all the oil in the system
to expand due to temperature changes. It also functions as a top cover and protects the
bearing. Oil level monitoring gauges are installed in the expansion tank.
The sealing system is based on cast iron sealing bars. To prevent the oil from flowing from
the high pressure side to the low pressure side, there is mounted cast iron sealing bars in
the rotor vanes and in the stoppers. The sealing bars are spring loaded. To prevent the oil
from flowing over the upper bearing to the expansion tank, there is a spring loaded cast iron
sealing ring in the cover.
2.3 Hydraulic System

The hydraulic system consists of hydraulic power units, valve blocks and hydraulic piping.
2.3.1 Hydraulic power units

A Porsgrunn steering gear is equipped with hydraulic power units, which are mounted
directly onto the steering gear actuator or onto separate foundations on the deck, depending
on type and size of steering gear.
The main parts of the hydraulic power unit are arranged together into a compact unit and
consist of a pump tank with filter, pump housing, pump, electric motor and flexible coupling.
Each pump tank has a built-in filter unit. The return pipe line from the main valve block is
connected to the filter, where the return oil from the steering gear actuator is filtered. The
filter is an integral part of the pump tank, and the unit is equipped with a filter clogged
indicator, which monitors the pressure drop over the filter. An alarm contact in the indicator
is connected to the steering gear alarm system.
On top of the pump tank there is a low level switch, which will give an alarm if the oil level
drops. An alarm contact in the level switch is connected to the steering gear alarm system.
There is also a connection from the steering gear expansion tank on top of the pump tank,
allowing excessive system oil to flow freely back to the pump tank through the expansion
pipe line.
Underneath the pump tank there is a drain plug for draining the oil reservoir.
The pump is a fixed displacement screw pump, and is mounted to the cast iron pump
housing. This unit is mounted onto the pump tank, so that the suction side of the pump is
submerged in the oil reservoir in the pump tank. The pump’s pressure side is connected by
pipes to the hydraulic valve block.

The pump is connected to the electric motor through the flexible coupling. The flexible insert
will reduce any short period torsional shocks. The shaft ends of the pump and the motor are
mounted into each side of the coupling.
2.3.2 Directional Valve Block

The hydraulic fluid flow into the actuator is controlled by the directional valve blocks. The
directional valve blocks are mounted on the steering gear actuator. The valve block consists
of the directional valve itself, pilot valves with solenoids, an idling valve and a check valve.
Figure 2.3 Directional Valve Block
2.3.3 Relief Valve Block

The actuator is protected from excessive rudder torque caused by external forces by the
relief valves blocks. The relief pressure is set according to class requirements. The relief
valve blocks are mounted directly on the steering gear actuator.
Figure 2.4 Relief Valve Block

2.4 Electrical System
The electrical system consists of motors, starter cabinets and control and indication panels.
2.4.1 Motors
Each hydraulic power unit is equipped with an electric motor. The electric motor is installed
together with the hydraulic pump. The motor is equipped with stand-still heating.
2.4.2 Starter cabinets

In the steering gear room there is installed one starter cabinet for each hydraulic power unit.
Each starter cabinet normally includes the following functions:
• Starting and stopping of electrical motor. The starters are typically a direct starter (DOL)
connected to the main switchboard and a star delta starter connected to the emergency
switchboard. Sometimes other starting methods are used, such as a soft starter, an
autotrafo or a frequency inverter.
• Supply power to the steering control system. This also acts as a junction box for rudder
angle limit switches and output to the pilot valves on the hydraulic power unit.
• Provision of PLC based alarm monitoring with automatic change over to stand-by pump
upon fail. The alarm system communicates with the general vessel system and the
Voyage Data Recorder.
2.4.3 Control and indication panels

In the engine control room there is normally one indication panel showing the alarms and
pump status for the steering gear.
On the bridge there is a control and indication panel for starting, stopping and monitoring the
pumps and for monitoring and acknowledging the alarms. The function for each alarm is
described in the Chapter 3.
Optionally a rudder angle indicator system is delivered. Please refer to separate drawings
for details. Optionally a steering control system is delivered. In this case a separate user
manual is provided.

3 FUNCTIONAL DESCRIPTION
3.1 General
This chapter gives an overview of the operation of the steering gear and hydraulic power
units. A description of all alarms and consequence of each alarm is also included.
3.2 Rudder fall-off, Follow-up/Autopilot (FU) and non-Follow-up

(NFU) modes
A rotary vane steering gear is in principal a hydraulic motor with limited rotational movement.
There are electrical limit switches which limit the rotational movement within specified
degrees. In addition, the rotational movement is mechanically limited by stoppers inside the
actuator housing. The operational range, limited by the limit switches and stoppers is given
in the Technical Specification, Annex A.
The rudder carrier and the bearings in the actuator are automatically lubricated by the
hydraulic oil in the system. The oil lubrication is generated by a flow of hydraulic oil from the
pressure side to the low pressure side in the actuator. Due to this flow, the rudder will fall off
to the side with the lowest pressure. The magnitude of the fall off effect is dependent on
several factors, of which vessel type, rudder and steering gear configuration is the most
important.
The steering control system for a rotary vane steering gear includes a Follow-up (FU) mode.
This mode ensures that the rudder keep the rudder in position within the dead band
specified. The dead band of the follow-up system will be dependent of the vessel and
system configuration. Normally at least 1.0 degree is required.
Switching the steering control system to non-Follow-up (NFU) mode, the rudder will fall-off to
the side with the lowest pressure. The angle velocity for rudder falling off depends on actual
rudder force, rudder angle, speed of vessel and actuator type. This time will be different for
each steering gear and type of vessel.
3.3 Operation from bridge

The steering gear is operated from the bridge by the Control/Indication Panel shown in
Figure 3.1.
For operation from the bridge, the Local/Remote switch on the starter cabinet
has to be in Remote Position.

Figure 3.1 Bridge Panel
The function of each control button is shown in Table 3.1, while the description for the
indication lamps is given in Table 3.2. The description for the alarm lamps is given in Section
3.3.2.
Table 3.1 Control Button Description

Button Function Description
Pressing the button will start the hydraulic power

Start hydraulic
unit. Green lamp will light when hydraulic power unit
power unit
is running.
Pressing the button will stop the hydraulic power

Stop hydraulic
unit. Red lamp will light when hydraulic power unit is
power unit
stopped.
Pressing the button will start the stand-by/auto

Auto On start/auto stop 1 function. Green light will light when
the Auto On is activated.
Pressing the Auto Off button will disable the stand-

Auto Off by/auto start/auto stop1 function. Green light will light
when the Auto Off is activated.
1
The auto stop function may not be enabled depending on restrictions in class rules.

Pressing the lamp test button will engage lamps in all

Lamp Test buttons and the buzzer. The button is used to verify
that all lamps and the buzzer are working.
Pressing the dimmer up button will increase the lamp

Dimmer up
intensity to maximum.
Pressing the dimmer down button will decrease the

Dimmer down
lamp intensity to minimum.
Pressing the Acknowledge button during an alarm

Acknowledge will stop the buzzer and change the alarm light from
flashing to fixed.
Table 3.2 Indication lamp description

A white lamp will light when the steering control is
Bridge Control switched to Remote on the starter cabinet and the
Ready hydraulic power unit is running. The hydraulic power
unit can be operated from the bridge.
A white lamp will light when the steering control is

Local Control switched to Local on the starter cabinet. The
Ready hydraulic power unit can only be operated from the
starter cabinet in the steering room compartment.
A blue light shows that the hydraulic power unit is in

Pump Standby
standby mode.
3.3.1 Normal operation

Normal operation of the steering gear from the bridge involves starting and stopping of the
hydraulic power units and switching between auto on and auto off.
Start of hydraulic power unit

In order to start one of the hydraulic power units, the following procedure applies:
1. Press the Start / Run button to start the hydraulic power unit.
2. A green lamp will light when the hydraulic power unit is running. Please note that for
autotrafo start of two speed motor, the light will flash until the start-up sequence is
finished.
Stop of hydraulic power unit

In order to stop one of the hydraulic power units, the following procedure applies:
1. Press the Stop button to stop the hydraulic power units.
2. A red lamp will light when power unit is stopped.

Use of stand-by / auto start / auto stop function
The stand-by / auto start / auto stop1 function is activated by the following procedure:
1. Press the Auto On button to activate the stand-by / auto start / auto stop function.
2. A green lamp will light when Auto On is activated.
3. The standby function is indicated by a blue light in the Pump Standby lamp.
The functions of the stand-by / auto start / auto stop are as follows:
1. When one hydraulic power unit is started, the stand-by of the second hydraulic power
unit will automatically be set.
2. If both power units are running and one is stopped, the stopped power unit will
automatically go to stand-by mode.
3. The stand-by function is disabled when the Local / Remote switch is in Local Position.
4. The stand-by function will be disabled in an alarm condition.
5. The consequence of each alarm when operating in Auto On mode is described in
Section 3.3.2.
The stand-by / auto start / auto stop function is disengaged by the following procedure:
1. Press the Auto Off button to disable the stand-by / auto start / auto stop function.
2. A green lamp will light when Auto Off is activated.
Check of lamps
The lamps and buzzer can be checked by pressing the Lamp Test button. All lamps will light
and buzzer will sound if they are working properly.
Use of dimmer
The dimmer buttons can be used to increase or decrease the lamp intensity between
minimum and maximum.
3.3.2 Alarms
The alarms will show on the control/indication panel on the bridge and on the indication
panel in the engine control room.
An alarm will be indicated by a flashing light and a buzzer sound. Pressing the Acknowledge
button will stop the buzzer sound and the light will change from flashing to fixed. The light
will only disappear when the function is back to normal.
The description of each alarm and the consequence for the steering gear system is shown in
Table 3.3. Information regarding alarm troubleshooting is given in Table 4.10 in Section
4.7.2.
1
The auto-stop function may not be enabled depending on restriction in class rules.

Table 3.3 Alarm lamp description
Alarm Description Consequence
A red lamp will light when there In Auto On mode:
is a failure in the steering control The other hydraulic power unit will
circuit or when the Remote / start and the unit with failure will be
Local is on Local Position stopped 1.
In Auto On mode:
A red lamp will light when phase
The other hydraulic power unit will
sequence is wrong or if one or
start and the unit with failure will be
more of the phases are missing.
stopped1.
A red lamp will light when there In Auto On mode:

is an overload of the electric The other hydraulic power unit will
motor for the hydraulic power start and the unit with failure will be
unit. stopped1.
A red lamp will light for one of

the following failures:
• If the main spool in the main
valve block is stuck in open In Auto On mode:
position, without any signal The other hydraulic power unit will
to the solenoid valve. start and the unit with failure will be
• If a signal to the solenoid stopped1.
valve is given and the main
spool in the main valve block
is not fully responding.
A red lamp will light when the

The hydraulic power unit will keep
differential pressure over the
running.
filter exceeds 0.7 bar
In Auto On mode:
A red lamp will light when oil
The other hydraulic power unit will
level in the hydraulic power unit
start and the unit with failure will be
tank is below a certain level.
stopped1.
A red lamp will light when a fail

in the power supply for the In Auto On mode:
start/stop control circuit appear. The other hydraulic power unit will
The alarm may be combined start. The unit with failure will not stop.
with phase alarm.
In Auto On mode:
If Low Oil Pump Alarm occurs
A red lamp will light when oil
together with Low Oil Common Alarm,
level in the expansion tank is
the other hydraulic power unit will start
below a certain level.
and the unit with failure will be
stopped1.
1
The auto-stop function may not be enabled depending on restrictions in class rules.

A hydraulic power unit with a failure/alarm will not stop before the stand-by unit
has started and is running, in order to maintain steering ability of the vessel.
No combination of failures and / or alarms will automatically stop all hydraulic

power units.
3.4 Surveillance from engine control room

An Indication panel is installed in the engine control room. The panel is for indication only
and has the same alarm buttons as the Control and indication panel on the bridge.
No operation of the steering gear system can be done from the engine control
room. The panel is for indication only.
All alarms on the indication panel are shown by flashing light. When the Acknowledge button
is pressed on the bridge control panel, the light will be fixed. The light will disappear when
the function is back to normal.
3.5 Operation from steering gear room

The steering gear can be operated from the steering gear room, using the control buttons on
the starter cabinets. The steering gear can also be manually operated by using the manual
control of the valve blocks on the steering gear itself. A typical starter cabinet is shown in
Figure 3.3, while the valve block is shown in Figure 3.2.
When the steering gear system is switched to “Local” on the starter cabinet,
operation of the steering gear from the bridge will not work. The bridge will
receive an alarm when the steering gear system is switched to “Local”
Pilot for main spool
Pilot for idling valve
Figure 3.2 Hydraulic valve block

Figure 3.3 Outline of a typical starter cabinet front
3.5.1 Operation from the starter cabinet

In order to be able to operate the steering gear from the starter cabinet, the steering control
switch has to be switched to “Local”. A description of each control switch is given in Table
3.4
Table 3.4 Starter cabinet control switch description

Switch Function Description
With the switch in “Remote” position, the steering

Steering control system can only be controlled from the bridge,
switch With the switch in “Local” position, the steering gear
can only be controlled locally on the starter cabinets.

Switch Function Description
Switch for start

Turning the switch to “Start” position will start the
and stop of
hydraulic power unit. Turning the switch to “Stop”
hydraulic power
position will stop the hydraulic power unit.
unit
The buttons shall only be used when the steering

control switch is on “Local” position.
Buttons for
By pressing the “P.” button, the rudder will turn
manual steering
against port side.
(NFU)
By pressing the “S.B” button, the rudder will turn
against starboard side.
The local NFU shall normally be used for testing and service purposes only, e.g. rudder limit
switch adjustment.
3.5.2 Emergency steering from steering gear room

The steering of the vessel can be operated from the steering gear room. Emergency
steering can be done by pressing the push buttons on the hydraulic valve blocks, see Figure
3.2.
The buttons on the starter cabinet, see Figure 3.3, may also be used for emergency
steering. However, then an unrestricted view to the Rudder Angle Indicator on the actuator
is required.
Procedure for emergency steering is:

1. Establish communication with the bridge.
2. Switch over to local control on all starter cabinets.
3. Control the rudder on command from the bridge by operating the pilot valves on the
main valve block, see Figure 3.2.
4. Activate the pilot for main spool, then the pilot for idling valve.
5. When rudder is at given order, release the pilot for idling valve and then the pilot for
main valve.
The pressure will increase to relief valve setting if only the idling valve is
activated.
Alternatively the buttons for manual steering on the starter cabinet may be used
The electrical limit switches are not in operation when the steering gear is
operated directly by the push buttons on the main valve block.

4 MAINTENANCE
4.1 General
The steering gear is amongst the most critical equipment onboard a modern vessel. Failure
in the steering system may lead to operational problems, off-hire, extensive maintenance
and in worst case fatal accidents.
Proper inspection and maintenance are key issues for trouble-free operations during the
lifetime of the vessel.
4.2 Inspection and maintenance during normal operation

The inspection and maintenance requirements during normal operation of the Porsgrunn
steering gear are very limited. The vessel crew should be capable of performing this work,
using the information given in the Owner’s Manual.
Reference is also made to SOLAS, part I, Chapter V, regulation 19-2.
4.2.1 Maintenance after start-up

After commissioning and start-up of the steering gear are performed, minor additional
maintenance is required during the initial period of service. Complete checklists from the
start-up and commissioning should be available for the vessels records.
During the initial period in service we recommend that the following items are inspected and
checked.
Table 4.1 Inspection and maintenance after start-up

Inspection
Item Inspection point Corrective action
interval
Flexible coupling and alignment
Proper alignment to be
1 Initial for free standing hydraulic power
performed
units.
Change from flushing filter to
2 3 months Oil filter
normal filter
The oil filters are not washable. The filters shall be replaced, not cleaned.
4.2.2 Preventive maintenance during operation

The operational requirements stated in SOLAS Part I, Chapter V, regulation 19-2 govern the
overall testing of the steering gear units. Porsgrunn steering gears require only a very low
level of continuous inspection and maintenance during operation. It is however important to
follow up the inspection requirements specified below, as early indications of faults and
wrong operation is necessary to avoid major maintenance of the steering gear.

Table 4.2 Preventive inspection and maintenance manual
Inspection
interval
Refill oil if below required
amount. Be aware of the thermal
Check of oil level in expansion
D.1 Daily expansion of the oil.
tank
If problem persist, see inspection
item D.2
Re-tighten the leaking connection
if possible. If not possible,
contact Porsgrunn for further
Check the steering gear for any
D.2 Daily information. Re-tightening of
abnormal leakages
hydraulic blocks should be
performed according to
Porsgrunn recommendations
Re-tighten loose bolts and
Perform a visual control of all
connections, if any.
components such as indicators,
D.3 Daily Damaged parts to be replaced or
piping, link arms, electrical
repaired immediately, contact
connections
Porsgrunn for further information
Control pump units and actuator
D.4 Daily for abnormal noises and/or
vibrations
Check hydraulic power units for Sealing to be replaced if leakage
W.1 Weekly
leakage is found
Visual check of all bolted
M.1 Monthly Tighten loose bolts
connections
Pipes and pipe connections to be Tighten loose bolts. See also
M.2 Monthly
visually checked Item D.2 for further information
Check adjustment of electric limit Adjustment to be performed if
M.3 Monthly
switches required. See Section 4.4.2
For functional test procedure, see
M.4 Monthly Functional test of alarm system
Section 4.4.3 for details
Check adjustment of rudder Adjustment to be performed if
M.5 Monthly
indicators. required.
Check flexible coupling between
M.6 Monthly Replace flexible element if worn
electrical motor and pump
Perform oil sampling according to
Q.1 Quarterly Perform oil sampling
Section 4.5.1.
Every 6 Replace filter cartridge also when
Y.1 Check filters
month filter clogged alarm is given
Every 6
Y.2 Check magnetic bars, if installed Clean magnetic bars, if required
month
Check electrical terminals in
Y.3 Yearly starter cabinets and on pilot valve Repair connection if dirty
solenoids
Repair or replace level indicator if
Y.4 Yearly Check of level indicators
damaged
Replace if required. For further
Y.5 Yearly Check of lower packing gland
details, see Section 4.4.4
Y.6 Yearly Check of relief valve setting Adjust setting if required

4.3 Recommended main inspection and maintenance intervals
The maintenance interval of the steering gear actuator is dependent on many factors.
Among the most important ones are:
• Proper alignment and installation of the actuator
• Hydraulic oil maintenance
• Average service temperature of hydraulic oil
• Type of rudder
• Type of vessel and trade
• Steering control system
During the design and delivery of the steering gear, these factors are taken into account.
However, as some of them involve large uncertainties, it is difficult to specify standard
service intervals for steering gears.
4.3.1 Main Inspection intervals

The following main inspection interval is recommended based on service history and
knowledge of steering gear operation from many years.
Maintenance of a steering gear may be needed for various reasons. The

inspection intervals given below are only a recommendation. If any
abnormalities or malfunction is experienced during normal operation,
Porsgrunn should be consulted.
Table 4.3 Recommended main inspection intervals

Inspection
interval
1 4000 hours Motor - pump units Lubrication of bearings
2 2 years Magnetic bars To be replaced

Switching relays for pilot valve
3 2 years To be replaced
Timer blocks for switching relays
Hydraulic power units pump and
4 5 years Replace bearings
motor
Based on measured clearances,
Upper bearing
5 5 years renewal of bearings might be
Rudder carrier
required
Sealing to be changed. General
6 5 years Main Valve Blocks
overhauling
Sealing to be changed. General
7 5 years Relief valve
overhauling
General inspection of steering
8 5 years General overhauling if required
gear

4.4 Test, adjustment, repair and disassembly/assembly
instructions
Disassembly and assembly of the steering gear actuator shall normally be performed by
skilled service engineers from Porsgrunn. However, in some cases it may be necessary for
the vessel crew to be able to disassemble the steering gear without assistance from external
service engineers. This section describes the tests and adjustments which can be performed
by the vessel crew. For disassembly of the steering gear, contact Porsgrunn for further
instructions.
The steering gear actuator is a mechanical component made with fine

tolerances. Make sure that the internal parts of the steering gear are not
contaminated or damaged during the work.
Breaking the actuator seal during the guarantee period may lead to loss of
guarantee from Porsgrunn
4.4.1 Functional test of steering gear

Requirements for functional testing of steering gears are described in SOLAS, part I,
Chapter V, regulation 19-2.
The tests shall be performed within 12 hrs before departure. For ships operating regularly on
voyages of short duration, the tests may be performed weekly.
The test shall include the following items:

• The main steering gear
• The auxiliary steering gear
• The remote steering gear control system
• The steering positions located on the navigation bridge
• The emergency power supply
• The rudder angle indicators in relation to the actual position of the rudder
• The remote steering gear control system power failure alarms
• The steering gear power unit failure alarm
• Automatic isolation arrangements and other automatic equipment
The tests and checks shall include the following:

• The full movement of the rudder according to the required capabilities of the steering
gear.
• A visual inspection of the steering gear and its connecting linkage
• The operation of the means of communication between the navigation bridge and the
steering gear compartment.
All tests shall be noted in the logbook of the vessel.
4.4.2 Adjustment of electrical limit switches

The following procedure shall be used for adjustment of the electric limit switches:
1. Identify which switch goes to which starter and which is starboard and port respectively.
2. Use the NFU steering control on the starter cabinet during this operation.

3. The limit switches shall break the electrical signal before the rotor reaches the
mechanical stoppers. See the technical specification for the electrical angle limitation set
point.
4. Adjust the set point by moving the cam on the mechanical rudder indicator and the roller
activator on the limit switch until the correct set point is achieved.
5. If a second set of limit switches for reduced angle is installed, see technical specification
for set point. Adjustment is similar as for the first limit switch.
6. The same procedure is to be followed until all limit switches are adjusted to the correct
set point.
4.4.3 Functional test of alarm system

The following alarms are to be tested during a functional test of the alarm system:
1. Steering control alarm. Test the alarm by taking out automatic fuse F1 in starter cabinet.
Monitor alarm in both bridge and engine control room panels.
2. Phase alarm. Test the alarm by taking out fuse F4 in starter cabinet. Monitor alarm in
both bridge and engine control room panels.
3. No Volt alarm (may be combined by phase alarm). Test the alarm by taking out fuse F6
in starter cabinet. Monitor alarm in both bridge and engine control room panels.
4. Overload alarm. Test the alarm by activating the test switch on overload relay F0 in
starter cabinet. Monitor alarm in both bridge and engine control room panels.
5. Hydraulic lock alarm. Test the alarm with the system in remote position and NFU
steering mode. Test the alarm by activating the pilot valve and close the bypass valve
(see Section 3.5.2 for details) and move the rudder against starboard. Monitor alarm in
both bridge and engine control room panels. The alarm shall occur after a delay,
normally 5-10 seconds. Perform the same test against port side.
6. Filter clogged alarm. Test the alarm by removing the plug from the filter indicator.
Monitor alarm in both bridge and engine control room panels. Note that there is normally
a 5 minutes delay after start up of motor. After 5 minutes, the delay is reduced to 10
seconds.
7. Oil level common alarm. Test the alarm by activating the test button inside level switch
junction box on top of expansion tank. Monitor alarm in both bridge and engine control
room panels. The alarm shall occur after a delay, normally 5-10 seconds.
8. Oil level pump tank alarm. Test the alarm by activating the test button inside level switch
junction box on pump tank. Monitor alarm in both bridge and engine control room panels.
The alarm shall occur after a delay, normally 0-5 seconds.
4.4.4 Re-packing of lower packing gland

1. Drain actuator if a complete re-packing shall be done. Draining is performed by using the
drain plugs in the actuator housing
2. Unscrew bolts and lower the gland carefully
3. Use a packing extractor and pull out all packing rings (normally 5 pcs.)
4. Repack with recommended packing. See spare parts in Annex E.
5. Packing rings for rotary applications have to be fitted using a straight cut, perpendicular
to the shaft. In this case, the ends of cut are between an angle of 12°- 20° to each other.
6. The packing is to be cut to length with a packing cutter. If the packing cutter is
unavailable, please proceed as follows:
7. The correct cut length is calculated according to the following formula:
• L M = (d + s) •π + x (mm)
• x = allowance factor,
• x ≈ 2 to 3% depending on the shaft Ø and has to be checked while cutting the first
ring
8. Examine for pits and scoring before installation of packing. Clean the sealing surfaces
thoroughly.

9. In order to facilitate installation it may be necessary to re-size the packing. Our packing
can be re-sized without problems manually therefore improving flexibility in installation.
The packing may easily be resized by rolling with a small piece of pipe, no special roller
equipment should be needed.
supporting effect packing
LM
housing
Figure 4.1 Dimensions
Asbestos-free materials under no circumstances should be re-sized in a vise

or with a hammer or similar. This will lead to destruction of the internal structure
of the packing.
10. The five packing rings are fitted separately and with the cut offset to each other when
installed (90°-180° rotated).
1
2
3
Figure 4.2 Packing
11. The installation of each packing ring is performed as follows.

• The ends of cut are at first pressed into the stuffing box. Pay attention that the cut
ends do not slip.
• The opposite point of the ring to the cut is then to be pressed into the stuffing box.
• The remainder of the ring is pressed finally into the stuffing box.
12. The cut ends have to butt against each other and the rings also have to press against
the outside of the stuffing box. Avoid possible over-compression since this will cause the
packing to grip the shaft and cause twisting when the shaft is rotated.
13. In the installed state, the rings must not protrude over the stuffing-box edge. The gland
must fit into the stuffing-box with a gland recess > 0.5 x packing width.
14. At first, tighten the gland nuts quickly and compress the packing 10 to 15 % of H (H=
complete height of all installed rings). Afterwards, release the gland screws.
15. Then position the gland follower by manually tightening the nuts. When hand-tight,
tighten nuts a further 1/2 turn with a spanner.

4.4.5 Alignment of motor and pump
Depending on the type of the steering gear, the HPU’s can either be mounted directly on the
steering gear unit or be installed on supports on the deck.
For both cases it is very important that the alignment of the pump/motor coupling
is correct, see Figure 4.3, Table 4.4 and Table 4.5. Porsgrunn takes no
responsibility if the pumps are started without the correct alignment.
Adjustment of alignment is performed by loosening of the motor foundation bolts and adjusts
the motor according to Figure 4.3, Table 4.4 and Table 4.5.
Figure 4.3 Flexible coupling
Table 4.4 Deviation values for flexible coupling alignment. See Technical Specification for
Coupling Type.
COUPLING TYPE Max Max Min Max
Kr (mm) Kw (°) S (mm) S (mm)
A 24/32 SINT 0,10 0,7 2,0 2,7
A 28/38 SINT 0,12 0,7 2,5 3,25
A 38/45 GG 0,12 0,7 3,0 3,9
A 42/55 GG 0,15 0,7 3,0 4,0
A 48/60 GG 0,17 0,8 3,5 4,55
A 55/70 GG 0,18 0,9 4,0 5,1
A 65/75 GG 0,20 0,9 4,5 5,8
A 75/90 GG 0,20 0,9 5,0 6,5
Table 4.5 Proportional displacement table

AD RD
0% 100 % In case of angular displacement
10 % 90 % (AD) and radial displacements
20 % 80 % (RD) at the same time, you can
30 % 70 % use the values only proportionally.
40 % 60 %
50 % 50 % Example:
60 % 40 % AD 90% => RD max. 10%
70 % 30 %
80 % 20 %
90 % 10 %
100 % 0%

4.4.6 Check adjustment of relief valve setting
The relief valves may be checked and adjusted using the following procedure.
Before the relief valve setting is checked a notice shall be given to the captain
and/ or the Chief Engineer, that rudder has to be turned hard over. A warning
notice “Work in progress”, or similar shall be placed on bridge and in engine
control room.
Do not run the power unit at relief valve pressure for longer periods as this will
damage the pump.
Check relief valve setting on valve blocks:

1. Switch Local/Remote on starters to Local position.
2. Connect pressure gauge to TPP on main valve block
3. Close the ball valve block
4. Start the power unit
5. Manually activate pilot valve for idling valve and read the pressure on the pressure
gauge
6. If the pressure is not in accordance with the technical specification, adjustment is
necessary
7. Remove cap nut and locking nut. It is important that the adjustment screw is kept in
position when removing the nuts
8. Turn adjustment screw clockwise to increase the pressure setting and counter clockwise
to decrease the pressure
9. When the opening pressure is correct, tighten the secure nut
10. Check the opening pressure after nut has been tightened
11. Mount the cap nut when the pressure setting is in accordance with the technical
specification
12. Open the ball valve block
Check actuator relief valve setting:

1. Follow the procedure for adjustment of relief valve setting for directional valve block and
adjust the opening pressure to 100 bar for one valve block
2. Open the ball valve block
3. Turn the steering gear to port until the mechanical stopper by manually activating the
pilot valves
4. Read the pressure on the pressure gauge when reaching the stopper
5. Turn the rudder to starboard mechanical stopper by manually activating the pilot valves
6. Read the pressure on the pressure gauges when reaching the stopper
7. Adjustment is necessary it the pressure is not in accordance with the technical
specification. If relief valve pressure is in accordance with the technical specification,
skip item 8 to 15.
8. Open cap nut and locking nut on both relief valves
9. Turn the adjustment screw on the relief valve on port side clockwise fully in
10. Turn the adjustment screw on the relief valve on starboard side counter clockwise fully
out
11. Manually activate the pilot valves and adjust the port relief valve setting to the value
listed in the technical specification by turning adjustment screw clockwise
12. Tighten locking nut
13. Adjust starboard relief valve to the value listed in the technical specification by turning
adjustment screw counter clockwise.
14. Tighten locking nut
15. Turn the rudder to the mechanical stopper at the other side and check that the relief
valve opening pressure is in accordance with the technical specification.

16. Mount cap nut on both relief valves
17. Close ball valve
18. Adjust relief valve on valve block to the value listed in the technical specification and
tighten locking nut
19. Mount cap nut and open ball valve
4.5 Hydraulic oil maintenance

Properly hydraulic oil maintenance is vital for obtaining low failure rates and long lifetime for
hydraulic systems.
4.5.1 Oil sampling and maintenance

It is recommended to follow the inspection and sampling intervals specified in Section 4.2.2.
High particle level or considerable increase in particle level in hydraulic oil is an early
indicator of possible defects. This may lead to excessive wear in the steering gear internal
parts.
Visual Inspection
A visual inspection shall at least include the items in Table 4.6. Other items may be included
based on owner’s requirements.
Table 4.6 Check points for visual inspection

Item Checkpoint Description and requirement Corrective action
Oil level in the expansion tank
1 Oil level shall always be between ¼ and Top up if required
¾ of the sight glass
If steering gear is continuously
The temperature shall in
running with too high
2 Oil temperature normal conditions not be above
temperature, Porsgrunn should
80°C.
be contacted
Oil filter If oil filters are clogged, replace
3
indicators filters
Fluid visibility If sudden changes, oil sampling
5 Oil appearance Fluid colour should be performed or fluid
Fluid odour changed
Oil sampling
Oil sampling shall be performed at recommended intervals, see Section 4.2.2. Oil samples
shall be sent to a recognized laboratory for analysis.
Oil samples shall always be taken from the TPP/MP connection on the directional valve
block.
It is recommended that the fluid sampling is performed according to ISO 4021:1992, which
at least includes the following steps.
1. Before extracting or collecting the sample, a quantity of oil should be allowed to flush
from the assembly equal to at least five times the volume between the port and the
existing point.
2. Sufficient sample should be withdrawn from the line to yield enough oil to fill
approximately 70% of the sample bottle volume. This leaves enough room to effectively
shake the bottle volume.

3. Although the rate of sample flow does not affect the quality of the sample, this flow
should in general not exceed 1% of the main line flow.
4. Oil is extracted through fully open connection from high pressure line. To reduce the oil
velocity in the sample line, the size or length of the hypodermic or capillary tubing can be
varied.
The reason for sampling through an open and flushed sample valve is to
minimize tramp and generated particles from the valve itself.
5. Take at least two samples from each sampling place in the system.
6. Mark the bottles clearly.
The test bottles must be properly sealed immediately after the sampling is
done, to avoid contamination of the sample.
Typical check points for oil samples are given in Table 4.7. Note that this is a general
recommendation only and that each laboratory and oil supplier may have other procedures
for fluid analysis.
Table 4.7 General check points for hydraulic fluid sampling

Item Checkpoint Description and requirement Corrective action
Perform new sampling as soon
Particle contamination level as possible. If a considerable
Particle
1 shall be within 20/18/15 ISO increase is seen through
contamination
4406:1999 several samplings, change
fluid.
Perform new sampling as soon
Hydraulic fluid shall be of ISO as possible. If viscosity index is
2 Viscosity VG 68. The fluid viscosity index considerable decreasing or
shall be above 130 outside specified limits, change
fluid
Perform new sampling if sharp
pH-value within the oil suppliers change in pH-value (factor 2-3).
3 Acid contents
recommendation If the problem remains, change
fluid.
Additive Content according to oil According to oil suppliers
4
contents suppliers specification recommendation
4.5.2 Fluid change procedure

It is recommended that the following procedure is used when hydraulic fluid is to be
changed. The fluid stored in the pipes and components is normally not changed, as this is a
very small volume compared to the tank and actuator volume.
Before starting the work, make sure that the pumps cannot be started while the
oil tank is empty. It is recommended that the pump used for pumping hydraulic
fluid is used only for this purpose, as mixing of different oil qualities may cause
chemical reactions.
Secure rudder stock/rudder properly before the work is started

1. Empty the oil from the tanks and the actuator through drain plugs and pump the oil into
spill-fluid barrels.
2. Spill fluid barrels should be marked properly and stored separately in order to avoid
mixing of used and new hydraulic fluid.
3. Tank covers should not be opened unnecessarily, unless it is required to clean the tank
bottom. This to avoid exposure of tank internals to possible pollution.
If the system fluid is heavily contaminated by water, slough formation or

breakdown of some system components, the hydraulic system needs to be
flushed. We recommend that Aker Porsgrunn is contacted for assistance and
supervision in such cases.
4. Check that the new fluid barrels have been properly sealed during storage and that they
contain correct fluid type
5. Check that the equipment used for fluid filling is clean
The steering gear shall always be filled up with fluid through a filter pump with
maximum 25 micron abs filter element, as tests have shown that particle
contamination level in new sealed oil barrels may be higher than
recommended.
6. Check that the tank is clean and dry if it has been opened for cleaning.
7. Oil filling of the actuator is done through the ventilation holes on the cover. Before filling,
ensure that all ventilation holes are open and that the air valves/pipes/gauges are
unscrewed. For this filling procedure it is assumed that the oil is properly filtered.
8. Oil filling of the expansion tank and the hydraulic power units is done from the storage
tank. Before filling, ensure that valves for expansion pipes are open. Air bleeding of oil
tanks is done by removing the plug on top of filter housings.
When emptying barrels, ensure that the hydraulic oil is not contaminated by
water and/or sludge in the bottom of the barrel.
9. When the level in the sight glass on the expansion tank is approximately half full, the
steering gear is ready for testing.
10. Before air bleeding, make sure that there is enough oil in the expansion tank during the
whole operation. The tank should be at least half full.
11. Start one pump and give the port and starboard buttons on the respective starter cabinet
short pulses, See Section 3.5.1.
12. Take short breaks during the operation and let the air bleed through the vent screw on
the manometers
13. Turn the rudder approximately 15° to both sides for air bleeding minimum 3 times.
14. During this first operation the oil level will decrease. Refill if necessary.
15. Let the pumps run for about 30 minutes and stop the hydraulic power unit if there are
any abnormal noises, vibrations etc.

4.5.3 Recommended oil type
It is advised to use hydraulic oil from a well known supplier with a widespread distribution
network. The hydraulic oil should be chosen based on recommendations from the oil
supplier. The following main requirements apply:
• The oil must comply with the specifications for the installation, in particular with regards
to viscosity limits, viscosity index, temperature range and additives.
• The selection of hydraulic oil shall normally be taken from the list of recommended
hydraulic oil types. Deviations shall be approved by Porsgrunn.
• Mixing of two different oil qualities and / or oil from different suppliers shall be avoided.
• Hydraulic oil shall always be delivered in sealed barrels.
The list of recommended oil types is given in Table 4.8.
Table 4.8 Recommended oil types

Supplier /
Type Oil type: ISO 68 Vi>130
Brand name
Shell Tellus T 68 ISO Grade 68 Viscosity Index 150
BP Energol SHF-HV 68 ISO Grade 68 Viscosity Index 149
Univis N 68 ISO Grade 68 Viscosity Index 151
Esso DTE 10 Excel ISO Grade 68 Viscosity Index 156
Mobil
SHC 526 ISO Grade 68 Viscosity Index 158
VISGA 68 ISO Grade 68 Viscosity Index 155
Total
Equivis ZS 68 ISO Grade 68 Viscosity Index 161
Statoil HydraWay HVXA 68 ISO Grade 68 Viscosity Index 156

SK ZIC SUPERVIS X68 ISO Grade 68 Viscosity Index 150
Chevron Rando HDZ 68 ISO Grade 68 Viscosity Index 155

Texaco Mechanism LPS 68 ISO Grade 68 Viscosity Index 154
Castrol Hyspin AWH-M 68 ISO Grade 68 Viscosity Index 150
Sealed oil barrels shall always be stored according to suppliers’ recommendation. If half
filled barrels are put away for storage, check that the plugs are properly closed.
The suppliers Material Safety Data Sheet for hydraulic oil shall always be
available. All requirements and recommendations shall always be followed.

4.6 Spare parts
The Porsgrunn steering gear is normally delivered with a small number of spare parts.
These spare parts are intended for start-up and first time operation of the steering gear. The
exact list of spare parts delivered together with the steering gear can be found in Annex A –
Technical Specification.
For continuous and trouble-free operation of the steering gear and in order to prevent off-
hire for the vessel, it is recommended to keep spare parts as specified in Table 4.9 onboard
the vessel at any time. Complete list of available spare parts are found in Annex E – Spare
Parts.
Table 4.9 Recommended list of spare parts to be kept onboard at any time
Spare part No. off Description
Screw pump 1
Set of pilot valves 1
Filter cartridge for operation 2
Seal kit for screw pump 1
Complete coupling between motor and pump 1
Flexible element for coupling 2
Ball bearing for electrical motor 1 1 set
Power supply for steering control circuit 1
Motor contactors 1 1 off each
Sensor for hydraulic lock 2
Timer block 2
Diodes 6
Switching relay for pilot valve 2
Porsgrunn steering gears are made up of high quality components and equipment, selected
specially for this type of machinery and operation. It is strongly recommended to use original
spare parts, in order to maintain safe and sound operation of the steering gear.
Complete spare part lists for the steering gear is included in Annex E – Spare Parts.
Aker Porsgrunn has established a spare part program for all type of Porsgrunn steering
gears. Commonly used spare parts are available from stock. When ordering spare parts, the
following information is required:
• Steering gear serial number (format S-xxxx)
• Steering gear type
• Vessel name, yard and hull number
• Drawing number and item number
• Article number and description
A spare part ordering form is included in Annex E – Spare Parts. When ordering spare parts,
please use this form and send the request to:
Aker Porsgrunn AS
Dokkveien 8
NO-3920 Porsgrunn
Norway
Mail: spareparts.porsgrunn@akersolutions.com
Fax: +47 35 93 12 01 / +47 35 93 12 02

4.7 Troubleshooting
The steering gear is a critical component in operation of the vessel. Any alarm or
malfunction should therefore be carefully considered in each case. Proper reaction upon
alarms or other malfunction may prevent damages to the equipment and subsequent
incidents.
This section is included in the owner’s manual in order to give the crew recommendations on
how to handle alarms and other failure modes. It should also help the crew to report serious
problems to Porsgrunn in order to give the best and fastest support to the vessel.
4.7.1 General procedure when rudder does not follow order

In order to maintain the steering of the vessel, the following procedure should be followed in
cases where the rudder does not follow order. By using this procedure, the crew will be able
to regain steering of the vessel in most cases.
1. Change over to NFU steering mode and perform emergency steering according to
Section 3.5.2.
2. If the problem remains, stop one pump and let the system run on one pump only.
3. If the problem still remains, change to the other pump.
4. During the incident or immediately after, write down course of events as detailed as
possible. This will ease troubleshooting later. Include at least the following items:
• What happened to the rudder?
• What steering mode was used – autopilot, FU hand wheel, NFU?
• What system was active, 1 or 2?
• What order was given?
• Which pump(s) were running?
• Which actions were taken?
• Vessel speed and course?
• Weather conditions?
4.7.2 Alarms
Main alarms, causes and possible solutions are given in Table 4.10. See Table 3.2 in
Section 3.3.2 for alarm lamp identification.
Table 4.10 Alarm troubleshooting guide

Alarm Steering control alarm
Cause
a) Ensure that remote / local switch is in “remote” position
b) Check circuit breaker F1 and F2.
Solution
c) Check power supply G2 by measuring voltage on primary and secondary
side.
Alarm Overload
Cause
a) Check motor current and listen for abnormal noise.
b) Check and reset overload relay F0
Solution c) Stop pump, switch off main power and check that the pump runs freely.
d) Check flexible coupling.
e) Check that shut off ball valves are open.

Alarm Phase / No Volt alarm
Cause
If no light in the “Main supply” lamp in the starter panel front:
a) Check that Main switch Q1 is “ON”
b) Check phase monitoring relay K8 and relay K5.
c) Check circuit breaker F3/F4/F5/F7 and F9
d) Check voltage:
• primary on Q1
• secondary on Q1
Solution
• primary on T1
• secondary on T1
• primary on T2
• secondary on T2
If light in the “Main supply” lamp in the starter panel front:

e) Check phase monitoring relay K8 and relay K5.
Alarm Hydraulic lock

Hydraulic lock alarm is based on classification society rules and is a
Cause
phenomenon that may happen when a failure makes the main valve jam.
The hydraulic lock alarm is based on input signals from the steering gear
remote control (FU/NFU/ Autopilot-system) and the response from the
inductive sensors on the main hydraulic valve blocks.
These signals are compared in the programmable logic controller (PLC) and
if the response of the valve does not correspond to the given order the
“Hydraulic lock” alarm will activate.
In order to find a solution for a “hydraulic lock” alarm problem, do the

following investigation onboard and give Porsgrunn a report of your
observations:
• Switch over to local steering mode on starter cabinet for the actual pump
and open the door to get access to the PLC.
• When the rudder is activated by the local NFU control on the front of
starter door, LED 1CH03 shall follow LED1CH01 for port rudder
movement and LED 1CH04 shall follow LED 1CH02 for starboard rudder
Solution movement.
• The difference in activating time must be less than 5 sec.
• Try to make some large rudder movements and observe the LED’s
• LED 1CH01 followed by LED 1CH03, record the time.
• LED 1CH02 followed by LED 1CH04, record the time.
If the sensor plugs (2 pc. on each hydraulic block) is equipped with LED’s
(Not mounted on all system):
• “Green light”, indicate “Supply Power On”
• “Yellow light”, indicate rudder movement (Sensor is activated)
Note: It shall be mentioned that most hydraulic lock alarms are false and
caused by a defect or dirty inductive sensor. Indication of a defect /dirty
indicator is that the yellow light is not activated when the rudder moves or the
light is constantly lit.

Alarm Filter Clogged
Cause Differential pressure over filter is above set value
a) Check oil temperature. Cold oil may give filter clogged alarm.
Solution b) Check that the filter indicator is working
c) Renew filter. Do not wash or reinstall used filters.
Alarm Oil level common

Cause Low oil level in expansion tank
a) Check oil level in expansion tank
Solution
b) Check that the level switch is working
Alarm Oil level pump tank

Cause Low oil level in pump tank
a) Check oil level in expansion tank
Solution b) Check that the ball valve is open
c) Check that the level switch is working
4.7.3 Other failure modes

Other failure modes, not giving any alarm, might be caused by many reasons and systems
outside the steering gear. In such situations it is recommended that Porsgrunn is contacted
for further assistance.
Contact information for service assistance is:
Aker Porsgrunn AS
Dokkveien 8
NO-3920 Porsgrunn
Norway
Mail: service.porsgrunn@akersolutions.com
Phone: +47 35 93 12 00
Fax: +47 35 93 12 01 / +47 35 93 12 02

APPENDIX A
TECHNICAL SPECIFICATION
GENERAL:
Porsgrunn steering gear no. : S-1995
Purchasing yard : Jiangsu Hantong Shipyard
Yard ref. no's : HT57-126
Ship's size and type : 57,000 DWT Bulk Carrier
Rules and regulations : Loyd’s Register of Shipping and SOLAS latest edition.
Model : 425-80/2
PREPARATION / REVISIONS OF THIS DOCUMENT:
Rev. Date Description Signature
Original specification checked by:
Sign. Date
Project Mgr. Eirik Kjenndalen

El. Eng. Magne Løvskeid
Aker Porsgrunn AS Confidential © 2012 Aker Solutions
Dokkvn. 10, 3920 PORSGRUNN, Norway

Tel +47 35 93 12 00 Fax +47 35 93 12 01 www.akersolutions.com
Registered in Norway , registration no. 936 933 378 VAT
PORSGRUNN STEERING GEAR NO : S-1995
Type : 425-80/2
Yard : Jiangsu Hantong Shipyard
Yard no. : HT57-126
Date prepared : 30.11.2012
Classification society : LRS
Steering gear to be delivered according to : LRS and SOLAS w/Amendments
(57,000 DWT Bulk Carrier)
INFORMATION FROM THE CUSTOMER
Rudder stock diameter : 425 mm at the lower end of the upper cone
Type of rudder : Semi-spade rudder
Vessel’s service speed : 14,2 knots
Rudder balance : not specified
Angle velocity w/one pump : 35 degr. to 30 degr. i.e.
65 degr. in max 28 sec.
Angle velocity w/two pumps : 35 degr. to 30 degr. i.e.
65 degr. in max 14 sec.
Maximum rudder angle : 2 x 36 degr. to internal mechanical stoppers
Angle limitation - electrical : 2 x 35 degr.
Weight of rudder and rudderstock : not specified
Rudder force : not specified
Torque requirements : 750 kNm
Customers rudder drawing :-
Current characteristics : 440 V. 60Hz. 3 Phase
CALCULATED VALUES
Working torque at 60 bar : 760 kNm

Design pressure (relief valve set) : 75 bar
Test pressure : 112,5 bar
Calculated load at 60 bar : 40 kW.
Calculated velocity w/one pump running : 35 degr to 30 degr i.e.

65 degr in 24,3 sec. theoretical.
Angle velocity w/two pumps running : 35 degr to 30 degr i.e.

65 degr in 12,1 sec. theoretical.
Technical spec. Hantong Shipyard S-1995 Page 2 of 9 Confidential © 2012 Aker Solutions
INSTALLATION
Rotor fitting to the rudder stock : Keyless friction connection, cone 1:15 (on diameter)
Liquid in hand pump for rotor expansion : Oil
Necessary pulling up length : 9,10 mm
Necessary pulling up force (approximately) : 4000kN
TESTING
Pressure test under supervision of class society representative for approval, closed steering gear.
Test pressure (1,5 x relief valve set) : 112,5 bar
Function test, steering gear unloaded : Continuously running without load, alternating between
maximum rudder angles Port and Starboard according
to maker's standard procedure.
-------------------------------------------------------------------------------------------------------------------------
CERTIFICATES
Vane - material : Class Material certificate
Housing - material : Class Material certificate
Cover - material : Class Material certificate
Stoppers - material : Maker’s Work certificate
Pumps : Class Material certificate
El.motors : Maker’s test certificate
Steering gear pressure test : Class. society cert. - LRS.
-------------------------------------------------------------------------------------------------------------------------
RUDDER ACTUATOR MAIN COMPONENTS:

Type of rotor : Cast in one piece w/two vanes
Material - rotor : Nodular iron: GGG-50 with min. A5 = 12%
Rm (min.): 440 N/mm2
Rp 0,2 (min.): 320 N/mm2
A5 (min.): 12 %
Test piece: 70x70 mm acc. DIN St. 1693/2
Material - housing : Nodular iron: GGG-50 with min. A5 = 12%
Rm (min.): 420 N/mm2
Rp 0,2 (min.): 290 N/mm2
A5 (min.): 12 %
Test piece: 70x70 mm acc. DIN St. 1693/2
Material - cover : Same as housing
Material - stoppers : Same as housing
Mechanical stopper rudder angle : 36 degrees to each side
Material – linings and rudder bearing : GZ-Rg5 according to DIN 1705
Cu 85%, Sn 4-6%, Pb 4-6%, Zn 4-6%
2 2
Area linings proj.area : 544 cm (upper), 640 cm (lower)
2
Area - rudder carrier : 1,200 cm T= 20mm
Material sealings : Unpressurized sealing rudderstock/steering gear:
Box sealing
Sealing rotor/cover: Spring loaded cast iron sealing
ring.
Sealing in vanes and stoppers: founded iron GG-25
w/tensioned springs.
POWER UNITS / HYDRAULIC EQUIPMENT
Pump aggregate type (x2) : T-100. Mounted onto the actuator

Pump type (x2) : L3ME 52/85 Constant delivery screw pump
Pump capacity : 362 l/min. at 3,600 r.p.m. and 20 bar, 68 cst.
Control block type (x2) : VB 500 CV

Valve function : ON/OFF
Main valve spool detector (x4) : Balluff BHS B135V-PSD15
Voltage solenoids : 24 V DC 40 W
Safety valve steering gear (x2) : RV600

Safety valve steering gear- setting : 75 bar
Safety valve pump - setting : 75 bar
Valve type-shut off valve (x2) : Double ball valve DN50
Piping dim/type - main pipes : Ø 60 x 3 mm (pressure/return, ready bent)

Piping dim/type – expansion : Ø 60 x 3 mm (ready bent)
Piping dim/type - drain pipe : Ø 42 x 3 mm (from lower bearing, ready bent)
Piping dim/type - drain pipe : Ø 18 x 2 mm (from hydraulic blocks, ready bent)
Filter type (x2) : IN-AGB 3-500

Filter insert type for service (x2) : TXW 8C-GDL20
Filter insert type for flushing (x2) : TXX 8C-10
Deairation system actuator : Manually operated

Deairation system oil tanks : Automatic through exp. tank
Oil specification : ISO-grade 68 Vi > 140

Oil quantity actuator : Approx. 300 l
Oil quantity pump tanks : Approx. 100 l each
Total oil quantity steering gear : Approx. 600 l
Recommended storage tank volume : Minimum 600 l
-------------------------------------------------------------------------------------------------------------------------
ADJUSTMENT OF ANGLE
Maximum rudder angle: : 2 x 36 degr. (limited by internal mech. stoppers)
Angle limitation electrical : 2 x 35 degr.
ELECTRIC MOTORS 2 units
Make : MEZ
Type : 14BG 183-2
Power at/load endurance : 24.5 kW S1-100 %

42 kW S6- 25 %
Nominal current : 40 A
Voltage : 440 V/ 60Hz /3-Phase
Start current, star/delta – Port side : 94 Amp.

Start current, DOL – Starboard side : 283 Amp.
Revolutions per/min. : 3,540
Insulation class :F
Temp. class :F
Protection : IP-55
Frame type : B3/B5
Heating of element type : 220 V AC. Load acc. to Makers standard
Number of shaftends : One
Coupling : 42/55 GG Raja-Spidex (ø28 x ø48)
Ball bearings : D: 6310.C3 N: 6310.C3
Cable gland : PSG
-------------------------------------------------------------------------------------------------------------------------
MOTOR STARTERS 2 units
Type : Rittal AE 1180 IP 65
Dimensions : 800 x 1000 x 300 Starter cabinet.
Main switch : INS 63 MG
Start/Stop equipment : Pulse switch w/locker K&N
Trafo start/stop : 440/220 V 130 V.A. Noratel
Power pilotvalve : 440/24 V 120 W Noratel
Contactor, star/delta : LC1-D40 Telemec.
Contactor, D.O.L. : LC1–D50 Telemec.
Over current relay, star/delta : LR D3353 (23-32 Amp.) Telemec.
Over current relay, D.O.L. : LR D3357 (37-50 Amp.) Telemec.
Indication lamps : Running : Green

Heating : Blue
Supply P.E.C. : White
Main supply : Blue
Overload : Red
Heating of element type : 220V AC - Load acc. to Makers standard
Other functions : Restart after "black out"

: Steering control. Remote/ Local (Isolation of bridge)
: Auto start stand by-system based on failure.
: P.E.C. controlling system.
: 440 V 1-phase output for auto-pilot
: Door stopper in open position
: Pot.free contacts for VDR
Start method : D.O.L. No.1 - Starboard

Star/Delta No.2 - Port
Instruments : Amp. Meter

Hour counter
Steering NFU : Push buttons Port – SB (In front of starter cabinet)
Painting outside cabinets : RAL 7035
CONTROL AND ALARM PANELS: W.H. CONSOLE : 1 UNIT. PUMP 1 AND 2
E.C.R CONSOLE : 1 UNIT. PUMP 1 AND 2
Panel type wheel house (WH) : One panel with separate control and alarms for pump 1 and 2,
and common functions.
Panel type engine control room : One panel with separate control and alarms for pump 1 and 2, (ECR)
and common functions.
Dimension (H & B & D) : 240 x 144 x 150 (mm) (WH + ECR)
Push buttons (x2) : Start (WH only)

(x2) : Stop (WH only)
Switch (x1) : Stand by (WH only)
Indication lamps (x2) : Run Green (WH + ECR)

(x1) : Steering control ready, WH White (WH + ECR)
(x1) : Steering control ready, local White (WH + ECR)
(x1) : Stand by Blue (WH only)
Alarm lamps (x2) : Overload Red (WH + ECR)

(x2) : Phase / No Volt Red (WH + ECR)
(x2) : Steering control/power Red (WH + ECR)
(x2) : Oil level exp.tank Red (WH + ECR)
(x2) : Oil level pump tank Red (WH + ECR)
(x2) : Hydraulic lock Red (WH + ECR)
(x2) : Filter clogged Red (WH + ECR)
Acoustic signal (x1) : Buzzer (when any alarm) (WH only)
Other functions : Blinking alarm until acknowledge, then

fixed light. (WH + ECR)
Acknowledge button (WH only)
: Lamp test, each panel (WH + ECR)
: Panel dimmer (WH only)
Connecting cables : Panels delivered w/2,5 m multicables
Colour WH panel : Black
Colour ECR panel : Black
PAINT SPECIFICATION
All steering gear parts are primed with Jotun Cromoprimer-

approx. 35 my. and painted with Jotun Pilot II - colour Munsell 7.5 BG 7/2.
Approx. 30 my.
-------------------------------------------------------------------------------------------------------------------------
RUDDER ANGLE INDICATION EQUIPMENT:
Mechanical rudder indicator : (x1) PSG
3-way panorama indicator for WH, ceiling mounting : (x1) PSG TRI-2
(Internal dimmer can be moved to console)
Indicator for bridge wings, wall mounting, IP66 : (x2) PSG BW 144
Indicator for ECR, flush mounting : (x1) PSG XL 144
Indicator for wheel house, flush mounting : (x1) PSG XL 144
Indicator for steering gear room, wall mounting, IP66 : (x1) PSG BW 144
Rudder angle transmitter : (x1) PSG RT2
-------------------------------------------------------------------------------------------------------------------------
OTHER SIGNAL TRANSMITTERS
Rudder angle limit switch : (x4) T4VH335-11y Schmersal
Low oil level switches exp.tank : (x1) AB 1, 5MSS-L285 -SB40 w/test
Low oil level switches pump tank : (x2) AB 1,5MSS-L215-SB40 w/test
OTHER EQUIPMENT
Ring piston for pull up : (x1) PSG

Rudder stock nut : (x1) PSG
Seat for feedback equipment : (x3) PSG (according to drawing from yard) *)
Connecting rods for feedback equipment : (x3) PSG
Operating instruction according to class : (x2) PSG (for WH and s.g. compartment)
*) The drawings to be received by Porsgrunn max. 1 month after receiving the approval drawings.
------------------------------------------------------------------------------------------------------------------------
TOOLS
1 x Special hydraulic tool for stay bolts : M 64 Option (Optional - not necessary for mounting)
1 x key for cover bolts : NW Hexagon 22
-------------------------------------------------------------------------------------------------------------------------
SPARE PARTS
(According to Class and PSG standard):
O-ring for top cover : (x1)

Filter insert : (x1) TXW 8C-GDL20
Flexible element for coupling : (x1) M42
Bulb for starter : (x3) 28 V.
APPENDIX B
DRAWINGS
APPENDIX C
ELECTRICAL DRAWINGS
Jiangsu Hantong Shipyard
Hull No.: HT57-126
Steering Gear No.:

S-1995
part of Aker
Aker Porsgrunn AS
1 2 3 4 5 6
STEERING COLUMN / AUTOPILOT
A A
W.H.
START SIGNAL AND ALARM PANEL WHEELHOUSE START
STOP STOP
DRAW.NO. E****-04 PAGE 1,2 AND 3.
SIGNAL AND ALARM PANEL E.C.R.

E.C.R.
DRAW.NO. E****-05 PAGE 1,2 AND 3.
B STARTER STARTER B
STEERING
GEAR PORT S.B.
ROOM
DRAW.NO. DRAW.NO.
E****-03 E****-02
PAGE 1-5 PAGE 1-5
STEERING GEAR
C C
MOTOR/PUMP 2 MOTOR/PUMP 1
M M
PORT S.B.
**** = 1995
D D
A Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD MAP OF DRAWINGS Project no.
Hull number changed 29.11.2012 TEF
Perf.by ML HN: HT57-126 S-1995
part of Aker
Appr.by CLASS: LRS Scale Drawing no. Page 1
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of 1:1 E1995-01 N.pg. 2
1 2 3 4 5 6
1 2 3 4 5 6
44 STEERING COLUMN / AUTOPILOT 14
START CONTROL AND ALARM PANEL START

A STOP
W.H.
STOP
24 A
82 54 W.H.
23
SIGNALS 20x1.5 SIGNALS 20x1.5
BLACK OUT SIGNAL EMGR. GEN.RUNNING 2x1.5
45 15
STEERING CONTROL 4x4
SUPPLY AUTOPILOT 440V 2x1.5

STEERING CONTROL 4x4
53
CONTROL AND ALARM PANEL
EXT. RUN SIGNAL 2x1.5

2X1.5
2x1,5
E.C.R.
PORTFREE CONTACTS FOR VDR 12x1.5 ALARM FOR VDR 12x1.5
49 19
SIGNALS 14x1.5 SIGNALS 14x1.5
42 12
SUPPLY AUTOPILOT 440V
E.C.R. EXT.COM. ALARM 2x1,5 EXT.COM.ALARM 2x1.5

41 11
EXT. RUN SIGNAL
SIGNALS-AUTOSTART/AUTOSTOP 11x1.5
10
OIL LEVEL EXP.TANK 2x1.5 OIL LEVEL EXP.TANK 2x1.5
38 8
M32
M40
M32
M32
M20
M32
M20
M20
M32
M20
M32
M32
M40
M32
M20 M25 35 DEG. LIMIT SWITCH STB. 2X2.5 35 DEG. LIMIT SWITCH STB. 2X2.5 M25
37 7
M25 35 DEG. LIMIT SWITCH PORT 2X2.5 35 DEG. LIMIT SWITCH PORT 2X2.5 M25 M20
B STARTER
36 6
STARTER
B
M20 M25 PILOT VALVE STB 2X2.5 PILOT VALVE STB 2X2.5 M25 M25
35 5
M25 Y. M25 PILOT VALVE PORT 2X2.5 PILOT VALVE PORT 2X2.5 M25
34 4 D.O.L.
M20 M20 VALVE BLOCK MONITOR PORT 3X1.5 VALVE BLOCK MONITOR PORT 3X1.5 M20
46 16
M20 VALVE BLOCK MONITOR STB. 3X1.5 VALVE BLOCK MONITOR STB. 3X1.5 M20
47 17
PORT M25 BY PASS VALVE 2x2.5 BY PASS VALVE 2x2.5 M25 S.B.
50 20
M50
M20
M20
M20
M40
M40
M20
M20
M50
M20
M20
M50
M20
OIL LEV.P.TANK 2x1.5
OIL LEV.P.TANK 2x1.5
FILTER CLOGGED 2x1,5
FILTER CLOGGED 2x1,5

HEATING MOTOR 2x1,5
HEATING MOTOR 2x1,5

230V ESSENTIAL-ALARM 2x1.5
230V ESSENTIAL-ALARM 2x1.5

MOTOR 3x-
MOTOR 3x-
MOTOR 3x-
440V 60Hz 3x-
440V 60Hz 3x-

39 MOTOR/PUMP 2 MOTOR/PUMP 1 9
C 30 1 C
31 STEERING GEAR
32 2
M M
33 3
55 56 25 26
PORT S.B.
FROM E.S.B.
FROM M.S.B.
MOTOR DATA MOTOR DATA
MAKE MEZ MAKE MEZ
TYPE 14BG183-2 TYPE 14BG183-2
KW 24,5 KW 24,5
NOMINAL CURRENT 40A NOMINAL CURRENT 40A

RPM 3540 RPM 3540
D D
A Hull number changed 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD CABLE PLAN Project no.
Perf.by ML HN: HT57-126 S-1995

part of Aker
Appr.by CLASS: LRS Scale Drawing no. Page 2
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of 1:1 E1995-01 N.pg.
1 2 3 4 5 6
1 2 3 4 5 6
Ø10
742
A A
STEERING CONTROL RUN H1 GREEN PUMP
REMOTE LOC. STOP START
MAIN
H3 WHITE
S1 SUPPLY S5
A HOUR
P2 P3 COUNTER
9999,9 SIGNAL
H4 WHITE
SUPPLY
MOTOR H2 BLUE
HEATING
MOTOR HEATING
OFF
ON
B S4 B
N.F.U.
S1 S5
1000
1030
P. S.B.
S2 S3
S4
N.F.U.
P. S.B.
MAIN SWITCH
S2 S3
0
1 MOUNTED INSIDE
Q1
C -F1 -F5 C
STEERING CONTROL AUTOPILOT
-F2 -F6
CONTROL CIRCUIT 440V CONTROL CIRCUIT 220V
-F3 -F7
CONTROL CIRCUIT 440V MOTOR HEATING
-F4 -F8
CONTROL CIRCUIT 440V PLC SUPPLY
NAME PLATE
AE
CABLE ENTRANCE WITH CABLE GLAND.
D 800 D
DEPTH: 300
A Hull number changed 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STARTER CABINET Project nbr.
Perf. by ML HULL NO. HT57-126 RITTAL AE1180 S-1995

part of Aker
CLASS: LRS COLOR RAL 7035 Scale Drawingnbr. Page 1
Appr. by
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of STARBOARD PUMP 1:1 E1995-02 N.pg. 2
1 2 3 4 5 6
1 2 3 4 5 6
-W14 4 -W14 1 -W14 2 -W14 3

-X1 21 -X1 18 -X1 19 -X1 20
REMOTE
LOCAL
A A
3 11
1 -S1 -S1 13 -S1
-S1 TO PAGE 3.5
13 2 (2.2) 4 13 (2.2) 10 (2.2) 12
-S2 -S3
14 14
-X1 17 -X1 15
-W6 2 -W7 2
LIMIT
SWITCH
-W6 1 -W7 1
B B
-X1 16 -X1 14
65 65
-K2 -K1
(2.3) 66 (2.2) 66
03 03
-K1 -K2
-V2 (2.2) 04 (2.3) 04
-V1 -X1 11 -X1 13

C -X1 9
C
-W4 2 -W5 2
-W20 1 -V3 -V4
-V5 -V6
(3.1)
A2 A2 A2 G2 3
-W20 2 -W4 1 -W5 1 - L3
5
-K1 -K2 -K3 _ (3.1)
-X1 8 -X1 10 -X1 12 L2
3
A1 A1 A1 2
63
64
~ L1
1
+ (3.1)
PORT DIRECTIONAL
1
(3.2)
-K4
STB. DIRECTIONAL
-F1
03 04 (2.2) 03 04 (2.3) 14 11 (4.1)
BYPASS VALVE
13 14 (4.4) 13 14 (4.5) 12
21 22 21 22 24 21
31 32 31 32 22
43 44 43 44 34 31
VALVE
VALVE
57 58 57 58 32
D 65 66
(2.3)
65 66
(2.2)
44 41 D
42
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STEERING CONTROL CIRCUIT Project nbr.
Perf. by ML HULL NO. HT57-126 24V DC NEGATIVE TO AUTOPILOT S-1995

part of Aker
CLASS: LRS LOKOMEC Scale Drawingnbr. Page 2
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
AUTOPILOT RUN SIGNAL INTERFACE WITH NEXT STARTER START/STOP FROM WH PANEL
-X2 74 -X2 75 -X2 78
MAIN SUPPLY -W24 1 -W24 2 -W23 1 -W23 2 -W10 9 -W10 10 -W10 11

15 16 18 -X1 3 -X1 4 -X1 70 -X1 71 -X1 72 -X1 73 -X1 78
-W25 3 2 4 32 34
PHASE 13 13 -W15 1 -W15 2 -W15 3
A -W25 2
U -F5 -K4 -K6 -K7 -X1 5 -X1 6 -X1 7 A
-W25 1 (3.2) 14 (3.5) 14 (3.6) 31
-K8 1 3
1 3 5 61 71 81
L1 L2 L3
-Q1 -K6 -K6 -K6
2 4 6 (3.5) 62 (3.5) 72 (3.5) 82
FROM PAGE 2.5
-F2
4
1 2 440 220 1 5
-F3
2
1 2 0 0 4 8
19
-F4 -T1 -S1 -T2 12 14 12 14 2
-F6
1 2 (2.2) 18 -K20 -K21 -S5
4
(4.4) 11 (4.4) 11 1 3
-P2 A 6 mm2
2
12 14
-F7
2
B -P1 -K7 83 B
(3.6) 11 1 3 -K4
-S4 (3.2) 84
2 4
(2.6)
3
(2.6) 21
2 -K4
(3.2) 22
(2.6)
1
1 3 5 A1 A1 A1 A1 B1
-K4 -K19 -P3 h -K6 -K5 -K7
(3.2) 2 4 6 A2 A2 A2 A2 B2
A1
-K4
A2 -X1 1 -X1 2
1 3 5
C -F10 C
-W2 1 -W2 2
2 4 6
1 2
03 04 14 11 (4.1) 14 11 (3.2)
3 4
(3.1) 13 14 (3.4) 12 12
5 6
21 22 (4.3) 24 21 (5.1) 24 21 (4.1)
13 14 14 11 (5.2)
(3.3) 31 32 22 22
21 22 12
(3.4) 43 44 34 31 34 31 (3.4)
-W1 -1
-W1 -3
-W1 -2
53 54 24 21
(4.2) 53 54 32 32
63 64 22 (4.2)
HOUR COUNTER
(2.3) 61 62 44 41 44 41 (4.4)
73 74 34 31 (3.6)
71 72 42 42
83 84 32 (3.6)
CONTACTOR
(3.4) 81 82
44 41 (3.6)
U1 V1 W1
REMOTE/
HEATING
NO VOLT
42
POWER/
START
LOCAL
STOP/
MAIN
-M3 M
D D
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STARTER CIRCUIT DOL Project nbr.
Perf. by ML HULL NO. HT57-126 440V 60HZ S-1995

part of Aker
CLASS: LRS HEATING 220V AC Scale Drawingnbr. Page 3
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
COMMON FOR LAMPS (-)

TO PANELS WH AND ECR DRW. E****-04 PAGE 1-3 / E****-05 PAGE 1-3
OIL LEVEL PUMP TANK
OIL LEVEL EXP. TANK

STEERING CONTROL
STEERING CONTROL
STEERING CONTROL
-X2 65 -X2 66 -X2 67
STAND BY SELECT
MOTOR STOPPED
HYDRAULIC LOCK
FILTER CLOGGED
PHASE / NO VOLT
-W10 4 -W10 5 -W10 6 -W26 1 -W26 2
READY REMOTE
ACKNOWLEDGE
-W11 1 -W11 2 -X1 22 -X1 23
READY LOCAL
TO STARTER CIRCUIT
COMMON (+)
-X1 61 -X1 62 -X1 63 -X1 47 -X1 48
OVERLOAD
STAND BY
A A
BUZZER
POWER
1 3
SIGNAL SUPPLY
RUN
-F8
12 14 12 14 12 14
-K22 -K23 -K24 2 4
-W15 -20
-W12 -14
(4.5) 11 (4.5) 11 (4.6) 11
-W15 -10
-W15 -11
-W15 -12
-W15 -13
-W15 -14
-W15 -15
-W15 -16
-W12 -10
-W15 -17
-W12 -11
-W15 -18
-W12 -12
-W15 -19
-W12 -13
-W15 -4
-W12 -1
-W15 -5
-W15 -6
-W15 -7
-W12 -2
-W15 -8
-W12 -3
-W15 -9
-W12 -4
-W12 -5
-W12 -6
-W12 -7
-W12 -8
-W12 -9
-X1 41 41
POWER
AUTOSTART NEXT STARTER COM.ALARM
-X1 25 -X1 28 28 -X1 30 30 -X1 32 32 -X1 34 34 -X1 36 36 -X1 38 38 -X1 40 40

A2 A2 A2 A2 A2
-K20 -K21 -K22 -K23 -K24 -H4
-X1 24 24 -X1 26 -X1 29 29 -X1 31 31 -X1 33 33 -X1 35 -X1 37 37 -X1 39 39
G1
A1 A1 A1 A1 A1
-0CH 00 -0CH 01
100CH 01 100CH 03 100CH 05 100CH 07 101CH 01
53 42 44
-K6 -K7
+ 100CH 00 100CH 02 100CH 04 100CH 06 101CH 00 101CH 02 101CH 03 101CH 04 101CH 05 101CH 06 101CH 07
B (3.5) 54 (3.6) 41 B
-A2 14 11 (3.6) 14 11 (3.6) 14 11 (4.5) 14 11 (4.5) 14 11 (4.5)

COM. (-)
12 12 12 12 12
24 21 24 21 24 21 24 21 24 21
22 22 22 22 22
-0CH 02 -0CH 03 -0CH 04 -0CH 05 -0CH 06 -0CH 07 -0CH 08 -0CH 09 -0CH 10 -0CH 11 -1CH 00 -1CH 01 -1CH 02 -1CH 03 -1CH 04 -1CH 05
-X1 55 -X1 58
-X1 49 -X1 66 -X1 67 -X1 51 -X1 53 -X1 75
-W16 1 -W17 1
12 14 -W3 1 -W10 2 -W10 3 -W9 1 -W8 1 -W10 8
4 4
-K5 -X2 62 -X2 63 -X2 73
1 1 1
(3.5) 11
2 2 2 3 1 3 1
-X2 61 13 13 -X2 72
22 24 16 18 12 14 21 -W3 2 -W9 2 -W8 2 -K1 -K2
C 53 95 C
-K7 -K8 -K3 -K4 -H1 -F0 -K6 -W10 1 (2.2) 14 (2.3) 14 -W16 3 -W16 2 -W17 3 -W17 2 -W10 7
(3.6) 21 (3.2) 15 (2.4) 11 (3.2) 54 96 (3.5) 22 -X1 50 -X1 65 -X1 52 -X1 54 -X1 57 -X1 56 -X1 60 -X1 59 -X1 74
(5.1)
4
(5.1)
5
STEERING CONTROL POWER
MAIN VALVE SENSOR PORT

REMOTE/LOCAL STEERING
MAIN VALVE SENSOR STB.

RUDDER ORDER PORT
OIL LEVEL PUMP TANK
RUDDER ORDER STB.

FROM NEXT STARTER
OIL LEVEL EXP. TANK

FILTER INDICATOR
MAIN CONTACTOR
FROM NEXT PUMP

PHASE/NO VOLT
REMOTE/LOCAL
START/STOP
AUTOSTART
OVERLOAD
D D
RUN
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD SIGNAL / ALARM CIRCUIT Project nbr.
Perf. by ML HULL NO. HT57-126 PLC A2 S-1995

part of Aker
CLASS: LRS Scale Drawingnbr. Page 4
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
POTFREE OUTPUTS FOR VDR
OIL LEVEL PUMP TANK
OIL LEVEL EXP. TANK

STEERING CONTROL
HYDRAULIC LOCK
PHASE/ NO VOLT
-W19 1 -W19 3 -W19 5 -W19 7 -W19 9 -W19 11
OVERLOAD
-X1 79 -X1 81 -X1 83 -X1 85 -X1 87 -X1 89
A A
POWER
12 14 12 14 12 14 12 14 12 14 12 14
-K25 -K26 -K27 -K28 -K29 -K30
(5.2) 11 (5.2) 11 (5.3) 11 (5.3) 11 (5.3) 11 (5.4) 11
-X1 80 -X1 82 -X1 84 -X1 86 -X1 88 -X1 90
-W19 2 -W19 4 -W19 6 -W19 8 -W19 10 -W19 12
-X1 42 42
A2 A2 A2 A2 A2 A2
-K25 -K26 -K27 -K28 -K29 -K30
B A1 A1 A1 A1 A1 A1 B
-102CH 00 102CH 01 102CH 02 102CH 03 102CH 04 102CH 05 102CH 06 -102CH 07
-A2
14 11 (5.2) 14 11 (5.2) 14 11 (5.3) 14 11 (5.3) 14 11 (5.3) 14 11 (5.4)
12 12 12 12 12 12
24 21 24 21 24 21 24 21 24 21 24 21
22 22 22 22 22 22
-COM (-) -COM (+)
C C
-H3 -H2
22 24 12 14
-K5 -K19
(3.5) 21 (3.4) 11
(4.6)
+
4
MAIN SUPPLY
(4.6)
5
-
HEATING
D D
A TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD SIGNAL / ALARM CIRCUIT Project nbr.
Changed hull number 29.11.2012
part of Aker
Appr. by
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of STARBOARD PUMP 1:1 E1995-02 N.pg.
1 2 3 4 5 6
1 2 3 4 5 6
Ø10
742
A A
STEERING CONTROL RUN H1 GREEN PUMP
REMOTE LOC. STOP START
MAIN
H3 WHITE
S1 SUPPLY S5
A HOUR
P2 P3 COUNTER
9999,9 SIGNAL
H4 WHITE
SUPPLY
MOTOR H2 BLUE
HEATING
MOTOR HEATING
OFF
ON
B S4 B
N.F.U.
S1 S5
1000
1030
P. S.B.
S2 S3
S4
N.F.U.
P. S.B.
MAIN SWITCH
S2 S3
0
1 MOUNTED INSIDE
Q1
C -F1 -F5 C
STEERING CONTROL AUTOPILOT
-F2 -F6
CONTROL CIRCUIT 440V CONTROL CIRCUIT 220V
-F3 -F7
CONTROL CIRCUIT 440V MOTOR HEATING
-F4 -F8
CONTROL CIRCUIT 440V PLC SUPPLY
NAME PLATE
AE
CABLE ENTRANCE WITH CABLE GLAND.
D 800 D
DEPTH: 300
A Hull number changed 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STARTER CABINET Project nbr.
Perf. by ML HULL NO. HT57-126 RITTAL AE1180 S-1995

part of Aker
CLASS: LRS COLOR RAL 7035 Scale Drawingnbr. Page 1
Appr. by
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of PORT PUMP 1:1 E1995-03 N.pg. 2
1 2 3 4 5 6
1 2 3 4 5 6
-W44 4 -W44 1 -W44 2 -W44 3

-X2 21 -X2 18 -X2 19 -X2 20
REMOTE
LOCAL
A A
3 11
1 -S1 -S1 13 -S1
-S1 TO PAGE 3.5
13 2 (2.2) 4 13 (2.2) 10 (2.2) 12
-S2 -S3
14 14
-X2 17 -X2 15
-W36 2 -W37 2
LIMIT
SWITCH
-W36 1 -W37 1
B B
-X2 16 -X2 14
65 65
-K2 -K1
(2.3) 66 (2.2) 66
03 03
-K1 -K2
-V2 (2.2) 04 (2.3) 04
-V1 -X2 11 -X2 13

C -X2 9 C
-W34 2 -W35 2
-W50 1 -V3 -V6 -V4
-V5
(3.1)
A2 A2 A2 G2 3
- L3
5
-W50 2 -K1 -W34 1 -W35 1 -K2 -K3
-X2 8 -X2 10 -X2 12 _ (3.1)
L2
3
163
A1 A1 164 A1 2
~ L1
1
+ (3.1)
PORT DIRECTIONAL
1
(3.3)
-K4
-F1
STB. DIRECTIONAL
03 04 (2.2) 03 04 (2.3) 14 11 (4.1)

BYPASS VALVE
13 14 (4.4) 13 14 (4.5) 12
21 22 21 22 24 21
31 32 31 32 22
43 44 43 44 34 31
VALVE
VALVE
57 58 57 58 32
D 65 66
(2.3)
65 66
(2.2)
44 41 D
42
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STEERING CONTROL CIRCUIT Project nbr.
Perf. by ML HULL NO. HT57-126 24V DC NEGATIVE TO AUTOPILOT S-1995

part of Aker
CLASS: LRS LOKOMEC Scale Drawingnbr. Page 2
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
AUTOPILOT RUN SIGNAL INTERFACE WITH NEXT STARTER START/STOP FROM WH PANEL
-X1 74 -X1 75
MAIN SUPPLY -W54 1 -W53 1 -W53 2 -W10 7 -W10 8

-W54 2
15 16 18 -X2 3 -X2 4 -X2 70 -X2 71 -X2 73
-W55 3 2 4
PHASE 13 13 -W45 1 -W45 2 -W45 3
A -W55 2
U -F5 -K4 -K6 -X2 5 -X2 6 -X2 7 A
-W55 1 (3.3) 14 (3.5) 14
-K8 1 3
1 3 5 61 71 81
L1 L2 L3 -X2 72
-Q1 -K6 -K6 -K6
2 4 6 (3.5) 62 (3.5) 72 (3.5) 82
FROM PAGE 2.5
-F2
4
1 2 440 220 1 5
-F3
2
1 2 0 0 4 8
19
-F4 -T1 -S1 -T2 12 14 12 14 2
-F6
1 2 (2.2) 18 -K20 -K21 -S5
4
(4.4) 11 (4.4) 11 1 3
-P2 A 6 mm2
2
12 14
-K7
-F7
2
B -P1 (3.6) 11
183 B
173 1 3 -K4
-K4 -S4 (3.3) 184
(3.3) 174 2 4
(2.6)
1
(2.6) 13 21
2 -K11 -K4
(3.3) 14 (3.3) 22
(2.6)
3
1 3 5 1 3 5 1 3 5 67 21 A1 A1 A1 A1 B1
-K4 -K10 -K11 -K4 -K10 -K19 -P3 h -K6 -K5 -K7
(3.3) 2 4 6 (3.3) 2 4 6 (3.3) 2 4 6 (3.3) 68 (3.3) 22 A2 A2 A2 A2 B2
21 55
-K11 -K4 -X2 1 -X2 2
1 3 5
C -F0 (3.3) 22 (3.3) 56 C
-W32 1 -W32 2
2 4 6 A1 A1 A1
-K4 -K10 -K11
A2 A2 A2
03 04 14 11 (4.1) 14 11 (3.3)
13 14 (3.4) 12 12
-W30 -1
-W30 -2
-W30 -3
-W31 -1
-W31 -3
-W31 -2
21 22 (4.3) 24 21 (5.1) 24 21 (4.1)

1 2 1 2 1 2 14 11 (5.2) 31 32 22 22
3 4 3 4 3 4 12
(3.1) (3.2) (3.2) 43 44 34 31 34 31
5 6 5 6 5 6 24 21 53 54 32 32
13 14 13 14 13 14 22 (4.2)
HOUR COUNTER
W1 V2 (3.3) (3.3) 61 62 44 41 44 41 (4.4)
21 22 21 22 21 22 34 31 (3.6)
(3.4) (3.3) (3.3) 71 72 42 42
V1 M U2 153 154 32 (3.6)
CONTACTOR
(4.2) 81 82
U1 W2 163 164 44 41 (3.6)
(2.3)
REMOTE/
HEATING
NO VOLT
173 174 42
POWER/
(3.3)
START
LOCAL
-M1
STOP/
183 184
MAIN
(3.4)
55 56
(3.3)
D 67 68
(3.3)
D
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD STARTER CIRCUIT STAR / DELTA Project nbr.
Perf. by ML HULL NO. HT57-126 440V 60HZ S-1995

part of Aker
CLASS: LRS HEATING 220V AC Scale Drawingnbr. Page 3
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
COMMON FOR LAMPS (-)

TO PANELS WH AND ECR DRW. E****-04 PAGE 1-3 / E****-05 PAGE 1-3
OIL LEVEL PUMP TANK
OIL LEVEL EXP. TANK

STEERING CONTROL
STEERING CONTROL
STEERING CONTROL
-X1 65 -X1 66 -X1 67
STAND BY SELECT
MOTOR STOPPED
HYDRAULIC LOCK
FILTER CLOGGED
PHASE / NO VOLT
-W10 1 -W10 2 -W10 3 -W56 1 -W56 2
READY REMOTE
ACKNOWLEDGE
-W41 1 -W41 2 -X2 22 -X2 23
READY LOCAL
TO STARTER CIRCUIT
COMMON (+)
-X2 61 -X2 62 -X2 63 -X2 47 -X2 48
OVERLOAD
STAND BY
A A
BUZZER
POWER
1 3
SIGNAL SUPPLY
RUN
-F8
12 14 12 14 12 14
-K22 -K23 -K24 2 4
-W45 -20
-W42 -14
(4.5) 11 (4.5) 11 (4.6) 11
-W45 -10
-W45 -11
-W45 -12
-W45 -13
-W45 -14
-W45 -15
-W45 -16
-W42 -10
-W45 -17
-W42 -11
-W45 -18
-W42 -12
-W45 -19
-W42 -13
-W45 -4
-W42 -1
-W45 -5
-W45 -6
-W45 -7
-W42 -2
-W45 -8
-W42 -3
-W45 -9
-W42 -4
-W42 -5
-W42 -6
-W42 -7
-W42 -8
-W42 -9
-X2 41 41
POWER
AUTOSTART NEXT STARTER COM.ALARM
-X2 25 -X2 28 28 -X2 30 30 -X2 32 32 -X2 34 34 -X2 36 36 -X2 38 38 -X2 40 40

A2 A2 A2 A2 A2
-K20 -K21 -K22 -K23 -K24 -H4
-X2 24 24 -X2 26 -X2 29 29 -X2 31 31 -X2 33 33 -X2 35 -X2 37 37 -X2 39 39
G1
A1 A1 A1 A1 A1
-0CH 00 -0CH 01
100CH 01 100CH 03 100CH 05 100CH 07 101CH 01
53 42 44
-K6 -K7
+ 100CH 00 100CH 02 100CH 04 100CH 06 101CH 00 101CH 02 101CH 03 101CH 04 101CH 05 101CH 06 101CH 07
B (3.5) 54 (3.6) 41 B
-A1 14 11 (3.6) 14 11 (3.6) 14 11 (4.5) 14 11 (4.5) 14 11 (4.5)

COM. (-)
12 12 12 12 12
24 21 24 21 24 21 24 21 24 21
22 22 22 22 22
-0CH 02 -0CH 03 -0CH 04 -0CH 05 -0CH 06 -0CH 07 -0CH 08 -0CH 09 -0CH 10 -0CH 11 -1CH 00 -1CH 01 -1CH 02 -1CH 03 -1CH 04 -1CH 05 -1CH 06 -1CH 07
-X2 77 -X2 78
-X2 55 -X2 58
-X2 49 -X2 66 -X2 67 -X2 51 -X2 53 -X2 75 -W10 11
-W46 1 -W47 1 -W82 1 -X1 78
12 14 -W33 1 -W10 5 -W10 6 -W39 1 -W38 1 -W10 10
4 4
-K5 -X1 62 -X1 63 -X1 73
1 1 1
(3.5) 11
2 2 2 3 1 3 1
-X1 61 13 13 -X1 72
22 24 16 18 12 14 21 -W33 2 -W39 2 -W38 2 -K1 -K2
C 153 95 C
-K7 -K8 -K3 -K4 -H1 -F0 -K6 -W10 4 (2.2) 14 (2.3) 14 -W46 3 -W46 2 -W47 3 -W47 2 -W10 9 -W82 2
(3.6) 21 (3.2) 15 (2.4) 11 (3.3) 154 (3.1) 96 (3.5) 22 -X2 50 -X2 65 -X2 52 -X2 54 -X2 57 -X2 56 -X2 60 -X2 59 -X2 74 -X2 76
(5.1)
4
(5.1)
5
STEERING CONTROL POWER
MAIN VALVE SENSOR PORT

REMOTE/LOCAL STEERING
MAIN VALVE SENSOR STB.
BLACK OUT SIGNAL FROM

RUDDER ORDER PORT
OIL LEVEL PUMP TANK
RUDDER ORDER STB.

FROM NEXT STARTER
EMERG. GENERATOR
OIL LEVEL EXP. TANK
INTERLOCK WITH K7
FILTER INDICATOR
MAIN CONTACTOR
FROM NEXT PUMP

PHASE/NO VOLT
REMOTE/LOCAL
STB. STARTER
START/STOP
AUTOSTART
OVERLOAD
D D
RUN

part of Aker
Appr. by
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
POTFREE OUTPUTS FOR VDR
OIL LEVEL PUMP TANK
OIL LEVEL EXP. TANK

STEERING CONTROL
HYDRAULIC LOCK
PHASE/ NO VOLT
-W49 1 -W49 3 -W49 5 -W49 7 -W49 9 -W49 11
OVERLOAD
-X2 79 -X2 81 -X2 83 -X2 85 -X2 87 -X2 89
A A
POWER
12 14 12 14 12 14 12 14 12 14 12 14
-K25 -K26 -K27 -K28 -K29 -K30
(5.2) 11 (5.2) 11 (5.3) 11 (5.3) 11 (5.3) 11 (5.4) 11
-X2 80 -X2 82 -X2 84 -X2 86 -X2 88 -X2 90
-W49 2 -W49 4 -W49 6 -W49 8 -W49 10 -W49 12
-X2 42 42
A2 A2 A2 A2 A2 A2
-K25 -K26 -K27 -K28 -K29 -K30
B A1 A1 A1 A1 A1 A1 B
-102CH 00 102CH 01 102CH 02 102CH 03 102CH 04 102CH 05 102CH 06 -102CH 07
-A1
14 11 (5.2) 14 11 (5.2) 14 11 (5.3) 14 11 (5.3) 14 11 (5.3) 14 11 (5.4)
12 12 12 12 12 12
24 21 24 21 24 21 24 21 24 21 24 21
22 22 22 22 22 22
-COM (-) -COM (+)
C C
-H3 -H2
22 24 12 14
-K5 -K19
(3.5) 21 (3.4) 11
(4.6)
+
4
MAIN SUPPLY
(4.6)
5
-
HEATING
D D

part of Aker
Appr. by
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of PORT PUMP 1:1 E1995-03 N.pg.
1 2 3 4 5 6
1 2 3 4 5 6
A A
240
6
6
PORT STARBOARD
PUMP UNIT STEERING GEAR PUMP UNIT
BRIDGE LOCAL BRIDGE LOCAL

LOW OIL LOW OIL
CONTROL CONTROL CONTROL CONTROL
READY COMMON COMMON READY
READY READY
PUMP PUMP
B STANDBY
SPARE SPARE SPARE
STANDBY
SPARE B
STEERING STEERING
PHASE SPARE SPARE PHASE
CONTROL CONTROL
NO VOLT. NO VOLT.
POWER POWER
144
OVER HYDR. OVER HYDR.
LOAD LOCK LOAD LOCK
SPARE SPARE
FILTER LOW OIL FILTER LOW OIL

CLOGGED PUMPTANK CLOGGED PUMPTANK
SPARE SPARE 210

SPARE SPARE SPARE SPARE
AUTO AUTO
SPARE SPARE ACKN. SPARE SPARE
ON OFF
C LAMP
C
130
START START
STOP TEST STOP CUT OUT
RUN RUN
FREE DEPT: 150
D D
A Changed Hull Number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.
Perf.by ML HN: HT57-126 WH S-1995

part of Aker
Appr.by CLASS: LRS LAY OUT Scale Drawing no. Page 1
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
A A
STEERING CONTROL/POWER
BRIDGE PANEL
OIL LEVEL COMMON TANK

BRIDGE CONTROL READY
LOCAL CONTROL READY
OIL LEVEL PUMP TANK

PHASE/NO VOLTAGE
HYDRAULIC LOCK
FILTER CLOGGED
ACNOWLEDGE
OVERLOAD
STAND BY
BUZZER
START
+24VV
AUTO
STOP
STOP
RUN
0V
B B
-X12 10 -X12 12 -X12 11 -X12 7 -X12 8 -X12 9 -X8 15 -X8 16 -X8 3 -X8 1 -X8 2 -X8 5 -X8 6 -X8 7 -X8 8 -X8 10 -X8 9 -X6 2 -X5 2 -X10 3 -X10 4
CABLE NO.2 YELLOW/BROWN
CABLE NO.2 WHITE/YELLOW

CABLE NO.2 GREY/BROWN
CABLE NO.2 WHITE/GREEN

CABLE NO.2 WHITE/GREY
CABLE NO.2 PINK/BROWN
CABLE NO.2 WHITE/BLUE
CABLE NO.2 WHITE/PINK
CABLE NO.2 GREY/PINK
CABLE NO.2 RED/BLUE

CABLE NO.2 BROWN
CABLE NO.2 YELLOW

CABLE NO.2 GREEN
CABLE NO.2 WHITE

CABLE NO.2 VIOLET
CABLE NO.2 BLACK

CABLE NO.2 GREY
CABLE NO.2 BLUE

CABLE NO.2 PINK
CABLE NO.2 RED

C C
WHEELHOUSE
STEERING
-X1 5 -X1 6 -X1 7 -X1 26 -X1 25 -X1 28 -X1 40 -X1 29 -X1 30 -X1 31 -X1 32 -X1 34 -X1 33 -X1 36 -X1 37 -X1 39 -X1 38 -X1 35 -X1 24 -X1 41 GEAR
ROM
15
TERMINALS IN STARBOARD STARTER

(DRAWING Exxxx-02 - PAGE 3 AND 4)
D D
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.

part of Aker
Appr.by CLASS: LRS WIRING DIAGRAM Scale Drawing no. Page 2
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of STARBOARD PUMP UNIT 1:1 E1995-04 N.pg. 3
1 2 3 4 5 6
1 2 3 4 5 6
A A
BRIDGE PANEL

LOCAL CONTROL READY
OIL LEVEL PUMP TANK

PHASE/NO VOLTAGE
HYDRAULIC LOCK
FILTER CLOGGED
ACNOWLEDGE
OVERLOAD
STAND BY
BUZZER
START
+24VV
AUTO
STOP
STOP
RUN
0V
B B
-X12 4 -X12 6 -X12 5 -X12 1 -X12 2 -X12 3 -X4 15 -X4 16 -X4 3 -X4 1 -X4 2 -X4 5 -X4 6 -X4 7 -X4 8 -X4 10 -X4 9 -X6 1 -X5 1 -X10 1 -X10 2
CABLE NO.1 YELLOW/BROWN
CABLE NO.1 WHITE/YELLOW

CABLE NO.1 GREY/BROWN
CABLE NO.1 WHITE/GREEN

CABLE NO.1 PINK/BROWN
CABLE NO.1 WHITE/GREY

CABLE NO.1 WHITE/BLUE
CABLE NO.1 WHITE/PINK
CABLE NO.1 GREY/PINK
CABLE NO.1 RED/BLUE

CABLE NO.1 BROWN
CABLE NO.1 YELLOW

CABLE NO.1 GREEN
CABLE NO.1 WHITE

CABLE NO.1 VIOLET
CABLE NO.1 BLACK

CABLE NO.1 GREY
CABLE NO.1 BLUE

CABLE NO.1 PINK
CABLE NO.1 RED

C C
WHEELHOUSE
STEERING
-X2 5 -X2 6 -X2 7 -X2 26 -X2 25 -X2 28 -X2 40 -X2 29 -X2 30 -X2 31 -X2 32 -X2 34 -X2 33 -X2 36 -X2 37 -X2 39 -X2 38 -X2 35 -X2 24 -X2 41 GEAR
ROM
45
TERMINALS IN PORT STARTER
(DRAWING Exxxx-3 - PAGE 3 AND 4)
D D
TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.
A Changed hull number 29.11.2012
part of Aker
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of PORT PUMP UNIT 1:1 E1995-04 N.pg.
1 2 3 4 5 6
1 2 3 4 5 6
A A
240
6
6
PORT STARBOARD
PUMP UNIT STEERING GEAR PUMP UNIT
BRIDGE LOCAL BRIDGE LOCAL

LOW OIL LOW OIL CONTROL
CONTROL CONTROL CONTROL
READY COMMON COMMON READY
READY READY
B PUMP
STANDBY
SPARE SPARE SPARE PUMP
STANDBY
SPARE B
STEERING STEERING
CONTROL PHASE SPARE SPARE CONTROL PHASE
NO VOLT. NO VOLT.
POWER POWER
144
OVER HYDR. OVER HYDR.
LOAD LOCK LOAD LOCK
SPARE SPARE
FILTER LOW OIL FILTER LOW OIL

CLOGGED PUMPTANK CLOGGED PUMPTANK
210
C C
LAMP
130
RUN STOP TEST RUN STOP CUT OUT
FREE DEPT: 150
D D
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.
Perf.by ML HN: HT57-126 ECR S-1995

part of Aker
Appr.by CLASS: LRS LAY OUT Scale Drawing no. Page 1
Aker Porsgrunn AS
1 2 3 4 5 6
1 2 3 4 5 6
A A
ECR PANEL

LOCAL CONTROL READY
OIL LEVEL PUMP TANK

PHASE/NO VOLTAGE
HYDRAULIC LOCK
FILTER CLOGGED
OVERLOAD
STAND BY
+24VV
STOP
RUN
0V
B B
-X8 15 -X8 16 -X8 3 -X8 1 -X8 2 -X8 5 -X8 6 -X8 7 -X8 8 -X8 10 -X8 9 -X6 2 -X10 3 -X10 4
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2
PANEL CABLE NO.2

BROWN /GREEN
WHITE/YELLOW
WHITE/GREEN
GREY/PINK
YELLOW
BROWN
VIOLET
GREEN
WHITE
BLACK
GREY
BLUE
PINK
RED
C C
ENGINE CONTROL ROOM
STEERING GEAR ROOM
-X1 28 -X1 40 -X1 29 -X1 30 -X1 31 -X1 32 -X1 34 -X1 33 -X1 36 -X1 37 -X1 39 -X1 38 -X1 24 -X1 41
12
TERMINALS IN STARBOARD STARTER

(DRAWING Exxxx-02 - PAGE 3)
D D
29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.
A Changed hull number
part of Aker
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of STARBOARD PUMP UNIT 1:1 E1995-05 N.pg. 3
1 2 3 4 5 6
1 2 3 4 5 6
A A
ECR PANEL

LOCAL CONTROL READY
OIL LEVEL PUMP TANK

PHASE/NO VOLTAGE
HYDRAULIC LOCK
FILTER CLOGGED
OVERLOAD
STAND BY
+24VV
STOP
RUN
0V
B B
-X4 15 -X4 16 -X4 3 -X4 1 -X4 2 -X4 5 -X4 6 -X4 7 -X4 8 -X4 10 -X4 9 -X6 1 -X10 1 -X10 2
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1
PANEL CABLE NO.1

BROWN /GREEN
WHITE/YELLOW
WHITE/GREEN
GREY/PINK
YELLOW
BROWN
VIOLET
GREEN
WHITE
BLACK
GREY
BLUE
PINK
RED
C C
ENGINE CONTROL ROOM
STEERING GEAR ROOM
-X2 28 -X2 40 -X2 29 -X2 30 -X2 31 -X2 32 -X2 34 -X2 33 -X2 36 -X2 37 -X2 39 -X2 38 -X2 24 -X2 41
42
TERMINALS IN PORT STARTER

(DRAWING Exxxx-03 - PAGE 3)
D D
Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD START / STOP - ALARM PANEL Project no.
A
part of Aker
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl.for Repl.of PORT PUMP UNIT 1:1 E1995-05 N.pg.
1 2 3 4 5 6
1 2 3 4 5 6
BULKHEAD CONTROL 3-WAY BULKHEAD
PORT BRIDGEWING CONSOLE PANORAMA RUDDER INDICATOR STARBOARD BRIDGEWING
100 99 POWER
SUPPLY
24V DC
A 102 106 101

A
JUNCTION BOX 107 +/-10V SIGNAL

TO VOYAGE RECORDER
YARD SUPPLY
B B
BRIDGE
ECR
ENGINE CONTROL ROOM
104
JUNCTION BOX
YARD SUPPLY
STEERING GEAR ROOM
STEERING GEAR ROOM
C C
103
JUNCTION BOX
YARD SUPPLY
105
RUDDER FEEDBACK
AND ANGLE IND. TRANSMITTER
CORE ENCABLES DIM. = 1,5
= NUMBER OF CORES
RT2
CABLE SCREEN CONNECTED IN ONE END - PREFERABLY IN RT2
D DIMMER INCLUDED IN PANORAMA AND BW TYPE D
29.11.2012 TEF Date Project nbr.

A Changed hull number 03.08.11 YARD: JIANGSU HANTONG SHIPYARD RUDDER ANGLE INDICATOR SYSTEM
Perf. by ML HULL NO. HT57-126 CABLE PLAN S-1995
part of Aker
Scale Drawingnbr. Page 1
Appr. by CLASS: LRS
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of 1:1 E1995-06 N.pg. 2
1 2 3 4 5 6
1 2 3 4 5 6
BULKHEAD CONTROL BULKHEAD
PORT BRIDGEWING CONSOLE PANORAMA INDICATOR STB. BRIDGEWING
BW 144 XL 144 BW 144

TRI2
DIMMER
0 0 INCLUDED 0
ILLUM
INST.
NC
3+ 4- 6 7 8 1 2 3+ 4- 6 7 8 1 2 3+ 4- 6 7 8 1 2
A 2 1 3 4 5
A
+ - + -
-R -R - SUPPLY -R
JUNCTION BOX
YARD SUPPLY + 24VDC
U-
U+
+24VDC WEIDMULLER
8
GND3 WAS 4
4 5
IN 1- OUT 1+ TO VOYAGER
1 6 RECORDER
IN 1+ OUT 1- W.H
B B
XL 144
ENGINE CONTROL ROOM

JUNCTION BOX 0
YARD SUPPLY
4- 3+ 6 7 8 1 2
E.C.R
BW 144 S.G.R.
C C
STEERING GEAR ROOM
JUNCTION BOX 0
YARD SUPPLY
4- 3+ 6 7 8 1 2
2+
3-
SUPPLY 4-20mA
4+
1-
24V
RT2
D RUDDER FEEDBACK UNIT
D
A Changed hull number 29.11.2012 TEF Date 03.08.11 YARD: JIANGSU HANTONG SHIPYARD RUDDER ANGLE INDICATOR SYSTEM Project nbr.
Perf. by ML HULL NO. HT57-126 S-1995

part of Aker
CLASS: LRS WIRING DIAGRAM Scale Drawingnbr. Page 2
Appr. by
Aker Porsgrunn AS
Ver. Revision Date Sign. Norm NEK400 Original Repl. for Repl. of 1:1 E1995-06 N.pg.
1 2 3 4 5 6
Drawing: E1995-02
Project: S-1995 Page 1 of 5
External connection table

S-1995 - JIANGSU HANTONG SHIPYARD HN: HT57-126 - STARTER STARBOARD
-W1
Description Ref. desc. Color Page External Page Internal Page
Motor -W1:-1 3.1 -M3:U1 3.1 -F10:2 3.1
Motor -W1:-2 3.1 -M3:V1 3.1 -F10:4 3.1
Motor -W1:-3 3.1 -M3:W1 3.1 -F10:6 3.1
-W2
Heating Motor -W2:1 3.4 3.4 -X1:1 3.4
Heating Motor -W2:2 3.4 3.4 -X1:2 3.4
-W3
Filter -W3:1 4.3 1:1 4.3 -X1:49 4.3
Filter -W3:2 4.3 1:2 4.3 -X1:50 4.3
-W4
Pilot Valve Port -W4:1 2.2 -Y2:A2 2.2 -X1:10 2.2
-W5
Pilot Valve Stb. -W5:1 2.3 -Y3:A2 2.3 -X1:12 2.3
-W6
Max Limit Switch Port -W6:1 2.2 -Y5:2 2.2 -X1:16 2.2
Document: E1995-02 Date: 30.11.2012

Aker Porsgrunn ElCad Skjema 2000 1.1
Drawing: E1995-02
-W7
Max Limit Switch Stb. -W7:1 2.3 -Y4:2 2.3 -X1:14 2.3
-W8
Oil Level Exp.Tank -W8:1 4.4 -Y10:1 4.4 -X1:53 4.4
-W9
Oil Level Pump Tank -W9:1 4.4 -Y9:1 4.4 -X1:51 4.4
-W10
Interface With Next Starter -W10:1 4.3 -X2:61 4.3 -X1:65 4.3
-W11
Ext. Com. Alarm -W11:1 4.5 4.5 -X1:47 4.5
Ext. Com. Alarm -W11:2 4.6 4.6 -X1:48 4.6
-W12
Signals To ECR Panel -W12:-1 4.1 4.1 -X1:24 4.1
Document: E1995-02 Date: 30.11.2012

Drawing: E1995-02

-W14
Steering Control -W14:1 2.2 2.2 -X1:18 2.2
-W15
Signals To WH Panel -W15:1 3.6 3.6 -X1:5 3.6
Signals To WH Panel -W15:-4 4.1 4.1 -X1:24 4.1
-W16
Valve Block Sensor Port -W16:1 Black 4.5 -S6:4 4.5 -X1:55 4.5
Valve Block Sensor Port -W16:2 Brown 4.5 -S6:1 4.5 -X1:56 4.5
Valve Block Sensor Port -W16:3 Blue 4.5 -S6:3 4.5 -X1:57 4.5
Document: E1995-02 Date: 30.11.2012

Drawing: E1995-02
-W17
Valve Block Sensor Stb. -W17:1 Black 4.6 -1:4 4.6 -X1:58 4.6
Valve Block Sensor Stb. -W17:2 Brown 4.6 -1:1 4.6 -X1:59 4.6
Valve Block Sensor Stb. -W17:3 Blue 4.5-6 -1:3 4.6 -X1:60 4.5
-W19
To VDR -W19:1 5.2 5.2 -X1:79 5.2
To VDR -W19:2 5.2 5.2 -X1:80 5.2
To VDR -W19:3 5.2 5.2 -X1:81 5.2
To VDR -W19:4 5.2 5.2 -X1:82 5.2
To VDR -W19:5 5.3 5.3 -X1:83 5.3
To VDR -W19:6 5.3 5.3 -X1:84 5.3
To VDR -W19:7 5.3 5.3 -X1:85 5.3
To VDR -W19:8 5.3 5.3 -X1:86 5.3
To VDR -W19:9 5.3 5.3 -X1:87 5.3
To VDR -W19:10 5.3 5.3 -X1:88 5.3
To VDR -W19:11 5.4 5.4 -X1:89 5.4
To VDR -W19:12 5.4 5.4 -X1:90 5.4
-W20
Bypass Valve -W20:1 2.1 -Y1:A1 2.1 -X1:9 2.1
-W23
External Run Signal -W23:1 3.3 3.3 -X1:70 3.3
-W24
To Autopilot -W24:1 3.2 3.2 -X1:3 3.2
To Autopilot -W24:2 3.3 3.3 -X1:4 3.3
Document: E1995-02 Date: 30.11.2012

Drawing: E1995-02
-W25
440V Supply -W25:1 3.1 3.1 -Q1:1 3.1
440V Supply -W25:2 3.1 3.1 -Q1:3 3.1
440V Supply -W25:3 3.1 3.1 -Q1:5 3.1
-W26
Essensial Supply 220V -W26:1 4.6 4.6 -X1:22 4.6
Essensial Supply 220V -W26:2 4.6 4.6 -X1:23 4.6
Document: E1995-02 Date: 30.11.2012

Drawing: E1995-03
External connection table

S-1995 - JIANGSU HANTONG SHIPYARD HN: HT57-126 - STARTER PORT
-W10
-W30
Motor -W30:-1 3.1 -M1:U1 3.1 -F0:2 3.1
Motor -W30:-2 3.1 -M1:V1 3.1 -F0:4 3.1
Motor -W30:-3 3.1 -M1:W1 3.1 -F0:6 3.1
-W31
Motor -W31:-1 3.1-2 -M1:V2 3.1 -K10:2 3.2
Motor -W31:-2 3.1-2 -M1:U2 3.1 -K10:4 3.2
Motor -W31:-3 3.1-2 -M1:W2 3.1 -K10:6 3.2
-W32
Heating Motor -W32:1 3.4 3.4 -X2:1 3.4
Heating Motor -W32:2 3.4 3.4 -X2:2 3.4
-W33
Filter -W33:1 4.3 1:1 4.3 -X2:49 4.3
Filter -W33:2 4.3 1:2 4.3 -X2:50 4.3
Document: E1995-03 Date: 30.11.2012

Drawing: E1995-03
-W34
-W35
-W36
-W37
-W38
-W39
-W41
Ext. Com. Alarm -W41:1 4.5 4.5 -X2:47 4.5
Ext. Com. Alarm -W41:2 4.6 4.6 -X2:48 4.6
Document: E1995-03 Date: 30.11.2012

Drawing: E1995-03
-W42
Signels To ECR Panel -W42:-9 4.3 4.3 -X2:36 4.3
-W44
-W45
Document: E1995-03 Date: 30.11.2012

Drawing: E1995-03
-W46
Valve Block Sensor Port -W46:1 Black 4.5 -S6:4 4.5 -X2:55 4.5
Valve Block Sensor Port -W46:2 Brown 4.5 -S6:1 4.5 -X2:56 4.5
Valve Block Sensor Port -W46:3 Blue 4.5 -S6:3 4.5 -X2:57 4.5
-W47
Valve Block Sensor Stb. -W47:1 Black 4.6 -1:4 4.6 -X2:58 4.6
Valve Block Sensor Stb. -W47:2 Brown 4.6 -1:1 4.6 -X2:59 4.6
Valve Block Sensor Stb. -W47:3 Blue 4.5-6 -1:3 4.6 -X2:60 4.5
-W49
To VDR -W49:1 5.2 5.2 -X2:79 5.2
To VDR -W49:2 5.2 5.2 -X2:80 5.2
To VDR -W49:3 5.2 5.2 -X2:81 5.2
To VDR -W49:4 5.2 5.2 -X2:82 5.2
To VDR -W49:5 5.3 5.3 -X2:83 5.3
To VDR -W49:6 5.3 5.3 -X2:84 5.3
To VDR -W49:7 5.3 5.3 -X2:85 5.3
To VDR -W49:8 5.3 5.3 -X2:86 5.3
To VDR -W49:9 5.3 5.3 -X2:87 5.3
To VDR -W49:10 5.3 5.3 -X2:88 5.3
To VDR -W49:11 5.4 5.4 -X2:89 5.4
To VDR -W49:12 5.4 5.4 -X2:90 5.4
-W50
-W53
Document: E1995-03 Date: 30.11.2012

Drawing: E1995-03
-W54
Autopilot Supply -W54:1 3.2 3.2 -X2:3 3.2
Autopilot Supply -W54:2 3.3 3.3 -X2:4 3.3
-W55
440V Supply -W55:1 3.1 3.1 -Q1:1 3.1
440V Supply -W55:2 3.1 3.1 -Q1:3 3.1
440V Supply -W55:3 3.1 3.1 -Q1:5 3.1
-W56
Essensial 220V Supply -W56:1 4.6 4.6 -X2:22 4.6
Essensial 220V Supply -W56:2 4.6 4.6 -X2:23 4.6
-W82
Black Out Signal From Emergency -W82:1 4.6 4.6 -X2:77 4.6
Generator
Black Out Signal From Emergency -W82:2 4.6 4.6 -X2:76 4.6
Generator
Document: E1995-03 Date: 30.11.2012

APPENDIX D
CERTIFICATES
APPENDIX E
SPARE PARTS
Page 1 of 2
PORSGRUNN STEERING GEAR AS
SPARE PARTS LIST FOR: STEERING GEAR ACTUATOR This drawing (print) and/or specification is (are)
our property and is (are) not to be used or
disclosed for any third person.
DRAW NO.: S-13752

PORSGRUNN STEERING GEAR, TYPE: 425-80/2 B.no. Gr.no.
HANTONG SHIPYARD
Total Number Item Name Type Dim. Code no. Comments
number pr. unit no.
11 1 Cover 013-005-15
11 2 Expansion tank 019-510-70
11 3 Level indicator 084-005-10
1 1 4 Low level switch 084-146-00

16 16 5 Screw for brackets, M10x25 044-025-00
2 2 6 Rudder indicator scale 033-013-00

1 1 7 Mechanical rudder angle indicator S-13500
1 1 8 Hexagon screw ” ”
2 2 9 Hexagon nut ” ”
4 4 10 Split pin, ø3x15 ” ”
3 3 11 Washer, M10 ” ”
3 3 12 Screw, M10x30. ” ”
1 1 13 Washer Ø105 for exp. tank 033-008-20
11 14 Shaft seal 062-028-50
5 5 15 Screw for rudderstock shaft 044-038-00

1 1 16 Ring piston for pull-up 085-015-45
11 18 Upper bearing 030-033-02
1 1 19 O-ring for cover 060-264-20

88 20 Screw, M16x50 044-062-00
44 21 Non-return valve 081-080-00

8 2 22 Nut for staybolt, M64x4 038-032-00
4 1 23 O-ring for staybolt 060-111-00
1 1 24 O-ring for housing 060-300-30
36 36 25.1 Sock. Bolts for cover, M30x130 044-100-10
22 25.2 Sock. Bolts for cover, M30x110 044-100-00
4 2 26 Plug for stopper, 1” 056-007-00
11 27 Rudderstock - Yard delivery
11 28 Rudder carrier 030-056-05
1 1 29 Sealing for lower packing gland 061-023-50
1 1 30 Lower packing gland 011-531-15
.
Page 2 of 2
PORSGRUNN STEERING GEAR AS
SPARE PARTS LIST FOR: STEERING GEAR ACTUATOR This drawing (print) and/or specification is (are)
our property and is (are) not to be used or
disclosed for any third person.
DRAW NO.: S-13752

PORSGRUNN STEERING GEAR, TYPE: 425-80/2 B.no. Gr.no.
HANTONG SHIPYARD
Total Number Item Name Type Dim. Code no. Comments
number pr. unit no.
12 2 31 Nut for studbolt, M20 042-011-00

66 32 Studbolt, M20x110 041-018-10
11 33 Housing 012-005-11
11 34 Lower bearing 030-010-10
42 35 Staybolt 029-012-00
4 1 36 O-ring for staybolt 060-111-00

4 4 37 Drain plug, M20x40 044-079-00
4 4 38 Bonded seal for drain plug, M20 063-005-00
2 4 39 O-ring for stoppers 061-009-00
22 40 Mechanical stopper 010-017-05 2x36º

1 1 41 Sealing ring 031-100-03 Incl. lip seal
4 2 42 Sealing bar for stoppers - S-21762

1 1 44 Tab washer - Yard delivery
4 4 45 Screw for tab washer - Yard delivery
2 2 46 Securing wire for tab washer - Yard delivery

12 6 48 Sealing bar for rotor - Item 1-3, S-
21762
288 288 49 Spring for sealing bars 034-002-00
11 50 Rotor 010-005-19 Ø425mm
4 4 51 Electrical limit switch 232-014-00
2 2 52 Arrow for rudder angle scale 033-010-01
2 2 53 Connection for drain pipe, ½” 052-010-00

1 1 54 Connection assembly for storage tank, 1” -
22 55 Manometer 084-001-00
22 56 Manometer valve 054-020-00
2 2 57 Air vent valve 084-041-12
2 2 58 Connection assembly for expansion line, 2” -
2 2 59 Cam for limit switch 033-004-50
11 60 Filling cap 082-026-00
.
S30808A/instr/. doc
page 1 of 1
LIST FOR: POWER UNIT w/ RETURN FILTER This drawing (print) and/or specification is (are) our
IN-AGB3-500 property and is (are) not to be used or disclosed for any
third person.
DRAW NO.: S-30808B
Date: Constr. Contr.: Trac:

19.02.04
BP
rev. 16.08.96
SPARE PARTS LIST B.no. Gr.no.
PORSGRUNN STEERING GEAR 036

TYPE: 425-80/2
HANTONG SHIPYARD
Att: Dwg. no.:
Repl. for: S-40361
Total Number Item no. Name Type Dim. Matr. / DR.STD Article no.
number pr. unit
2 1 1 PUMP TANK 024-502-30

2 1 2 BONDED SEAL -
2 1 3 PLUG 056-004-00
2 1 5 SCREW PUMP, L3ME 52/85 SEE S-40650
24 12 6 SOCKET SCREW 044-041-00
2 1 7 O-RING 060-257-70
12 6 8 STUDBOLT 041-011-00
12 6 11 SOCKET SCR. 044-039-00
4 2 12 SECURING SCREW, TREADED PIN -
2 1 13 COUPLING INSERT 072-010-00
2 1 15 ELECTRIC MOTOR, 14BG 183-2 070-107-50
8 4 16 HEX. SCREW 047-088-00
2 1 17 FLEXIBLE COUPLING, COMPLETE 072-023-12
2 1 18 PUMP HOUSING 014-005-00
2 1 19 CONN. FOR EXP. PIPE -
2 1 20 FILTER COMPLETE, IN-AGB3 500 SEE S-40638
2 1 27 BONDED SEAL -
2 1 28 FILTER INDICATOR 082-020-00
2 1 29 LOW LEVEL SWITCH 084-145-00
Porsgrunn Steering Gear, Safety First
For safe operation of your Vessel - Steering Gear, following Parts

are recommended to be kept on board at any time :
1 off. Cartridge Pump

2 off. Solenoids For Pilot Valve
2 off. Filter Cartridge For Pump Tank
1 off. Seal Set For All Hydraulic Valves
1 off. Seal Set For Cartridge Pump
1 off. Complete Coupling For Electric Motor And Cartridge Pump
2 off. Flexible Elements For Coupling
1 off. O-Ring Sealing For Top Cover - Expansion Tank
1 off. Set Seal For Hydraulic Pipes
1 off. Set Ball Bearings For Electric Motor
1 off. Main Contactor For Starter
1 off. Power For Pilot Valve
1 off. Sensor For Valve Block
1 off. Pressure Gauge
1 off. Set Light Bulbs And Fuses
Please Note !
When enquiring or ordering, please confirm following :
- Vessel name
- Steering Gear serial no.
- Description or Art. no. of Parts
- Drawing no. and Pos. No.
Porsgrunn Steering Gear Safety First RES 002.doc

07.02.03
CHECK LIST - STEERING GEAR
ROUTINE ACTIVITY DATE DATE DATE DATE DATE DATE DATE DATE DATE DATE DATE DATE
CHECK
ONBOARD
MAINTENANCE
EMERGENCY
DRILL
FUNCTION
TEST
ALARM TEST
MECHANICAL
CONTROL
ADJUSTMENT
SAFETY VALVE
ADJUSTMENT
INDICATORS
OTHER
OIL SYSTEM ACTIVITY DATE REMARK DATE REMARK DATE REMARK DATE REMARK
TEST
FILTERS
TYPE OF OIL
OIL TEST
FILTERS
CLEANED /
RENEWED
OIL
CHANGED
OTHER
SERVICE ACTIVITY DATE DATE DATE DATE DATE DATE

OVERHAUL
REPAIR
GENERAL
SERVICE
REPAIRS
RUDDERST.
REMOVAL
SPARE
PARTS
TYPE ORDER DEL TYPE ORDER DEL

Owner's Manual For Porsgrunn Rotary Vane Steering Gear S-1995

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Owner's Manual For Porsgrunn Rotary Vane Steering Gear S-1995

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OWNER’S MANUAL

Jiangsu Hantong Shipyard

ANNEX A – TECHNICAL SPECIFICATION

Owners’ Manual July 2012 2

Owners’ Manual July 2012 3

Owners’ Manual July 2012 4

CONTROL AND INDICATION

PORT VALVE BLOCKS STARBOARD

Figure 2.1 Porsgrunn Rotary Vane Steering Gear System

Owners’ Manual July 2012 5

Pilot valve Rudder stock nut

Valve block Hydraulic ring piston

Foundation bolt Upper bearing

By-pass valve Rotor

Relief valve Lower bearing

Figure 2.2 Steering Gear Actuator

Owners’ Manual July 2012 6

2.3 Hydraulic System

2.3.1 Hydraulic power units

Owners’ Manual July 2012 7

2.3.2 Directional Valve Block

Figure 2.3 Directional Valve Block

2.3.3 Relief Valve Block

Figure 2.4 Relief Valve Block

Owners’ Manual July 2012 8

2.4.2 Starter cabinets

2.4.3 Control and indication panels

Owners’ Manual July 2012 9

3.2 Rudder fall-off, Follow-up/Autopilot (FU) and non-Follow-up

3.3 Operation from bridge

Owners’ Manual July 2012 10

Table 3.1 Control Button Description

Pressing the button will start the hydraulic power

Pressing the button will stop the hydraulic power

Pressing the button will start the stand-by/auto

Pressing the Auto Off button will disable the stand-

Owners’ Manual July 2012 11

Pressing the lamp test button will engage lamps in all

Pressing the dimmer up button will increase the lamp

Pressing the dimmer down button will decrease the

Pressing the Acknowledge button during an alarm

Table 3.2 Indication lamp description

A white lamp will light when the steering control is

A blue light shows that the hydraulic power unit is in

3.3.1 Normal operation

Start of hydraulic power unit

Stop of hydraulic power unit

Owners’ Manual July 2012 12

Owners’ Manual July 2012 13

A red lamp will light when there In Auto On mode:

A red lamp will light for one of

A red lamp will light when the

A red lamp will light when a fail

Owners’ Manual July 2012 14

No combination of failures and / or alarms will automatically stop all hydraulic

3.4 Surveillance from engine control room

3.5 Operation from steering gear room

Pilot for main spool

Pilot for idling valve

Figure 3.2 Hydraulic valve block

Owners’ Manual July 2012 15

3.5.1 Operation from the starter cabinet

Table 3.4 Starter cabinet control switch description