Steering Gear

USER MANUAL
Rolls-Royce Steering Gear

Mechanical/ Hydraulic system
Yard : SPP Shipbuilding Co., Ltd.

Hull no. : H4098, H4099
RR project no. : 13S000193, 13S000194
Revision :A
Date : 13.Aug.2014
TABLE OF CONTENTS
1 INTRODUCTION ......................................................................................3
1.1 Purpose ........................................................................................................................3
1.2 Warranty.......................................................................................................................3
1.3 Structure of this manual ................................................................................................3
1.4 Abbreviations ................................................................................................................4
2 SAFETY ...................................................................................................5
2.1 General statement ........................................................................................................5
2.2 Safety Annotations........................................................................................................6
2.3 Declaration of conformity ..............................................................................................6
3 SYSTEM DESCRIPTION .........................................................................7

3.1 System overview...........................................................................................................7
3.2 Design ..........................................................................................................................8
3.2.1 Rudder Actuator............................................................................................................9
3.2.2 Power Pack ................................................................................................................ 10
3.2.3 Rudderstock Connection ............................................................................................. 12
3.2.4 Hydraulic Nut .............................................................................................................. 12
3.2.5 Foundation ................................................................................................................. 12
3.2.6 Stuffing Box ................................................................................................................ 13
3.3 Function ..................................................................................................................... 14
3.3.1 Control Valve .............................................................................................................. 15
3.3.2 Safety Relief Valve ..................................................................................................... 18
4 DELIVERY SPECIFICATIONS ...............................................................19

4.1 Scope of supply .......................................................................................................... 19
4.1.1 General ...................................................................................................................... 19
4.1.2 Steering Gear ............................................................................................................. 19
5 TECHNICAL DATA ................................................................................21

5.1 Oil recommendations .................................................................................................. 23
5.2 Standard paint specification ........................................................................................ 24
6 OPERATING INSTRUCTION .................................................................25

6.1 Normal operation - Remote control.............................................................................. 25
6.2 Emergency operation - Local control ........................................................................... 26
6.3 Alarm condition ........................................................................................................... 27
7 MAINTENANCE INSTRUCTION ............................................................28

7.1 Maintenance overview ................................................................................................ 29
7.2 Routine maintenance .................................................................................................. 30
7.3 Oil sampling................................................................................................................ 31
7.4 Filling/refilling of oil ..................................................................................................... 33
7.5 Venting ....................................................................................................................... 35
7.6 Filter element replacement.......................................................................................... 37
7.7 Replacement of flexible coupling in Pump Unit ............................................................ 40
7.8 Cleaning of the Water Oil Cooler ................................................................................. 41
7.9 Creeping test .............................................................................................................. 42
Rolls-Royce Steering Gear User Manual Page 1 of 49

Yard: SPP Hull no: H4098, H4099 Project no: 13S000193, 13S000194 Revision: A Date: 13.Aug.2014
8 TROUBLE SHOOTING ......................................................................... 43
8.1 Power pack................................................................................................................. 43
8.2 Rudder actuator .......................................................................................................... 43
9 SPARE PARTS ..................................................................................... 46
10 CONTACT LIST .................................................................................... 47
11 DESIGN DRAWINGS ............................................................................ 48
12 REVISION .............................................................................................. 49
Page 2 of 49 User Manual Rolls-Royce Steering Gear

1 INTRODUCTION
1.1 Purpose
This manual describes operation and maintenance procedures required on board for the Rolls-
Royce Steering Gear. Always make the manual available to the technical staff.
The manual includes general information about the Rolls-Royce Steering Gear product line, as well
as project specific information and technical data.
The User manual provides the information necessary to operate and maintain the Rolls-Royce
Steering Gear system safely and correctly
1.2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is
misused or not handled in accordance to prescribed standards, for example dismantling the
equipment to a level greater than described.
1.3 Structure of this manual

Chapter 3 of this manual contains a system description of the Steering Gear and its main
components.
Chapter 4 and 5 provides project specific information, including scope of supply and technical data
of the system.
Chapter 6 contains instructions for operating the Steering Gear system.
Chapters 7 and 8 describe relevant maintenance procedures and a diagram for trouble shooting.
Chapter 9 contains Rolls-Royce Marine contact details.
Note!
All illustrations in this manual are for illustration only.`

1.4 Abbreviations
Abbreviation Description
C Degrees Celsius (temperature)
cSt Centistokes (oil viscosity)
CCW Counter clockwise (rotational direction)
CW Clockwise (rotational direction)
Hz Hertz (frequency)
kg Kilogram (weight)
kW Kilowatt (power)
l/min Liters per minute (flow)
mm Millimeters (length)
rpm Revolutions per minute (rotation speed)
V Volt (voltage)
Amp Ampere (electric current)

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

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

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

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

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

Rolls-Royce Steering Gears are designed and built as per the following standards according to
existing requirements from:
IMO
SOLAS
The Steering Gears are also designed according to requirements by the following classification
societies:
Det Norske Veritas (DNV).

American Bureau of Shipping (ABS).
Lloyds Register (LR).
Germanisher Lloyds (GL).
Bureau Veritas (BV).
Registro Italiano Navale (RINA)
Nippon Kaiji Kyokai (ClassNK)
China Classification Society (CCS)
Russian Maritime Register of Shipping (RS)
Korean Register of Shipping (KR)
A Class Certificate is issued for each Steering gear in accordance with the Class of the vessel.

3 SYSTEM DESCRIPTION
The purpose of this section is to give a better understanding of the Steering Gear and its main
components.
3.1 System overview
The Rolls-Royce Steering Gear on this vessel is composed of one hydraulic rudder actuator
mounted directly on the rudder stock, served by a power pack delivering the necessary oil flow for
operating the rudder.
The power pack consists of two pump units which may be operated together or separately. Each
pump unit will provide oil with sufficient flow to develop the specified rudder angle. When cruising at
sea, only one pump unit is normally in operation, while the other is acting as a stand-by unit, but
when the shortest possible steering time is required, it is possible to run both pump units
simultaneously and thereby doubling the turning rate.
The pump units are for normal operation remotely controlled, but for emergency situations they
may be operated manually from the steering gear room.

3.2 Design
The main components of the Steering Gear are shown in the illustration below:
Pos. Steering Gear Chapter

1. Rudder actuator 3.2.1
2. Valves 3.2.1.1, 3.2.1.2
3. Power Pack 3.2.2
4. Pump units 3.2.2.1
5. Oil tank 3.2.2.2
6. Oil cooler 3.2.2.3
7. Filter 3.2.2.4
8. Rudderstock connection 3.2.3
9. Hydraulic nut 3.2.4
10. Foundation (yard supply) 3.2.5
11. Stuffing box (yard supply) 3.2.6

3.2.1 Rudder Actuator
The Rudder actuator main components are:
Rotor [1]
Rotor housing [2]
Top cover [3]
The rotor, turning in bearings at top and

bottom, is equipped with vanes upon which
the oil pressure is acting and thereby
developing the turning torque. The turning
movement is limited by stoppers fixed to the
housing.
The stoppers also act as mechanical rudder

stoppers in hard-over position. In addition to
the stoppers, the actuator is equipped with
electrical limit switches stopping the turning
movement at the predetermined angle.
The rudder carrier bearing of the actuator has

sufficient capacity to carry the full weight of
rudder, rudderstock and rotor, eliminating the
need for a separate rudder carrier bearing.
The bearing is lubricated by the system oil.
The sealing system consists of synthetic oil

resistant material resting in seal grooves. The
sealing system prevents both internal and
external leakage from happening.
3.2.1.1 Control Valve
The control valves [1] are mounted on the

rudder actuator.
Steering is normally remotely operated from
the bridge. When steering signal is given to
the solenoid valve [2], the control valve will be
activated according to command and rudder
movement initiated.
The valve incorporates an automatic lock

valve. If there should be a loss of oil pressure
due to possible external failures, the lock
valve will close immediately and keep the
rudder actuator intact for operation by means
of the stand-by pumps.
The valve is also equipped with a safety relief

valve. If the maximum working pressure is
exceeded, the relief valve opens and excess
oil is directed directly to the return channel.

For emergency operation, the solenoid valves
are equipped with push button controls which
make it possible to operate the steering gear
from the steering gear room. For easy use
there are steering handles [3] mounted on the
valve.
3.2.1.2 Safety Relief Valve
A safety relief valve is mounted on the rudder

actuator protecting against excessive external
pressure transmitted from the rudder.
3.2.2 Power Pack
3.2.2.1 Pump Unit
The power pack consists of two individual

pump units. Main components for each unit
are:
Electric motor [1]

Flexible coupling inside the bell house [2]
Pump [3]
The pumps are submerged in the oil tank;

each pump will provide oil with sufficient
pressure to develop the specified rudder
angle. The two pump units may be operated
together or separately.
Only one pump unit is in operation normally

while the other is acting as a stand-by unit. It
is recommended to change pump unit in
operation at regular intervals. During
maneuvering of the vessel, when the shortest
possible steering time is required, it is
possible to run both pump units
simultaneously thereby doubling the rudder
turning rate.

3.2.2.2 Oil Tank
The oil tank is divided into chambers; one for

each pump unit, and one for the integrated
storage tank. The oil tanks main components
are:
Low oil level alarm switch [1]

Hand pump [2] for re-filling of oil from
storage tank to the oil tank. (Electrical oil
pump optional)
Breather filter with dipstick [3]
Breather filter for integrated storage tank
(hidden behind electro motor)
Level gauge [4] for storage tank
Manhole [5]
Thermometer [6] (optional)
Heating element [7] (optional)
Manifold [8]
3.2.2.3 Click here to enter text.Oil Cooler
To keep the oil temperature to an acceptable

level, parts of the return oil is directed through
a water oil cooler [1] for heat transfer
The cooler assembly is fitted with a closing

valve [2] on the water inlet side and a non -
return valve [3] on the water outlet side.
A high temperature alarm switch [4] is

installed, and an alarm is given if the oil
temperature exceeds 70C.
Note!
Only fresh water to be used
3.2.2.4 Filter
Depending on pump capacity one or two full

flow return line filters are mounted on the
power pack for each pump unit, to prevent
contaminated oil from leaking back into the
system.
The filters are installed with an electrical

clogged filter alarm switch [1] which is
providing an alarm on the alarm panel if the
differential pressure exceeds a preset limit.
The filter is equipped with a bypass function

letting oil pass by if the oil pressure within the
filters exceeds 1.5 Bar.

3.2.3 Rudderstock Connection
The rudderstock and the rudder actuator are

connected by means of a keyless taper
fitting.
3.2.4 Hydraulic Nut

The hydraulic [1] nut is used during the
hydraulic pull-up of the rudderstock. After the
equipment has been installed, the hydraulic
nut and the lock plate [2] act as a safety
device in way of securing the rudderstock
connection.
3.2.5 Foundation
Note!
The foundation is the Ship yards
responsibility
Manholes to be made in foundation (ref

General Arrangement drawing) for easy
access during maintenance or overhauling of
Steering Gear.
The rudder actuator to be fixed to the

foundation with welded stoppers, foundation
bolts and steelchocks, as illustrated in the
picture

3.2.6 Stuffing Box
Note!
The stuffing box is the ship yards
responsibility
The Stuffing box is mounted to the

rudderstock. It consists of a high grade
sealing system which acts as a seal between
the steering gear room and the sea water.

3.3 Function
The rudder actuator is divided into chambers by rotor vanes [1] and stoppers [2] fixed to the
housing. Depending on the rudder command signals to the solenoid(s) on the control valve(s) the
oil flow will be directed to either the red or blue chambers illustrated. The oil pressure against the
rotor vanes letting the rudder stock which are fixed to the rotor turn in the direction corresponding
to the signal. When the selected rudder position is reached, the automatic lock valve will block the
position of the rudder.
The internal stoppers act as mechanical rudder stopper. During maneuvering the rudder will be
limited by electrical end switches.

3.3.1 Control Valve
The control valve consists of

the following internal valves:
Solenoid valve [1]

Safety relief valve [2]
Control (main) valve [3]
By-Pass valve [4]
Lock valve [5]
Pump running, no steering

signal:
When no steering signal is

given, the solenoid valve
spindle and main spool are
kept in center position, and the
lock valve is kept closed by
spring loads.

Beginning of steering
(modulated flow):
Steering is carried out by

operating the solenoid valve.
The illustration shows the
beginning of the steering
process, when the right
solenoid is operated. The
main spool will be pushed
over to the right side, by the oil
pressure in the left chamber.
The control valve is now at the

beginning of its stroke. Some
of its oil flows through the
throttling slots to the lock
valve, which begins to open
on both sides; any overflow is
by-passed at the by-pass
valve back to the suction side
of the pump. The gradually
increasing oilflow directed to
the actuator will give a soft
start.

Steering:
After approximately one

second, the main spool is
moved over to its end position,
and the by-pass valve is
closed as illustrated. The oil-
flow from the pump has now
free passage from channel (1)
into pipe (B) leading to the
lock valve which is now fully
open. The return oil from the
Steering gear flows through
pipe (A) and has free passage
to channel (2) and back to the
suction side of the pump.
Relief valve:
When oil pressure (C),

exceeds the preset value of
the valve spring load, the
safety relief valve will open as
illustrated. The pressure oil
will flow to channel (2) and the
pressure behind the by-pass
valve will drop. Now the by-
pass valve will open, allowing
the oil (D) to flow to the return
channel (2).

3.3.2 Safety Relief Valve
The valve is designed as

double acting relief valve with
one main piston [1], two
adjustable spring loaded pilots
[2], and two check valves [3]
Normal operation:
The valve is positioned on the

actuator exterior with holes
connected to pressure and
return side of the dividing walls
For normal operation the valve

is kept in locked position, and
the pressure and return
chambers are isolated.
Safety relief valve opens:
The valve will open in the case

when the external load on the
rudder exceeds the setting
value of the relief valve.
Allowing the pressure side to
be relieved to the return
chamber. At the same time the
rudder will move until the load
has reached a level below the
setting value, and the valve will
close. Normal operation is
continued.

4 DELIVERY SPECIFICATIONS
This chapter contains delivery specifications defined by the Rolls-Royce Marine sales
representative in agreement with the customer.
4.1 Scope of supply
4.1.1 General
Technical documentation
Dimension drawings, hydraulic diagram, electrical diagram and technical data for the steering gear
system will be delivered, together with 1 soft copy and 3 hard copies of both the
mechanical/hydraulic and the electrical user manual. All documentation will be delivered in English
language.
4.1.2 Steering Gear
Note!
The scope of supply for one Steering Gear is given below; if two steering gears are delivered the
quantity is to be doubled
1 pc. Hydraulic rudder actuator consisting of:

House, rotor and cover(s) made from ductile iron.
Taper bored rotor with vanes.
Sealing made of first class oil resistant material.
Internal rudder stoppers.
Safety relief valve.
Pressure gauges.
Main control valve with 24V solenoid operated pilot valve for connection to
electric steering/ autopilot. Flanges for welding: SAE 3000 psi.
Modulated flow control system for smooth steering and accurate course
keeping. This ensures soft start and reduces the hydraulic peak pressure.
Manual emergency steering control.
Automatic lock-valves which close automatically if an oil leakage should occur.
Mechanical rudder angle indicator.
The actuator is designed for hydraulic mounting on a tapered rudderstock
without key and key way. (Class approval provided). Grooves for oil injection to
be made in rotor
Rudder carrier bearing integrated in the actuator (no other carrier is necessary).
Prepared for installation with welded stoppers and steelchocks.
Thrust ring measuring device
Lifting devices
1 pc. Electro hydraulic power pack consisting of two independent pump units mounted
on a two-compartment tank with storage tank included, each with:
Submerged hydraulic screw pump.
Full flow return filter with clogged filter alarm .
Air breather and dip stick.
Flanges for welding: 3000 psi.
Marine type electric motor.
Flexible coupling between pump and electric motor.
Fresh water oil cooler.
Sensor for high oil temperature alarm
Low oil level alarm switch
Hand pump for refilling of oil from integrated storage tank
Thermometer
Lifting devices
1 pc. Hydraulic nut
For pull-up and locking of rudderstock to steering gear.
1 set Pipes
Pipes for 2 inch SAE welding flanges, 4x 6 meters.
Pipe parts for 2 inch pipes.
Leak oil pipe.
1 set. Foundation bolts
Foundation bolts for actuator
1 pc. Arrangement for external feedbacks
For 3 external units (customer supply).
Spare parts
For spare parts see attached spare part list

5 TECHNICAL DATA
This chapter contains project specific data, and similar relevant information.
Steering Gear
Type RV1350-3
Class LRS
Rudder actuator
Effective torque [kNm] 1230
Max working pressure [bar] 80
Allowable axial load [kN] 700
Allowable radial load [kN] 1800
Rudder stock diameter [mm] 450
Max. mechanical rudder angle [] 2x46.5
Max. electrical rudder angle [] 2x45.0
Additional electrical rudder angle limitation [] 2x35.0
Steering time at 30 0 - 35 with one pump unit in 28
line [s]
Steering time at 30 - 0 - 35 with two pump units in 14
line [s]
Oil volume [L] See General Arrangement
drawing
Weight without oil [kg] See General Arrangement
drawing
Power Pack
Pressure Pump type L3MF 52/104 3500
Relief valve setting [bar] 80
Test pressure [bar] 120
Pump capacity* [L/min] 430
Oil volume of working tank [L] See General Arrangement
drawing
Oil volume of integrated storage tank [L] See General Arrangement
drawing
Weight without oil [kg] See General Arrangement
drawing

Electric motor Unit1/ (Unit2)
Power (S1) [kW] 43
Current (IN) [A] 67
Starting current (IS) [A] 442
Rotational speed (rpm) 3500
Voltage (V) 3x440-460
Frequency (Hz) 60
Type M3AA 200 MLB-2
Protection IP55
Design B5
Insulation class F
Heating element [V] 240
Weight each/total [kg] See General Arrangement
drawing
Water oil cooler

Type B1030
High temperature alarm [C] 70
Max inlet water temperature [C] 36
Max water working pressure [bar] 15
Min water pressure drop over cooler [bar] 0.1
Min water flow rate [l/min] 25
Cooling capacity [kW/C] ~ 0.5
Component Color
Panels : RAL 9011
Cabinets : RAL 7035
Electric motor : Munsell 7.5BG 7/2
Rudder Actuator : Munsell 7.5BG 7/2
Power Pack : Munsell 7.5BG 7/2

5.1 Oil recommendations
. Warning
Using oil other than specified by Rolls-Royce Marine may cause malfunctions
when maneuvering the vessel. This may cause personal injury and equipment
damage. Before using other brands, please contact Rolls-Royce Marine.
Do not mix hydraulic oils
Note!
Performance of the Steering Gear is highly dependent on the viscosity of the hydraulic oil.
When choosing oil for the hydraulic equipment, it is important that the temperature
conditions where the equipment is to be operating are considered.

Oil temperature must be limited to 70 C.
For vessels operating worldwide, we recommend oil according to ISO-VG 68. Viscosity
Index of minimum 110.
The following hydraulic oils are approved and recommended by Rolls Royce Marine:
Viscosity Kinematic Viscosity (cSt) Pour point

Manufacturer Oil type Index
0oC 40oC 100oC [oC]
BP Energol bartran HV68 153 550 67 10,8 - 30

CASTROL Hyspin AWH-m 68 150 580 68 10,9 - 39
CHEVRON EP hydraulic oil 68HV 152 650 68 8,8 - 30
TOTAL Visga 68 155 700 73 11,7 - 36
ESSO Unvis N 68 155 560 66 10,7 - 36
GULF GulfSea Hydraulic HVI 148 - 68,9 - - 30
Plus 68
MOBIL Mobil DTE 10 Excel 68 156 - 68,4 11,17 - 39
NYNS Hydol 68 150 500 58 9,6 - 39
REGINOL Reginol AOR-68 110 830 64 8,5 - 30
SHELL Tellus T 68 161 500 64,2 10,9 - 42
TEXACO Rando HDZ 68 181 500 69 12,3 - 36
STATOIL Hydraway HVXA 68 172 - 62 11,0 - 39
For storage of hydraulic oil follow practice recommended from the relevant oil company. All
oil drums shall be stored in horizontal position, with oil cap below max level in drums.
For the hydraulic oil circulating in the Steering Gear, it is highly recommended to keep the
cleanliness within 20/18/15 according to ISO 4406-1999 (comparable to NAS 1638 or SAE
AS 4059 class 9). If oil cleanliness is no longer within the above limits, renew the filter
elements.
The oil must be checked regularly for contamination, and the relevant oil company and
Rolls-Royce recommendation for change of oil to be followed. Change the oil if
components in the hydraulic system have been broken down, if color or smell has changed
significantly, or when laboratory tests shows a change in the amount of additives, or a high
amount of insoluble particles in oil. If the water content exceeds 300ppm, use a separator
or similar for water removal.

5.2 Standard paint specification
The paint coating offers protection against corrosion under normal transportation, storage, and
outfitting periods.
The Steering Gear is painted according to the following specification:
Component Layer Type DFT [m]

Priming I
Interprime 306 50
(interior/exterior)
Priming II Intercure 202
Rudder actuator 75
(exterior) EPA233 / EPA240
Top coat Interlac 645,
50
(exterior) for color see technical data
Priming I
Intergard 269 40
(interior/exterior)
Priming II Intercure 202
Power Pack 75
(exterior) EPA 234 / EPA 240
Top coat Interlac 645,
50
(exterior) for color see technical data
Note!
The paint system Top Coat consists of a single component alkyd. This means that any
touch-up or repainting after delivery must be done with alkyd based paintings. Technical
data sheets for the paint systems are available at; http://www.international-pc.com
All surfaces to be coated should be clean, dry and free from contamination.
Prior to paint application all surfaces should be assessed and treated in accordance with
ISO 8504.

6 OPERATING INSTRUCTION
Warning
If any malfunction is detected when operating the Rolls-Royce Steering Gear, the
malfunction must be investigated and remedied. Operating a Rolls-Royce Steering
Gear with a malfunction in the control system or hydraulic system may cause
personal injury or equipment damage. Similarly, any malfunction that might occur
in the systems when the Rolls-Royce Steering Gear is in operation must be
remedied or the Steering gear taken out of service.
Caution!
Before operating the equipment, please see Chapter 2 for the General Statement, Safety and
Warnings instructions, and ensure that:
Nobody is working with the equipment before operating it.

The maintenance instructions (Chapter 7 and 8) are strictly followed.
The solenoid valve is disconnected during first-time start-up
6.1 Normal operation - Remote control

Note!
For technical reasons the pump units shall be running for approximately the same number
of working hours
There is no control system delivered with this installation, refer to manufacturers manuals
1. Connect power with the main switch located on the

motor controllers, and ensure that power is available.
2. Check that there are no alarms on the alarm panel
3. Set the selector switch located on the motor controller

to position 1 Remote control
4. Start one pump at the time. By pushing the run pump

push button [1] on the control panel. The green lamp
will be turned on.
5. Stop one pump at the time from the bridge, by pushing

the Stop Pump push button [2]. The red lamp will be
turned on.

6. Turn the selector switch on the motor controller to
position 2. Stop
7. Stop the power supply to the Steering gear by

switching of the main switch.
6.2 Emergency operation - Local control
Warning
When performing emergency operation, always be in contact with the bridge.
Note!
Only one of the pumps to be running
1. Connect power with the main switch located on the

motor controllers, and ensure that power is available.
2. Set the selector switch located on the motor controller

to position 3 Local control
3. The steering gear can now be operated manually from

the steering gear compartment, by using the red and
green handles as illustrated below.
4. When finished operating locally, turn the selector

switch on the motor controller to position 2 stop

5. Stop the power supply to the steering gear by
switching of the main switch
6.3 Alarm condition

In case an alarm condition is present for more than 3 seconds the buzzers are turned on and the
alarm lamp start to flash on both alarm panels independently.
1. Push the ACK button on the alarm panel once, to turn off the local buzzer. The alarm lamps
are still flashing.
2. Push the ACK button once more. If the alarm condition is still present, the local alarm lamps
go from flashing to steady light. If not, it is turned off.
Note!
If an alarm (other than low or low low oil level alarm) occurs for one of the pump systems,
the stand-by pump unit will be started automatically. The Auto Start indication light on the
control panel is turned on for about 3 seconds. The faulty pump system must be stopped
manually.
If both pumps are running, and an alarm (other than low or low low oil level alarm) occur on
both pump systems. Stop pump 1. If no response start pump 1 and stop pump 2. If still no
response, emergency steering to be performed from Steering Gear compartment.
When a pump has started due to automatic start, it is not possible to stop this pump before
the auto-start alarm light is turned off. If necessary the pump can be stopped by using the
selector switch on the starter in the steering gear room.

7 MAINTENANCE INSTRUCTION
This chapter describes relevant maintenance procedures and activities to be carried out at regular
intervals.
Warning
Never work alone when installing heavy components, even when using
secure lifting equipment such as lockable block and tackle. Most lifting
devices require two people, one to oversee to the lifting device and the
other to ensure that the components do not get caught and damaged.
Always wear protective goggles if there is a risk of splinters, grinding
sparks and splashes from acid or other chemicals. Eyes are extremely
sensitive and an injury to them can result in loss of sight.
Using hydraulic oil other than the one specified in this manual may cause
malfunctions when operating the equipment. This may cause personal
injury and equipment damage
Caution!
Most chemicals intended for the product (engine and gearbox oils, glycol, gasoline and
diesel), or the workshop (degreasing agent, paints and solvents) can be harmful to your
health. Read the instructions on packaging carefully! Always follow protective measures
such as using a protective mask, goggles, gloves etc. Ensure that other personnel are not
unknowingly exposed to harmful substances in the air that they breathe; ensure adequate
ventilation. Dispose used and excess chemicals according to instructions.
Ensure that the warning or information labels on the product are always visible. Replace
labels that are damaged or painted over.
Take care of the hydraulic oil when replacing parts in the hydraulic system. Any oil spillage,
even a small one, will cause environmental damage. Used filter elements and worn out
hydraulic oil should be disposed safely.
Note!
To avoid unexpected stops, we will emphasize the importance to maintain the equipment
on a regular basis.
Use spare parts supplied by Rolls-Royce Marine. Use of other than Rolls-Royce marine
approved spare parts will void the warranty and may result in system failure or reduced
lifetime.
For scheduled class survey, general overhaul or repair we advise to use Rolls-Royce
service engineers. This will limit the time of repair to a minimum and ensure continuous
safe operation.
It is requested that any failures or maintenance work on the equipment shall be reported to
Rolls Royce Marine dep. Steering Gear - Hagavik. By reporting failures and maintenance
work, an accurate equipment history can be maintained by Rolls-Royce. This history will be
continuously monitored and compared to other vessels with similar equipment. With this
information, we can provide better service, faster delivery of spare parts, and guidance for
preventive maintenance.

7.1 Maintenance overview
The following table lists maintenance procedures described in the following chapters. For further
assistance please contact Rolls-Royce Marine.
Procedures Condition Chapter
Routine maintenance See separate table 7.2
Oil sampling At regular intervals 7.3
Filling / refilling of oil Contaminated oil or external leakage 7.4
Venting Air in the system is causing noise and/or rudder 7.5

movement problems.
Filter element replacement Clogged filter 7.6
Replacement of the flexible Noise and vibration 7.7

coupling in pump unit
Cleaning of the water oil Reduced cooling capacity 7.8

cooler
Creeping test At regular intervals 7.9

7.2 Routine maintenance
Maintenance activities to be carried out by the ships crew at regular intervals:
Activity: How often:
D W M 6M 12M 24M
1 Visual check for external leakage, and control

X
that oil level in power pack is within min and max
2 Visual check of paint work and damages X
3 Functional test of steering modes from all

X
steering stations, normal and emergency mode.
4 Alarm system testing X
5 Visual check of the oil cooler X
6 Oil sampling X
7 Filter element replacement* X
8 Visual check of all components included in the

X
alarm, control and steering system.
9 Test operation of switches, contractors, cable

X
connection properties of the electric motor.
10 Local start of pump units directly from each motor

X
controller.
11 Steering time test, 30-0-35 deg. X
12 Creeping test X
*If a filter alarm or the filter indicator is in the red zone replace the filter element at the first possible occasion

7.3 Oil sampling
Spare parts Ref. no Special tools and test equipment Qty

None Sample bottle, min.200ml 2
Sampling hose 1
Container bucket 1
Reference documents Consumables Qty

None Linen rag As req.
Oil As req.
An oil sample test as described in this procedure shall be taken right before handover. A document
proving that the oil quality is within specification shall be available to Rolls-Royce service personnel
during commissioning.
1. Start one of the pump units by turning the selector

switch on the corresponding motor controller to
position 3 local control.
2 Let the pump unit run for at least five minutes.
3 Turn the selector switch on the motor controller to

position 2 Stop.
4 Unscrew an unused plug [1] in the return filter.
5 Connect a measuring hose (preferable with a

valve mounted on it) and make sure the other end
is secured in a bucket.
6 Again start the same pump unit by turning the

selector switch on the relevant motor controller to
position 3 local control.
7 Make sure the hose valve (if mounted) is

completely open, and let the pump run until you
are completely sure that the hose is flushed
thoroughly.
8 Fill a new and chemically pure sample bottle with

oil, min 200ml.
9 Close the sample bottle
10 Turn the selector switch on the motor controller to

position 2 Stop.
11 Disconnect the sampling equipment and mount

the plug.
12 Again start the pump unit and let it run for at least
one minute. This will make sure that any trapped
air will evacuate through the filter and into the
tank.
13 Manually move the rudder by using the red and

green steering gear handles as illustrated. If any
noise or steering problems are presented perform
the venting procedure as described in chapter
7.5.
14 Mark the bottle with AQM type and number, date,

oil type, sample taken by and how long used.
15 Repeat steps 1-14 for the opposite pump system.
16 Compare the oil sample with new oil. If color or

smell has significantly changed or there are
impurities in the oil, change the oil.
17 Send the oil samples to be examined

immediately.

7.4 Filling/refilling of oil
None Oil pump 1

10m mesh sized filter 1
Oil recommendations (ch.5.1) Hydraulic oil As req.
Note!
Ensure that the cleanliness of the new hydraulic oil is within what is recommended; 20/18/15
according to ISO 4406-1999 (comparable to NAS 1638 or SAE AS 4059 class 9). If the
cleanliness level cannot be stated, or is not within what is recommended, use a 10m mesh
sized filter, to filter the oil before filling it into the Steering Gear.

position 2 Stop.
2. Open the breathing filter [1] and fill oil into the oil
tank.
3. Open the venting plugs [2] on top of the rudder

actuator as illustrated.
4. Start the pump units by turning the selector switch

on the motor controller to position 3 Local control

5. Fill oil into the rudder actuator by operating the
handles on the control valve manually for a few
seconds.
6. Pay attention to oil level in oil tank and repeat the

procedure until the rudder actuator is filled up with
oil.

position 2 Stop.
8. Repeat the same procedure on the second pump

unit.
9. Oil level in oil tank to be within min and max
10. Perform the venting procedure, as described in

chapter 7.5.

7.5 Venting
None None
None None
1. Start the pump unit not connected to the leakage pipe

by turning the selector switch on the corresponding
motor controller to position 3 local control.
2. While the pump is idling, open the venting plugs [1]

one at a time and evacuate all air. Close the plugs
when oil is coming out.
Note!
Do not open the venting plugs more than 2-3 rotations
3. Manually move the rudder from hard over to hard over

a few times by using the handles on the control valve.
4. Loosen the leakage pipe coupling [2] and fill the pipe
connector with oil while turning the rudder.
5. While the pump is idling, open the venting plugs one

at a time and evacuate all air. Close the plugs when
oil is coming out.
Note!
Do not open the venting plugs more than 2-3 rotations
6. Stop the pump unit by turning the selector switch on

the motor controller to position 2 stop
7. Start the other pump unit (connected to the leakage

pipe), by turning the corresponding selector switch on
the motor controller to position 3 local
8. Repeat step 3 and 4 above
9. Vent the leakage pipe by turning the coupling 1-2

rotations
10. Repeat step 6 above
11. Stop the pump unit by turning the selector switch on

the motor controller to position 2 stop
Note!
The system shall now operate smoothly without noise. If
noise still exists, repeat the venting procedure.

7.6 Filter element replacement
Disposable filter None

element
None Linen rag As req.
Note!
After the first 200 hours running, every oil filter units shall be opened for inspection and the
disposable filter elements changed if necessary. If any impurities are found, the element must be
replaced at short intervals until it stays clean. From now on, replace the relevant filter element if a
clogged filter alarm is given on the alarm panel. It is recommended to change the filter elements at
least once a year.

position 2 stop.
2. Open the cover on the filter housing by loosening the

nuts in diagonal order.
Note!
Be aware of spring-loaded cover

3. Lift the disposable filter element with the filter holder
out of the housing.
4. Place a bucket underneath the filter bowl.
5. Using an allen key unscrew the bolt [1] on top of the

filter element holder.
6. Remove the supporter ring [2].

7. Remove the internal disposable filter element from its
holder, and then replace with new disposable filter.
Note!
The filter elements are disposable, and shall be replaced
with new filter elements when clogged. Never rinse or air
blow a clogged filter element for reuse, though it will
destroy the filter.
8. Before replacing the supporter ring [2], check the

condition of the o-ring. Change to new one if
necessary.
9. Fasten the new disposable filter element by replacing

the supporter ring [2] and fastening the bolt [1] on top
of the element holder.
10. Insert the new filter element with its holder to the
housing
11. Replace the cover and tighten the screws in a

diagonal order.
12. Perform the venting procedure, as described in

chapter 7.5.

position 1 remote control.

7.7 Replacement of flexible coupling in Pump Unit
Spare parts Ref. Special tools and test equipment Qty

no
Flexible coupling None

None None

position 2 stop
2. Disconnect the electrical cables in the outlet box
3. Loosen the bolts [1] and remove the electric motor
4. Replace the flexible coupling [2]
5. Align the couplings and lower the motor vertically on

to the bell house.
6. Fasten the motor, oil tank cover, SAE flanges, pipes

and electrical cables.

position 1 remote control

7.8 Cleaning of the Water Oil Cooler

no
None None

None Water As req.
Organic acid As req.
Clogging will reduce the heat transfer capacity of the Water/Oil cooler. Methods for
establishing clogging :
Check water inlet and outlet temperature. Clogging results in reduced difference in
water inlet and outlet temperatures and a rise in oil temperature.
Check for pressure drop across the cooler. Clogged and narrow passages will cause
acceleration in flow rate and increased pressure drop.
If temperature or pressure measuring reveals a clogged cooler:
1. Clean the water oil cooler by removing all minor deposits by back flushing the cooler with
water.
Fouling can be dealt with using a light acid.
2. Use 5% phosphoric acid or, when cleaned frequently, 5% oxalic acid or similar light
organic acid.
3. Rinse the cooler with a large quantity of water.
Note!
Make sure all acid are removed before restarting the system.

7.9 Creeping test

no
None None

None None
1. Take the ship out to open sea
2. Operate the ship at service speed
3. Set the Steering Gear mode to non follow up (as an alternative one can stop the power
packs after setting the rudder at a given angle)
4. Set the rudder angle to 20 port. Read and note the pressure.
5. If it seems that the rudder creeps at an unacceptable rate, measure how many seconds it
takes for the rudder to creep from 20 to 15
6. Set the rudder angle to 20 starboard
7. Repeat point 5
Note!
Contact Rolls-Royce for assistance

8 TROUBLE SHOOTING
Please see the tables below for trouble shooting and corrective actions. Be aware that a problem
may be a result of a combination of more than one failure.
8.1 Power pack

Symptoms Possible faults Components Corrective Refer to
actions procedure
Air in the system Air Venting system 7.5
Renew filter
Clogged filter Filter 7.6
element
Worn pump shaft Contact
Sealing Renew sealing
sealing RR
Noise from the power pack Worn coupling Flexible Renew the
7.7
element element element
Worn pump Contact
Bearing Renew bearing
bearing RR7.7
Worn elmotor Contact
Bearing Renew bearing
bearing RR
8.2 Rudder actuator

actions procedure
Worn internal
Contact
seals in the Seals Renew seals
RR
Steering gear
Control valves Loose, clean
Main control Contact
main spool may and resemble
valve RR
stick valve
Loose and
Solenoid spool Solenoid Contact
clean valve, or
The Steering may stick valve RR
gear does not replace spool
Rudder
movement move even Solenoids may Contact
problems when steering not get current Solenoids Repair
RR
signal is given
Fault on rudder Rudder Contact
Repair/renew
indicator indicator RR
Air in the oil 7.5
Air Venting system
system
Fault on pump Pump 7.7

unit/ pump unit/pump Repair/renew
cartridge cartridge

actions procedure
Control valve Loose, clean
valve RR
Rudder stick valve
moves to
Loose and
hard-over, Solenoid spool Solenoid Contact
clean valve, or
even if may stick valve RR
replace spool
opposite
signal is given
Solenoids may Contact
Solenoids Repair
not get current RR
Internal seals is Contact

Seals Renew seals
worn RR
Rudder is
Rudder continuously
movement creeping Air in the oil
Air Venting system 7.5
problems system
Contact
Lock valve
RR
Seals Renew seals
worn RR
Repair/renew
Rudder indicator indicator RR
moves slower Air in the oil
than spec. Air Venting system 7.5
system
Fault on pump Pump Contact
cartridge cartridge RR

Seals Renew seals
worn out RR
Control valve Loose, clean
valves RR
stick valve
Solenoid spool Loose and
may stick Solenoid Contact
clean valve, or
Rudder react valve RR
replace spool
slower than
usual on Solenoids may Contact
steering Solenoids Repair
not get current RR
signals
Repair/renew
indicator indicator RR
Air in the oil
Air Venting system 7.5
system
Fault on pump Pump
Contact
RR
cartridge cartridge

actions procedure
Running two Run only one
Contact
Rudder pumps at the Pumps pump when
RR
movement Rudder same time normal sailing
problems hunting Excessive
Contact
sensitivity of Autopilot Adjust autopilot
RR
autopilot
Renew gland Contact

Worn gland seal Gland seal
seal RR
Gland ring is Contact

Oil leakages from gland Gland ring Tighten gland
loose RR
Contact
Worn liners Liner Replace liner
RR
For failure related to the electrical system please see the electrical part.

9 SPARE PARTS
For delivered spare parts see attached spare part list. If additional spare parts are to be ordered,
the following information must be given:
Installation No. (T- Followed by a number), vessels name and owners name.
Shipping and invoicing address.
Drawing Number, Position Number, Article Number (Art. no.) and Quantity.
Note!
Information regarding the Steering Gear type and
installation number is found on the signs mounted
on the rudder Actuator housing and on the power
pack unit, one sign for each pump.
The information is also found on the front page
and in the technical data chapter of this manual.

10 CONTACT LIST
For any question regarding your Rolls-Royce product, please contact the Rolls-Royce 24/7 Marine
Technical Support function:
Rotterdam: +31 20 700 6474

Houston: +1 312 725 5727
Singapore: +65 6818 5665
marine247support@rolls-royce.com
Contacting any of this numbers will put you through to the Rolls-Royce global support team. For
local access numbers please visit us at www.rolls-royce.com/marine247

11 DESIGN DRAWINGS
The following documents are used as reference.
Drawing/ document Document number Revision

General Arrangement 0003-4555 E
Hydraulic diagram 46212 A
Top End Rudderstock 13350 D
Hydraulic Nut 0003-2459 B
Part List Hydraulic Nut 000100740 A
Lock Plate 45534 -
Pressure Gauge Actuator 32407 C
Assembly Actuator 16195 D
Part List Actuator 000115394 A
Assembly Power Pack 16927 -
Part List Power Pack 000108078 C
Feedback Arrangement 0003-4618 A
Procedure for Steering Loss and Recovery 33990 C
Measuring device for thrust bearing 33447 D
Pull up Calculation 0003-4557 B
Foundation Calculation with stopper on steelchock 0003-4558 B
Spare Part List P80927 -
For electrical drawings see electrical part.

12 REVISION
Revision Reason for revision Date Signature
A Release 13 August 2014 KBP

Part List
Item ID 000100740 Revision A

Description Hydraulic Nut Status RELEASED
Effective Date 6/24/2014 Levels 1
Level Pos Qty Unit Item ID Rev Description Size Extra information El-reference
0 piece 000100740 A Hydraulic Nut RV700-2/900-2/1050-3/1350-3/1400-2
1 0010 1 piece 000093135 A Housing RV700-2/900-2/1050-3/1350-3/1400-2
1 0020 1 piece 000093144 A Piston RV700-2/900-2/1050-3/1350-3/1400-2
1 0030 1 piece 45793-02 # O-Ring 1/4" 03
1 0040 1 piece 45793-05 # O-Ring 1/4" 04
1 0050 1 piece N31112 # Bleed Plug 1/4" 05
1 0060 1 piece 400-021_FR # Seal Washer 1/4"BSP 06
1 0070 1 piece 45534 # Locking Plate 700 SERIES 07
1 0080 4 piece 3261-573 # Hexagon Head Screw M20X50MM 08
End of Report
Page 1 of 1 Print Date: 6/24/2014

Part List

Description Rudder Actuator Status UNDEFINED
0 piece 000115394 A Rudder Actuator RV 1350-3
1 0010 1 piece 16190_FR C Housing RV1350-3 01
1 0020 1 piece 16207 # Cover 700 SERIES 02
1 0030 1 piece 000115413 A Rotor RV1350-3 2X46.5 (D=450 L=750)
1 0040 2 piece 2 32199 # Gland 610/501 X 17 04
1 0050 1 piece 1 23317 B Safety Valve 05
1 0060 2 piece 24354 C Valve 2" 06
1 0070 6 piece 2 41601 # Pressure Relief Valve 07
1 0080 2 piece 24224 # Bracket 700 SERIES 08
1 0081 8 piece 45600 # Rod M12 X 160 08
1 0090 4 piece N30773 # Socket Head Screw M6X12MM 09
1 0091 2 piece 45597 F Pointer 700 SERIES/1100 SERIES 09
1 0100 1 piece GE 22-LR2 # Pipe Coupling 22LR1/2 10
1 0110 1 piece P80364 C Seal Kit RV 1350/HS 360 11
1 0120 4 piece 45009 # O-Ring 580.00X20.50 12
1 0130 2 piece 33293-02 # Gasket 597.00X6.35 13
1 0140 1 piece 33034-7 # Gasket 1155X6.35 14
1 0150 2 piece 202-738 # O-Ring 64.50X3.00 15
1 0200 6 piece N16674 # Plug R1/2" 20
1 0210 2 piece 2 42140 # Plug 1"M/1/4"BSP 21
1 0220 4 piece 2 44334 # Adjusting Screw 1.1/4" 22
1 0230 4 piece 44735 # Screw 23
1 0240 30 piece 3241-789 # Socket Head Screw M30X150MM 24

Description Rudder Actuator Status UNDEFINED
1 0250 16 piece 3262-378 # Hexagon Head Screw M12X35MM 25
1 0261 6 piece 3451-222 # Washer 10.5 26
1 0290 24 piece 3293-424 # Nut M12 29
1 0300 30 piece 3451-834 # Washer 31 30
1 0320 6 piece 3451-838 # Washer 37 32
1 0440 2 piece 33997_FR B Connection Box 44
1 9002 1 piece 46066 # Nameplate 00
1 9003 2 piece 70061_FR # Shackle H 13.5T 00
1 9006 1 piece P82239 - Sign 000
1 9007 1 piece 000087630 A Foundation RV850-1350
End of Report

Part List
Item ID 000108078 Revision C

Description Power Pack Status UNDEFINED
0 piece 000108078 C Power Pack PPSMI 2" SMALL
1 01 2 piece A20542432 # Electrical Motor 200L2 440/60 43KW
1 03 8 piece N20266 # Stud Bolt M16X40
1 04 8 piece 3293-426 # Hexagon Nut M16
1 05 8 piece 3451-826 # Washer 17
1 09 2 piece N34690 # Pump L3MF52-104-IFOKOO-W
1 11 8 piece 3241-471 # Socket Head Screw M16X30MM
1 13 2 piece N34420 # Bell Housing PL400/5/48
1 15 2 piece 45747 # Gasket
1 17 2 piece 42A28 # Coupling 42/55-28
1 18 2 piece 42K # Flexible Coupling Element 42/55
1 19 2 piece 42B55 # Coupling 42/55-55
1 25 2 piece 24135 J Manifold PPS 2"
1 26 2 piece 45696 # Gasket 2MM
1 27 2 piece 15275 # Cover 2"2X300L
1 29 2 piece 45230 # Connection Pipe L3MF52/16-18-200 50X5MM
1 36 2 piece 45890 # Adapter Plate
1 37 2 piece 000098658 A Filter TTF1020QLBS41
1 38 2 piece 70117_FR # Indicator FPCG10XS-NO/NC250VG1/8
1 40 8 piece 3262-332 # Hexagon Head Screw M10X25MM
1 41 4 piece N31704 # Flange SAE3000 2"

1 43 4 piece N35225 # O-Ring 69.52X2.62
1 47 1 piece GE 22-LR2 # Pipe Coupling 22LR1/2
1 48 2 piece N16674 # Plug R1/2"
1 49 3 piece 400-025_FR # Seal Washer 1/2"BSP
1 50 44 piece 3451-224 # Washer 13
1 51 44 piece 3262-377 # Hexagon Head Screw M12X30MM
1 53 1 piece 000110494 A Oil Tank PPSI 2" - 15325
1 54 2 piece 45542 A Extension 38/1"BSP X 115
1 55 2 piece N34903 # Breathing Filter L320/300/250MM
1 56 2 piece 34041_FR # Manometer
1 58 2 piece N35122 # Level Switch V=415MM
1 62 4 piece 3223-164 # Countersunk Screw M4X16
1 63 2 piece 000102525 B Connection Pipe
1 65 2 piece N16672 # Plug R1/4"
1 67 1 piece N16681 # Plug R1.1/2"
1 68 1 piece 400-033_FR # Seal Washer 1.1/2"BSP
1 69 2 piece N16678 # Plug R1"
1 70 2 piece 400-030_FR # Seal Washer 1"BSP
1 71 2 piece P82074 B Cooler
1 72 1 piece 000109647 A Part List
1 73 8 piece P82521 - Lifting Device PPS 2"
1 74 2 piece 33999_FR A Connection Box
1 80 2 piece N14599 # Thermometer 3/8"X40 90GR0-100C
1 88 2 piece P81430 C Cable Gland
1 89 1 piece P81328 A Sign
1 90 1 piece 44806 # Flange

End of Report

Pull up no: 0003-4557
O. no. 13s000193-1Sheet 1 of 2
Rolls-Royce Marine AS, dep. Steering Gears - Frydenb Date: 20-Jun-14 Sign : KBP
TAPERFITTING OF RUDDERSTOCK
CALCULATION ACCORDING TO LRS
TECHNICAL DATA RV1350-3

GEOMETRY DATA:
MAX. DESIGN TORQUE, ACTUATOR.____________________M= 1640 kNm
RUDDERSTOCK DIA.__________________________________ D= 450 mm
RUDDERSTOCK MEAN DIA. Dm=D-L/(2*K)_______________Dm= 425.0 mm
RUDDERSTOCK RULE DIAMETER Dt = 326 mm
ROTOR DIA.__________________________________________Dr= 790 mm
ROTOR NECK DIA.____________________________________ Drn= 575 mm
LOWER ROTOR NECK HEIGHT_________________________ Hln= 152 mm
DISTANCE FROM UNDERSIDE ROTOR TO START TAPER__Hst= 72 mm
TAPER LENGHT_______________________________________L= 750 mm
ACTIVE FRICTION LENGHT____________________________Lf= 750 mm
LENGTH OF TAPER AREA IN UPPER ROTOR NECK_______ Lun= 0 mm
LENGTH OF TAPER AREA IN LOWER ROTOR NECK_______Lln= 80 mm
HEIGHT OF ROTOR HUB_______________________________Hrb= 670 mm
MEAN DIA of ROTOR HUB (at taperarea)___________________Drm= 767.1 mm
TAPER 1:K_____TAPERFACTOR________________________K= 15
MATERIALS:
POISSONS RATIO RUDDERSTOCK_____________________ r= 0.3
POISSONS RATIO ROTOR_(HUB)________________________h= 0.26
MODULUS OF ELASTICITY RUDDERSTOCK______________Er= 206000 N/mm
MODULUS OF ELASTICITY ROTOR_(HUB)_______________Eh= 167000 N/mm
COEFF. OF FRICTION, DRY_____________________________t= 0.14
COEFF. OF FRICTION, BY OIL PRESSURE________________ s= 0.03
COEFF.OF SAFETY, WITH KEY_________________________ n= 0
COEFF. OF SAFETY WITHOUT KEY_____________________ n= 2
e= 0.75
YIELDPOINT OF RUDDERSTOCK_______________________ r= 345 N/mm
YIELDPOINT OF ROTOR_(HUB)_________________________h= 350 N/mm
ROLLS-ROYCE MARINE AS
dep.: Steering gear - Frydenb
Printed: 6/20/2014 Tel. +47 56 571600. Fax +47 56 308241 Rev.11, 22.06.12
Pull up no: 0003-4557
O. no. 13s000193-1Sheet 2 of 2
Rolls-Royce Marine AS, dep. Steering Gears - Frydenb Date: 20-Jun-14 Sign : KBP
TORQUE TO BE USED:
RULE TORQUE M=0,0135Dt3/(235/f)e __________________________ 624 kNm

MAX. DESIGN TORQUE______________________________________ 1640 kNm
ACC. TO LRS, MAX. DESIGN TORQUE TO BE USED IN CALC. ____ 1640 kNM
SURFACE PRESSURE (P) IN TAPERFITTING:

A = L f D m A= 1001383 mm
n M 2 Dm
Pmin = Pmin= 125.2 N/mm
2 A 2 (n A (2 K )) 2

h
(

D
r
)
D 2 1

P = Pmax= 130.0 N/mm
3 (D )
max 4
/ D +1
r
PULL UP LENGTH (Lp): I = REQUIRED INTERFERENCE
1 (D D )2 + 1 1
I min = Pmin Dm r m 2 + h + (1 r )
Eh (Dr Dm ) 1
Imin= 0.8646
Er
1 (Dr Dm )2 + 1 1
I max = Pmax Dm +
h + (1 )
r
Eh (Dr Dm ) 1
2 Imax= 0.8976
E r
L P m i n= I m i n K Lpmin= 12.97 mm
L P m a x= I m a x K Lpmax= 13.46 mm
MAX.EQUIVALENT UNIAXIAL STRESS ( e )

(VON MISES CRITERION)
e = P
3 (Dr / D ) + 1
4
e
(Dr D ) 1
2 = 337 N/mm
ACCORDING TO LRS MUST e <= 1,00 Rp Rp >= 337 N/mm
WHERE Rp= YIELD POINT OR 0,2% PROOF

STRESS OF THE MATERIAL IN THE BOSS
PULL UP LOAD (Pu)
Pu min = Pmin Dm L f ( s + 1 (2 K )) Pumin= 7900 kN
Pu max = Pmax Dm L f ( s + 1 (2 K )) Pumax= 8200 kN
ROLLS-ROYCE MARINE AS
dep.: Steering gear - Frydenb
Printed: 6/20/2014 Tel. +47 56 571600. Fax +47 56 308241 Rev.11, 22.06.12
Pull up loads
Hydraulic Performance curve for: Pull up length, max: 13.46 mm
SPP Shipbuilding Pull up length, min: 12.97 mm
hull no. H-4098/99 Piston area: 940 cm
Frydenb order no: 13s000193-194 Pull up load: 7900 kN
Classification: Lloyds Reg. Max. oil pressure at taper area: 1280 bar
Pull up load at various friction coeff.
1200
Oilpressure in
hyd. nut,
t=0.03
1000
Oilpressure in
hyd. nut,
t=0.02
Oilpressure in
hyd. nut,
t=0.015
800
Pressure in hydraulic nut, (bar)
Note! Keep the pressure on taper as high

as possible during the pull up procedure.
600
400
200
0
0.0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0
Starting position:
Pressure starts to increase, max 10 bar
Printed: 6/20/2014 Page 4 of 4 Filename: 0003-4557 rev. 11

Project data
Calc. no.: 0003-4558 Order no13S000193/194
Class: LRS Calc. Re B
Date: 6/23/2014 Sign: KBP
RUDDER ACTUATOR TYPE: RV 1350-3

CALCULATION FOR FOUNDATION w/STOPPERS MOUNTED ON STEELCHOCK
TORQUE USED IN CALCULATION_________________________(M d or M r )_______________ M: 1640 kNm

RADIAL LOAD USED IN CALCULATION_____________________________________________R: 1800 kN
MAX FORCE UPWARDS_________________________________________________________ Ap: 1200 kN
YIELD POINT OF ROTORHOUSING__________________________________________________h: 280 N/mm
AMOUNT OF STOPPERS___________________________________________________________ ns: 2
BOLT DATA (HOLDING DOWN BOLTS)______________________________________________M 42
BOLT DIAMETER (HOLDING DOWN BOLTS)_________________________________________ db: 37.61
YIELD POINT OF BOLT____________________________________________________________ b: 1080 N/mm
AMOUNT OF HOLDING DOWN BOLTS_______________________________________________nb: 8
BOLT DATA (ADJUSTING BOLT)____________________________________________________: 1 1/4" BSP
BOLT DIAMETER (ADJUSTING BOLT)_______________________________________________dAB: 41.91 mm
AMOUNT OF ADJUSTING BOLTS___________________________________________________ nAB: 4
WEIGHT OF RUDDER______________________________________________________________wr: 24450 kg
WEIGHT OF RUDDERSTOCK_______________________________________________________ ws: 24290 kg
WEIGHT OF ACTUATOR___________________________________________________________ wa: 6000 kg
TOTAL WEIGHT___________________________________________________________________wt: 54740 kg
DISTANCE FROM OUTER STOPPER TO CENTER ACTUATOR___________________________DS: 950 mm
SAFETY FACTOR FOR CALCULATION OF STOPPERS_______________________________Sf: 2
ACTUATOR FLANGE:
THICKNESS OF ACTUATOR FLANGE________________________________________________T: 80 mm
LENGTH OF STOPPER____________________________________________________________ LS: 300 mm
CALCULATED WIDTH OF STOPPER BASED ON DISTANCE FROM CENT._______________ WS: 164.2 mm
CALCULATED REQUIRED WIDTH OF CONTACTAREA FOR STOPPER___________________Wst1: 165 mm
CORRESPONDING CALCULATED ARM FOR STOPPERS________________________________as: 868 mm
DISTANCE FROM STOPPER TO FLANGE CUT-OUT____________________________________DF: 15 mm
DISTANCE FROM OUTER STOPPER TO CUT-OUT ON FLANGE_________________________ Dco: 180 mm
Doc. no. : 08.43.01 ROLLS-ROYCE MARINE AS

Doc. rev. : 4, SP Dep. Steering gear - Hagavik
Rev. date : 04.02.2011 N-5217 HAGAVIK, NORWAY page 1 of 2
Project data
Calc. no.: 0003-4558 Order no13S000193/194
Class: LRS Calc. Re B
Date: 6/23/2014 Sign: KBP
LOAD ON STOPPER no. 1 (WHEN 2 STOPPERS ONLY):

LOAD FROM TORQUE AND RADIAL LOAD WILL BE DISTRIBUTED AS FOLLOWS:
TORQUE: EACH STOPPER WILL TAKE 1/2 OF LOAD FROM TORQUE: 820 kNm
RADIAL LOAD: EACH STOPPER WILL TAKE 1/2 OF LOAD FROM RADIAL LOAD: 900 kN
LOAD ON EACH STOPPER FROM TORQUE: 945 kN
TOTAL LOAD ON EACH STOPPER FROM TORQUE AND RADIAL LOAD: 1845 kN
M 1000 R
+ S f =
a n 2
LOAD ON EACH STOPPER INCLUDING Sf (2)_________________________________________L st1: 3689 kN
s s
Lst 1 (T LS ) =
SHEAR STRESS OF STOPPER_______________________________________________________ : 154 N/mm
Lst 1 1000

=
h
REQUIRED MIN AREA OF STOPPERS________________________________________________
Ast1: 13175 mm
(contact area between stopper and rotorhousing)
L st1 1000
T
=
h
REQUIRED WIDTH OF CONTACTAREA FOR STOPPER_________________________________Wst1: 165 mm
LOAD ON STOPPER no. 2 (WHEN 2 STOPPERS ONLY):
LOAD ON EACH STOPPER INCLUDING Sf (2)___Lst2 = RSf = ___________________________Lst2: 3600 kN
MAX SURFACE PRESSURE OF STOPPER______Pst2 = h = _____________________________ Pst2: 280 N/mm
REQUIRED MIN AREA OF STOPPERS_______Ast2 = Lst/Pst2 = ___________________________Ast2: 12857 mm
REQUIRED WIDTH OF CONTACTAREA FOR STOPPER___Wst2 = Ast2/T = ________________Wst2: 161 mm
BOLTS - TAKING UPWARD FORCE:

F = AP nb
FORCE ON EACH BOLT____________________________________________________________F: 150000 N
F
p= 2 =
db / 4
STRESS IN BOLTS_________________________________________________________________p: 135 N/mm
CALCULATED PRESTRESS IN EACH BOLT FROM Ap:_________________________________ PS_Ap: 150000 N
PRESTRESS IN BOLT FROM Ap______________________________________________________: 12.5 %
REQUIRED TIGHTENING TORQUE FOR BOLTS FOR COMPENSATING Ap:_______________ Mb_Ap: 1222 Nm
TIGHTENING TORQUE FOR BOLTS (2x Mb_Ap)_____________________________________Mb: 2444 Nm
Doc. no. : 08.43.01 ROLLS-ROYCE MARINE AS

Doc. rev. : 4, SP Dep. Steering gear - Hagavik
Rev. date : 04.02.2011 N-5217 HAGAVIK, NORWAY page 2 of 2
Part List
Item ID P80927 Revision #

Description Spare Parts Status RELEASED
0 piece P80927 # Spare Parts RV 700
1 0120 1 piece P80674 # Seal Kit HS 240/700 SERIES 12/13
1 0140 2 piece N35359 # Filter Cartridge TTF 20MY 14
1 0310 1 piece 33034-7 # Gasket 1155X6.35 31
End of Report

USER MANUAL
Electrical system
Yard : SPP Shipbuilding Co., Ltd.

Hull no. : H4098, H4099
RR project no. : 13S000193, 13S000194
Revision :A
Date : 13.Aug.2014
TABLE OF CONTENTS
1 INTRODUCTION ..................................................................................... 4
1.1 Purpose ........................................................................................................................ 4
1.2 Warranty....................................................................................................................... 4
1.3 Structure of this manual ................................................................................................ 4
1.4 Abbreviations................................................................................................................ 5
2 SAFETY................................................................................................... 6
2.1 General statement ........................................................................................................ 6
2.2 Safety Annotations........................................................................................................ 7
2.3 Declaration of conformity .............................................................................................. 7
3 SYSTEM DESCRIPTION......................................................................... 8
3.1.1 Frequency controlled pumps and Conventional manoeuvring valve (FCON).................. 8
3.1.2 Control Panels .............................................................................................................. 9
3.1.3 Alarm Panel .................................................................................................................. 9
3.1.4 Rudder Angle Indicator (RAI) ........................................................................................ 9
3.1.5 Control System Cabinet ................................................................................................ 9
3.1.6 Rudder Angle Indicator Amplifier................................................................................... 9
3.1.7 Run/Stop/Auto start Indication....................................................................................... 9
3.1.8 Motor Controller .......................................................................................................... 10
3.1.9 Frequency Converter .................................................................................................. 10
3.1.10 Feedback Unit ............................................................................................................ 10
3.2 Control System ........................................................................................................... 11
3.2.1 Frequency Controlled Pump (FCP) ............................................................................. 11
3.2.2 Control panel .............................................................................................................. 12
3.2.3 Alarm system .............................................................................................................. 12
3.2.4 Control system unit ..................................................................................................... 14
3.2.5 Panel Units ................................................................................................................. 14
3.2.5.1 Pump Start/Stop/Auto start Panel................................................................................ 14
3.2.5.2 Control Panel for Override/Emergency Steering (from the Bridge) ............................... 15
3.2.5.3 High/Low Rudder Angle .............................................................................................. 16
3.2.6 Motor controller........................................................................................................... 16
3.2.7 General power unit ..................................................................................................... 19
3.2.8 Feedback unit ............................................................................................................. 19
3.3 Function ..................................................................................................................... 20
4 DELIVERY SPECIFICATIONS .............................................................. 22

4.1 Scope of supply .......................................................................................................... 22
4.1.1 General ...................................................................................................................... 22
4.2 Electrical system......................................................................................................... 23
5 TECHNICAL DATA ............................................................................... 25
6 OPERATING INSTRUCTION ................................................................ 26

6.1 Operator facilities........................................................................................................ 27
6.1.1 Control Panel .............................................................................................................. 27
6.1.2 Alarm panels .............................................................................................................. 28
6.1.2.1 Main alarm system AS02 ............................................................................................ 28
6.2 Normal operation - Remote control ............................................................................. 32
6.2.1 Start ........................................................................................................................... 32
6.2.2 Stop............................................................................................................................ 33
6.3 If an alarm occur ......................................................................................................... 33
6.4 Emergency operation Local control .......................................................................... 33
6.4.1 Start ........................................................................................................................... 33
6.4.2 Steering ...................................................................................................................... 34
6.4.3 Stop............................................................................................................................ 34
7 MAINTENANCE .....................................................................................35
7.1 Maintenance overview ................................................................................................ 36
7.2 Routine maintenance .................................................................................................. 37
7.3 Renew pump control card ........................................................................................... 38
7.4 Adjustment of limit switches in feed back unit .............................................................. 39
7.5 Renew start relay ........................................................................................................ 40
7.6 Renew solenoid driver ................................................................................................ 41
7.7 Renew bulb on control panel ....................................................................................... 42
7.8 Adjustment of dimmer ................................................................................................. 43
7.9 Renew alarm system cards ......................................................................................... 44
8 TROUBLE SHOOTING ..........................................................................45

8.1 Trouble shooting when an alarm is present ................................................................. 45
8.2 Trouble shooting when no alarms present ................................................................... 46
8.2.1 Electrical system ......................................................................................................... 46
8.2.2 Alarm system .............................................................................................................. 48
8.2.3 Lamp control panel ..................................................................................................... 48
9 CONTACT LIST .....................................................................................49
10 SPARE PARTS ......................................................................................53
11 TOOLS ...................................................................................................54
11.1 Light bulb dismounting tool ......................................................................................... 54
12 DOCUMENTS, DRAWINGS AND DATASHEETS .................................55
13 REVISION ..............................................................................................56

1 INTRODUCTION
1.1 Purpose
This manual describes operation and maintenance procedures required on board for the Rolls-
Royce Steering Gear Electrical system. Always make the manual available to the technical
staff.
The manual includes general information about the Rolls-Royce Steering Gear Electrical system
product line, as well as project specific information and technical data.
The User manual provides the information necessary to operate and maintain the Rolls-Royce
Steering Gear Electrical system safely and correctly
1.2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is
misused or not handled in accordance to prescribed standards, for example dismantling the
equipment to a level greater than described.
1.3 Structure of this manual

The first part of this manual describes the Rolls-Royce Steering Gear Electrical system. This helps
in understanding the maintenance procedures in the subsequent chapters.
Chapter 3 describes the Rolls-Royce Steering Gear electrical systems main components.
Chapters 6, 7 and 8 describe the relevant operation and maintenance procedures.
Chapters 4, 5 and 12 provide project specific information.
Note!
A separate manual for installation is available, and may be ordered specifically from Rolls-Royce
Marine as required.
Note!
All pictures used in this manual are for illustration only.

1.4 Abbreviations
Abbreviation Description
DP Dynamic positioning
DOL Direct Online start
E0 General alarm
ESD Electrostatic Discharge
ECR Engine Control Room
LED Light Emitting Diode

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

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

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

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

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

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

3 SYSTEM DESCRIPTION
This section provides detailed information about the Steering Gear electrical system. To ensure
safe and efficient operations.
3.1.1 Frequency controlled pumps and Conventional manoeuvring valve

(FCON)
For larger size steering gears the FCP solution cannot be used due to technical reasons. To
achieve a power saving system we have developed the FCON; A frequency converter (one for
each pump) is used to reduce the pump speed to the control valves idling pressure when there is
no steering command signal. When a steering command is given, the pump speed will increase to
maximum again after approx. 1, 5 second. This ramp up time will result in reduced pump speed on
long voyages when the rudder is controlled by the autopilot and hence save power. The direction
signals, (port/stbd) is carried out by conventional control valves.
Pos. Component
(1) Control panels without steering controls
2 Control panels with steering controls
2 Emergency steering
3 Alarmsystem
(3) Steering failure alarm
4 Rudder indication system

Pos. Component
5 Control system
6 Motor controller
7 General power unit
8 Feed back unit
The following is a brief description of the Steering Gear Electrical System main components:
3.1.2 Control Panels
The control panels have the following function:
Start/Stop/Auto start
Override (Emergency Steering)
High/Low Rudder Angle
In Command
Follow Up Controller.
3.1.3 Alarm Panel
The alarm panel provides indication of faults in the Steering Gear System to the Bridge and the
Engine Control Room. The alarm panel in the Engine Control Room has full lighting intensity. The
lighting intensity of the alarm panel on the Bridge can be adjusted.
3.1.4 Rudder Angle Indicator (RAI)
The Rudder Angle Indicator provides real time position indication of the rudder.
The indicator is available in three types of mounting:
Panel Mounting
3 Face Ceiling Mounting
Bulkhead Mounting.
3.1.5 Control System Cabinet
The Control System Cabinet is installed on the Bridge or adjacent to the Bridge. It receives input
from the control panel and the feedback unit and provides command signals to the Steering Gear.
3.1.6 Rudder Angle Indicator Amplifier
Rudder Angle Indicator Amplifier is installed on the Bridge or adjacent to the Bridge. It receives
rudder position signal from the feedback potentiometer and amplifies the signal to a suitable level
for the Rudder Angle Indicator.
3.1.7 Run/Stop/Auto start Indication
Run/Stop/Auto start Indication is provided in the Engine Control Room and shows the status of the
pump units.
3.1.8 Motor Controller
The Motor Controller is installed in the Steering Gear Room. It receives signal from the Control
System Cabinet and controls the pump unit.
3.1.9 Frequency Converter
The Frequency Converter is installed in the Steering Gear Room and controls the speed and
direction of the motor pump unit.
3.1.10 Feedback Unit
Feedback Unit is installed in the Steering Gear Room and provides end stop limit switches and
transmitter for the rudder position to the Control System and Rudder Angle Indicator System.

3.2 Control System
The Control System provides monitoring and control of the Steering Gear Unit.
The power supply to the Control System is from the corresponding Motor Controller.
The Control System consists of:
Frequency Controlled Pump Unit

Panel Unit
Control Unit
Alarm system
Feedback Unit.
3.2.1 Frequency Controlled Pump (FCP)
The frequency controlled pump units (Figure 2) provide smooth start and stop of the Steering Gear
and an accurate analogue Control System.
The pump units rotate only when a steering command signal is given. In this way, power saving is
achieved.
The system uses reversible electric motors driving hydraulic pumps, together with Frequency
Converters to control the speed and direction of the pumps.
1 Motor controller
2 Frequency converter
3 Feedback unit
Figure 1 Frequency Controlled Pump System

3.2.2 Control panel
The control panels consist of:
Panel front with overlay (color: black RAL 9011).
Operating components connected to printed circuit board.
Terminal plate wired to control panel.
The panel shall be placed easy visible and accessible on the

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

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

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

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

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

3.2.4 Control system unit
The control system CS is

designed to control the electro
hydraulic Steering Gears. The
control system consists of
pump control card one for
each pump. The pump control
cards shall be interfaced with
an external steering system.
Note!
The control system is made for

bulkhead mounting and is
normally mounted on the
bridge or in a room adjacent to
the dridge. The cable length
from the control system to the
bridge equipment must not be
more than 100 m
1 Pump control card 4 Back plane

2 Selector card 5 Interface card
3 Amplifier card
3.2.5 Panel Units
The Panel Units are installed on the Bridge and in the Engine Control Room. There are varying
layouts for each section of the panels, the general functions of each section are detailed below.
A control panel has the following:
Panel front
Operating components connected to the printed circuit board
Terminal plate connected (wired) to the control panel.
Each control panel can contain different modules depending on the required installation for the
vessel. Following are the main functions:
Pump Start/Stop/Auto startOverride/Emergency Steering

High/Low Rudder Angle
In Command
Follow-Up Controller.
3.2.5.1 Pump Start/Stop/Auto start Panel
The pump Start/Stop/Auto start panel (Figure 4) provides control of two steering gear pump units.
It also provides indication of the running status of each pump unit.

Figure 2 Pump Start/Stop/Auto start Panel
3.2.5.2 Control Panel for Override/Emergency Steering (from the Bridge)
The Control Panel for Override/Emergency steering provides local emergency control from the
Bridge.
The main control panel has PORT and STBD steering buttons for emergency steering control
(Figure 5). The control is of Non-Follow-Up type i.e. the steering gear will move in the direction
indicated on the button until the steering gear reaches end stop limit or the button is released.
To operate the Steering Gear from the Bridge, at least one pump unit must be operational.
Figure 3 Emergency Steering Control Panel

3.2.5.3 High/Low Rudder Angle
The Low Angle Pump 1 and 2 lamp provides indication of reduced available maximum rudder angle
(Figure 6). The functions is used in combination with the ships speed log and enabled by pressing
the High/Low Rudder Angle push button, depressing the button will override the automatic
selection of available rudder angle.. With the system enabled available rudder angle is reduced to
the setting of the Low Rudder angle End stop Limit Switches at a preset speed limit in the speed
log, normally at 6 knots.
Figure 4 High / Low Rudder Angle
3.2.6 Motor controller
There is a selector switch on the front of the motor

controller door, which has the following positions:
Remote control (steering from the bridge).
Stop (maintenance).
Local control (only emergency steering from the

steering gear room is possible).
Normal position is "Remote control". Start, stop and

steering commands are done from the bridge.
The stop position is used to prevent unintentional start

from the bridge during repair of the steering gear or
rudder.
"Local control" is used for function testing the steering

gear, or emergency operation of the maneuvering valves.
In this position the steering control from the bridge is
disconnected. A fault in this system will therefore not
interfere with the emergency steering. The motor
controller will turn on the power supply to the electric
motor. The maneuvering valves on the rudder motor can
then be operated manually by use of the emergency

device on the solenoids.
The alarm Power failure control will be activated in position "stop" and "local control" as an
information to the crew on the bridge that remote control is out of function.
Solenoid driver:
The driver has been developed to avoid the problems with switching of high inductive current
solenoids. The two main problems are:
Voltage drop on the supply lines due to long distance between bridge and steering gear
compartment.
Welding and heavy wear of relay- and switch contacts due to high inductive of the solenoids.

Principle diagram:
Solenoid driver connected

for steering signal
common (+)
Solenoid driver connected

for steering signal
common (-).
If common (-) is selected

see also jumper setting for
control system CS-**
(Pump control card).
Function:
The driver is a dual electronic power relay with the following features:
Low input current. The input resistance of the relay is 1k which gives an input current of 24 mA
at 24 V supply. This current is high enough to ensure reliable contact function of mechanical
switches, and low enough to avoid problems with wear and welding of contacts. Besides, the
current is purely resistive.
Input filter. The input signal is low pass filtered through a RC-circuit to avoid noise from trigging
the output transistor.
Threshold limit. To make the output transistor turn on, the input signal has to exceed 15 V. This
is accomplished by means of a zener diode in the signal line and helps shut out false signals.
Protected output. A zener diode protects the output transistor from over voltage due to kickback
from the solenoid.
Choice of polarity. Connection to the appropriate input terminals give the user a choice of
common plus or common minus to suit the polarity at the output of the control system.

Alarms relay output. The driver is equipped with two change over relay contact set. The relay is
energized as long as the power supply to the driver is present.
3.2.7 General power unit
The pumps are continuously running with modulated

flow controlled maneuvering valves. The pumps have
three different starting methods as described below.
Direct-On-Line start (DOL) Y/D Start (StarDelta) AutoTransformer
The most common way to If it is necessary to reduce Starting current can be

start a squirrel cage the starting current of a reduced with
motor is to connect the motor due to supply AutoTransformer. The
main supply directly to limitation, use StarDelta voltage will be increased in
the motor. The starting starting. (Start current = 1.3 steps when the motor is
current for this method is 2.6*In). starting. (Starting current =
high, it has no limitation. 1.7 4*In).
(Start current = 6 - 8*In).
3.2.8 Feedback unit
The feedback unit contains the transmitter [1] for the

rudder indicating system, switches for limitation of the
rudder travel and transmitter for the control system.
The drive shaft follows the turning of the rudder stock and
transfer the movement to the transmitters [1] and the
tripping releaser for the limit switches [2].
The potentiometers can be single, double or triple

depending on the installation.
The tripping cams are adjusted to interrupt the steering

signal about 2 degrees before the rotor reaches
mechanical stop.

3.3 Function
Each Steering gear are supplied with two independent pump units each driven by an electric motor.
The motor controller for the electric motor on each pump unit has separate and independent supply
from the switch boards.
The supply for the control system is powered from corresponding motor controller. The two
systems are therefore both hydraulically and electrically separate and independent.
The pump control card can be used as a separate control system or together with Aux. steering
unit. The pump control card can be interfaced to different steering modes and external equipment.
Component Function(s)
Control panels (without steering controls) Start/stop/auto-start for each pump unit
Dimmer
Rudder angle selection (optional)
Alarm system Overload
Phase failure
Power failure
Power failure control
Low oil level
Hydraulic lock alarm
Power failure aux steering
Clogged filter (optional)
High oil temp (optional)
Earth failure alarm (optional)
Rudder sync failure (optional)
Control system unit Pump control card:

Interface to 3 NFU steering modes
Signal to/from motor controller
Start/stop circuit
Signal from alarm unit
Signal to external equipment
Power supply
Motor controller Interface card for the alarm unit
Start/stop of pump motor

Component Function(s)
Power supply to steering system
Alarm transmitter (contact/circuit) to alarm

system
Power supply to steering system
General power unit Different starting methods
Feedback unit Transmitter for the rudder indication system

4 DELIVERY SPECIFICATIONS
This chapter contains delivery specifications defined by Rolls-Royce Marine sales representative in
agreement with the customer.
4.1 Scope of supply
4.1.1 General
Equipment not supplied
Not included in scope of supply are:
Foundation
Autopilot, DP and joystick
Wiring
Technical information - Drawings
Dimension drawings, hydraulic diagram, electrical diagram and technical data for the steering gear
system will be delivered. All according to documentation list issued for each order.
Steering gear design
The steering gear design is based on well-proved technology as well as long experience.
Workshop testing
The steering gear system is workshop tested according to the class requirement and RRM
standard.
Corrosion protection and surface treatment
The steering gear actuator is provided with corrosion preventing coat, which is intended for
protection under normal transport conditions. The rotor is finish treated according to RRM standard.
Shipment
Depending on transport methods and delivery times components may be shipped separately.
Installation into the ship and mounting of components are customer's responsibility if not otherwise
is stated.
Safe storage
All equipment are prepared for storage in dry and dust free environments up to 6 months from
delivery.
Piping and cabling
Connections between components supplied by RRM are the customer's responsibility. However,
type of pipes and cables are given in the diagrams and mounting instructions.

Installation, inspection, starting up and sea trial
Installation of the steering gear system in the ship and mounting of components are the customer's
responsibility if not otherwise stated.
Instruction manuals Language
1 CD with English user manuals
3 pcs. Users Manuals covering the mechanical/hydraulic parts in English language
3 pcs. Users Manuals covering the electrical parts in English language
All drawings, documents and sign plates on the equipment will also be delivered in English
language.
4.2 Electrical system

Note!
The scope of supply for one Steering Gear is given below; if two steering gears are delivered the
quantity is to be doubled
Start/Stopp and Control system
2 pcs. Motor controllers (FCON) (IP44)
For bulkhead mounting in the steering gear room with source on light, ampere meter,
hour counter and power supply for heating elements in electrical motor.
2 pcs. Frequency converters (IP44)
For bulkhead mounting in the steering gear room with ammeter, hour counter indication
and power supply for heating of electrical motor through the windings.Vibration dampers
included. Output from frequency converter: 3x440V, 60Hz.
1 pc. Control system unit (IP44)
For bulkhead mounting in the bridge with interface to external steering control system.
1 pc. Control panel (IP22)
For desk mounting in the forward bridge console with start/stop push buttons and
common dimmer.
1 pc. Indication panel (IP22)
For run/stop/autostart indication and for desk mounting in the engine control room
console.
2pc. Feed back units
With limit switches for mounting on the steering gear
Alarm System

1 pc.
Alarm panel (IP22)
For desk mounting in engine control room with alarm lights for overload, phase failure,
low oil level, power failure, clogged filter, high oil temperature and hydraulic lock and
push buttons for alarm test, alarm acknowledge, alarm buzzer and with one common
steering gear failure alarm contact (voltage free) to ships main alarm system.
1 pc.
Alarm panel (IP22)
For desk mounting in bridge console with alarm light and push buttons for alarm test,
alarm acknowledge, alarm buzzer and with interface to VDR on RS422 NMEA.
Spare Parts
For spare parts see attacked spare part list
Tools
1 pc. Light bulb dismounting tool

1 pc. Push button cover dismounting tool

5 TECHNICAL DATA
For project specific technical data not found on this page
Steering Gear
Type RV1350-3
Class LRS
Electric motor Unit1/ (Unit2)

Power (S1) [kW] 43
Current (IN) [A] 67
Starting current (IS) [A] 442
Rotational speed (rpm) 3500
Voltage (V) 3x440-460
Frequency (Hz) 60
Type M3AA 200 MLB-2
Protection IP55
Design B5
Insulation class F
Heating element [V] 240
Alarm System
Power consumption 100W

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

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

6.1 Operator facilities
6.1.1 Control Panel
2 pumps 4 pumps
Start/stop
Rudder angle selection

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

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

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

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

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

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

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

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

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

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

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

6.2 Normal operation - Remote control
Note!
For technical reasons the pump units shall be running for approximately the same number
of working hours
There is no control system delivered with this installation, refer to manufacturers manuals
6.2.1 Start
1. Connect power with the main switch located on the motor controllers, and ensure that
power is available.
2. Check that there are no alarms on the alarm panel
3. Set the selector switch located on the motor controller to position 1 Remote control
4. Start one pump at the time. By pushing the Run Pump push button [1] on the control panel.
The green lamp will be turned on.
Note!
If an alarm occurs for one of the pump units, the stand-by pump unit will be started
automatically. The Auto Start indication light [2] on the control panel is turned on for about
3 seconds. The faulty pump must be stopped manually.
If both pumps are running, and an alarm occur on both pump unit. Stop pump 1. If no
response start pump 1 and stop pump 2. If still no response, emergency steering to be
performed from Steering Gear Compartment.

6.2.2 Stop
1. Stop one pump at the time from the bridge, by pushing the Stop Pump push button [3]. The
red lamp will be turned on.
2. Turn the selector switch on the motor controller to position 2. Stop
3. Stop the power supply to the Steering gear by switching of the main switch.
6.3 If an alarm occur

In case an alarm condition is present for more than 3 seconds the buzzers are turned on and
the alarm lamp start to flash on both alarm panels independently.
1. Push the ACK button once, to turn off the local buzzer. The alarm lamps are still
flashing.
2. Push the ACK button once more, and the flashing alarm lamp will be disabled.
If the alarm condition is still present, the local alarm lamps goes from flashing to steady light.
If not, it is turned off.
6.4 Emergency operation Local control
Warning
When performing emergency operation, always be in contact with the bridge.
6.4.1 Start
1. Connect power with the main switch located on the motor controllers, and ensure that
power is available.
2. Set the selector switch located on the motor controller to position 3 Local control

6.4.2 Steering
1. The steering gear can now be operated manually from the steering gear compartment, by
using the red and green handles to push the emergency run buttons on the solenoids.
Note!
Only one of the pumps to be running.
6.4.3 Stop
1. Turn the selector switch on the motor controller to position 2 stop
2. Stop the power supply to the steering gear by switching of the main switch

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

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

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

activities.
Renew the pump control No starting 7.3

card
Rudder movement problems
Adjustment of limit switches The rudder cannot be moved from hard over 7.4
in feedback unit position to mid-ship
Renew start relay No starting 7.5
Renew solenoid driver Rudder movement problems 7.6
Renew bulb on control panel Defect bulb 7.7
Adjustment of dimmer Dimmer not correct adjusted 7.8
Renew alarm cards Fault in alarm system 7.9

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

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

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

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

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

7.3 Renew pump control card

no
Pump control card 1 None

Control system unit drawing None
1. Switch off power supply for the control system
1. Check that the wiring connection between the control system and motor controller are ok.
2. Loosen all connected wires [1].
3. Loosen the screws [2].
4. Replace the faulty pump control card.
5. Refit all wires and screws.

7.4 Adjustment of limit switches in feed back unit

no
None None

Technical data chap. 5 None
1. Remove cover on the feed back unit.
2. Switch off power supply for the Feed back unit.
3. Open the locking screws [1] using a hexagonal key.
4. Move the Steering gear to the limit switch position.
The tripping cams are adjusted to interrupt the steering

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

7.5 Renew start relay

no
Start relay 1 None

Drawing of motor controller None
1. Check wiring connection.
2. Check pump control card.
If the above mentioned items are checked and found in order, the start relay must be
renewed.
3. Ensure power supply to the motor controller is

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

7.6 Renew solenoid driver

no
Solenoid driver 1 None

Drawing of motor controller None
1. Start the actual pump unit.
2. Turn the selector switch in the motor controller door to remote position.
3. Check the solenoid driver by first make a

strap between terminal [3] and [4] on the
solenoid driver
Rudder should move to port.
4. Make a strap between terminal [4] and [16].
Rudder should move to stbd.
If the Steering gear moves to neither port nor stbd, the solenoid driver must be renewed.
5. Ensure power supply to the starter cabinet

is switched off.
6. Loosen all wires and screws.
7. Renew the solenoid driver [1].
8. Refit wires and screws

7.7 Renew bulb on control panel

no
Bulb 1 Dismantling tools 2

Cable diagram None
1. Remove the cover protecting the bulb using the

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

7.8 Adjustment of dimmer

no
None None

Technical data chap. 5 None
1. Locate the PC1024 card located on the terminal list

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

7.9 Renew alarm system cards

no
None None

Drawing alarm panels None
If the trouble shooting has concluded that alarm cards

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

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

8 TROUBLE SHOOTING
8.1 Trouble shooting when an alarm is present

One alarm system monitors two pumps.
Alarms Reason Corrective

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

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

actions
Defect pump Renew the

Control card
control card. control card
Renew the start

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

Defective micro switch in feed
switches in the back unit
limit switch box Limit switch
FB or in the
The Steering Renew the limit
steering lever
gear can only be switch in the
operated to one steering lever
side
Locate the defect
Failure in the
Wiring wiring
wiring
connections connection(s)
connections
and renew.

actions
Defective Repair the
Frequency
frequency frequency
converter
converter converter
Defect solenoid
driver Solenoid driver in
Renew driver
(conventional motor controller
pumps)
The steering Defect micro
gear goes to Renew the micro
switch in the Not starting
hard over switch
steering lever
position without
Rudder rudder command
movement when one of the Defect solenoid
problems pump units is driver Solenoid driver in Renew solenoid
started, without (conventional motor controller driver
giving rudder pumps)
command
The rudder
cannot be
Defect micro
brought from Renew the micro
switch in the feed Micro switch
hard over switch
back unit
position to mid-
ship
Defect amplifier Renew amplifier
Amplifier card
card card
Defect selector Renew selector
Selector card
card card
Defect pump Renew control
Control card
The Steering control card card
gear fails to
respond when Defect wiring
Locate the defect
connections
given rudder Wiring wiring
between control
command connections connection(s)
system and
and renew.
motor controller
Defect solenoid
driver Solenoid driver in Renew solenoid
(conventional motor controller driver
pumps)
Defect amplifier Renew amplify
Amplifier card
card card
Defect wiring
connections Locate the defect
Rudder cannot between control Wiring wiring
be moved out of system and connections connection(s)
centre position feedback /control and renew.
panel
Defect solenoid Solenoid driver in Renew solenoid
driver motor controller driver
(conventional

actions
pumps)
Rudder Rudder cannot

movement be moved from Adjustment of
Wrong adjusted
problems hard over Limit switches limit switches in
limit switch
position to mid- feed back unit
ship
Feed back
The rudder potentiometer not Locate and
movement is not correct adjusted adjust the
Potentiometer
equal to each FU controller incorrect
side (port/stbd) potentiometer not potentiometer
correct adjusted
8.2.2 Alarm system

actions
Defect fuse Back plane card Renew fuse
Defect back
Back plane card Renew card
plane card
Missing power Loose internal
supply Cables Reconnect
cables
Alarm system Change placing

Wrong placing of
problems Alarm ponds of panels (ECR /
panels
bridge)
Change placing
Wrong placing of
Alarm ponds of panels (ECR /
Missing signals panels
bridge)
to VDR
Defect piggy
Piggy back card Renew card
back card
8.2.3 Lamp control panel

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

9 CONTACT LIST
Country Address Telephone Fax
Rolls-Royce Marine AS +47 815 20 070* +47 70 20 86 00
Deck Machinery & Steering gear
Brattvaag
Serviceboks 1522
Norway
N-6025 LESUND, NORWAY
Deck.machinery.brattvaag@rolls-
royce.com
* 24 hr emergency
North America
Rolls-Royce Canada Ltd +1 902 468 2883 +1 902 468 2759
(GSN Commercial Marine)
196 Joseph Zatzman Drive, Unit 9
Canada
Dartmouth, Nova Scotia B3B 1N4
Canada B3B 1N4
UMLH@rolls-royce.com
Rolls-Royce Marine Inc. New Orleans +1 504 464 4561 +1 504 464 4565
200 James Drive West
St. Rose, LA 70087 USA
marianne.leine@rolls-royce.com
Rolls-Royce Commercial Marine +1 954 436 7100 +1 954 436 7101
10125 USA Today Way
Miramar, Fort Lauderdale
Florida 33025 USA
USA
Rolls-Royce Marine Inc +1 508 668 9610 +1 508 668 2497
110 Norfolk Street
Walpole, MA 02081 USA
marineinfo@rolls-royce.com
Rolls-Royce Marine Seattle +1 206 782 9190 +1 206 782 0176
1731 13th Avenue SW
Seattle, WA 98134-1009
seattle.marine@rolls-royce.com
South America
Rolls-Royce Marine Ltda +55 21 3860 8787 +55 21 3860 4410
Rua General Jose Cristino 31
20921400 So Cristovo
Brazil
RIO DE JANEIRO RJ, Brazil

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

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

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

10 SPARE PARTS
For delivered spare parts see attached spare part list. If additional spare parts are to be ordered,
the following information must be given:
Installation No. (T- Followed by a number), vessels name and owners name.
Shipping and invoicing address.
Drawing Number, Position Number, Article Number (Art. no.) and Quantity.
Note!
Information regarding the Steering gear electrical
system is found on a sticker inside the door on every
electrical cabinet.
The information is also found on the front page of this

manual.

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

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

12 DOCUMENTS, DRAWINGS AND DATASHEETS
The following documents should be used as reference.
Drawing/ document Document no Revision

Electrical Installation DMN227-061 K
Interface description for Steering gear control system 0002-4810 H
Configuration Steering gear 0003-4664 B
Cable diagram 0003-4659 C
Cable list 0003-4660 B
Terminal diagram 0003-4661 B
Power consumption 0003-4662 A
Emergency Steering Procedure 0002-4999 C
0002-9247 B
Motor Controller (FCON)
L-1799-00-03 D
0000-0319 A
Frequency Converter
0000-0324 A
0002-1030 B
Run/Stop/autostart panel in ECR
0002-1251 A
Alarm panel in ECR & Bridge W-1802-00-01 H
W-1221-01-00 C
Control system
L-1299-00-01 C
0003-4734 A
Main control panel on bridge
L-1320-01-20 -
W-1600-01-06 -
Feed back unit
A-9703 / A-10046 A/C
Connection box on Power Pack 0000-0639 A
Connection box on Actuator 0000-0640 B
SP-34014 B
For Mechanical drawings see mechanical part

13 REVISION
Revision Reason for revision Date Signature
A Release 13 August 2014 KBP

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

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

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

Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
rsundveien 24, N-6270 Brattvg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
1. GUIDELINES FOR INSTALLATION ACCORDING TO EMC
The following 10 rules are the basics for designing systems in compliance with EMC. Rules 1 to 7 are generally valid.
Rules 8 to 10 are especially important to limit noise emission.
Rule 1 All metal parts of the switch cabinet should be connected with one another through the largest possible
surface area so that the best electrical connection is established (no paint on paint!). If necessary, use contact
or scraper discs. The cabinet door should be connected to the cabinet using the shortest possible grounding
straps.
Rule 2 Signal, line supply, motor and power cables should be routed away from another (this eliminates mutual
interference!). The minimum clearance is 30 cm. Barriers should be provided between power and signal
cables. These barriers should be grounded at several locations.
Rule 3 Contactors, relays, solenoid valves, electromechanical operating hour counters etc. in the cabinet must be
provided with noise suppression devices, e.g. using RC elements, diodes, varistors. These devices must be
connected directly at the coil.
Rule 4 Non-shielded cables belonging to the same circuit (feeder and return cables) should be twisted with the
smallest possible distance between them. Wires, which are not used must be grounded at minimum one end.
Rule 5 Generally, noise which is coupled in, can be reduced by routing cables as closely as possible to g rounded
steel panels. For this reason, cables and wires should not be routed freely in the cabinet, but as closely as
possible to the cabinet itself and the mounting panels. This is also true for reserve cables. Connect the
reserve cables/conductors to ground at both ends to achieve an additional shielding effect.
Rule 6 Incremental encoders must be connected using shielded cables. The shield must be connected at the
incremental encoder and at the AC drive converter through the whole circumference of the screen to ensure
best high frequeny cable contact. The shield may not be interrupted, e.g. using intermediate terminals.
Rule 7 The shields of signal cables must be connected to ground at one end only, through the whole circumference
of the screen, to establish a good electrical connection (transmitter and receiver). If the potential bonding
between the screen connections is poor, an additional potential bonding conductor with a cross-section of at
least 10 mm should be connected in parallel with the shield to reduce the shield current. The shields can be
connected to ground at several locations, e.g. on the cabinet housing and on cable trays. Foil shields are not
recommended. Braided screens provide a better shielding effect (factor of 5).
Rule 8 Always place a radio interference suppression filter close to the noise source. The filter is to be connected
flush with the cabinet housing, mounting plate, etc. The best solution is a bare metal mounting panel (e.g.
stainless steel, galvanized steel), because the complete mounting surface can be used to establish good
electrical contact. The incoming and outgoing cables of the radio interference suppression filter should be
separated.
Rule 9 All variable-speed motors should be connected using shielded cables, whereby the shield is connected at
both ends to the housings through the largest possible surface area to minimize the inductance. The motor
feeder cables should also be shielded outside the cabinet, or at least screened using barriers. Cables with steel
shields are not suitable.
To connect the shield at the motor, a suitable cable gland with shield connection must be used. It should be
ensured that the connection between the motor terminal box and the motor housing has low impedance.
Otherwise, use an additional grounding strap between them. Never use Plastic motor terminal boxes!
Rule 10 Installing components such as output reactors, sinusoidal filters, motor filters, fuses, contactors, etc may not
interrupt the shield between the motor and the frequency converter. The components must be mounted on
mounting panels, which also simultaneously serve as the shield connection for the incoming and outgoing
motor cables. Metal barriers may be required to shield the components.

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2. DOCUMENT REVISIONS
Change Date Sign Description

D 28.11.05 RHj Update of document.
Added information regarding selection of fire resistance or flame
retardant cable type. (Ch. 3)
E 12.01.07 RHj
Added new requirements regarding cables for frequency converter
duty. (Ch. 4.2)
F 12.03.05 bten Corrected outdated IEC norms with new norms
Added information regarding recommendation og Halogen free
G 29.06.07 RHj cable (Ch. 3) and specified insulation level on power cables for
frequency converter duty. (Ch. 4.2)
H 14.01.09 RHj Updated reference to project specific cable list.
I 08.06.11 RHj Adjusted to include steering gear. (Info from TS)
K| 19.11.13 SL Update of document regarding minimum clearence and shield

grounding.

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

4.2 Redundant power supply

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

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

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

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

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

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

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

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

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

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

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

Approved by : DNV certificate E-9274

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

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

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

The fibre optical cables must be of multimode type with a core diameter of 50 or 62.5 m, and cladding diameter 125
m. ST connectors (also known as BFOC) are to be used in both ends of the cable. Each fibre optical link requires a
duplex connection, i.e. a total of four single fibres for each connection box.
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Cable Data:
Type: Multimode.
Cable Core Diameter 50 or 62.5 m.
Cladding Diameter: 125 m.
Recommended cables:
Nexans Gx-62,5 QIQI-3.7-R1.0 or Gx-62,5 QIQG-3.7-R1.0,
Draka Gx-50/125 AXXI-I/O-W or Gx-62.5/125 AXXI-I/O-W
Optronics OM1LST08UBK
8. INSTALLATION
8.1 General
According to classification requirements.
The following precautions must be taken in regards to cabling:
Ensure that there is sufficient space for the cables and cable-ducts used.
Ensure that there are no cable bends that reduce cable performance,
special attention to optical cables.
Ensure that power and signal cables are separated.
As a general rule, the minimum distance between power cables and signal cables is 0.3 meter.
Avoid routing of cables near power generator cables.

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

Power cable shield grounded in both ends.
8.6 Control cables

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

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

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8.8 Bus cables
Communication cable shield grounded according to documentation.
Each wire pair must be connected according to documentation.
8.9 Connecting load cells

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

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

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Steering Gear Brattvaag
0002-4810
Interface for Steering Gear

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

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

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

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

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

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

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

x=A-B
Sign.: SMO : 06.06.13 Appr.HMO : 06.06.13 0002-4810, rev. H Page 1 of 5

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

Note: only B when 2 rudders
Mode Signal type Terminal Group name Common NO NC
1 Potential free switching contact CO +CSx-U11: 7 8 9
x=A-B
Pulse signal, leaving DP/DP3/Joystick

Signal type Terminal Group name Common NO
Potential free switching contact CO +CSx-Kn, 15 18
x=A-B, n=2-4
Remote/Stop/Local indication, pump xn (x=A-B, n=1-2)

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

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

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

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

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E0-Alarm from alarmpanel APxn (x=A-B, n=1-2)
Potential free contact NO +APxn-X3: 1 2
x=A-B, n=1-2
Autostart signal from alarmpanel APxn (x=A-B, n=1-2)

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

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

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

Signal type Terminal Group name Clockw. Wiper Counter Clockw Mid.point
5kohm potmeter 2 +FBxn 4 5 6 7
5kohm potmeter 3 +FBxn 8 9 10 11
x=A-B, n=1-2
Note: Only for use as rudder indication to DP
Check Cable diagram for occupied potmeters ( e.g. to CS or RAI in SGR )

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Signals to Steering Gear control system from external equipment
In command pulse for modes CSx (x=A-B)
Mode Signal type Terminal Group name Common NO
1 Potential free contact, pulse NO +CSx-U11: 1 2
x=A-B
Eneable request from DP/Joystick CSx (x=A-B)

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

Mode From Signal type Terminal Group name Common NO
x=A-B
Analog steering signal, +/-10V CSx (x=A-B)

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

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

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

Digital Start/Stop signal for pump xn (x=A-B, n=1-2)
Start +CSx-+Un-X3: 1 2
Stop +CSx-+Un-X3: 1 3
Only to be used when Oil Transfer Pump is included in RR scope of supply:

Digital Start/Stop (auto-release button) signal for transfer pump, xn (x=A-B, n=1-2)
NO, Close to run pump
Signal type Terminal Group name L1 L2
Start/Stop +MCxn-X12: 1 2

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Doc. ID: 0003-4664 Rev: B

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

Classification drawing control system W-1007-00-00
Classification dwg. Rudder ind. System
Classification drawing Deviation alarm
Class. drawing bypass & Separation system
Power consumption pump unit 35kW
Voltage pump unit 440-460V
Connection type
Frequency pump unit 60 Hz
Current pump unit 67A
Yard SPP Shipbuilding Co. Ltd
Hull no. H-4098,H-4099
Rolls Royce Marine order no. 13S000193-94
Software alarm panel 5250-W18020001-1

Software motor controller 5250-W18020001-2
Classing company: LRS
One man bridge operation? No
Emergency steering procedure Doc. No. 0002-4999
Steering System? Yes
Originator: T.Hel. Verifier: T.Sel Page 1 of 7

Doc. ID: 0003-4664 Rev: B
Alarm List Steering Gear

Alarm List Steering Gear
Description Al.Nr Light Al.Nr Description
STEERING GEAR STEERING GEAR
PUMP NO. 2 PUMP NO. 1
Overload 10 20 Overload
Phase failure 11 21 Phase failure
Power Failure 12 22 Power Failure
Power Failure Control 13 23 Power Failure Control
Low Oil Level 14 24 Low Oil Level
Hydraulic Lock 15 25 Hydraulic Lock
Clogged Filter 16 26 Clogged Filter
High Oil Temp 17 27 High Oil Temp
Not used 18 28 Not used
Aux. Steering 19 29 Aux. Steering
Note: The alarms are indicated on bridge and in machinery space area

Doc. ID: 0003-4664 Rev: B
Lamp Text For Control Panel

Motor/Pump ordering (from-to): STBD
Main Control Panel:

Reference Lamp text
Pump A (A1) Pump 2

Pump B (A2) Pump 1

Doc. ID: 0003-4664 Rev: B
Jumper setting for control system

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

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

Steering
Description Internal Conection
mode
(-X10:1) Ext. Steering System -X10:5 To -U11:11

(-X10:2) Not used -X10:6 to -U11:24
(-X10:3) Not used -X10:7 to -U11:37
(-X10:4) Not used -X10:8 to

Doc. ID: 0003-4664 Rev: B
Jumper Setting for AUX Steering:

Steering Description Jumper Setting CS1 CS2
(-U10) Feed back connected JP20 = Yes
(-U41) Feed back connected JP60 = Yes
1 (-U42) Ext. Steering System JP50 = FU EXT, JP51 = Slave Slave

2 (-U42) Not used JP60 = FU EXT, JP61 = Master Slave
3 (-U42) Not used JP70 = FU EXT, JP71 = Master Slave
Note: For Jumper setting on backplane, see drawing for control system
Note 0: If NFU Steering is not used apply internal connection X6:3 to X6:6
Note 1: Setting for JP3 and JP4 should be "NO" for classification societies GL and ABS, except when
notation for "One man bridge operation". See also jumper setting for control panel
Note 2: For Vessels with frequency controled pumps delivered with NFU Steering an internal
connection -X7:6 to-X7:7 must be applied.

Doc. ID: 0003-4664 Rev: B
Jumper setting for alarm system:

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

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

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

Main Control Panel:
Jumper setting for override modules:
JP1 External override NO

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

JP30-Ch.9 Supply to channel External

Doc. ID: 0003-4664 Rev: B

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

Location Equipment El-drawing Layout
+FBA1 Feedback unit 1 steering gear W-1600-01-06
+FBA2 Feedback unit 2 steering gear W-1600-01-06
+CBA1 Connection box 1 0000-0640
+MCA1 Motor Controller no.: 1 0002-9247 L-1799-00-03
+MCA2 Motor Controller no.: 2 0002-9247 L-1799-00-03
+FCA1 Frequency converter no.: 1 0000-0319 0000-0324
+FCA2 Frequency converter no.: 2 0000-0319 0000-0324
+APA2 Alarm panel ECR W-1802-00-01
+CP9 Indication panel ECR 0002-1030 0002-1251
+CSA Control system W-1221-01-00 L-1299-00-01
+APA1 Alarm panel bridge W-1802-00-01
+CP1 Main control panel 0003-4734 L-1320-01-20
Part List
Item ID SP-34014 Revision B

Description Spare Part Kit Status RELEASED
0 piece SP-34014 B Spare Part Kit ELECTR., CS, 2 YEARS
1 0004 5 piece 000103689 A Fuse FUSE 5X25, 4A, 450V, TIME-LAG MC
1 0006 5 piece 10498 B Fuse FUSE 5X20MM 4A, SLOW MC
1 0008 5 piece 10499 A Fuse 5X20MM 6.3A, SLOW MC
1 0010 10 piece 000079851 A Lamp 031-963.5 SERIES 31, 36V-30mA CM,CU
1 0012 5 piece 56075 B Fuse 5X20MM 2,0A SLOW AS
1 0030 1 piece 000079850 A Mounting Tool MOUNTING TOOL FOR EAO, 61-9730.0
1 0040 1 piece 11127 # Tool Kit LAMP REMOVER FOR SERIES 06
End of Report

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USER MANUAL

Rolls-Royce Steering Gear

Yard : SPP Shipbuilding Co., Ltd.

3 SYSTEM DESCRIPTION .........................................................................7

4 DELIVERY SPECIFICATIONS ...............................................................19

5 TECHNICAL DATA ................................................................................21

6 OPERATING INSTRUCTION .................................................................25

7 MAINTENANCE INSTRUCTION ............................................................28

Rolls-Royce Steering Gear User Manual Page 1 of 49

9 SPARE PARTS ..................................................................................... 46

10 CONTACT LIST .................................................................................... 47

11 DESIGN DRAWINGS ............................................................................ 48

Page 2 of 49 User Manual Rolls-Royce Steering Gear

1.3 Structure of this manual

Chapter 6 contains instructions for operating the Steering Gear system.

Chapter 9 contains Rolls-Royce Marine contact details.

Rolls-Royce Steering Gear User Manual Page 3 of 49

Page 4 of 49 User Manual Rolls-Royce Steering Gear

2.1 General statement

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

IT IS ALSO THE USERS RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

Rolls-Royce Steering Gear User Manual Page 5 of 49

2.3 Declaration of conformity

Det Norske Veritas (DNV).

Page 6 of 49 User Manual Rolls-Royce Steering Gear

3.1 System overview

Rolls-Royce Steering Gear User Manual Page 7 of 49

Pos. Steering Gear Chapter

Page 8 of 49 User Manual Rolls-Royce Steering Gear

The Rudder actuator main components are:

The rotor, turning in bearings at top and

The stoppers also act as mechanical rudder

The rudder carrier bearing of the actuator has

The sealing system consists of synthetic oil

3.2.1.1 Control Valve

The control valves [1] are mounted on the

The valve incorporates an automatic lock

The valve is also equipped with a safety relief

Rolls-Royce Steering Gear User Manual Page 9 of 49

3.2.1.2 Safety Relief Valve

A safety relief valve is mounted on the rudder

3.2.2 Power Pack

3.2.2.1 Pump Unit

The power pack consists of two individual

Electric motor [1]

The pumps are submerged in the oil tank;

Only one pump unit is in operation normally

Page 10 of 49 User Manual Rolls-Royce Steering Gear

The oil tank is divided into chambers; one for

Low oil level alarm switch [1]

3.2.2.3 Click here to enter text.Oil Cooler

To keep the oil temperature to an acceptable

The cooler assembly is fitted with a closing

A high temperature alarm switch [4] is

Depending on pump capacity one or two full

The filters are installed with an electrical

The filter is equipped with a bypass function

Rolls-Royce Steering Gear User Manual Page 11 of 49

The rudderstock and the rudder actuator are