Steering Gear

STEERING GEAR
• TECHNICAL DATA
• TYPE ELECTRO - HYDRAULIC, FOUR CYLINDER, RAM TYPE
• TYPE OF RUDDER - SEMI BALANCED
• RUDDER BLADE AREA - 12 m2
• RUDDER BLADE PROJECTION BEYOND BASIC PLANE - 514 mm
• TORQUE DEVELOPED ON RUDDER STOCK AT RUDDER ANGLE
35° & PRESSURE OF 130 KG/CM2 = 630 KNM
• RUDDER WORKING ANGLE TO EITHER SIDE =35°-1°
• CRITICAL ANGLE OF RUDDER = 36° + 1°
1135.6TT/ENGG/STEERING/ 1
• SERVICE LIQUID : TURBINE OIL ТП-46
• DURATION OF RUDDER MOVING FROM 35° OF ONE SIDE TO 30°

OF THE OTHER SIDE:-
• AT ONE POWER UNIT OPERATING < 28 s
• AT TWO POWER UNITS OPERATING <15 s
• SAFETY VALVE OPERATING PRESSURE : 165+10 kg/cm2
• PRESSURE DROP LIMIT ACROSS FILTER : 9-1.0 + 0.5 kgf/cm2
• MASS OF SERVICE LIQUID IN STEERING SYSTEM - 700 kgs
• RESERVE TANKS CAPACITY - 380 kgs

• CONTROL PRESSURE CIRCUIT SAFETY VALVE SET : 65 kgf/ cm2
• SAFETY VALVE SETTING OF FILLING AND DRAINING UNIT : 20

kgf/cm2
• HYDRAULIC PUMP
- VARIABLE DELIVERY AXIAL PISTON TYPE
- TURNING ANGLE OF PUMP SWINGER :
-OPERATING : ±210 (± 0.3665 RAD)
- MAXIMUM : ±250 (± 0.436 RAD )
- PUMP RPM : 970
- DELIVERY CAPACITY : 185 l/min

•AUXILIARY/MAKEUP PUMP
• DELIVERY : 31 l/min
• RATED CONTROL PRESSURE : 40-50 kgf/cm2
• OPERATING MAKE-UP PRESSURE 10-0.2 kgf/cm2
• FILTER TYPE – NETTED.
• BY PASS VALVE OF FILTER OPERATES AT : 9 +0.5 -1.0 kgf/cm2
STEERING GEAR
COMPONENTS
• POWER DRIVE:- THE POWER DRIVE DEVELOPS TORQUE
NECESSARY FOR RUDDER PUTTING OVER. THIS CONSISTS OF
STOCK DRIVE, TWO MAIN POWER UNITS AND ONE RESERVE
POWER UNIT.
• STOCK DRIVE:– THIS IS USED FOR RUDDER PUTTING OVER,
CONSISTS OF GUIDE BEAM, CYLINDRICAL BLOCK AND TILLER.
THE CYLINDRICAL BLOCK CONTAINS FOUR HYDRAULIC
CYLINDERS.
STOCK DRIVE
• MAIN POWER UNITS :–MAIN POWER UNITS SUPPLY
SERVICE LIQUID TO STOCK DRIVE CYLINDERS FOR RUDDER

PUTTING OVER. EACH UNIT CONSISTS OF PUMP НК32,
ELECTRIC MOTOR, OIL COOLER, OIL FILTER, AUXILIARY
CONTROL AND MAKE UP PUMP.
• AUXILIARY RESERVE POWER UNIT:- LOCATED IN
RESERVE PUMP COMPARTMENT FOR SUPPLY OF SERVICE

LIQUID TO STOCK DRIVE’S CYLINDERS FOR RUDDER
PUTTING OVER. THIS CONSISTS OF PUMP НК32, ELECTRIC
MOTOR, OIL COOLER, OIL FILTER AUXILIARY CONTROL AND
MAKE UP PUMP.
MAIN PUMPING UNIT
• MAIN VALVE BOX - CONSISTS OF 7 STOP VALVES:-
• H1 AND H2 CONTROLS LINKING OF POWER UNIT
• K1 AND K2 CONTROLS LINKING OF CYLINDERS
• B1 CONTROL LINKING OF COAXIAL CYLINDERS
• K31 AND K32 CONTROL LINKING OF STEERING ENGINE
HYDRAULIC SYSTEM WITH FILLING AND DRAIN UNIT.
MAIN VALVE BOX
H1 H2
K1 K2
K32
K31
B1
MAIN VALVE BOX FLOW DIAGRAM
TO VALVE BOX
K1 K2
H1 H2
TO PUMP TO PUMP
Б1
TO CYLINDER K31 K32 TO CYLINDER
TO FILLING AND
DRAINING SYSTEM
KП1
KП2
• VALVE BOX : IT CONSISTS OF THE ПK-500 SAFETY VALVES,
THE MAKE UP AND THE SAFETY VALVE BOX. THE SAFETY
VALVE BOX IS INTENDED FOR PROTECTING THE MAIN
HYDRAULIC PUMP WHEN THE LIMITING PRESSURE VALUES
ARE ATTAINED. WITH PRESSURE IN THE DELIVERY SPACE
RISING ABOVE THE PERMISSIBLE VALUE THE SAFETY VALVE
COMMUNICATING WITH THE DELIVERY SPACE OPENS AND THE
WORKING FLUID STARTS FLOWING OVER FROM THE DELIVERY
SPACE INTO THE SUCTION SPACE. WITH THE DELIVERY
PRESSURE FALLING DOWN TO PERMISSIBLE LIMITS, THE
VALVE CLOSES AND THE WORKING FLUID OVER FLOW FROM
ONE SPACE INTO THE OTHER IS STOPPED.
ПK-500 SAFETY
VALVE BOX
VALVE
VALVE BOX
VALVE BOX
SAFETY VALVE MAKE UP VALVE
VALVE BOX
MAKE UP VALVE
VALVE BOX FLOW DIAGRAM
SAFETY VALVE
•CUT-OFF VALVE. THE CUT OFF VALVES ARE INTENDED TO
AUTOMATICALLY COMMUNICATE THE PUMPS AND THE DRIVE
WITH RUDDER STOCK CYLINDERS. CUT OFF VALVES ARE
MOUNTED ON THE PUMPING UNITS.
• RESERVE TANK -A STORING RESERVOIR OF SERVICE LIQUID
NECESSARY FOR REPLENISHING HYDRAULIC SYSTEM.
CUT-OFF VALVES
KR-44
CUT-OFF
VALVES 1135.6TT/ENGG/STEERING/ 21
CUTOFF VALVE
OIL DRAIN
BUSHING
VALVE OIL OUTLET
BODY
OIL INLET
BUSHING
CONTROL OIL PRESSURE

• FILLING AND DRAIN UNIT
• USED FOR :-
• FILLING HYDRAULIC SYSTEM OF STEERING GEAR AND
RESERVE TANKS WITH SERVICE LIQUID FROM RESERVOIR
• REPLENISHING LEAKAGE
• DRAINING UNDER REPLACEMENT OF SERVICE LIQUID
• CONSISTS OF:-
• GEAR-TYPE PUMP
• ELECTRIC MOTOR
• FILTER
• MANOMETER PANEL
•REPLENISHING TANK - THESE ARE FOR REPLENISHING OF
LOSSES UNDER LEAKAGE OF SERVICE LIQUID IN HYDRAULIC
SYSTEM. TWO ARE LOCATED IN STEERING GEAR
COMPARTMENT AND ONE IN RESERVE PUMP COMPARTMENT.
• HYDRAULIC CYLINDERS - HYDRAULIC CYLINDERS ARE FOUR
IN NUMBER. EACH HYDRAULIC CYLINDER IS EQUIPPED WITH A
SET OF TWO VALVES, ONE EACH AT ITS EXTREMITIES
PROVIDED FOR EITHER INLET OR OUTLET OF OIL. THE OTHER
VALVE IS FOR PRESSURE GAUGE CONNECTION.
FOR MOVEMENT OF THE RUDDER TO THE STARBOARD OR TO
THE PORT DIRECTION, OIL IS LET INTO OR LET OUT OF A PAIR
OF DIAGONALLY OPPOSITE CYLINDERS. FOR INSTANCE IF, THE
MOVEMENT OF RUDDER IS TO BE TOWARDS STARBOARD, OIL IS
SUPPLIED TO CYLINDERS 2 AND 3, AND LET OUT OF 1 AND 4. IN
THE EVENT OF DAMAGE TO ANY CYLINDER, MOVEMENT OF
RUDDER CAN STILL BE ACHIEVED BY USING ONLY A SINGLE
PAIR OF CYLINDERS OF THE SAME SIDE.
LAY OUT OF HYDRAULIC CYLINDERS
1 2
PISTONS Tiller
3 4
• RUDDER :- RUDDER IS INSTALLED IN THE CENTRE PLANE OF
SHIP AND CONSISTS OF RUDDER BLADE, RUDDER STOCK AND
RUDDER BEARINGS (LOWER, MIDDLE AND UPPER). RUDDER
BLADE IS A STEEL WELDED STRUCTURE. THE INNER CAVITY OF
THE RUDDER BLADE IS FILLED WITH PLASTIC FOAM ПХВ‑1.
DETACHABLE PLATE PROVIDING ACCESS TO THE RUDDER
STOCK BOLT IS LOCATED ON THE SURFACE OF RUDDER BLADE
SHELL-PLATE FROM PORT SIDE. THE INTERNAL CAVITY OF
RUDDER BLADE UNDER DETACHABLE PLATE IS FILLED WITH
LUBRICANT ЛИТОЛ‑24 (LITOL-24).

• RUDDER STOCK : THIS IS MADE OF STEEL AND ROTATES IN
THREE IN NUMBER SLIDE BEARINGS. RUDDER LOWER BEARING
IS LOCATED IN STERN-FRAME SOLE. IT CONSISTS OF BEARING
SLEEVE PRESSED IN STERN-FRAME SOLE. BEARING SLEEVE IS
MADE OF BRONZE. RUDDER MIDDLE BEARING IS LOCATED AT
THE FANTAIL OF SHIP HULL. IT CONSISTS OF BEARING
SLEEVE PRESSED IN STERN-FRAME, COATING SLEEVE, PRESS-ON
SLEEVE AND STUFFING BOX. BEARING SLEEVES AND COATING
ARE MADE OF BRONZE. PRESS-ON SLEEVE IS MADE OF BRONZE
AND CONSISTS OF TWO HALVES CONNECTED WITH EACH
OTHER BY TWO STOPPER PLATES

RUDDER UPPER BEARING IS LOCATED ON THE PLATFORM OF
STEERING GEAR COMPARTMENT. IT CONTAINS BEARING SLEEVE
PRESSED IN UPPER BEARING BODY. BEARING SLEEVE IS MADE
OF BRONZE. UPPER BEARING BODY IS MADE OF STEEL.
• STUFFING BOX:- THIS IS OF MULTIPLE-LAYER BRAIDED TYPE.

COMPRESSION OF STUFFING BOX IS PERFORMED BY PRESS-ON
SLEEVE WITH THE USE OF NUTS AND PINIONS LOCATED ON
PINS ALONG THE PERIMETER OF PRESS ON SLEEVE. ALL THE
RUDDER BEARINGS ARE SUPPLIED WITH LUBRICANT ЛИТОЛ-24
BY MEANS OF THREE PISTON-TYPE GREASERS LOCATED IN THE
STEERING GEAR COMPARTMENT.
RUDDER
STOCK PLUG
TILLER KEY TILLER KEY
TILLER
UPPER BEARING
STUFFING BOX
MIDDLE BEARING
STIFFENING RIB
AFT HAWSE LUBRICATION FEED PIPE
STERN FRAME
LOWER BEARING
FORWARD HAWSE
SEMI BALANCED
RUDDER
MODES OF OPERATION OF HYDRAULIC CIRCUIT
• NORMAL MODE - IN THIS MODE OF OPERATION ONE PUMPING
UNIT WORKS IN TURN FOR ALL THE FOUR CYLINDERS AND
ENSURES NOMINAL CHARACTERISTICS OF THE STEERING GEAR
WITH REGARD TO TORQUE PRODUCED AND THE TIME TAKEN
FOR SHIFTING RUDDER. IDLE PUMPING UNITS ARE IN STANDBY
POSITION AND ARE NOT DISCONNECTED FROM THE
HYDRAULIC CIRCUIT BY CLOSING OF VALVES ON THE MAIN
VALVE BOX. SIMULTANEOUS OPERATION OF TWO PUMPING
UNITS FOR ALL FOUR CYLINDERS IS PERMITTED IN THIS MODE
OF OPERATION IN NARROW WATERS. IN THIS CONFIGURATION
OF OPERATION, THE TIME FOR SHIFTING THE RUDDER IS
REDUCED BY HALF.
RESERVE MODE. THE STEERING GEAR CAN OPERATE IN
FOLLOWING RESERVE MODES IN CASE OF ITS COMPONENTS
FAILURE:-
(I) WITH ONE MAIN PUMPING UNIT DAMAGED
(II) WHEN ANY OF THE CYLINDERS OR ITS PIPELINE IS

DAMAGED.
IN SUCH A CASE, THE STEERING GEAR FUNCTIONS WITH

ONE PAIR OF COAXIAL CYLINDERS FROM ANY ONE OF THE
PUMPING UNIT WITH THE PAIR OF DAMAGED CYLINDERS
ISOLATED FROM THE PRESSURE CIRCUIT .THE SPEED OF
RUDDER SHIFTING IS DOUBLED WITH HALF THE VALUE OF
NOMINAL TORQUE PRODUCED.
• EMERGENCY MODE. FOLLOWING ARE CLASSIFIED AS
EMERGENCY MODES OF OPERATION:-
• TWO MAIN PUMPING UNITS ARE DAMAGED. STANDBY

PUMPING UNIT ENSURES NORMAL STEERING GEAR
OPERATION.
• TILLER COMPARTMENT IS FLOODED. STANDBY PUMPING

UNIT ENSURES NORMAL STEERING GEAR OPERATION.
• ELECTRICAL REMOTE CONTROL SYSTEM NON-

OPERATIONAL. THE STEERING GEAR CAN BE OPERATED
FROM ANY OF THE THREE PUMPING UNITS IN MANUAL MODE
BY DIRECT MANUAL CONTROL OF THE KR 44 DEVICE.
CONTROL SYSTEM
PURPOSE:-THE STEERING GEAR CONTROL SYSTEM “CORRAX01”
PERFORMS THE FOLLOWING FUNCTION :-
• REMOTE STARTING OF PUMPING UNITS AND REMOTE
CONTROL OF STEERING GEAR FROM BRIDGE AND OPS ROOM.
• LOCAL STARTING OF PUMPING UNITS FROM TILLER
COMPARTMENT AND EMERGENCY TILLER POST AND
REMOTE CONTROL OF STEERING GEAR FROM THE LOCAL
CONTROL PANELS
• MANUAL CONTROL OF THE STEERING GEAR BY USING THE
KNOB OF ELECTRO HYDRAULIC CONTROL DEVICE “KR 44”.
• CONTROL OF ALL STEERING MODES
MODES OF STEERING
• AUTOMATIC
• PRECISION - AUTOMATIC STEERING FOR PRESET COURSE
WITH MAXIMUM ACCURACY
• ADAPTATION -AUTOMATIC STEERING OF SHIP FOR PRESET
COURSE WITH ADAPTATION TO THE CHANGING EXTERNAL

CONDITIONS.
• ECONOMICAL - AUTOMATIC STEERING FOR PRESET COURSE
WITH MINIMUM NUMBER OF RUDDER PUTTING OVER.

• TURN PORT –AUTOMATIC STEERING LEFT WITH DIFFERENT
VALUES OF PRESET CIRCULATION RADIUS

• TURN STBD – AUTOMATIC STEERING RIGHT WITH DIFFERENT
VALUES OF PRESET TURNING RADIUS
• MODE HAND - IS TRACKING CONTROL OF POWER UNITS
FROM THE HELM OF ANY OF CONTROL PANELS.
NOTE:- SIMULTANEOUS OPERATION OF ANY TWO POWER
UNITS IS PROVIDED FOR ONLY IN «AUTO» AND «HAND»
(FOLLOW-UP) MODES.
• MODE NFU –REMOTE STEERING FROM PUSH BUTTONS «PORT»
AND «STBD» ON CONTROL PANEL KR1 IN OPS ROOM OR BRIDGE,
OR LOCAL STEERING FROM PUSH BUTTONS «PORT» AND «STBD»
ON CONTROL PANEL KR2 IN STEERING GEAR COMPARTMENT IS
USED IN CASE OF INTERRUPTION IN OPERATION OF STEERING
SYSTEM IN THE MODE «HAND».
• «MODE MANUAL» - EMERGENCY STEERING MODE
PERFORMED BY MEANS OF A HANDLE OF DEVICE KR44 FROM
ONE OF THE POWER UNITS AND IS USED IN CASE OF FAILURE
OF REMOTE CONTROL MEANS.
• ORDER OF PRIORITY. THE THREE STEERING POSITIONS
HAVE THE FOLLOWING ORDER OF PRIORITY:-
• LOCAL CONTROL CONSOLE (“KR2” PANELS, ONE EACH

FOR EACH PUMP, IN THE STEERING GEAR COMPARTMENT
AND EMERGENCY STEERING POST).
• CONTROL CONSOLE IN POST NO 21 (“KR 1” PANEL IN OPS

ROOM).
• CONTROL CONSOLE IN POST NO19 (“KR1” PANEL IN

BRIDGE).
• ELECTRICAL DEVICES
NAME QTY LOCATION NOTE
“KR1” 02 •OPS ROOM POST CONTROL CONSOLE
DEVICE NO. 21- ONE
• ENCLOSED BRIDGE
POST NO. 19 - ONE
“KR2” 03 ONE EACH NEAR LOCAL CONTROL
DEVICE EVERY POWER UNIT CONSOLE
“KR3” 04 • OPS ROOM POST RUDDER INDICATOR
DEVICE NO. 21- ONE
• ENCLOSED BRIDGE
POST NO. 19 - ONE
• MCR & DCHQ POST
NO. 27 - TWO
“KR8” 02 STEERING GEAR RUDDER SENSOR
DEVICE COMPARTMENT
“KR44” 03 ELECTRO-HYDRAULIC
DEVICE DEVICE
• CONTROL PANELS (“KR1”). INSTALLED IN BRIDGE AND OPS
ROOM. SELECTION OF THE MODE OF THE FUNCTIONAL SYSTEM
“AUTOMATIC” (INCLUDING ALL SUB MODES), “HAND” AND
“REMOTE NON FOLLOW UP”, REMOTE START AND STOP OF THE
PUMPS CAN BE DONE FROM THIS CONSOLE.

• LOCAL CONTROL PANELS (“KR2”). IT IS INSTALLED NEAR
THE RESPECTIVE POWER UNIT OF THE RUDDER ENGINE AND
PROVIDES CONTROL OVER ELECTRIC HYDRAULIC DEVICES
“KR44” IN “AUTOMATIC” AND “HAND” MODES BY SIGNALS
FROM THE “KR1” DEVICE AND IN “LOCAL NON FOLLOW UP”
MODE FROM BUTTONS OF LOCAL CONSOLE.

CONTROL PANEL (KR1)
CONTROL PANEL (KR1)
ON
PUMP 3 HOOTER
OFF
LAMP TEST
ON
PUMP 2 QUIET
OFF SCREEN
ON AUTO
PUMP 1
OFF HAND
NFU
POST 21
POST 19 KEYBOARD
LOCAL
NON FOLLOW UP MODE

2A FUSE
220 V FUSE
P S
50 HZ FUSE
CONSOLE
POWER ON
OPERATING
ON ON
OFF OFF
KR1 PANEL
CONTROL PANEL (KR1)
CONTROL PANEL (KR1)
SCREEN OF KR1 PANEL
SUB MODE
SPEED
COURSE
TURN RATE
ACTUAL
SET COURSE OFF
SUB MODE
91 PRECISION
SET
RUDDER
92 ADAPTATION 55
40
51 COURSE
40 30 20 10 0 10 20 30
93 ECONOMICAL 400
52 TURNING RADIUS
95 STBD
53 TURN RATE
35
96 PORT Diagnostic Mode Values 54 TURN RATE LIMIT
11 LEDS SCREEN
01 GRAY
12 SET TIME
02 DARK GREEN
13 GRAPHICS
03 BLACK
• RUDDER INDICATORS (“KR3”). IT IS DESIGNED TO BE USED
AS A REMOTE RUDDER ANGLE INDICATOR AND PROVIDES
DISPLAY OF CURRENT RUDDER POSITION ON SEMI SEGMENTAL
DIGITAL INDICATORS WITH DISCRETENESS OF 1 DEGREE.
• ELECTRICAL HYDRAULIC DEVICES (“KR44”). IT IS
INSTALLED DIRECTLY ON THE POWER UNITS OF THE RUDDER
ENGINE. IT SERVES AS A ELECTRO- HYDRAULIC, ONE STAGE
PROPORTIONAL REGULATING DEVICE IN HYDRAULIC LOOPS OF
PUMPS. IT CONVERTS THE INPUT ELECTRIC SIGNAL INTO A
MECHANICAL OUTPUT TO CONTROL THE OIL FLOW INTO THE
CONTROL SLIDE VALVE THEREBY CONTROLLING THE
MOVEMENT OF HYDRAULIC PUMP SWASH PLATE AND FINALLY
THE RUDDER POSITION.
• STEERING SENSORS (“KR8”). THIS DEVICE GENERATES AC

SIGNALS PROPORTIONAL TO THE TURNING ANGLE OF THE
RUDDER WHICH IS DISPLAYED ON THE “KR-1” AND “KR-2”
PANEL.
ELECTRICAL HYDRAULIC DEVICES (“KR44”).
STEERING SENSORS (“KR8”).
EXPLOITATION
• PRE-START CHECKS :-
• CHECK THE LAST ENTRY IN THE LOG BOOK.
• CHECK THE OIL LEVEL IN THE SYSTEM AND MAKE UP TANK.
FILL THE OIL IN THE MAKE UP TANK FROM THE RESERVE
TANK, IF REQUIRED.
• CHECK VISUALLY THE STEERING GEAR COMPONENT PARTS
AND MAKE SURE THEY ARE IN GOOD WORKING ORDER AND
THERE ARE NO FOREIGN OBJECTS NEAR THE MOVING PARTS.
• VISUALLY INSPECT THE RUDDER STOCK, AND CHECK FOR
AVAILABILITY OF GREASE ON THE GUIDING BEAMS. CHECK
ALL THE GREASE CUPS FOR PRESENCE OF ADEQUATE AMOUNT
OF GREASE.
• THE INSULATION RESISTANCE OF ENGINE ELECTRIC DRIVE
MUST NOT BE LESS THAN 0.5 MΩ.
• INFORM SWITCH BOARD TO PROVIDE ELECTRIC SUPPLY.
• CHECK THE COOLING WATER SUPPLY LINE PRESSURE, IT
SHOULD BE NOT LESS THAN 1.0 kg/cm2.
• CHECK RELIABILITY OF OPERATION OF INTERCOM AND
TELEPHONE COMMUNICATION BETWEEN STEERING GEAR
COMPARTMENT, STEERING GEAR RESERVE PUMP
COMPARTMENT, OPS ROOM (POST NO. 21) AND POST NO. 19.
(BRIDGE)
• CHECK THE ENTIRE INDICATION LAMPS ON POST NO. 21 & 19
AND STEERING COMPARTMENT BY THE “TEST CHECK” BUTTON.
ENSURE ALL THE LEDS ARE GLOWING.
• CHECK THE FOLLOWING:
• IN TILLER COMPARTMENT SET THE KNOBS OF SA CIRCUIT

BREAKER (ELECTRICAL SWITCH) IN “1” POSITION AND
KNOBS OF THE CONTROL MODE SWITCHES ON DEVICES “KR
2” (LOCAL PANEL OF “CORRACS-01”) CONTROL SYSTEM INTO
“LOCAL POSITION”.
• ENERGIZE THE MAIN AND EMERGENCY POWER SUPPLY

FEEDERS OF THE MOTOR STARTERS.
• ENERGIZE THE FEEDER OF CONTROL SYSTEM “CORRACS-01”
INSTRUMENTS FED FROM THE SHIP’S MAIN.
• SET THE KNOBS OF AUTOMATIC CIRCUIT BREAKERS “QI---

Q4” OF THE POWER SUPPLY SWITCHBOARDS AS1, AS2, AND
AS3 INTO POSITION “ON”
• CHECK THE POSITION OF ALL THE SYSTEM VALVES TO BE IN

RESPECTIVE CLOSED OR OPEN POSITION AS PER THE VALVE
BLOCK POSITION TABLE (APPENDIX ‘D’). ENSURE THAT THE
RESERVE TANK VALVES SUPPLYING OIL TO THE FOUR
CYLINDERS OF THE RUDDERSTOCK AND THE VALVES OF
DRAINING AND FILLING UNIT ARE CLOSED.
• START ANY ONE PUMP FROM THE LOCAL POSITION AND
TURN THE RUDDER FROM 35O PORT TO 35O STBD AND THEN
BRING THE RUDDER INTO MIDSHIP POSITION BY THE “KR-
44” DEVICE WHICH IS MOUNTED ON THE PUMP . DURING
THIS, WATCH THE PRESSURE OF HYDRAULIC SYSTEM AND
ALSO CHECK FOR OIL LEAKAGES, PURGE OUT THE AIR
FROM THE HYDRAULIC SYSTEM. IF THE DIFFERENCE OF
THE PRESSURE GAUGE ACROSS THE FILTER IS MORE THAN
9.0 kg/cm2, THE FILTER IS CLOGGED AND NEEDS CLEANING.
• PUT THE SYSTEM INTO “TEST MODE” BY DIALING “40”

FOLLOWED BY “ENTER” BUTTON IN THE DISPLAY FRAME
(SCREEN) AT “KR-1” WHICH CORRESPONDS TO STARTING OF
THE PUMPS. IN THE “DIAGNOSTIC VALUE WINDOW” (FIGURE
3.3) RESULT OF STEERING ENGINE DRIVE PERFORMANCE
(WITH WORKING PUMP) WILL SHOW UP.
• CHECK THE OPERATION OF PUMP AND RUDDER FROM ALL

THE MODES EXCEPT “AUTO” MODE, AS FOLLOWS :-
• LOCAL NON FOLLOW UP - FROM ASP
• REMOTE NON FOLLOW UP - FROM POSTS NOS. 21 AND 19.
• FOLLOW UP - FROM POST NO.21 AND POST 19.
• MANUAL – LOCAL - FROM KR-44 DEVICE MOUNTED ON

• STARTING PROCEDURE.
• PUT KNOB ON “KR2” PANEL FROM “LOCAL” TO “REMOTE”.
• SWITCH ON THE ELECTRIC DRIVE AFTER PERMISSION OF
COMMAND.
• REMOTE OPERATION OF PUMPING UNIT IS SELECTED FROM
“BRIDGE ” OR “OPS ROOM” ON “KR 1” PANEL.
• SHIFT THE RUDDER FROM ITS CENTRAL POSITION TO BOTH
SIDES AND BACK WITH THE KNOB OF KR-44.
• CHECK FOR LEAKAGES IN THE HYDRAULIC SYSTEM.
• CHECK THE COOLING WATER PRESSURE & TEMPERATURE.
• WATCH KEEPING: DURING OPERATION CHECK FOLLOWING:-
• SMOOTHNESS OF RUDDER PUTTING OVER
• LUBRICATE FRICTION PARTS ONCE IN A WATCH
• READINGS OF PRESSURE GAUGE PANEL IN STEERING GEAR
COMPARTMENT OR STEERING ENGINE RESERVE PUMP
COMPARTMENT.
• SIGNALING OF HIGH TEMPERATURE, LEVEL OF WORKING
FLUID IN REPLENISH TANKS AND CLOGGING OF FILTERS IN
CONTROL PANELS OF STEERING SYSTEM AND “ONEGA”.
• STOPPING PROCEDURE.
• BRING THE RUDDER “MIDSHIPS”.
• SHUT DOWN THE PUMP.
• CLOSE THE COOLING WATER VALVES.
• SWITCH “OFF” THE MAIN POWER SUPPLIES
KR2 PANEL
CONTROL CONSOLE
PUMP ON
REMOTE LOCAL
RUDDER ANGLE INDICATOR

LAMP
TEST
POWER FAIL NON FOLLOW UP

CONTROL
-24V -5V FILTER CLOGGED HIGH OIL TEMP
50Hz 127V LOW OIL LEVEL DRIVE
PORT STBD
FUSE
CONTROL PANEL (KR2)
DRIVE UNIT
SHOE SUPPORT
COLLAR BEARING PLATE
SHOE
MIDDLE JOURNAL CYLINDER BLOCK
BEARING RING DISTRIBUTOR
BUSH
DRIVE SHAFT
DISK SPRING
RADIAL BEARING
PISTON WITH ROD
DOUBLE RADIAL THRUST BEARING
BUILT IN MECHANISM
THRUST RING AIR RELEASE
FLANGE REGULATOR
BUSH BUSH
BEARING
CAGE
BEARING FLANGE
DRIVE UNIT
PLATE
RING
JOURNAL
REGULATOR
REGULATOR CASE DISK CYLINDER CASE
CONTROL
SHACKLE SLIDE VALVE
FLANGE
CONTROL SLIDE VALVE
PISTON BUSH
SLIDE VALVE PISTON
ROD
TO PUMP
REGULATOR
CAPACITY CONTROL SYSTEM
POWER SENSOR
5 6
N3 SAFETY
N2 VALVE
N4
1 2 3 4
N1 CONTROL SLIDE
KR-44 L1 S1 L2
S2 VALVE
Z1
Z2 TANK
REGULATOR
MAIN PUMP
AUXILIARY PUMP
MAKE-UP VALVE
PUMP CAPACITY CONTROL
CONTROL ELEMENTS
CONTROL ELEMENT
DISTRIBUTION BOX
POWER TRANSDUCER
INLET FROM PUMP

PRESSURE MANIFOLD
PISTON
DRAINAGE
INLET FROM CONTROL SPRING DISK

SLIDE VALVE
POWER TRANSDUCER
FROM MAIN DELIVERY LINE
FROM CONTROL SLIDE

VALVE PISTON
DRAIN CAVITY
STEERING GEAR
PRE SAILING ROUTINES
PRSR1 Make sure it is serviceable as follows:
(a) Check visually the steering gear compartment parts and
make sure they are in good working order and there are no
foreign objects near moving parts.
(b) During visual inspection of the pumping unit the
following must be checked.
i) Bleed out the air from pump housing.
ii) Sealing of joints of pump covers, flanges, plugs etc.
iii) State of bolt joints and connections of pump shafts with
electrical motors.
iv) oil level in the make up tanks which is to be between
the upper and lower marks of level gauges.
(C) During visual inspection of the drive to rudder stock
the following must be checked:
i) Presence of grease on the guiding beams.
ii) State of bolt joints(tighten the nuts if necessary)
iii) State of piston sealing joints ( tighten clamping flanges
in the leaking points).
iv) Replenish oil by the pressure lubricators if necessary.
(D) Check the state of pumping unit electrical equipment
for their compliance to the Technical Description and
Operating Instructions of electric drive (I I
IKA.364244.047.TOI).
PRSR2 Check stuffing box gland and associated system for leaks.
WEEKLY ROUTINES
W1 Check the control pressure drop across the filter of
pumping units. With the pressure drop over 9 +0.5 and –1.0
Kgf/Sq. cm, flush the filter as follows;
a) Turn out the sleeve from the filter cover.
b) Take out filtering element from the sleeve sand dip in
benzine solvent.
c) Take out the filtering element from benzine solvent.
d) Blow the filtering element off with clean compressed air
(2-3kg/sq. cm) for 15 minutes.
e) Insert the filtering element back in to the sleeve and the
sleeve into the filter cover.
W2 Turn the steering gear pump 2-3 revolution by hand.
MONTHLY ROUTINES
M1 Check air pressure in the shock absorbers(pressure shall be
1.0 – 3.0 kg/sq.cm).
M2 Clean filters.
M3 Carry out functional test of Steering Gear and control
system.
M4 Examine flexible hose for damage. Replace if required.
THREE MONTHLY ROUTINES
3M1 Withdraw oil sample and send it to laboratory for analysis.
Replace oil if condition is deteriorated.
3M2 Examine flexible hoses for damages. Replace if required.
3M3 PERFORMANCE TRIAL.
(a) With ship at full ahead, check time taken to move
rudder from 35 degree port to 30 degree stbd and vice
versa.The -
time taken with one hydraulic pump running should not
exceed 20 secs.
(b) With ship at full ahead run the emergency pump and
check the following timing:
(I) For rudder movement from 35 degrees port to 30
degrees stbd and vice versa ( max.2 min.).
(II) For rudder movement from 20 degrees port to 20
degrees stbd and vice versa ( max. one minute.).

Steering Gear

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Steering Gear

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STEERING GEAR

• TYPE ELECTRO - HYDRAULIC, FOUR CYLINDER, RAM TYPE

• TYPE OF RUDDER - SEMI BALANCED

• RUDDER BLADE AREA - 12 m2

• RUDDER BLADE PROJECTION BEYOND BASIC PLANE - 514 mm

• TORQUE DEVELOPED ON RUDDER STOCK AT RUDDER ANGLE

35° & PRESSURE OF 130 KG/CM2 = 630 KNM

• RUDDER WORKING ANGLE TO EITHER SIDE =35°-1°

• CRITICAL ANGLE OF RUDDER = 36° + 1°

• DURATION OF RUDDER MOVING FROM 35° OF ONE SIDE TO 30°

• AT ONE POWER UNIT OPERATING < 28 s

• AT TWO POWER UNITS OPERATING <15 s

• SAFETY VALVE OPERATING PRESSURE : 165+10 kg/cm2

• PRESSURE DROP LIMIT ACROSS FILTER : 9-1.0 + 0.5 kgf/cm2

• MASS OF SERVICE LIQUID IN STEERING SYSTEM - 700 kgs

• RESERVE TANKS CAPACITY - 380 kgs

• SAFETY VALVE SETTING OF FILLING AND DRAINING UNIT : 20

- VARIABLE DELIVERY AXIAL PISTON TYPE

- TURNING ANGLE OF PUMP SWINGER :

-OPERATING : ±210 (± 0.3665 RAD)

- MAXIMUM : ±250 (± 0.436 RAD )

- PUMP RPM : 970

- DELIVERY CAPACITY : 185 l/min

• RATED CONTROL PRESSURE : 40-50 kgf/cm2

• OPERATING MAKE-UP PRESSURE 10-0.2 kgf/cm2

• FILTER TYPE – NETTED.

• BY PASS VALVE OF FILTER OPERATES AT : 9 +0.5 -1.0 kgf/cm2

• POWER DRIVE:- THE POWER DRIVE DEVELOPS TORQUE

NECESSARY FOR RUDDER PUTTING OVER. THIS CONSISTS OF

STOCK DRIVE, TWO MAIN POWER UNITS AND ONE RESERVE

• STOCK DRIVE:– THIS IS USED FOR RUDDER PUTTING OVER,

CONSISTS OF GUIDE BEAM, CYLINDRICAL BLOCK AND TILLER.

THE CYLINDRICAL BLOCK CONTAINS FOUR HYDRAULIC

SERVICE LIQUID TO STOCK DRIVE CYLINDERS FOR RUDDER

• AUXILIARY RESERVE POWER UNIT:- LOCATED IN

RESERVE PUMP COMPARTMENT FOR SUPPLY OF SERVICE

• H1 AND H2 CONTROLS LINKING OF POWER UNIT

• K1 AND K2 CONTROLS LINKING OF CYLINDERS

• B1 CONTROL LINKING OF COAXIAL CYLINDERS

• K31 AND K32 CONTROL LINKING OF STEERING ENGINE

HYDRAULIC SYSTEM WITH FILLING AND DRAIN UNIT.

TO CYLINDER K31 K32 TO CYLINDER

SAFETY VALVE MAKE UP VALVE

AUTOMATICALLY COMMUNICATE THE PUMPS AND THE DRIVE

WITH RUDDER STOCK CYLINDERS. CUT OFF VALVES ARE

MOUNTED ON THE PUMPING UNITS.

• RESERVE TANK -A STORING RESERVOIR OF SERVICE LIQUID

NECESSARY FOR REPLENISHING HYDRAULIC SYSTEM.

VALVE OIL OUTLET

CONTROL OIL PRESSURE

LOSSES UNDER LEAKAGE OF SERVICE LIQUID IN HYDRAULIC

SYSTEM. TWO ARE LOCATED IN STEERING GEAR

COMPARTMENT AND ONE IN RESERVE PUMP COMPARTMENT.

• HYDRAULIC CYLINDERS - HYDRAULIC CYLINDERS ARE FOUR

IN NUMBER. EACH HYDRAULIC CYLINDER IS EQUIPPED WITH A

SET OF TWO VALVES, ONE EACH AT ITS EXTREMITIES

PROVIDED FOR EITHER INLET OR OUTLET OF OIL. THE OTHER

VALVE IS FOR PRESSURE GAUGE CONNECTION.

THE PORT DIRECTION, OIL IS LET INTO OR LET OUT OF A PAIR

OF DIAGONALLY OPPOSITE CYLINDERS. FOR INSTANCE IF, THE

MOVEMENT OF RUDDER IS TO BE TOWARDS STARBOARD, OIL IS

SUPPLIED TO CYLINDERS 2 AND 3, AND LET OUT OF 1 AND 4. IN

THE EVENT OF DAMAGE TO ANY CYLINDER, MOVEMENT OF