H2150 Final Drawing-Rev2.

Busan, Korea
Final drawing and

Instruction manual for
STEERING GEAR
(R4ST 1000-35)
Hull No. H2150

IMO.NO. 9456757
Ship Type 13.100 TEU Container
CLASS GL
Tel.: + 82-(0)51-972-9260 Managing Director :

KOREA CO.,LTD. Fax: + 82-(0)51-972-9270 Y. H. Roh
Busan Science Industrial Complex E-mail: sales@hatlapa.co.kr R. Nicolaisen
1212 Jisa-dong, Gangseo-gu http://www.hatlapa.co.kr
Busan, KOREA
Busan, Korea
Table of Contents
Yard / HN : Hyundai Samho H2150
Hatlapa : 08.6991
Type : R4ST1000 - 35
NO. DESCRIPTION Page

1 Table contents 2
2 List scope of supply 3~4
3 Technical Data Sheet 5~6
4 General comments 7~8
5 Safety 9~11
6 General information 12
7 General Arrangement of Steering Gear 13
8 General Arrangement R.A.U & R.B.U 14
9 Hydraullic flow diagram 15
10 Tiller 16
11 Key for tiller 17
12 Pressure cylinder 18~19
13 Ram 20~21
14 Oil tank 22
15 Pump unit 23~25
16 Manifold block 26
17 Block diagram 27
18 Junction Box 28~32
19 Axial Piston Variable Displacement Pump A4VG 33~41
20 Hydraulic locking 42~43
21 Interface Steering Gear : Control System 44~47
22 Mounting/Dismounting Procedure Tiller/Rudder Stock 48
23 Operating instructions 49
24 Fillings and starting of operation 50~51
25 Operation of steering gear 52
26 Installation Instruction for steering gear 53~62
27 Setup instruction 63~64
28 Guide to the installation of high pressure hydraulic line 65~66
29 Maintenance instruction 67~68
30 3 Phase Induction Motor Data Sheet & Motor Terminal Box 69~70
31 Installation and maintenance instructions for electric motors 71~77
32 Hydraulic Oil and Lubricating Grease 78
33 Grease Lubrication System 79~88
34 Inspection and test record 89~90
35 Spare Parts List 91~92
36 Weight list 93
37 Service 94~101
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Tel.: + 82-(0)51-972-9260 Managing Directors:
KOREA CO. LTD. Fax: + 82-(0)51-972-9270 Y. H. Roh
Busan, KOREA
2/101
Busan, Korea
List Scope of Supply

Yard / HN : Hyundai Heavy Industries H2150/51/52/53, H2170/71/72/73
Hatlapa : 08.6991/92/93/94/95/96/97/98
Type : R4ST1000 - 35
ITEM QTY COMPONENTS HATLAPA YARD

1 1 STEERING GEAR each existing of:
1 1 0 4 Cylinder O
1 2 0 2 Ram O
1 3 0 2 ram pin O
1 4 0 4 sliding block O
1 5 0 1 Tiller O
1 5 1 cone type
1 5 2 cone type with keyway
1 5 3 1 cone type with keyway and oil grooves O
1 5 4 - cone type with oil groove
1 6 0 1 tiller key O
1 7 0 2 Connection Beam O
1 8 0 4 pressure gauge O
1 9 0 2 mech. rudder angle indicator O
2 0 0 4 HYDRAULIC PUMP UNIT each existing of:

2 1 0 1 variable displacement pump, complete O
(hydr. locking; solenoid; emergency hand button)
2 1 1 1 pressure filter O
2 2 0 1 e- motor O
2 3 0 1 automatic pump isolation manifold O
2 4 0 2 manual actuator isolation valve O
2 5 0 1 oil- air cooler O
2 6 0 1 pressure gauge (boost-, servo pressure) O
2 7 0 1 piping, working line O
2 8 0 1 hydraulic oil expansion tank (one for two pump unit) O
3 0 0 1 LUBRICATION SYSTEM
3 1 0 1 autom. electr. greasing system O
3 2 0 1 el. contactor cabinet O
3 3 0 - grease nipple
3 4 0 - manual grease gun
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Busan, KOREA
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Busan, Korea
ITEM QTY COMPONENTS HATLAPA YARD

4 0 0 1 ELECTRIC PART
4 1 0 1 contactor cabinet pump 1 O
4 2 0 1 contactor cabinet pump 2 O
4 3 0 1 contactor cabinet alarm O
4 4 0 1 panel bridge (start/ stop) O
4 5 0 1 panel ecr (alarm) O
4 6 0 1 electrical limit switch O
4 7 0 2 junction box O
5 0 0 - SAFEMATIC
5 1 0 - single system isolation manifold
5 2 0 - add. level switches for expansion tank
5 3 0 - el. contactor cabinet
5 4 0 - alarm panel bridge
6 0 0 SPARE PARTS
6 1 0 1 set acc. to class rules O
7 0 0 RUDDER ANGLE INDICATOR SYSTEM O

7 1 0 panorama indicator, ceiling mounting O
7 2 0 indicator desk mounting O
7 3 0 indicator desk mounting, watertight O
7 4 0 indicator wall mounting O
7 5 0 indicator wall mounting, watertight O
7 5 0 dimmer O
7 7 0 amplifier O
7 8 0 transmitter O
7 9 0 connection rod for transmitter O
7 10 0 console at steering gear for transmitter O
8 0 0 ACCESSORIES
8 1 0 1 set of st/ gear, foundation bolt/ nut O
Pole and linkage for repeat back unit and rudder angle indica-
8 2 0 1 O
tor
8 3 0 1 Jack bolt O
8 4 0 1 set of stopper and liner O
8 5 1 1 storage tank O
8 6 0 1 hand pump for storage tank O
8 7 0 2 block diagram (incl. valve instruction) O
8 8 0 1 steering control console O
8 9 0 1 electric cable and wiring O
8 10 0 1 oil filling and grease O
8 11 0 1 installation O
8 12 0 1 commissioning O
8 13 0 1 Sea trail O
8 14 0 Hyd.pipe support (65x65x6t ANGLE:1.5M x 15EA), (u-bolt/nut :15SET) O
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Busan, KOREA
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Busan, Korea
Technical Data
Yard / HN : Hyundai Heavy Industries H2150/51/52/53, H2170/71/72/73
Hatlapa : 08.6991/92/93/94/95/96/97/98
Type : R4ST1000 - 35
NO. DESCRIPTION SPEC. UNIT

MECHANICAL DATA
Working torque 8120 KNm
2
Working pressure 208 (204) Kg/cm (bar
Design torque 10150 KNm
2
Design pressure 260 (255) Kg/cm (bar)
2
Pressure relief valve setting 260 (255) Kg/cm (bar)
Rudder angle (el. limit) 35
Rudder angle (mech. limit) 37
Rudder laying time (2/4 pump unit) 28 / 14 sec.
Tiller solid with key
Tiller cone ratio 1 : 15
Start diameter of cone 800 mm
Hydraulic pump type A4VG 250
Oil quantity expansion tanks 2 x 230 l
Oil quantity steering gear (incl. expansion tank) 1250 l
Oil quantity storage tank 1000 l
Dimension st/ gear (L x B x H) 7334x3560x2032 mm
Weight 48800 kg
Classification society GL
ELECTRICAL DATA
Power supply 440V/ 60Hz V/ Hz
E- motor protection degree 55 IP
E- motor insulation class F
E- motor ambient temperature 45 C
E- motor starting method Direct on Line
E- motor No. 2, 3, 4 1
E- motor output (S6 25%) 185 40/185 kW
E- motor starting current 2360 654/2360 A/ sec
E- motor rating current 299 84.9/299 A
E- motor space heater 180/ 220 W/ V (AC)
E- motor thermistor PTC
JIS B 1575 A-PT 1/8 or
E- motor grease nipple equivalent type, material :
brass
Weight 998 kg
1/2
1212 Jisa-dong, Gangseo-gu http:// www.hatlapa.co.kr
Busan, KOREA
5/101
Busan, Korea
NO. DESCRIPTION SPEC. UNIT

Displacement pump, proportional solenoid valve
- voltage 24 V (DC)
- start of control 250 mA
- end of control 650 mA
max. current for NFU control 750 mA
Oil air cooler e- motor

- voltage 440 V
- output 0,43 KW
- rating current 1.08 A
2/2
1212 Jisa-dong, Gangseo-gu http:// www.hatlapa.co.kr
Busan, KOREA
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General Comments
General Comments
Information on Instruction Manuals
This technical documentation includes all the information which is necessary for
guaranteeing the safety as well as for the operation and maintenance of the equipment.
It is directed at instructed and trained personnel who are responsible for the operation
and maintenance of the equipment.
Only knowledge of this technical documentation can guarantee faultless and correct
functioning of the equipment, and must be known by the responsible person. The
technical documentation should be kept on board so that the operating and maintenance
personnel have access at all times.
Copyright
The copyright for this technical documentation remains with Hatlapa.
This documentation is intended for the operator and their personnel only and may
neither be reproduced, copied, distributed in parts or as a whole without the written
permission of Hatlapa, nor be used for competitive purposes.
All rights reserved.
Guarantee
HATLAPA undertakes the guarantee that this technical documentation is in accordance
with the technical and functional parameters of the equipment supplied. HATLAPA
reserves the right to include additional information.
It is pointed out that guarantee claims cannot be derived from any lack of information
and details in case of incorrect operation, as operation and maintenance by trained
skilled workers is presupposed.
Guarantee claims will only be accepted in accordance with the conditions of the contract.
Guarantee and liability claims for damage to persons and/or objects are excluded when
caused by one or several of the following circumstances:
- inappropriate use of the equipment,
- neglecting the provisions of this documentation,
- faulty assembly, operation or maintenance,
- operation of the equipment with ineffective protective measures,
- arbitrary functional or constructive alteration of the equipment,
- removal of parts resp. installation of spare parts or additional components which
have not been supplied or approved by HATLAPA,
- repairs during the guarantee period which have not been authorized by
HATLAPA,
- effect of foreign bodies in case of catastrophes or Force Majeure.
date 23.02.2005 page 1 of 2

Created by Tanz
7/101
General Comments
Designations
Persons are defined as follows:
Operator is the (natural or corporate) person, on whose behalf the equipment is
used, e.g. the ships owner.
Operating personnel is personnel trained for the corresponding work who are
authorized to operate the equipment and to remedy disturbances. The operating
personnel must be trained in accordance with his tasks and meet the requirements of
handling the equipment. They must know the necessary protective devices and
protective measures, the relevant provisions, accident prevention rules, and
equipment conditions.
Assembly personnel is personnel trained for the corresponding work and who are
authorized to assembly the equipment. The assembly personnel must have
knowledge of mechanical, hydraulic, and electric engineering. They are able to carry
out the tasks assigned to them and recognise possible danger because of their
specialized training. In addition they must know the necessary protective devices and
Maintenance personnel is personnel trained for the corresponding work and who are
authorized to maintain, adjust and modify the equipment. They are able to carry out
the tasks assigned to then and recognise possible danger because of their
specialized training. In addition they must know the necessary protective devices and
An electrician has electro-technical knowledge gained by corresponding education,
masters the legal regulations, and is assigned by the operator to carry out work on their
electrical equipment and appliances.
date 23.02.2005 page 2 of 2

Created by Tanz
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Safety
1. General
HATLAPA steering gears are up to date in technique and reliable in operation. No direct
danger will be encountered during operation if the steering gear is properly installed,
conscientiously attended and maintained and if the specified hydraulic fluid and
lubricants are used.
2. Instructions on safety precautions
Considering the importance of the steering gear for the running ship, entire visibility of
and accessibility to the mechanical components are absolutely necessary. Unintentional
contact with the steering gear may lead to crushing. Therefore, it is highly recommended
to the Shipyard/Owners to provide a guard-rail around the working area of the steering
gear.
Setting up, commissioning, operation and maintenance must be done by authorized,

skilled and trained personnel only.
The ruling general and local safety rules and regulations for prevention of accidents
must be adhered to.
Commissioning, operation and maintenance must be in conformity with the instructions

of the present operation manual.
The ships management will be responsible for the steering gear to run only in
unobjectionable conditions, and for HATLAPA to be informed immediately about any
alteration which may be detrimental to safety.
3. Danger
The indicating plate as shown below includes the most important safety directions to be
observed for steering gear operation. This indicating plate is included in the HATLAPA
supply and must be fitted in a well visible position in the steering gear compartment.
page 1
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Safety
DANGER OF CRUSHING
No admittance to the working area of the steering gear except on business.
Admittance is allowed to authorized experts for maintenance and inspection
work taking into consideration the regulations for prevention of accidents.
Repair work is allowed only if the steering gear is shut down and after it has
been made sure that unintentional restarting is excluded.
Inadequate maintenance may lead to failure of the steering gear which may involve
serious danger to ship and crew.
Instructions on safety precautions as found in the operating manual, must

strictly be adhered to.
4. Particular safety instructions on the electrical equipment
Any work on the electrical equipment of the steering gear (installation, repair work,
modifications) must be carried out by authorized experts (licensed electrical engineers)
according to the ruling standard specification (e.g. VDE 0105, Part 1 dealing with work
on electrical equipment).
For work on electrical equipment, the main switches must be in OFF position and
secured against switching-on. There is danger of life if work is carried out by inexperts.
page 2
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Safety Instructions for Hoses
1 General
Hose pipes are safety relevant parts which may endanger persons and the environment
in case of failure.
1.1 Installation and maintenance
During installation the hoses must in no way be damaged, bent, twisted
or exerted to pressure. They must not be painted or have contact with
sharp objects!
For cleaning hose pipes and hoses neither aggressive cleaning agents
nor pressure cleaners may be used. They can damage the hose surface
resp. hose line!
Hose pipes must be inspected visually by the assembly/service personnel before

commissioning and once a year.
Inspection is carried out under the following aspects:
Damage to the outer layer
Decay of the outer layer
Deformation of the hose or hose pipe (alteration of the geometry, layer
separation, forming of blisters)
Damage or deformation of the hose fitting
Corrosion of the fitting (impairs function and strength)
Installation (chafing at sharp edges or smooth surfaces)
Exceeding the admissible storage resp. operational duration (stated below)
1.2 Storage and durability

According to DIN 7716 proper storage is to be understood as follows:
max storage time 2 years
dry, cool, dust-free
no direct sunlight or UV light
protection against ozone
protect against heat
store lying and without tension
According to EN 982 resp., DIN 20066 following must be observed:
1. Once installed, the hoses have a durability of 6 years and must be replaced after
this period.
2. If the max. storage time of 2 years is exceeded, then the hose may no longer be
used. If the hose is installed within this period, the durability of 6 years is reduced
by the period of storage accordingly.
It lies within the responsibility of the user that all hoses mentioned in this
manual are checked at regular intervals, and to guarantee correct and
safe function once the guarantee period has elapsed, thus preventing
damage to persons and the environment.
date 18.04.2005 page 1 of 1

Created by Tanz
11/101
Ruderanlage - Allgemeines
Steering Gear - General Information
Ruderanlage
Allgemeines
Die Ruderanlage ist im Rudermaschinenraum aufgestellt und dient zum Einstellen der
Ruderlage. Die Kontrolle des Ruderwinkels erfolgt durch die Fernsteuerung von der
Brcke aus. Die Ruderanlage besteht aus der mit 4 Zylindern ausgefhrten
Rudermaschine, dem auf dem Ruderschaft befestigten Ruderjoch, den elektromotorisch
angetriebenen Pumpenaggregaten und der Steuereinrichtung, die den durch die
Fernsteuerung eingeleiteten Steuerimpuls auf die Pumpenaggregate bertrgt.
Jedes Pumpenaggregat ist durch getrennte Leitungen aus nahtlosem Stahlrohr mit den
Zylindern der Rudermaschine verbunden. Ventile an den Zylindern gestatten das
Absperren von Anlageteilen im Reparaturfall.
Jedes Pumpenaggregat allein ist imstande, das Ruder in der vorgeschriebenen Zeit zu
legen, whrend das andere Pumpenaggregat jederzeit nur durch Anlassen des Motors
zugeschaltet werden kann.
Steering Gear
General Information
The steering gear arranged in the steering engine room serves for laying the rudder. The
control of the rudder angle is effected by means of the remote control from the bridge.
The steering gear consists of the steering engine with 4 cylinders, the rudder yoke fitted
to the rudder head, the motor operated pump units and the steering equipment, which
ransmits the control imulse initiated by the remote control to the pump units.
Each pump unit is connected with the cylinders of the rudder engine by means of
separate pipings of seamless steel tubes. Valves arranged at the cylinders make it
possible to disconnect parts of the steering engine in case of necessary repair work.
Each pump unit is capable of putting the rudder through the working angle in the
specified time. The other pump units can be connected at any moment, just by switching
in the motor.
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Pressure Cylinder Partlist
Title Spec Dwg No(rev) Q'ty Material
1 Pressure Cylinder, complete 117315 4
1-1 Pressure Cylinder 650134 4 FCD450
1-2 Leading Bush 650139 4 BC3
1-3 Roof shaped seal sets 420/450x52 4
1-4 Hex. Socket head cap screw M16x100 32 8.8galZn
1-5 Dirt scraper P6-420/450x25 4
1-6 stop cover 650125 SM490A
1-8 Screw plug PF 1/2 4
1-9 Packing ring A21x26x1.5 4
1-10 cover 114852 4 SM50A
1-11 O-ring 92x4 4
1-13 screw coupling PF 1/2 4
1-14 stop complete 117340 8
1-14-1 wedge 1 117341 8
1-14-2 Hex. Socket head cap screw M8x170 32 8.8galZn
1-15 spring pin 10x36 8
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Ram partlist
2 Ram, complete 650141 2
2-1 Ram 117325 2 S55C(N)
2-2 Ram pin 117327 2 SCM440
2-3 Upper sliding block 117329 2 TEGO30
2-4 Lower sliding block 117331 2 TEGO30
2-5 transportation lock 117331 2
2-6 Screw plug M12x1.5 2
2-7 packing ring A12x15.5x1.5 2
2-8 pointer 117328 2
2-9 Hex. Bolt M6x20 8 8.8galZn
2-10 Screw plug PF 1/2 2
2-11 packing ring A14x18 2
2-12 disc A 6.4 8
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Pump unit Partlist
5 pump set complete 117318 2
5-1 Pump foundation 650315 2
5-1-1 bracket 115993 8
5-2 axial piston pump A4VG250 4
5-4 pump support PK 660/2/4 4
5-5 Rotex coupling size75 4
5-6 screw pin M10x16 4
5-7 E-motor 4
5-8 oil-air cooler LR-type 4
5-10 fitting GE28LRCF 4
5-11 fitting WH28PLR 4
5-13 stud screw M20x40 16 8.8galZn
5-14 Hex. Nut M20 16 8.8galZn
5-15 oil filter 4
5-16 fitting RI 1 1/4x1 8
5-17 fitting EW 28-PLR-ED 8
5-18 fitting GE 42-PLM 4
5-19 fitting EVT 42-PL 4
5-20 fitting W 42-PL 2
5-21 fitting KOR 42/28-PL 4
5-22 fitting EVW 28-PL 8
5-23 non-return valve RHD 28-L 4
5-24 fitting EVL 28-PL 4
5-25 fitting GE 35-PLM 8
5-27 fitting WH10-PLR 8
5-28 pipe 28x3 18m st 37.4
5-29 pipe 10x1.5 8m st 37.4
5-30 valve block NG 25 117051 4
5-31 Hex. Scoket head cap screw M16x140 32 8.8galZn
5-32 screw plug PF 1/2 4
5-33 packing ring A21x26x1.5 4
5-34 fitting EVW 28-PLM 8
5-35 fitting EVW 15-PLM 4
5-37 filter bracket 114754 4
5-38 pipe 42x2 5m st 37.4
5-39 oil tank complete 650094 2
5-39-1 oil tank 650094-A, B 2
5-39-2 cover 440x280x5t 2 SS400
5-39-3 Hex. Bolt M16x12 32 8.8galZn
5-39-4 packing(gasket) 440x280x3.2t 650123 2 SS400
5-39-5 float switch LS-TM-2,3FS 2
5-39-6 oil filling filter ELF 3F 2
5-39-7 fluid indicator DLG-F-R-350 2
5-39-8 packing ring A 21x26x1.5 8
5-39-9 fitting GE 42-PLR 4
5-39-10 fitting GE 28LRCF 2
5-39-11 fitting WH28 PLR 4
5-39-12 fitting WH42 PLR 2
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5-39-13 screw plug PF 1/2 2
5-39-14 packing ring A 21x26x1.5 2
5-41 bracket 650098 2
5-42 Hex. Bolt M12x20 8
5-43 fitting EVW 10-PL 4
5-45 mating plug for HL-sensor 2
5-46 pressure gauge 4
5-46-1 pressure gauge type 213.53 4
5-46-2 connection PF1/4 PN630 4
5-46-3 bracket 116644 4
5-46-4 Hex. Bolt M10x45 4
5-46-5 Minimess hose S110-AB-AB-0200 4
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Uetersen, 2007-07-11
Hydraulic Locking
The steering gear is controlled by a steering control system.
The signal of the given rudder order provides the displacement of the steering gear pump
(via control/ amplifier box, starter box). The size of the pump displacement depends of the
size of the signal. The signal will be transformed by a proportional valve which is mounted at
the hydraulic pump, from a electrically signal into the mechanically displacement.
The signal of the rudder order will be monitored.
The displacement will be monitored also, via limit switches at the hydraulic pump.
Both signals, the signal of the rudder order as reference value and the signal of the limit
switches as actual value will be compared in the HLA transmitter box.
In a case of a deviation the HL- alarm would be appeared.
Hydraulic Locking, schematic
1/2
Tel.: + 49-(0) 4122 / 711-0 Geschftsfhrer / Amtsgericht Elmshorn:
Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49-(0) 4122 / 711-104 Managing Directors: HRA 0499
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nrnberg Verwaltungsgesellschaft: HRB 1560
25436 Uetersen / Germany www.hatlapa.de Jrg Tollmien UST.ID-Nr. DE 134527127
42/101
Uetersen, 2007-07-11
Hydraulic Locking Alarm Transmitter
2/2
Tel.: + 49-(0) 4122 / 711-0 Geschftsfhrer / Amtsgericht Elmshorn:
Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49-(0) 4122 / 711-104 Managing Directors: HRA 0499
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nrnberg Verwaltungsgesellschaft: HRB 1560
25436 Uetersen / Germany www.hatlapa.de Jrg Tollmien UST.ID-Nr. DE 134527127
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Interface Describtion
variable delivery pump
with analogue control
Interface
Steering gear : Control system
Contents:
1 Applicability
2 General requirements
3 Variable delivery pumps with analogue control
Valid for steering gear type R4ST file:VERANAE.DOC

Date:11.02.2004
44/101
1 Applicability
The purpose of this description is to define the interface between steering gear and
control system. This description includes important information about the control
characteristics of the steering gear and should, therefore, be submitted to the
manufacturer of the control system in order to reduce time and costs on control
system adjustment.
2 General requirements
The steering gear is part of a control circuit which also includes the ship itself, the
rudder and the control units for the ship's track and rudder angle. Even if the
components used for HATLAPA steering gears are high precision instruments,
some control characteristics arise which are dependent on the steering gear
system. This is caused by the elasticity in the aftship, rudder stock and rudder
blade, clearence in the bearing of the rudder stock, clearence in the transmission
rods and the angle transmitter itself as well as the ship's specific steering forces
and steering torques of the rudder. Therefore control units are to be recommended
for the steering control system, of which the amplification, responding threshold,
compensating time, minimum pump adjustment time and hysteresis can be
adjusted within certain limits. The adjustment of the control units should be made
on the completed gear when the ship is under way to ensure the best setting. The
exact setting, with which a minimum of desired-actual deviation is attained in the
case of a stable control circle, cannot be ascertained theoretically. The quoted
setting ranges are values gained from experience and which have proved to be
sufficient from the practice of designing usual aftship and rudder constructions. For
special designs or in the case of quicker rudder laying times, an extension of the
setting ranges may be necessary. Furthermore, when determining the setting
ranges, sufficient reserve must be considered to avoid hunting of the control
system by subsequent settings in the case of greatest possible wear of the steering
gear.
It applies to all steering gears with two pump units that the control valves of the
stand-by pump system may in no case be activated.
3 Variable delivery pumps and analogue control
On request HATLAPA supplies for each pump an amplifier unit with the required
setting possibilities for the proportional valves and the necessary rudder angle
feed back unit. But under normal circumstances this amplifier is part of the ship
control system. The interface between steering gear and rudder control (bridge) is
a voltage signal. This signal then corresponds to the desired value of the rudder
angle (e.g. +/- 10 V correspond to +/-35 acc. to technical supply specification).

Date:11.02.2004
45/101
If analogue control is to be fitted to a steering gear with variable delivery pump

control, then at least one proportional control unit is required. The delivery of the
pump is adjusted via a current signal. The current signal is to be limited at 800 mA
+ 10% for pumps of type A (pump type:A2P-series) resp. 650 mA + 10% for pumps
of Type B (pump type: A4V-series). The dependence of the pump delivery on the
control current as well as the setting range of a proportional control unit can be
taken from the following diagrams. The dead band of control unit XO should be
adjustable in the range of 0.1 to 0.5 rudder angle (desired-actual deviation). The
point X1, at which the control unit reaches its max. current of 800 mA (pumps A)
650 mA (pumps B), should at least be adjustable in the range of 3 to 6 rudder
angle.
General circuit diagram for steering gears

with pumps with variabel displacement
Abbreviations: 1 = Axial piston pump with adjusting cylinder

2 = Auxiliary pump
3 = Proportional valves
4 = Adjusting cylinder
5 = Pressure relief valve
6 = Motor
A+B = Connections of steering gear cylinders

Date:11.02.2004
46/101
Abbreviations: I = control current in mA

Q = pump delivery in % from nominal oil flow
= desired-actual deviation rudder angle

Date:11.02.2004
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Busan, Korea
Steering Gear Operating Instructions

STANDARD OPERATION
1. OPERATION FROM THE BRIDGE
-. WHEN USE PUMP UNIT 1 OR 2 FOR GENERAL OPERATION, CHANGE RUNNING PUMP
EVERY 24 HOURS.
-. USE PUMP UNIT 1 AND 2 FOR NORMAL OPERATION.
2. OPERATION FROM STEERING GEAR COMPARTMENT

-. CONTACT BRIDGE VIA TELEPHONE.
-. DISCONNECT THE SOLENOID VALVES FROM THE AUTO PILOT.
-. OPERATE SOLENOID VALVES MANUALLY WITH THE PUSH BUTTONS P/S ACCORDING
TO INSTRUCTIONS FROM THE BRIDGE.
EMERGENCY OPERATION
1. WHEN FAILURE OF HYDRAULIC SYSTEM
-. REDUCE THE SHIPS SPEED IMMEDIATELY TO MAX. 70%.
-. THE CHOICE OF SYSTEM(PUMP UNIT 1 OR 2) FOR OPERATING.
-. THE VALVES ARE TO BE ARRANGED ACCORDING TO THE VALVE POSITION PLATE
FOR OPERATING.
-. PUSH THE PROPORTIONAL SOLENOID VALVE(PUMP UNIT 1 OR 2), OPERATE THE
STEERING GEAR ACCORDING TO VALVE ADJUSTMENT PLATE WHICH IS LOCATED
ON THE TOP OF EACH PUMP UNIT.
2. PUMP UNIT ALARM ON THE BRIDGE

- STOP INOPERATIVE PUMP AND USE THE OTHER ONE.
-. REPAIR FAULT IMMEDIATELY.
3. LOSS OF STEERING CAPABILITY DUE TO HYD. LOCKING

-. REDUCE SHIPS SPEED IMMEDIATELY.
-. TRY THE OTHER PUMP.
-. TRY THE DIFFERENT CONTROL SYSTEMS.
-. REPAIR FAULT IMMEDIATELY.
4. LOW OIL LEVEL ALARM ON THE BRIDGE

-. REPAIR OIL FROM STORAGE TANK.
1/1
Busan, KOREA
49/101
Fllen und Inbetriebnahme
Filling and Starting of Operation
Fllen der Anlage und Inbetriebnahme

Filling the System and Starting of Operation
Fllen der Anlage und Inbetriebnahme
Fllen:
Alle Ventile und Luftschrauben werden geffnet. Das l wird ber ein Haarsieb
aufgefllt. Zweckmigerweise verfhrt man so, da zuerst die beiden Zylinderrume
und anschlieend die Pumpengehuse sowie der Nachsaugehochtank aufgefllt werden.
Die Luftschrauben werden nacheinander geschlossen, wenn l austritt. Die Anlage ist
gefllt, wenn der lspiegel im Nachsaugehochtank nicht mehr absinkt.
Inbetriebnahme:
Die Inbetriebnahme soll in folgender Reihenfolge geschehen: Nachdem man sich noch
einmal berzeugt hat, da alle Ventile geffnet sind, wird der Antriebsmotor
eingeschaltet. Es ist darauf zu achten, da dieser in der angegebenen Drehrichtung
luft.
ACHTUNG!
Falsche E-Motor-Drehrichtung fhrt zur Zerstrung der Pumpe!
Anschlieend wird die Nothandbettigung am Wegeventil mehrere Male gedrckt, wobei

die beiden Zylinderrume der Rudermaschine und das Pumpengehuse nochmals
grndlich entlftet werden.
Hierauf wird das Umlaufventil geschlossen. Die Anlage ist nun betriebsfertig. Es kann
jetzt sowohl elektrisch von der Brcke aus als auch mit der Nothandbettigung am
Wegeventil gefahren werden.
Sind zwei Pumpenaggregate vorhanden, so ist der gleiche Vorgang mit dem anderen
Pumpenaggregat zu wiederholen.
Filling the System and Starting of Operation
Filling Operation:
Open all valves and vent screws. Fill in the oil through a hair sieve into both cylinder
spaces first, then into the pump casings and into the overhead tank. Close the vent
screws one after the other when oil escapes. The gear is filled with oil, when the oil level
in the overhead tank does not drop any more.
Seite page 1
50/101
Fllen und Inbetriebnahme
Filling and Starting of Operation
Starting of Operation:
Starting of operation of the steering gear should be effected in the following sequence:
Check again, that all valves are open, switch in the pump motor of the steering gear and
make sure, that the motor rotates as indicated.
IMPORTANT!
Wrong direction of rotation of the electric motor causes damage to the pump.
Then press the push buttons for emergency control at the directional control valve for
several times, thus venting both cylinder spaces of the steering gear and the pump
casing once again.
Now close the by-pass valve. The steering gear is now ready for operation and can be
controlled either electrically from the bridge, or by means of the emergency control at the
directional control valve.
In case of two pump units being used with the steering gear, the above procedure will
have to be repeated with the other pump unit.
Seite page 2
51/101
Betrieb der Anlage
Operation of the Gear
Betrieb der Anlage
Im normalen Betrieb sind alle Ventile geffnet bis auf das Umlaufventil.
Gerusche in den Rohrleitungen zeigen, da Luft im l ist. Die Luft mu
durch Entlften entfernt werden, da sonst die Pumpen leiden und die lfllung
verdorben wird.
Die Manometer sollen whrend des normalen Betriebes geschlossen werden.
Bei gelegentlichen Kontrollen sind sie zu ffnen. Sie geben auch Aufschlu
ber die Lagerreibung in der Ruderschaftslagerung.
Die Ruderanlage kann in jeder Stellung elektrisch abgeschaltet werden.
Smtliche Ventile bleiben in Betriebsstellung. Irgendwelche besonderen
Manahmen nach dem Abstellen sind nicht erforderlich.
Operation of the Gear
During normal operation all C-valves are open. The by-pass valve is closed.
Noises in the piping indicate that air is contained in the oil.
The air has to be removed by venting, as otherwise the pumps will become
defective and the oil will deteriorate.
During normal operation, the pressure gauges must be closed. They can be
opened for occasional inspections.The pressure gauges also indicate the
degree of friction in the bearing of the rudder head.
The steering gear can be switched off electrically in any position.
All valves remain in operating positions. No special measures are necessary
after the gear has been cut out.
Datei:Betrieb der Anlage.doc
52/101
Decksmaschinen Kompressoren Ruderanlagen
Deck Machinery Compressors Steering Gears
INSTALLATION INSTRUCTIONS FOR HATLAPA NEW DESIGN 4- CYLINDER
STEERING GEARS
1. To prevent damage and rust, unpack the steering gear just before commissioning.
2. Start installation of the steering gear when foundation has been completed according to
HATLAPAs foundation plan. Finally the shipyard is responsible for a foundation accord-
ing to the rules.
ram pin tiller mechanical block pump unit
cylinder ram sliding locking piece/ connection

block pawl beam
picture 1: HATLAPA steering gear

1 / 10
HATLAPA Tel.:+ 49-4122/711-0 Geschftsfhrer/ UST.ID-Nr. DE 134527127

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49-4122/711-104 Managing director: Amtsgericht Elmshorn:
Tornescher Weg 5-7 Internet: http://www.hatlapa.de Dr.-Ing. Alexander Nrnberg HRA 0499
25436 Uetersen/Germany E-Mail: info@hatlapa.de Jrg Tollmien Verwaltungsgesellschaft: HRB 1560
53/101
3. Mount the tiller according to HATLAPAs installation drawing (if existing).

4. Clean and grease the slide ways in the tiller.
tiller
sliding block
slideway
picture 2: HATLAPA steering gear
5. Lift up the cylinder group and lead the sliding stones into the slide way of the tiller.
Set the cylinder group down on the top of the foundation.
Take care that the ram is more or less in the middle of the tiller arms (picture 11), use
the alignment screws in the cylinder feet.
picture 3: Cylinder Group
2 / 10
54/101
6. Adjust the measure X (table 1), check it with a measuring device via the centre holes in
the rudder stock and main bolt (picture 4).
NEW Poseidon 1280 1840 2120 2680 3050 4000 4450 5170 6980 7650
so far St/ G- 500 550 600 650 700 750 800 850 900 1000
R4ST Type R
X (mm) 600 700 750 820 880 950 970 1000 1080 1125
table 1
picture 4: adjust of the measure X
3 / 10
55/101
7. Use the provided distance setting jig and the prepared pins (located on the top surface
of the support arms) to set the measure X between the cylinders (picture 5)
picture 5: use of the distance setting jig
8. Check the parallelism of the cylinder groups in longitudinal direction. Check the meas-
ure G and H between both rams, according to picture 6. The measure should be ac-
cording to the HATLAPA QS test report and within the tolerance of table 2.
picture 6: measure of G and H
4 / 10
56/101
9. Adjust the parallelism of the cylinder groups in transverse direction and check it with a
ruler. The ruler should tightly lie against both stuffing covers, see picture 7 + 8.
stuffing covers
ruler
picture 7: use of the ruler
feeler gauge
stuffing cover
picture 8: use of ruler and feeler gauge
5 / 10
57/101
10. The measure A and B should be according to the HATLAPA QS test report, see pic-
ture 9. Adjust the steering gear in that way that the measure C is equal to F and E
equal to D and within the tolerance.
picture 9: adjustment
6 / 10
58/101
11. Adjust the height of the cylinder group by using the alignment screws in the cylinder
feet. Check the measure Z as shown in picture 10 (tolerance table 2). The distance be-
tween inner side of tiller arms and surface of the ram has to be the same (picture 11).
picture 10: side and top view of the steering gear (principle draft)
7 / 10
59/101
Picture 11: nearly same distance
12. Check the adjustment of the St/ G in the longitudinal and transverse direction, it must be
in the same way as the tiller. Check for example with a laser. Check the clearance of the
sliding block (L O) by means of a feeler gauge for the rectangularity of the rudder
stock axis to the cylinder group axis. At one cylinder group, the clearance of the sliding
block (L and M; N and O) has to be on the same side (top and below), see picture 10.
13. The exact alignment is given, if the measurements acc. to the HATLAPA QS test report
are within the tolerances (table 2).
14. Bore the holes for the foundation bolts.
15. Fit the chocks between the cylinder feet and foundation top plate according to class re-
quirements.
16. Install the chocks and, if planned, ream the holes for the fitting bolts.
17. Weld the cylinder stoppers on the foundation top plate. Install stopper keys and protect
them.
18. Dismount the adjustment pins from the top surface of the support arms of the pressure
cylinder.
19. Mount the pump units.
20. Fit the high pressure piping system.
21. Fit the oil tank and connection pipes (only valid with extra tank).
22. Fit the storage tank and connection pipe.
23. Start one pump unit and turn the steering gear carefully to 37 starboard. Take into ac-
count that the mechanical block is not complete until yet (next steps).
8 / 10
60/101
24. Fit the supplied wedge 2 according to picture 12 in direction (of big arrow) in. Mark the
needed length of the wedge 2, see below picture (red lines).
wedge 1
wedge 2
picture 12: adjustment of the mechanical block
25. Do the same procedure for the lower wedge (below the ram) and for the wedges on the
opposite tiller side.
26. Cut the wedges to the needed and marked length.
27. Turn the steering gear carefully to 0 rudder angle.
28. Tack weld the wedge 2 to the wedge 1.
29. Do the same procedure for all mechanical blocks.
30. Turn the steering gear carefully to 37 port. Take into account that the mechanical block
is not complete until yet (next steps).
31. Repeat step 24 to 29 for this side.
32. Mount the locking piece/pawl like on picture 1 shown.
33. Make a final check (protocol the measurements down in writing) before commissioning,
if possible under survey of a HATLAPA service engineer.
9 / 10
61/101
ALLOWABLE ALIGNMENT TOLERANCES
AB +/- 0,1 mm
C-F +/- 0,5 mm
X +/- 0,5 mm
Z +/- 0,15 mm
table 2
NOTE !
The given tolerances are only valid with the HATLAPA QS test report.
10 / 10
62/101
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64/101
Guide to the installation of high pressure
piping systems for
HATLAPA steering gears and deckmachinery
1.1 Installation of Piping
1.1.1 General remarks

To a considerable extent, the perfect functioning of high pressure hydraulic systems is
guaranteed by the proper laying of the pipe lines and accessories. Impurities such as
scale, welding beads, sand, machining residue and the like can jeopardize the
operational reliability of the hydraulic plant.
1.1.2 Materials for pipe lines

Preferably, tubes to DIN 2391 in material quality St 37,4 NBK phos. should be used.
Pressure pipe lines are subject to acceptance tests and must be made from tested
materials. The pipe sizes indicated in the HATLAPA piping diagram represent for the
particular application optimum cross-sections and wall thickness.
Any deviation from these recommendations may lead to undesirable consequences.
Therefore, in such cases, please consult our Design Department for advice. For pipe
joints, preferably use screwed unions to DIN 2353 (Ermeto or the like) according to the
enclosed instruction sheet.
1.1.3 Treatment of pipe lines

a) The pipes are to be cleaned only after being bent to form and pipe ends being
deburred. Heat treating and welding should also be terminated.
b) Then the pipes are to be scoured by putting them into a 10% hydrochloric acid
bath for about 12 to 15 hours.
c) The so treated pipes must then immediately be flushed out very thoroughly using
neutralization fluid, or put into a super-heated-steam cleaning plant.
d) This treatment is to be followed by spraying the pipes inside and out with an anti-
corrosive oil.
e) Until the pipes are finally installed, their ends should be sealed with plastic caps.
1.1.4 Commissioning the system

Before final fitment to the hydraulic components of the steering gear, the entire pipe
system ought to be cleaned with a suitable low viscosity flushing oil. The pipes can then
be attached hydraulic plant and the pump sets. Once it has been confirmed that all the
pipes have been laid in accordance with the piping diagram, they can be filled with a
suitable quality of hydraulic fluid (for table of fluids, see operating instructions).
Instructions for filling, venting and flushing the system are to be found on a separate
sheet.
Erstelldatum 13.07.2004 Seite 1 von 2
65/101
Guide to the installation of high pressure
piping systems for
HATLAPA steering gears and deckmachinery
1.2 Instructions for the installation of pipes With Ermeto screwed
Before tightening the cap nut After tightening the cap nut
Cut first the tube at a right angle and remove both the inside and outside burrs.
Lubricate with oil and not with grease the thread and the cutting ring. Place then the nut
and the ring on the tube end.
If the cutting ring cannot or only hardly be slided to the tube end, dont widen the ring but
file the tube end in order to make it thinner.
Screw first the cap nut by hand until it rests against the cutting ring. Push then the tube
against the edge of the inside cone and tighten the cap nut by about 3/4 revolution
whereby the cutting ring is driven into the tube thus making a further pressing of the tube
unnecessary. The final tightening is effected by turning the cap screw by a further
revolution. The ring is thereby driven into the tube and produces thus in front of the
edge a visible collar.
After tightening the cap nut, loosen and check whether the visible collar fills the space in
front of the edge. If this is not the case, tighten a little further.
Once the connection completed and whenever the screws have been loosened, tighten
the cap screw without key prolongation and without excessive force.
Install the pipings exactly as per drawing, i.e. in such a way that the whole system is
deaerated. Therefore arrange the tubes always in upward direction. The air raises then
to the highest point where it can be let out by unscrewing the vent screws. If it is not
possible to arrange a tube in such a way that its bend is directed in upward direction, a
vent valve must be installed on the highest point.
Tubes of a certain Iength must always be fitted with fixing straps in order to avoid that
the unavoidable oscillations on board destroy the pipings or make the screwed
connections untight.
Erstelldatum 13.07.2004 Seite 2 von 2
66/101
Maintenace Instructions
For ease of maintenance, the design of the steering gear is adapted to the latest
technique. The Rapsons slide mechanism is made of special bronze with excellent
antifriction properties.
1. Manual Greasing System
Every 24 hours, some cubic centimetres of grease as per the enclosed Schedule of
Lubricants have to be supplied to the greasing points of the Rapsons slide mechanism.
Greasing has to be continued until the used grease has completely emerged from the
greasing point. A rudder carrier, if any, needs about double the quantity for each
greasing point as required for the Rapsons slide mechnism.
2. Automatic Greasing System
A timer in the control box of the automatic greasing system allows separate adjustment
of intervals and time of greasing. It should be set so as to have some minutes of
operation every hour which has turned out as an optimum. The quantity of grease for
each pipe connection according to the proportion as mentioned in para. 1 above, can be
adjusted at the grease pump itself. Maybe the grease consumption is excessive so that
the basic adjustment must be amended at the control box.
3. Change of Hydraulic Fluid
The quantity of the hydraulic fluid which is necessary to fill the whole system, is
mentioned in the data sheet of the operations manual. The quality of the hydraulic fluid
can be gathered from the Oil Filling Chart. The first change of the hydraulic fluid should
take place not later than 2 (two) years after the first commissioning of the steering gear.
After that, it is recommended to change the hydraulic fluid every 3 years. Extraordinary
working conditions, especially operation outside the range of ambient temparature as
specified in the Oil Filling Chart, may require an earlier change of the hydraulic fluid.
The hydraulic fluid has to be drained at the provided points: bottom side of the pressure
cylinders and front side of the pump units (on pumps with variable displacement:
drainscrew at the side). If the hydraulic fluid is very dirty, clean also the tank bottom and
the pump inside in order to prevent sludge from being whirled up when fresh oil is filled
in.
Replace the filter cartridges of the oil filters at the pump units for the first time after
approx. 500 working hours, and then every approx. 2500 working hours. Metal felt
elements can be used repeatedly and must be rinced out with petrol used for cleaning
purposes. Steering gears with proportional valves have filters with mechanical dirt
indicator.
Page 1
67/101
Maintenace Instructions
A T T E N T I O N, important advice
Although the steering gear requires little maintenance, it should nevertheless be

inspectedat regular intervals in order to reveal, at the earliest, any possible damage
which may alsocome from outside (e.g. rudder blade touching the ground).The steering
gear is vital for ship and crew!
To the interest of our common environment, please care for proper disposal
of waste oil and used cleansers according to the regulations.
Page 2
68/101
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ENGLISH
In case the motors are stored for more than

READ CAREFULLY THIS MANUAL
two years, the bearings must be replaced or the
BEFORE INSTALLING THE MOTOR
lubrication grease must be totally removed after
cleaning.
RECEIVING CHECK Single phase motors when kept in stock
for 2 years or more must have their capacitors
Check if any damage has occured during
replaced (if any).
transportation.
We recommend to turn the shaft (by hands)
Check nameplate data.
at least once a month, and to measure the
Remove shaft locking device (if any) before
insulation resistance before installing it, in cases
operating the motor.
of motors stored for more than 6 months or when
Turn the shaft with the hand to make sure it
subject to high humidity areas.
is turning freely. If motor is fitted with space heaters, these
HANDLING AND TRANSPORTATION should be switched on.
1 - General Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY Measure the insulation resistance before
THE SHAFT, BUT BY THE EYEBOLTS operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor The resistance measured at 25C must be:
has two lifting devices then a double chain must
be used to lift it. Ri (20 x U) / (1000 + 2P) [M]
Lifting and lowering must be done gently (measured with a MEGGER at 500 V d.c.)
without any shocks, otherwise the bearings can where U = voltage (V); P = power (kW).
get damaged.
If the insulation resistance is less than 2
DURING TRANSPORTATION,
megaohms, the winding must be dried
MOTORS FITTED WITH ROLLER OR
according to the following:
ANGULAR CONTACT BEARINGS
Warm it up inside an oven at a minimum
ARE PROTECTED AGAINST
temperature of 80C increasing 5C every hour
BEARING DAMAGES WITH A
until 105C, remaining under this temperature
SHAFT LOCKING DEVICE.
for at least one hour.
Check if the stator insulation resistance
THIS LOCKING DEVICE MUST BE
remains constant within the accepted values. If
USED ON ANY FURTHER MOTOR
not, stator must be reimpregnated.
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE. INSTALLATION
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5C to 60C, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
72/101
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands THE MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0C 6 - Alignment
and 40C. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
73/101
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
WARNING: When the motor is supplied with

Voltage may be connected at standstill protective or monitor temperature device such
inside the terminal box for heating elements or as thermostats, thermistors, termal protector, etc,
direct winding heating. connect their terminals to the corresponding
devices on the control panel.
WARNING:
The capacitor on single-phase motors 10 - Start-Up
can retain a charge which appears across the
THE KEY MUST BE FASTENED OR
motor terminals, even when the motor has
REMOVED BEFORE STARTING THE
reached standstill.
MOTOR.
A WRONG CONNECTION CAN a) The motor must start and operate
BURN THE MOTOR. smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
Voltage and connection are indicated on
b) If there is excessive vibration, check if
the nameplate. The acceptable voltage the fastening screws are correctly fastened.
variation is 10%; the acceptable frequency Check also if the vibration comes from a
variation is 5% and the total acceptable neighbour machine. Periodical vibration checks
variation is 10%. must be done.
c) Run the motor under rated load for a
9 - Starting Methods short period of time and compare if the running
current is equal to that stamped on the
The motor is rather started through direct nameplate.
starting. In case this is not possible, use
compatible methods to the motor load and MAINTENANCE
voltage.
The rotation direction is clockwise if the WARNING:
motor is viewed from DE side and if the SAFETY CHECK LIST
phases are connected according to the
sequence L1, L2, L3. 1 - General Inspection
To change the rotation direction, inter-
change two of the connecting leads. Check the motor periodically.
Keep the motor clean and assure free air flow.
THE CONNECTION TO THE POWER Check the seals or V Ring and replace them, if
SUPPLY MUST BE DONE BY required.
QUALIFIED PERSONNEL AND WITH Check the connections as well as supporting
FULL ATTENTION TO ASSURE A SAFE screws.
AND PERMANENT CONNECTION. Check the bearings and observe: Any excessive
AFTER CONNECTING THE MOTOR, noise, vibration, bearing temperature and grease
CHECK FOR ANY STRANGE BODY condition.
INSIDE THE TERMINAL BOX. THE When a change, under normal conditions, is
CABLE INLETS NOT IN USE MUST BE detected, check the motor and replace the
CLOSED. required parts.
74/101
The frequency of the inspections depends 2 - Machines Fitted with Grease Nipples
on the motor type and on the application
conditions. It is strongly recommended to grease the
machine while running. This allows the grease
LUBRICATION renewal in the bearing housing. When this is
not possible due to turning parts by the grease
FOLLOW THE REGREASING device (pulleys, bushing, etc) that offer some
INTERVALS. THIS IS FUNDAMENTAL risk to the physical integrity of the operator,
FOR PROPER MOTOR OPERATION. proceed as follows:
Clean the area near the grease nipple.
1 - Machines without Grease Nipples Put approximately half of the total grease and
run the motor for 1 minute at full speed.
Motors up to frame 200 are normally fitted Then turn off the motor and insert the rest of the
without grease nipples. In these cases the grease.
regreasing shall be done at the preventive The injection of all the grease with the motor in
maintenance job observing the following standstill can make the grease penetrate into the
aspects: motor, through the inner seal of the bearing
housing.
Disassemble carefully the motors.
Take all the grease out. FOR LUBRICATION USE ONLY
Wash the bearing with querosene or diesel. MANUAL GREASE GUN.
Regrease the bearing immediately.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
Serie 62
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - Series NU 3

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
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Note: The stator grips must be applied over the
The ZZ bearings from 6201 to 6307 do not side face of the inner ring to be disassembled or
require relubrication as its life time is about over an adjacent part.
20,000 hours. It is essential that bearings assembly be
Tables 1 and 2 are intended for the lubrication done under cleanning conditions to ensure
period under bearing temperature of 70C (for good operation and to avoid damages. New
bearings up to 6312 and NU 312) and bearings shall only be taken out from their cases
temperature of 85C (for bearings 6314 and NU when assembling them.
314 and larger). Before installing a new bearing it is
For each 15C of temperature rise, the required to check the shaft fitting for any sharp
relubrication period is reduced by half. edge or strike signals.
The relubrication periods given above are For bearing assembly warm their inner
for those cases applying Polyrex EM grease. parts withsuitable equipment - inductive pocess
When motors are used on the vertical - or use suitable tools.
position, their relubrication interval is reduced SPARE PARTS
by half if compared to horizontal position
motors. When ordering spare parts, please specify
WE RECOMENDED TO USE BALL the full type designation and product code as
BEARINGS FOR MOTORS DIRECTLY stated on the motor nameplate. Please also
inform the motor serial number stated on the
COUPLED TO THE LOAD. nameplate.
WARNING: MOTORS FOR HAZARDOUS
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING LOCATIONS
RESULTING IN COMPLETE Besides the recommendations given
DAMARGE. previously, these ones must be also followed:
Compatibility of Polyrex EM grease with THE SPECIFICATION OF THE MOTOR

other types of grease: INSTALLATION PLACE IS FOR
CUSTOMERS RESPONSIBILITY,
Containing polyurea thickener and mineral WHO WILL ALSO DETERMINE THE
oil, the Polyrex EM grease is compatible with ENVIRONMENT CHARACTERISTICS.
other types of grease that contain:
Lithium base or complex of lithium or polyurea Motors for hazardous locations are
and highly refined mineral oil. manufactured according to specific standards
Inhibitor additive against corrosion, rust and for such environments and they are certified by
anti-oxidant additive. worldwide certifying entities.
Notes: 1 - Installation
Although Polyrex EM is compatible with types
of grease given above, we do not recommended The complete installation must follow
to mix it with any other greases. procedures given by the local legislation in effect.
If you intend to use a type of grease different
than those recommended above , first contact THE INSTALLATION OF HAZARDOUS
HATLAPA. LOCATION MOTORS MUST BE
On applications (with high or low temperatures, CARRIED OUT BY SKILLED PEOPLE,
speed variation, etc), the type of grease and
relubrification interval are given on an additional AND THE THERMAL PROTECTION
nameplate attached to the motor. MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
THE USE OF STANDARD MOTORS
MOTOR, OPERATING AT THE RATED
IN SPECIFIC AREAS OR SPECIAL
CURRENT.
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE 2 - Maintenance
MANUFACTURER OR HATLAPA
Maintenance must be carried out by repair
shops authorized by HATLAPA.
DISASSEMBLY AND ASSEMBLY Repair shops and people without HATLAPAs
authorization who will perform any service on
Disassembly and assembly must be done hazardous location motors will be fully
by qualified personnel using only suitable tools responsible for such service as well as for any
and appropriated methods. consequential damage.
76/101
Lower efficiency.
ANY ELECTRICAL OR MECHANICAL
Higher vibration.
MODIFICATION MADE ON
Higher noise level.
HAZARDOUS LOCATION MOTORS Higher rated current.
WILL VOID THE CERTIFICATION. Higher temperature rise.
When performing maintenance, Reduced motor insulation.
installation or relubrication, follow these Reduced bearing life.
instructions:
1- Standard Motors
Check if all components are free of edges,
knocks or dirt.
Make sure all parts are in perfect conditions. Voltages lower than 440V do not require filter.
Lubricate the surfaces of the endshield fittings Voltages equal or higher than 440V or lower
with protective oil to make the assembly easier. than 575V require filter for motor power supply
Use only rubber hammer to fit the parts. cables longer than 20 meters.
Check for correct bolts tightening. Voltages equal or higher than 575V require
Use clearance calibrator for correct T-box fitting filter for any size of power supply cables.
(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR IF SUCH RECOMMENDATIONS ARE
WORN PARTS. REPLACE THEM BY NOT FOLLOWED ACCORDINGLY,
NEW ONES SUPPLIED BY THE MOTOR WARRANTY WILL BE VOID.
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD Check power supply voltage of the forced
Applications using VFDs without filter cooling set.
can affect motor performance as follows: Filters are not required.
77/101
Hydraulic Oil and Lubricating Grease
for Steering Gears
1 Lubricant recommendations
The pressure fluid in hydraulic circuits must be chosen carefully when designing the
gear basing on the viscosities listed below for guaranteeing disturbance-free, economic
operation with the lowest wear and tear. HLP oils must be chosen according to DIN
51524 T2 and VDMA 24318.
Decisive for the choice of the hydraulic fluid are the ambient conditions under which the
steering gear is mainly operated.
Requirements on the hydraulic fluid
Ambient temperature from -10C to +30C from 0C to +40C from +10C to +50C
Climatic zone arctic moderate tropic
average ambient 10C (+/- 5C) 20C (+/- 5C) 30C (+/- 5C)
temperature
Prescribed viskosity ISO VG32 ISO VG46 ISO VG68
Any guarantee claim towards HATLAPA is automatically cancelled if hydraulic

fluids are used which do not conform with these requirements.
Grease lubricants
The use of suitable greases is necessary for reaching the highest grade of operational
safety and long working life of the steering gear. The lubrication points shown in the
instruction manual for HATLAPA steering gears must be re-greased. In case of
automatic grease lubrication this is carried out automatically at the set intervals, when
using hand grease guns this must be carried out every 24 hours.
For HATLAPA steering gears Li-grease NLGI-2 oder NLGI-3 is prescribed.
Recommendation
Use only hydraulic fluids and lubricants of well-known makes.
The viscosity and the class of lubricating grease must be adhered to for the
aforementioned ambient conditions.
In case of questions concerning the hydraulic fluids or grease lubricants please
contact the maker they are the experts.
date 07.07.2005 page 1 of 1
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Busan, Korea
Weight list
Yard / HN : Hyundai Heavy Industries 2150/51/52/53, 2170/71/72/73
Hatlapa : 08.6991/92/93/94/95/96/97/98
Type : R4ST1000 - 35
NO. PART Approx. Weight(kg)

1 Tiller 17,570
2 Cylinder Unit 1+3 13,500
3 Cylinder Unit 2+4 13,500
4 Pump Unit 1+2 2,715
5 Pump Unit 3+4 2,715
Total Weight Steering Gear 50,000
1/1
Busan, KOREA
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H2150 Final Drawing-Rev2.

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H2150 Final Drawing-Rev2.

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Busan, Korea

Final drawing and

Hull No. H2150

Tel.: + 82-(0)51-972-9260 Managing Director :

NO. DESCRIPTION Page

List Scope of Supply

ITEM QTY COMPONENTS HATLAPA YARD

2 0 0 4 HYDRAULIC PUMP UNIT each existing of:

ITEM QTY COMPONENTS HATLAPA YARD

7 0 0 RUDDER ANGLE INDICATOR SYSTEM O

NO. DESCRIPTION SPEC. UNIT

NO. DESCRIPTION SPEC. UNIT

Oil air cooler e- motor

date 23.02.2005 page 1 of 2

date 23.02.2005 page 2 of 2

2. Instructions on safety precautions

Setting up, commissioning, operation and maintenance must be done by authorized,

Commissioning, operation and maintenance must be in conformity with the instructions

Instructions on safety precautions as found in the operating manual, must

4. Particular safety instructions on the electrical equipment

Hose pipes must be inspected visually by the assembly/service personnel before

1.2 Storage and durability

date 18.04.2005 page 1 of 1

Hydraulic Locking, schematic

Hydraulic Locking Alarm Transmitter

Valid for steering gear type R4ST file:VERANAE.DOC

3 Variable delivery pumps and analogue control

Valid for steering gear type R4ST file:VERANAE.DOC

If analogue control is to be fitted to a steering gear with variable delivery pump

General circuit diagram for steering gears

Abbreviations: 1 = Axial piston pump with adjusting cylinder

Valid for steering gear type R4ST file:VERANAE.DOC

Abbreviations: I = control current in mA

Valid for steering gear type R4ST file:VERANAE.DOC

Steering Gear Operating Instructions

2. OPERATION FROM STEERING GEAR COMPARTMENT

2. PUMP UNIT ALARM ON THE BRIDGE

3. LOSS OF STEERING CAPABILITY DUE TO HYD. LOCKING

4. LOW OIL LEVEL ALARM ON THE BRIDGE

Fllen der Anlage und Inbetriebnahme

Anschlieend wird die Nothandbettigung am Wegeventil mehrere Male gedrckt, wobei

Filling the System and Starting of Operation

Betrieb der Anlage

Operation of the Gear

Datei:Betrieb der Anlage.doc

ram pin tiller mechanical block pump unit

cylinder ram sliding locking piece/ connection

picture 1: HATLAPA steering gear

HATLAPA Tel.:+ 49-4122/711-0 Geschftsfhrer/ UST.ID-Nr. DE 134527127

3. Mount the tiller according to HATLAPAs installation drawing (if existing).

picture 2: HATLAPA steering gear

picture 3: Cylinder Group

picture 4: adjust of the measure X

picture 5: use of the distance setting jig

picture 6: measure of G and H

picture 8: use of ruler and feeler gauge

Picture 11: nearly same distance

picture 12: adjustment of the mechanical block

ALLOWABLE ALIGNMENT TOLERANCES

1.1 Installation of Piping

1.1.1 General remarks

1.1.2 Materials for pipe lines

1.1.3 Treatment of pipe lines