TECHNICAL DOCUMENTATION

FOR

STEERING GEARS

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Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
Table of Contents

Section 1 Technical Data

Section 2 Instruction Manual

Section 3 Rudder Carrier

Section 4 Installation Drawings and Diagrams

Section 5 Spare Parts Lists

Section 6 E-Equipment
• Wiring Diagrams

Section 7 Addition Information

• E-Motor
• High Pressure Hydraulic Pump
• Coupling
• Filter
• Wing Pump
• Alert System

Section 8 Instructions for Correctly Ordering Spare Parts

Section 1 Technical Data
 15-02-10
TECHNICAL DATA
Shipyard / Customer Hull No. Our reference Rev.
HCY-165
Huanghai SY up to 14.6417-21 2
HCY 169

ref. to drawing
Item Description Value
no.
1. MECHANICAL DATA
1.1. steering gear type Neptune 500-65°
1.2. working torque [kNm] at 35° 570 kNm
1.3. design torque [kNm] at 35° 713 kNm
2 x -65°(electr.),
1.4. rudder angle
2 x -67° (mech.)
1.5. final tiller diameter øB [mm] 340-0,1
1.6. final rudder stock diameter øA [mm] 340,8
1.7. rudder stock yield strength [N/mm²] 300
1.8. rudder stock cone 1:15
Only the push up distance is important for the operation and approval. Other
1.9. given values are for guidance and information.
Max. widening pressure has not to be exceeded (deformation)!
290203
1.9.1. push up distance [mm] (min./proposal/max.) 7 / 7,5 / 8
1.9.2. widening pressure [bar] (min./proposal/max.) 1018 / 1142 / 1219
1.9.3. axial force [kN] (min./proposal/max.) 4078 / 4576 / 4886-
hydraulic nut supplied by Hatlapa
1.10. inner thread machined by Hatlapa
size of thread Tr 260x4
1.11. total weight approx. [kg] 3600
Fx [kN] 720
1.12. foundation force
Fy [kN] 720
axial load [kN] -
1.13. rudder carrier
radial load [kN] -
2. TEST DATA
2.1. cylinder [bar] 345
test pressure -
2.2. hydraulic circuit [bar] 345

1/2
Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:
Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 15-02-10
TECHNICAL DATA
Shipyard / Customer Hull No. Our reference Rev.
HCY-165
Huanghai SY up to 14.6417-21 2
HCY 169

Description ref. to drawing

Item Value
no.
3. ELECTRICAL DATA
3.1. main ship voltage supply 440 V / 60 Hz
3.2. e-motor size 200L
3.3. e-motor power [kW] 47 (S6-25% acc. to IEC)
3.4. e-motor speed [rpm] 1750
-
3.5. control voltage DC [V] 24
3.6. e-motor protection class IP 55
size -
3.7. oil-air cooler
e-motor [kW] -
4. HYDRAULICAL DATA
4.1. working pressure [bar] 182
design pressure
4.2. 228
(setting of pressure relief valves) [bar]
4.3. servo pressure [bar] -
4.4. boost pressure [bar] -
4.5. pressure switch adjusted to [bar] -
4.6. pump type constant displacement 290210
290216
4.7. displacement volume [cm³] 80
4.8. steering gear oil capacity [l] 100
4.9. working /expansion tank capacity [l] 2x300
4.10. storage tank supplied by Hatlapa
4.11. storage tank oil capacity [l] 500
4.12. complete oil capacity without storage tank [l] -
5. GENERAL DATA
5.1. classification LR
5.2. rudder laying time for 65° (35° - 0° - 30°) ½ pumps ≤ 28s/14s
5.3. ambient temperature [°C] 0-45

2/2
Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:
Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
Section 2 Instruction Manual
 Instruction Manual

Steering Gear
NEPTUNE 500–65°

2015-02-10
Techen, Kerstin

HATLAPA
Uetersener Maschinenfabrik GmbH & Co. KG
Tornescher Weg 5–7
25436 UETERSEN / GERMANY
Tel.: +49 4122 711–0
Fax: +49 4122 711–104
info@hatlapa.de
www.hatlapa.de
Steering Gear NEPTUNE 500–65°
Table of Contents

Table of Contents
1 General Comments................................................................................................................................. 4
1.1 Information on Manuals ..................................................................................................................... 4
1.2 Layout of these Instructions ............................................................................................................... 4
1.3 Copyright............................................................................................................................................ 5
1.4 Warranty ............................................................................................................................................ 5
1.5 Designations ...................................................................................................................................... 6
1.6 Signs Used......................................................................................................................................... 7
2 Safety ....................................................................................................................................................... 8
2.1 Intended Use ..................................................................................................................................... 8
2.2 Ban on Arbitrary Modifications ........................................................................................................... 8
2.3 General Safety Instructions ............................................................................................................... 8
2.4 Safety Instructions for Assembly ....................................................................................................... 9
2.5 Safety Instructions for Operation and Service ................................................................................... 9
2.6 Safety Instructions for Maintenance and Repairs .............................................................................. 9
2.7 Additional Safety Instructions for Electrical Installation ................................................................... 10
2.8 Hazard Zone .................................................................................................................................... 11
2.9 Safety Labels on the Machine ......................................................................................................... 11
2.10 Safety Equipment ............................................................................................................................ 13
2.11 Instruments for Operating Surveillance ........................................................................................... 14
2.12 Waste Disposal ................................................................................................................................ 14
3 Structure and Function ........................................................................................................................ 15
3.1 Steering Gear NEPTUNE ................................................................................................................ 15
3.2 Hydraulic Unit .................................................................................................................................. 17
3.3 Hydraulic Controls ........................................................................................................................... 18
3.4 Storage Tank ................................................................................................................................... 19
3.5 Rudder Angle Indication .................................................................................................................. 19
3.6 Control Sections .............................................................................................................................. 20
4 Assembly and Installation ................................................................................................................... 24
4.1 Shipping ........................................................................................................................................... 24
4.2 Storing after Delivery ....................................................................................................................... 24
4.3 Transport.......................................................................................................................................... 24
4.4 Assembly ......................................................................................................................................... 25
4.5 Installation ........................................................................................................................................ 35
4.6 Flushing High Pressure Hydraulic Systems .................................................................................... 41
5 Initial Operation .................................................................................................................................... 45
5.1 Removing Preservation ................................................................................................................... 45
5.2 Checks Prior to Initial Operation ...................................................................................................... 45
5.3 Fill Hydraulic System ....................................................................................................................... 46
5.4 Start Up Pump Units ........................................................................................................................ 48
5.5 Configure Hydraulic Controls ........................................................................................................... 48
5.6 Start Up Steering Gear .................................................................................................................... 49
6 Operation of Steering Gear ................................................................................................................. 50
6.1 Steering Control ............................................................................................................................... 50
6.2 Activate Steering Gear..................................................................................................................... 51

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 Steering Gear NEPTUNE 500–65°
Table of Contents

6.3 Normal Operation Mode .................................................................................................................. 51

6.4 Checks During Operation ................................................................................................................ 52
6.5 Emergency Operation ...................................................................................................................... 52
6.6 Switch Active Pump Unit.................................................................................................................. 53
6.7 Deactivate Steering Gear ................................................................................................................ 53
6.8 Stop Using Steering Gear ................................................................................................................ 53
7 Help in Case of Malfunctions .............................................................................................................. 54
7.1 Malfunctions Indicated by the Steering Gear Alert System ............................................................. 54
7.2 Function Called Not Executed ......................................................................................................... 60
7.3 No Rudder Movement Possible In One Direction ............................................................................ 60
7.4 Slow or No Movement of the Steering Gear .................................................................................... 60
7.5 Rudder Position Greater Than Nominal Rudder Angle ................................................................... 61
7.6 Maximum Rudder Angle Not Achieved When Ship Travelling At High Speeds .............................. 61
7.7 Imprecise Control ("Hunting") .......................................................................................................... 61
7.8 The Steering Gear Operates Without a Steering Command ........................................................... 61
7.9 Rudder Position Not Achieved ......................................................................................................... 61
7.10 Main Pump Does Not Achieve Full Delivery Rate ........................................................................... 62
7.11 Grating Noises from the Steering Gear ........................................................................................... 62
7.12 Pressure Increase on Movement of the Steering Gear ................................................................... 62
7.13 Noises in Pump Unit ........................................................................................................................ 62
7.14 Oil Leaks on Cylinder ....................................................................................................................... 62
7.15 Oil Level Too High ........................................................................................................................... 62
7.16 Oil Temperature Too High ............................................................................................................... 63
8 Maintenance .......................................................................................................................................... 64
8.1 Storing Spare Parts ......................................................................................................................... 64
8.2 Periodic Preventive Maintenance .................................................................................................... 67
8.3 Inspection......................................................................................................................................... 69
8.4 Venting the Hydraulic System.......................................................................................................... 74
8.5 Cleaning ........................................................................................................................................... 75
8.6 Oil Change ....................................................................................................................................... 77
8.7 Lubrication ....................................................................................................................................... 78
8.8 Disassemble Rudder Shaft Using the Hydraulic Nut ....................................................................... 80
8.9 When Decommissioning .................................................................................................................. 81

3
Steering Gear NEPTUNE 500–65°
General Comments

1 General Comments

1.1 Information on Manuals

This manual includes all information 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 manual can ensure faultless and correct functioning of the
equipment, so its contents must be known to the responsible persons. The manual
should be kept so that the operating and maintenance personnel have access to it
at all times.

1.2 Layout of these Instructions

1.2.1 Numeration
General numerations are indicated by dashes.
Example:
Observe the following in order to correctly store hoses:
– maximum storage time for assembled hoses is 2 years,
– maximum storage time for tubular goods is 4 years.

Individual handling instructions, or multiple handling instructions where order is not

important, are indicated by points.
Example:
• Check oil status.

Handling instructions, which must be executed in a defined order, are indicated

with numbers.
Example:
1. Activate main switch.
2. Press START button.

Interim results of handling instructions, or conditions which must be fulfilled, are

indicated with tick marks.
Example:
 The control now is ready for operation.
 The switch must be switched to automatic.

1.2.2 Labelling
Switch names and message texts are written in upper case.
Example:
START button

4
 Steering Gear NEPTUNE 500–65°
General Comments

1.2.3 Cross-references
The text contains cross-references (with page numbers) to other passages in the
document.
Example:
See Maintenance, p. 12.
See Figure 4, p. 5.
The text contains cross-references to positions in figures. The cross-references are
in brackets. The first number indicates the figure, the second the item in the figure.
Example:
(3-11) cross-reference to item 11 in figure 3.

1.2.4 Safety Instructions

Safety instructions are emphasised using symbols and signal words. The safety
instructions are described in detail in chapter Signs Used, p. 7.

1.3 Copyright
The copyright for this technical documentation remains with HATLAPA.
This documentation is intended for the operator and their personnel only.
All rights reserved.

1.4 Warranty
Warranty and liability claims for damage to persons and/or objects are excluded, if
caused by one or several of the following circumstances:
− inappropriate use of the equipment,
− neglect of the provisions of this documentation,
− improper assembly, operation or maintenance,
− operation of the equipment with ineffective protective devices,
− arbitrary functional or constructive alteration of the equipment,
− removal of parts or installation of spare parts or additional components,
respectively, which have not been supplied or approved by HATLAPA,
− repairs which have not been authorised by HATLAPA,
− impact of foreign bodies in case of catastrophes or Force Majeure.

5
Steering Gear NEPTUNE 500–65°
General Comments

1.5 Designations
Persons are defined as follows:
− The operator is the (natural or legal) person on whose behalf the equipment is
used, e.g. the ship’s owner.
− Operating personnel are personnel trained for the respective work, and who are
authorised to operate the equipment and to remedy disturbances. The operating
personnel must be trained for the tasks they are entrusted with, and meet the
requirements necessary to handle the equipment.
− Assembling personnel are personnel trained for the respective work, and who
are authorised to assemble the equipment. They are able to carry out the tasks
assigned to them and to recognise possible dangers because of their completed
specialised training.
− Maintenance personnel are personnel trained for the respective work, and who
are authorised to maintain, adjust and modify the equipment. They are able to
carry out the tasks assigned to then and to recognise possible dangers because
of their completed specialist training.
− An electrician has electro-technical skills gained by respective education,
masters the legal regulations, and is assigned by the operator to carry out work
on their electrical equipment and appliances.

6
 Steering Gear NEPTUNE 500–65°
General Comments

1.6 Signs Used

Sign for Danger

DANGER
Warning information about a hazard with a high level of risk, which, if not avoided,
will result in death or permanent injury.

Sign for Warning

WARNING
Warning information about a hazard with a moderate level of risk, which, if not
avoided, will result in death or permanent injury.

Sign for Caution

CAUTION
Warning information about a hazard with a low level of risk, which, if not avoided, will
result in slight or moderate injury.

Sign for Property Damage

PROPERTY DAMAGE

Warning information for damage, which if not avoided may lead to damage,
malfunction of the system or damage to the environment.

Sign for Hint

HINT
Information about hints and useful information which facilitate the operation of the
system or understanding of the documentation.

7
Steering Gear NEPTUNE 500–65°
Safety

2 Safety

2.1 Intended Use

The steering gear is used on board a vessel, is installed in the steering gear flat
and is intended for setting the rudder angle. It is not intended for any other use.
The intended use also includes the observance of this technical documentation,
the acknowledged rules of engineering as well as the relevant laws, standards and
regulations.

2.2 Ban on Arbitrary Modifications

Arbitrary modifications and changes to the machine/system are not permitted, as
they may put persons in danger and result in damage to the machine/system.
If you are planning modifications or changes, contact HATLAPA and request
written authorisation.

2.3 General Safety Instructions

In the addition to specific safety technology notes in these instructions and the sub
supplier's documentation, you must also observe the generally-applicable safety
and accident regulations, such as:
− recognised technical regulations for safe and professional work,
− regional and internal regulations,
− regulations from the responsible classification society,
− accident prevention regulations of German Social Accident Insurance Institution
for Transport and Traffic,
− safety signs and indicator plates on the machine/system,
− environmental protection regulations.
Incorrect handling or failure to comply with regulations during use can bear risks of
physical injury and death, and/or damage to property. Observe the limits specified
in the technical data.
Clean the deck in the work area regularly. Immediately remove oil, grease, water or
other residues that could result in accidents caused by slipping or tripping.
Find out about the fire detection and fire prevention options, and ensure that these
are fully functional and sufficient.

8
 Steering Gear NEPTUNE 500–65°
Safety

2.4 Safety Instructions for Assembly

During assembly and installation, the safety equipment cannot function effectively.
Therefore, the safety of the assembling personnel to a great extent depends on the
attentive execution of work.
Only trained and briefed personnel are permitted to carry out assembly and
installation work. The personnel must have special knowledge of hydraulic and
electrical engineering.
Only use suitable and fully functioning tools.
During torching or welding work, ensure that risks of fire or explosion are avoided.

2.5 Safety Instructions for Operation and Service

The machine/system must only be operated by trained and briefed operating
personnel. The valid regulations on safety at work and protection of minors must
be adhered to.
New personnel may only use the machine/system under the constant supervision
of trained and briefed operating personnel.
Give regular briefings on accident regulations and the requirements stated in this
documentation. Provide evidence of these briefings.

2.6 Safety Instructions for Maintenance and Repairs

The machine/system may only be maintained and repaired by trained and briefed
maintenance personnel. The personnel must have special knowledge of hydraulic
and electrical engineering.
Before starting repair work, deactivate the machine/system and prevent it from an
unintentional restart. If the work can only be carried out while the machine/system
is running, make the necessary safety arrangements. A second person must
monitor the work, and be ready to intervene if needed.
When carrying out maintenance and repair work, do not disable more than one
piece of safety equipment at a time.
Only use suitable and fully functioning tools.
DANGER
Deadly voltage!
The main switch remains energised even if it is deactivated.
Before starting maintenance work, switch off the main switch on the contactor
cabinet, and prevent it from an unintentional and unauthorised restart.

During torching or welding work, ensure that risks of fire or explosion are avoided.

WARNING
The steering gear may move suddenly and unexpectedly if the pump units and the
steering control are remotely controlled from the bridge. This may cause crushing
injuries.
If you need to switch on the main switches on the pump contactor cabinets for
individual tests and work, switch the pump units and the steering control to LOCAL.
Inform the bridge before starting work on the steering gear.

9
Steering Gear NEPTUNE 500–65°
Safety

2.7 Additional Safety Instructions for Electrical Installation

All work on the electrical systems is only allowed to be performed by qualified
electricians.
DANGER
Deadly voltage!
Before starting to work on electrical equipment, the machine/system must be de-
energized. Ensure that
− the mains supply is deactivated. Check that the disconnected parts are de-
energised before commencing work.
− the electricity supply cannot be reconnected unintentionally or without
authorization while work is being performed on the electrical installation.
− the electricity for parts which must remain connected for the maintenance and
repair work only remains connected for as long as is absolutely necessary for the
work in question.
The main switch remains energised even if it is deactivated.

Work carried out on electrical systems must be done so in accordance with the
valid safety regulations, as well as all other relevant state or local regulations.
Under no circumstances repair or bypass defective fuses. Fuses must only be
replaced by fuses of the same rating.
When working on electrical systems, only use permitted and suitable tools. Only
use non-conductive tools.
When taking measurements with the voltage supply of >65 V activated,
− you must under no circumstances touch the electrical connection points,
− the inspection equipment must be in good condition and safe to operate,
− you must not wear any jewellery on fingers or wrists,
− you must stand on insulated ground.

10
 Steering Gear NEPTUNE 500–65°
Safety

2.8 Hazard Zone

The fully functional steering gear is very important for the safety of the ship and its
crew. In order to be able to react quickly should malfunctions occur, the
mechanical and hydraulic components must be easily accessible and must not be
covered with a protective cover.
WARNING
There is a risk you could be crushed when the steering gear is moving.
For this reason, the construction yard or operator must use a safety railing to secure
the zone around the steering gear.

The area inside this safety railing is the hazard zone.

Only authorised personnel may enter the hazard zone during operation.

2.9 Safety Labels on the Machine

WARNING
If safety labels are not visible on the machine, possible risks of injury and death can
no longer be recognised.
Safety labels must not be changed, blocked or removed. Immediately replace
damaged or missing safety labels with labels that are true to the originals.

2.9.1 Warning Plates on the Contactor Cabinets

Figure 1: Warning plate on the contactor cabinet

Electrical components in contactor cabinets with this warning plate have a life-
threatening voltage.
The contactor cabinets must only be opened by qualified electrical specialists,
taking into account the valid safety regulations and all other relevant state or local
regulations.
2.9.2 Indicator Plate in Steering Gear Room
The indicator plate states the most important safety guidelines for operating the
steering gear. This indicator plate is delivered by HATLAPA, and must be fastened
in a well visible location in the steering gear room.

11
Steering Gear NEPTUNE 500–65°
Safety

Figure 2: Indicator plate

2.9.3 Block Diagram

The block diagram shows a hydraulic scheme of the steering gear, together with
abbreviated instructions for normal operation and emergency operation.
The block diagram is delivered by HATLAPA, and must be fastened in a well
visible location in the steering gear room.

12
 Steering Gear NEPTUNE 500–65°
Safety

2.10 Safety Equipment

WARNING
Faulty safety equipment may put lives and equipment at risk.
All safety equipment must always be in a flawless and fully operational condition.
You must not make the safety equipment inoperative in any way.
If a piece of safety equipment is defective, the machine/system must not be
operated.
Only remove safety equipment if the machine/system has been isolated and
secured.
Perform regular checks on the safety equipment, in accordance with the regulations
in this documentation and the sub suppliers' documentation.

2.10.1 Turning Angle Transmitter (shipyard’s supply)

A turning angle transmitter controls the tiller end positions. When the tiller is moved
to the end position, the controls deactivate the rudder movement.

2.10.2 End Position Stopper

The stoppers restrict the rudder movement should the turning angle transmitter
malfunction.

2.10.3 Hydraulic Locking Alarm

If a portside/starboard command is given, the cock in the distributing valve
disengages in order to release the oil flow to move the rudder in the corresponding
direction.
Limit switches are used to monitor the disengagement of the cock. It is then
compared with the rudder command issued from the bridge. If a difference is
identified during this comparison, an alarm is triggered.
If no rudder command is received, the cock must remain in neutral position. An
alarm is also triggered if the cock is disengaged while in neutral position.

2.10.4 Pressure Relief Valve

Pressure relief valves for limiting hydraulic pressure and starting pressure are
located in the hydraulic circuits.

13
Steering Gear NEPTUNE 500–65°
Safety

2.11 Instruments for Operating Surveillance

CAUTION
If instruments for operating surveillance are out of order, monitoring of the operating
conditions of the machine/system may lead to incorrect analyses. This may put lives
and/or equipment at risk.
Never decommission any instruments for operating surveillance.
If instruments for operating surveillance are defective, they must be changed as
soon as possible. Take utmost care when operating the machine/system until the
instruments have been exchanged.

2.11.1 Alarm System

In cases of malfunctions, audible and visual alarms on the contactor cabinet for the
alarm system as well as on the control panel are triggered, see Help in Case of
Malfunctions, p. 54.

2.11.2 Pressure Gauge

Pressure gauges monitor the hydraulic pressure. In normal operation, the pressure
gauges are separated from the hydraulic circuit.

2.11.3 Oil Level Switch

If the oil level in the working tank is too low, an alarm is triggered.

2.11.4 Filter Monitor

Filters are equipped with differential pressure switches. If a filter is blocked, an
alarm is triggered.

2.11.5 Overload Safety Device

The pumps' electronic engines are equipped with overload safety devices. If the
engine is overloaded, an alarm is triggered.

2.12 Waste Disposal

The following substances which resulting from operation of the machine/system
must be disposed of in an environmentally friendly manner, in accordance with the
applicable laws:
− used oils and grease as well as cloths with such substances on them;
− cleaning agents, and cloths with cleaning agents on them;
– seals made of cardboard, cork, rubber or plastic materials.

14
 Steering Gear NEPTUNE 500–65°
Structure and Function

3 Structure and Function

3.1 Steering Gear NEPTUNE

The steering gear unit is designed as a cylinder-type unit which is equipped with
two differential piston cylinders.
There are two independently hydraulic aggregates with the same capacity. Each of
these aggregates can fulfill the requirements to a main drive. The second
aggregate serves as redundant unit.
When required, the rudder laying time may be halved by parallel operation of both
aggregates.
The steering gear consists of the following components:

Figure 3: Steering gear

Item Description
1 Tiller
2 Cylinder fastening bolt
3 Working cylinder
4 Shut valve
5 Pipe connection to hydraulic unit
6 Thrust block

15
Steering Gear NEPTUNE 500–65°
Structure and Function

Item Description
7 Pressure relief valve
8 Support
9 End position stopper
10 Mechanical rudder angle indicator
The torque needed for the movement of the rudder stock is produced by the
double-acting working cylinders. The torque is transferred from the heads of the
piston rods of the working cylinders via the tiller to the rudder stock. The reacting
forces are taken by the thrust block.
In the thrust block, the working cylinders are supported in ball-and-socket joints.
These ball-and-socket joints and the ball-and-socket joints in the piston rod ends
absorb the rotating motions of the working cylinders caused by operation as well as
the limited vertical motions of the rudder stock.
The valve block with the fittings required for operation and safety is installed on the
thrust block. From there, oil is supplied via high pressure hoses to the working
cylinders.
By closing the shut valves at the crown sides of the cylinders the oil circuit of the
system can be interrupted. The rudder stock is fixed by the held hydraulic oil in the
working cylinders.

16
 Steering Gear NEPTUNE 500–65°
Structure and Function

3.2 Hydraulic Unit

Figure 4: Hydraulic unit

Item Description
1 Pump drive
2 Pipe connection to storage tank
3 Return filter
4 Oil dipstick
5 Oil drain screw
6 Working circuit “B”
7 Working circuit “A”
8 Emergency control
9 Measuring connection for working pressure
10 Control plate
11 Pump cover
12 Oil level switch
13 Oil filling air filter
14 Pressure gauge

17
Steering Gear NEPTUNE 500–65°
Structure and Function

The hydraulic unit consists of two separately operating pump units.

Both pump units are mounted on a double tank which contains two chambers (one
for each pump unit) and contains the amount of hydraulic fluid needed for the
system.
The constant pump (main pump) is screwed onto the pump support and is installed
with the aforementioned control hydraulics. The electric motor is connected to the
main pump through a flexible coupler, via the pump support.
The electric motors are equipped with anti-condensation heating.
The return filters are equipped with filter monitors. If a filter is blocked, an alarm is
triggered.
A by pass valve protects the filter element during a cold start.
A vent valve is used to vent the filter during initial operation and when changing the
filter element.

3.3 Hydraulic Controls

1 2 3

Figure 5: Hydraulic controls (basic sketch)

1 Constant pump
2 Pressure relief valve
3 Magnetic distributing valve (main control valve) 4/3 with 2 magnetic
coils 24 V
A+B Connections for cylinders
The hydraulic controls consist of a distributing valve, which is supplied
electromagnetically via a pilot valve. This releases the oil flow to the port or
starboard side of the steering gear.
Emergency control of the distributing valve makes it possible to adjust the flow of
oil if the remote control malfunctions.
The pressure relief valve is configured in the plant to the required pressure for the
steering gear. It protects the pump from overloading.
Limit switches on the magnetic valve override the position of the cock for the
hydraulic locking alarm. See Hydraulic Locking Alarm, p. 13.
The rudder angle is regulated by a three-step controller. The three-step controller
is configured upon initial operation to correspond with the ship-specific reaction
forces and rudder torque.

18
 Steering Gear NEPTUNE 500–65°
Structure and Function

3.4 Storage Tank

Figure 6: Storage tank

Item Description
1 Oil filling air filter (1 ×)
2 Hand pump (1 ×)
3 Oil drain screw (1 ×)
4 Oil level indicator (1 ×)
From storage tank hydraulic oil can be pumped into the hydraulic unit if the oil level
in the hydraulic unit is too low.
Pumps and piping for filling the storage tank, and piping from the storage tank to
the hydraulic unit are provided by the shipyard.

3.5 Rudder Angle Indication

3.5.1 Mechanical Rudder Angle Indicator
The rudder position is displayed directly on a mechanical rudder angle indicator on
the steering gear.
3.5.2 Turning Angle Transmitter
A rod transfers the rudder angle to a turning angle transmitter.
The turning angle transmitter transfers the signal to the display devices, which can,
for example, be located in the steering gear room, the engine control room, on the
bridge and in the bridge wings.
Turning angle transmitter as well as display devices are not provided by HATLAPA
in any case, but can be provided by the shipyard.

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Steering Gear NEPTUNE 500–65°
Structure and Function

3.5.3 Rudder Feedback Unit

A rod transfers the rudder angle to a rudder feedback unit.
Using the signal of the feedback unit the steering control steers the steering gear at
follow-up mode, see Steering Control, p. 50.
The rudder feedback unit is not provided by HATLAPA in any case, but can be
provided by the shipyard.

3.6 Control Sections

HINT
For help on how to remedy malfunctions, see Help in Case of Malfunctions, p. 54.

3.6.1 Overview of the Control Sections

On Pump Unit
Emergency control
– Steer steering gear directly if the steering control fails
In Steering Gear Room
Contactor cabinet for pump unit 1 / Contactor cabinet for pump unit 2
– Activate / deactivate supply for pump unit
– Start / stop pump units
– Changeover pump start bridge / local
– Changeover steering control bridge / local
– Steer steering gear local via time control
SOTERIA alert contactor cabinet with touch panel
– Display and acknowledge alert signals for steering gear, see Help in Case of
Malfunctions, p. 54
– Adjust settings and language for alerts (protected by password, only for service
personnel); see description SOTERIA alert system for steering gears in section
“Additional Information”
In engine control room (ECR)
SOTERIA alert touch panel
– Display alert signals for steering gear, see Help in Case of Malfunctions, p. 54
On the Bridge
Control panel for pump selection
– Start / stop pump units
SOTERIA alert touch panel
– Display alert signals for steering gear, see Help in Case of Malfunctions, p.
54
– Adjust the system time; see description SOTERIA alert system for steering
gears in section “Additional Information”

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 Steering Gear NEPTUNE 500–65°
Structure and Function

3.6.2 Contactor Cabinets for Pump Units

MAIN SWITCH (with interlocking device)

Activate and deactivate supply for pump unit.

MAIN SWITCH HEATING

Activate and deactivate anti-condensation heating.

Ammeter
Displays current intake of electric engine.

Running time meter

Displays the running time of the pump unit.

Selection switch PUMP START LOCAL / BRIDGE

– Turn the selection switch to the BRIDGE position in order to operate the pump
unit from the bridge.
– Turn the selection switch to the LOCAL position in order to operate the pump
unit from this contactor cabinet.
– If the switch is turned to LOCAL position, an alarm HYDR. PUMP FAILURE on
the bridge is triggered.

Green push button START

Start pump unit. The LOCAL / BRIDGE selection switch must be in the LOCAL
position.
– The electric drive is started.
– The PUMP ON SERVICE indicator light is illuminated.

Red push button STOP

Stop pump unit. The LOCAL / BRIDGE selection switch must be in the LOCAL
position.
– The electric drive is stopped.
– The PUMP ON SERVICE indicator light goes out.

Selection switch STEERING CONTROL LOCAL / BRIDGE

– Turn the selection switch to the BRIDGE position in order to operate the
steering gear via steering control (e. g. from the bridge).
– Turn the selection switch to the LOCAL position in order to operate the steering
gear from this contactor cabinet.
– If the switch is turned to LOCAL position, an alarm RUDDER CONTROL
FEEDER FAILURE on the bridge is triggered.

Red push button PORT

Position rudder in port direction. The rudder angle is changed as long as the push
button is pressed.
The LOCAL / BRIDGE selection switch must be in the LOCAL position.

Green push button STARBOARD

Position rudder in starboard direction. The rudder angle is changed as long as the
push button is pressed.

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Steering Gear NEPTUNE 500–65°
Structure and Function

The LOCAL / BRIDGE selection switch must be in the LOCAL position.

White indicator light SOURCE ON

Illuminated if power supply exists and the main switch is activated.

Blue indicator light HEATING ON

Illuminated if power supply of anti-condensation heating exists and anti-
condensation heating is activated.

Green indicator light PUMP ON SERVICE

Illuminates if the pump unit is started (from control panel or the contactor cabinet
for the pump unit).

3.6.3 Control Panel for Pump Selection

White illuminated push button DIMMER / LAMP TEST
Hold the push button pressed to check that all indicator lights work and to regulate
the brightness of the lights.

White illuminated push button START (with green writing)

Start pump unit. The LOCAL / BRIDGE selection switch must be in the BRIDGE
position.
– The electric drive is started.
– The PUMP ON SERVICE indicator light is illuminated.

White illuminated push button STOP (with red writing)

Stop pump unit. The LOCAL / BRIDGE selection switch must be in the BRIDGE
position.
– The electric drive is stopped.
– The PUMP ON SERVICE indicator light goes out.

Green indicator light PUMP ON SERVICE

Illuminates if the pump unit is started (from control panel or the contactor cabinet
for the pump unit).

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 Steering Gear NEPTUNE 500–65°
Structure and Function

3.6.4 Emergency Control on Pump Unit

Figure 7: Emergency control at distributing valve (mushroom button)

Keep mushroom button (7-1) on starboard or port side pressed to move the rudder
in the corresponding direction.
– The LOCAL / BRIDGE selection switch must be in the LOCAL position.
– The pump unit must be started (indicator light PUMP ON SERVICE illuminated).

23
Steering Gear NEPTUNE 500–65°
Assembly and Installation

4 Assembly and Installation

4.1 Shipping
The machine is suitably packaged for shipping.
When you receive it, immediately check that it is complete and undamaged.
Immediately report any damage to packaging or the machine to the transport
company and HATLAPA.

4.2 Storing after Delivery

HATLAPA steering gears are provided with sufficient preservative measures for a
storage period of 6 months.
The steering gear is stored on a transport frame and protected with foil.
Fasteners or fixings as well as blank surfaces are protected by TECTYL
anticorrosive wax.
Hydraulic components are supplied without oil and preserved inside with hydraulic
oil and sealed dustproof.

PROPERTY DAMAGE

In order for the machine to remain usable, it must be stored under the following
conditions, unless any special specifications exist:
– Frost-free, dry, under cover, and protected against dew,
– Protected against contamination,
– Protected against direct sunlight, UV radiation and ozone.
Remove protective packaging as well as anticorrosive wax only shortly before initial
commissioning!
Store the machine on the transport frame and without tension.
Renew preservation when the end of the storage period approaches, see When
Decommissioning, p. 81.

4.3 Transport
The steering gear must be transported using a fork-lift truck or a crane.
WARNING
Raised load during transport. The fork-lift truck/crane must have sufficient load
bearing capacity.
For the transport and storage of modules, observe the generally valid safety and
accident regulations, such as
− recognised technical regulations for safe and professional work,
− regional and internal regulations.

− Never walk under raised loads!

− Only use inspected lifting facilities!
− Wear a protective helmet, safety boots and gloves at work!
− After opening crates, immediately remove any nails sticking out!
− Only remove transport supports once the item has been removed!

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

HINT
For dimensions and weights, see installation diagram and delivery documents.

PROPERTY DAMAGE

Ensure that the hydraulic modules are free from strain. If necessary, use spreader
bar.

• Take great care when hoisting and depositing.

4.4 Assembly

4.4.1 Assembly of the Foundation (Provided by Shipyard)

The foundation must be designed according to the classification rules. The
approval is performed by the classification society.
Observe installation plan for the mounting dimensions of the steering gear!

4.4.2 Assembly of Rudder Stock

For dimensions of the rudder stock head see installation drawing as well as
Technical Data.
After mechanical preparation of the tiller, HATLAPA provides the dockyard with an
actual dimension record for the cone connection. This actual dimension record can
be used to complete the preparation of the rudder stock head.
Before installation of the rudder tiller, make sure that the blueprint test of tiller and
rudder stock shows a min. contact area of 70% and is approved by the class
surveyor.

4.4.3 Required tools

For assembly and installation of HATLAPA steering gears the following special
tools are needed:
− Hydraulic ring piston press with locking nut or
− Hydraulic nut,
− 2 High pressure hand pumps,
− Chain hoist, sufficient for the weight of the steering gear, rudder stock and
rudder blade,
− Lifting gear,
− Torque wrench.
Standard tool equipment (metric thread) is on board required.

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.4.4 Tightening Torque for Hexagon Head Bolt with Regular Type Screw Head

PROPERTY DAMAGE

If the retaining bolts are tightened with too little starting torque, the bolts must bear
part of the dynamic load, which should be adopted by the braced parts. This
overloads and destroys the bolts.
If retaining bolts are tightened with too much starting torque, the bolts are
overstretched and can be destroyed.
This table does not apply to extension bolts!

Select the starting torque Ma depending on the size of the thread and the strength
class of the bolt. You can find the thread size and strength class in the installation
diagram.
Use a torque wrench to tighten the retaining bolts.

Thread Size Strength Class, in Accordance with DIN 267

8.8 10.9 12.9
Ma [Nm] Ma [Nm] Ma [Nm]

M5 5 7 9
M6 9 13 15
M8 23 32 38
M 10 45 63 77
M 12 78 110 132
M 14 124 175 212
M 16 189 269 321
M 18 260 370 441
M 20 370 520 626
M 22 503 706 847
M 24 640 900 1076
M 27 944 1333 1598
M 30 1280 1809 2163
M 33 1739 2444 2939
M 36 2233 3142 3777
M 39 2903 4078 4899
M 42 3592 5048 6054
M 45 4493 6311 7573
M 48 5419 7626 9135
M 52 6972 9797 11783
M 56 8685 12224 14651
M 60 10768 15180 18182

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

Thread Size Strength Class, in Accordance with DIN 267

8.8 10.9 12.9
Ma [Nm] Ma [Nm] Ma [Nm]

M 64 12974 18270 21888

M 68 15854 22294 26753
M 72 18973 26681 32018
M 76 22476 31606 37927
M 80 26383 37100 44520
M 90 38273 53821 64585
M100 53280 74925 89910

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.4.5 Assembly of the steering gear

PROPERTY DAMAGE

Observe assembly instructions and installation dimensions in the installation plan!

Figure 8: Assembly of the steering gear

Item Description
1 Connection tiller / rudder stock (optionally: hydraulic nut / ring piston
press / clamping device)
2 Rudder stock
3 Tiller
4 Cylinder fastening bolts
5 Locking plate
6 Thrust block
7 Working cylinder
8 Support
9 Stopper
10 Mechanical rudder angle indicator

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

1. Install rudder stock and rudder carrier.

2. Make sure that the rudder is in zero position.

PROPERTY DAMAGE

If the centrelines of tiller and neck bearing are not aligned to each other, tension
may occur during operation which will lead to increased wear and tear or to
damage to the steering gear.
Therefore, the correct alignment of the tiller to the neck bearing is particularly
important!

Assemble the tiller to the rudder stock:

• In case of a connection without fitting key observe the markings on the tiller for
the correct positioning of the tiller.
• In case of connection with fitting key, the position is given by the fitting key.

Hydraulic nut

Tiller

Rudder stock

Fig. 9: Hydraulic nut, installed

3. Screw the hydraulic nut onto the thread of the rudder stock until it is tight
against the tiller.

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

High-pressure hand pump 2

High-pressure hand pump 1
Hose

Measuring device

Hydraulic nut

Hose

Tiller

Rudder stock

Fig. 10: Hydraulic Shrink Fit, hand pump 2 connected to tiller

4. Connect both hand pumps with high pressure hoses:

• Connect hand pump 1 to the hydraulic nut.
• Connect hand pump 2 to the tiller's oil groove.
5. Fill the hydraulic system of the hydraulic nut / the tiller with ISO VG 15 hydraulic
oil and vent thoroughly.
6. Check that the zero position of the rudder shaft (rudder blade) is aligned to the
zero position of the tiller; otherwise align the rudder shaft again.
7. Install the measuring equipment in order to check the push-up distance (see
installation drawing).

HINT
The tiller is widened by the hydraulic pressure, built up with hand pump 2. This
makes it easier to pulling in the rudder shaft.
The rudder shaft is pulled in by the hydraulic pressure, built up with hand pump 1.
8. Build up a light pressure with hand pump 1.

PROPERTY DAMAGE

Do not increase the pressure above the maximal widening pressure shown in the
installation drawing!

9. Build up pressure with hand pump 2 until the measuring device shows that the
rudder stock is moving.
10. Increase pressure with hand pump 1 until the push-up distance is reached.

HINT
If the rudder stock is not pulled in further although the push-up distance has not
been reached, increase the pressure by hand pump 2 until the maximal widening
pressure.
11. Release the pressure from hand pump 2.

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

12. Release the pressure from hand pump 1 after 30 minutes.

13. Remove the hydraulic hoses.

Locking plate Locking plate

Locknut Hydraulic nut

Hydraulic nut replaced with locknut Alternatively: hydraulic nut remains mounted
Fig. 11: Proposal for securing the hydraulic shrink fit

HINT
In principle there is the possibility to leave the hydraulic nut to function as nut on the
rudder stock. However, for each steering gear the shipyard would require one
hydraulic nut.
The hydraulic nut has to be tightened and mechanically secured to prevent
loosening (see alternatively in Fig. 12).
Locknut and locking plate are not supplied by HATLAPA.
14. Unscrew the hydraulic nut.
15. Screw on the locknut.
16. Secure the locknut against loosening. E.g. weld a locking plate all-round the
locknut and the rudder stock.
17. Check alignment of the steering gear and readjust if necessary until the correct
position of the steering gear has been reached:
− Vertical alignment of the tiller to the neck bearing,
− Zero positions of rudder, tiller and rudder stock aligned to each other,
− Push-up distance.
18. Remove the measuring equipment.

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

Figure 12: Cylinder fastening bolt (shown at the tiller)

Item Description
1 Fastening screw
2 Locking plate
3 Cylinder fastening bolt
4 Tiller eye / thrust block eye
5 Distance ring
6 Piston rod eye / cylinder eye

HINT
Prior to installation, the cylinder fastening bolts must be cooled down to –80 °C by
storage in dry ice for 24 hours.

WARNUNG
Only touch the cooled cylinder fastening bolts using gloves!

Fit the piston rod eyes to the tiller:

19. Fit the locking plates to the cylinder fastening bolts, using each two screws.
20. Lubricate the piston rod bearings and cylinder fastening bolts with grease.

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

PROPERTY DAMAGE

On installation, make sure that the distance rings are placed correctly between the
piston rod eye and the upper and lower tiller eye, to prevent the piston rod from
touching the tiller.

21. Place the greased distance rings onto the lower and upper side of the greased
piston rod bearings.
22. Push the piston rod eyes between the tiller eyes.

PROPERTY DAMAGE

When pressing the subcooled bolts into the tiller, take care to keep the locking plate
in correct position, i.e. the fastening screws in line with the threadholes of the tiller.

23. Press the greased cylinder fastening bolts from above into the tiller eyes until
the locking plate lies on the tiller.
24. Fit the locking plates to the tiller, using each two screws.
Fit the cylinder eyes to the thrust block:
25. Repeat steps 19 – 24 for the thrust block.

Figure 13: Adjust the steering gear

26. Adjust the thrust block until the dimensions „x“ and „y“ between the eye bolt
holes on the thrust block and on the tiller are identical (see Figure 14 and
installation drawing).
27. Check the height of the thrust block, see installation drawing. The ball-and-
socket joints in the hydraulic cylinders allow a max. horizontal deviation of
+/-1°.
28. Weld the thrust block to the foundation, see installation drawing.
29. Adjust the support and check the space between cylinders and support, see
installation drawing.
30. Weld the support to the foundation.

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

Figure 14: Mounting the stopper and pointer

Item Description
1 Pointer mechanical rudder angle indicator
2 Scale mechanical rudder angle indicator
3 Contact surface for stopper at the tiller
4 Fitting plate
5 Stopper
31. Adjust the stopper, see installation drawing.
32. Remove the fitting plates and check that the contact surfaces of the tiller match
the stopper faces exactly in PS/SB hardover position.
33. Weld the stopper to the foundation.
34. Move the tiller in each hardover position and measure the exact distance
between the stopper and the contact surface at the tiller.

PROPERTY DAMAGE

On welding, take care to leave no gap at all between face plate and stopper!

35. Machine down the fitting plates to the measured dimension and weld them to
the stopper with a 5-mm fillet weld.
36. Adjust the pointer of the mechanical rudder angle indicator to the scale and
weld it to the stopper.
37. Lubricate the grease nipples of the piston rod eyes and cylinder eyes with
molybdenum disulfide grease, see Demands on Lubricant, p. 78.

PROPERTY DAMAGE

If the main engine trial causes rudder vibrations of more than 0.25 Hz, the cylinders
have to be disconnected from the tiller, the rod be pushed in and the cylinders be
supported safely in a horizontal position.
The rudder is to be secured by appropriate means (e.g. chain blocks).

34
 Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.5 Installation

4.5.1 Overview of Modules to Be Installed

PROPERTY DAMAGE

For pipe installation, observe the notes in Installation Directions for High-
Pressure Hydraulic Piping Systems, p. 35!
Perform the installation in accordance with the hydraulic diagram and wiring
diagrams.

Install the following modules:

– Hydraulic unit as well as hydraulic lines from hydraulic unit to steering gear, see
hydraulic diagram,
− Storage tank,
– Hydraulic lines from storage tank to hydraulic unit,
– Contactor cabinets, control panels and components of steering control, see
Control Sections, p. 20,
– Electrical installation according connection diagram steering gear, see wiring
diagrams.

4.5.2 Installation Directions for High-Pressure Hydraulic Piping Systems

PROPERTY DAMAGE

The correct functioning of high-pressure, hydraulic piping systems is largely

guaranteed by the proper laying of piping and accessories. Impurities such as
scales, welding beads, sand, residues from processing, can put the operational
reliability at risk.

Materials for Piping

• Primarily use pipes in accordance with DIN 2391, with a material quality
St 37.4 NBK phos. Also observe the notes in the hydraulic circuit plan or pipe
diagram, resp. Pressure pipes must be approved and made of tested materials.
• The pipe dimensions specified in the HATLAPA hydraulic circuit plan are ideal
for the respective application, with regard to cross-section and wall thickness.
Deviations from this recommendation may affect the operational reliability of the
system. For this reason, you should contact the HATLAPA construction
department before making any arbitrary alterations.
• As pipe connections, you should primarily use fittings that correspond to
DIN 2353.

Treating Piping
1. Only clean pipes that are bent, and the ends of which have been carefully
deburred. Heat treatments and welding procedures must also have been
completed.
2. Place pipes in an acid bath with a 10% hydrochloric acid solution for
approximately 12 - 15 hours.
3. Immediately clean the etched pipes with a neutralisation agent, taking great
care. A superheated steam cleaning system can be used for this purpose.
4. Spray the inside and outside of the pipes with an anti-corrosion oil.
5. Seal the pipe ends from both sides with plastic plugs until installation.

35
Steering Gear NEPTUNE 500–65°
Assembly and Installation

Installation
• When installing piping, observe the piping diagram very carefully and install the
piping in such a way that it is possible to completely vent the system. To do this,
ensure that you install the piping with the size increasing as you move upwards.
If it is impossible to avoid installing a pipe with an upwards bend, venting should
be used at the highest point.
• Place the piping along the shortest possible straight path from the hydraulic unit
to the user, and avoid changes in level in the main pipe.
• In case of changes in direction, use elbow pipes where possible.
• Ensure that there is no stress on the pipes.
• Vibrations on board put a lot of pressure on pipes. The pipes or their fittings
could become loose. Always mount pipes in suitable clamped joints, in order to
avoid fittings being loosened by vibrations. Preserve pipes before securing them
in the clamped joints.
• Before the final installation in the hydraulic system's hydraulic components,
clean the entire pipe system with suitable low-viscosity cleaning oil. See
Flushing High Pressure Hydraulic Systems, p. 41. Only then should you
connect the piping to the hydraulic system.

4.5.3 Assembly Using Cutting Ring Couplings

Prepare Pipe

Figure 15: Prepare Pipe

1. Cut the pipe square. See the following table:

Series L S
Outer diameter pipe 6 8 10 12 15 18 22 28 35 42 6 8 10 12 14 16 20 25 30 38
Minimum length of 31 31 33 33 36 38 42 42 48 48 35 35 37 37 43 43 50 54 58 65
straight tube with
pipe bends (H)
Minimum straight 39 39 42 42 45 48 53 53 60 60 44 44 47 47 54 54 63 68 73 82
pipe length (L)

2. Deburr the inside and outside of the pipe ends. Remove burr residue and
shavings from the inside and outside.
3. Lubricate well the thread and cutting ring of the coupling.
4. Slide the screw nut and cutting ring over the end of the pipe.

36
 Steering Gear NEPTUNE 500–65°
Assembly and Installation

Assemble Pipe

Figure 16: Assemble Pipe

1. Push the nut and the cutting ring onto the pipe.
2. Screw on the nut until contact is detected.
3. Press the pipe against the stop in the coupling body for correct pipe incision.
With a wrench, tighten the nut approximately 1½ turns, whilst holding the
coupling body in position.
4. Checking: Disassemble the tube connection by slackening the nut. A visible cut
edge must be apparent in front of the cutting ring. The cutting ring may rotate,
but will not allow to be displaced axially.

PROPERTY DAMAGE

If the connection is released subsequently, the cap nut should be retightened

without extending the key or using more force.

4.5.4 Assembly of the Hydraulic Unit

1. Fasten the hydraulic unit to the respective foundation either by bolts or by
welding.
2. Connect the pipe connections for working circuits “A” and “B” of pump 1 and 2
on hydraulic unit with the pipe connections on the steering gear cylinders: A
with A, B with B.
3. Connect the pipe connection of the storage tank with the pipe connection on the
hydraulic unit.

HINT
See Installation Directions for High-Pressure Hydraulic Piping Systems, p. 35
as well as hydraulic diagram.

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.5.5 Installation of Hoses

Flexible hoses are required to connect an elastically supported assembly to a rigid
piping system. It must be guaranteed that the assembly can move freely in all
directions.
The installation guidelines apply to both fluid and gaseous media.

CAUTION
Hoses may be under extreme pressure. If they are damaged, it can lead to persons
being injured or other machine parts being damaged.
Hoses must not be damaged, cracked, twisted or in tension during installation.
Points at which the hose rubs against other components or hoses must be avoided.
If it is not possible to guarantee that rubbing spots are avoided by purposefully
arranging and fastening hoses, the hoses must be secured using protective coatings
or covers on the sharpest edges.
Hoses must not be painted.

No pressure

Subject to pressure

The movement of the hose must not be obstructed.

Don’t attach the hose in the flexible part using hose brackets!

Incorrect Correct

A twisted hose may be damaged. The hose connections can loosen.

Make sure that the hose is not twisted during installation (torsion)!

PROPERTY DAMAGE

If the bending radius is too small, the hose will kink. This can damage the hose.
For the minimum bending radius refer to the contract specific installation documents.

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

Incorrect Correct

Install the hose in a way, that it has exactly one bend!

Use elbow fittings where needed!!

Incorrect Correct

Choose a sufficient length of hose!

39
Steering Gear NEPTUNE 500–65°
Assembly and Installation

Incorrect Correct

Don’t install the hose straight or with multiple bends!

In case of collinear installations use elbow fittings!

PROPERTY DAMAGE

High temperatures considerably reduce the service life of hoses.

Incorrect Correct

Use a heat shield to protect the hose against heat sources!

40
 Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.6 Flushing High Pressure Hydraulic Systems

When installing extensive manifold hydro systems with long pipes, dirt may enter
the pipelines and components during fitting. It is therefore necessary to flush out
the dirt to ensure a long working life of the components.
During flushing, hydraulic fluid is flushed through the system at a high speed. Due
to the high speed, all foreign bodies are swept out and separated by a separate
filter circuit.

4.6.1 Flushing Equipment

PROPERTY DAMAGE

Use external pumps for flushing.

Flushing with pumps belonging to the hydraulic system is not permitted, as the
required speed of volume flow is not reached in this case. It can also damage the
pumps.

The following components are required to flush the piping system:

− Pumps
− Heating device
− Double filter
− Storage tank
− Hose connections
The tank size must be at least 3 times as large as the pump delivery rate per
minute. Furthermore, the tank must be at least as large as the contents of the
system to be flushed (see Technical Data or installation drawing).
The pumps must be equipped with adjustable pressure relief valves. The pressure
relief valves must be set to flush in such a way that the full pump volume is fed to
all system components to be flushed.
Use double filters to enable the cleaning and replacement of filter elements without
interrupting the flushing procedure.

PROPERTY DAMAGE

Use filter elements with a mesh aperture of 10 µm!

41
Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.6.2 Flushing Liquid

The flushing liquid must be compatible with the hydraulic liquid used in operations,
and with the materials used in the hydraulic system.

PROPERTY DAMAGE

In the case of gaskets, pay particular attention to the compatibility with the flushing
liquid, as gaskets could otherwise be damaged!

You can use the same hydraulic liquid as is used in operating the system.
Examples of alternatives to mineral oils are:
− Water in oil emulsions
− Water-glycol

HINT
A flushing liquid with a lower viscosity and without high value additives can
accelerate the flushing procedure, and is often cheaper.

PROPERTY DAMAGE

If the hydraulic system is not filled with hydraulic oil for longer than 20 weeks prior
to the initial operation, flush the system with preserving oil!

4.6.3 Flushing Speeds and Flushing Temperatures

The flushing speed and flushing temperature should be as high as possible, so that
the hydraulic system can be flushed quickly and effectively.
Where possible, the flushing temperature should be higher than the operating
temperature.
We recommend the following flushing temperatures:

Flushing Liquid Flushing Temperature

Mineral oils 60 °C
Water in oil emulsions 50 °C
Water-glycol 50 °C
The flow speed of the flushing liquid in the piping system should be at least twice
as high as the flow speed when operating the system. The flow speed must lie
within the range of turbulent flow at all positions.
f

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 Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.6.4 Preparatory Work for Flushing the Piping System

• Replace components that may be damaged during flushing (such as control
valves, motors and cylinders) with corresponding components from the flushing
equipment, or use bypass lines (such as hose lines) to bypass the components.
• Use bypass lines (such as hose lines) to bypass high-pressure hydraulic
pumps.
• Replace any servo valves with flushing plates.
• Remove filter elements from the filter installed in the system.
• Install possible venting at the highest points in the piping system (e.g. air
valves).
• Install drain holes at the lowest points and on cylinder clearances.
• Install flushing connections for subcircuits. Fittings that are large enough for the
flushing liquid to flow through without losing much pressure are particularly
suitable for this purpose.
• Assemble flushing equipment.

HINT
Smaller systems can be flushed in one cycle. In the case of larger systems, it may
be necessary to proceed in sections.

4.6.5 System Cleanness

When flushing has been completed, the cleanness must be in accordance with
grade NAS 1638, class 9, or according to ISO DIS 4406, class 20/18/15.
The cleanness attained must be proved by counting and size rating of the solid dirt.
This is done either by using a microscope or an electronic particle counter.

PROPERTY DAMAGE

The system may be taken into operation only after proof of system cleanness!

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Steering Gear NEPTUNE 500–65°
Assembly and Installation

4.6.6 Execution of Flushing Process

1. Use a filter to fill the flushing unit's container with flushing liquid.
2. Heat flushing liquid to the recommended temperature.
3. Activate flushing pumps.
• Ensure that the hydraulic system has been sufficiently vented.
• During the flushing process, regularly check the clogging indicators for the
flushing filters, and replace or clean the filter elements in due time.
4. Reverse the volume flow direction after approximately one hour of flushing.
Flush the hydraulic system until the clogging indicators shows no clogging for at
least one hour. Reverse the volume flow direction every hour.
5. Take liquid samples from the system, and check whether the flushing liquid has
achieved the required degree of cleanliness.
Flush the hydraulic system until the required degree of cleanliness has been
achieved.

PROPERTY DAMAGE

Hydraulic systems, in which servo valves are used, must be flushed for up to
48 hours in order to achieve the required degree of cleanliness!

6. Once the flushing process is complete, drain all flushing agent residues from
the hydraulic system.

PROPERTY DAMAGE

Ensure that the flushing residues are also removed from the dead centres of the
hydraulic system.

7. Dismantle all bypass lines.

8. Dismantle flushing equipment.
9. Install filter elements for the filter installed in the system.
10. Remove any flushing plates and install servo valves.
The hydraulic system is now ready for use.

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 Steering Gear NEPTUNE 500–65°
Initial Operation

5 Initial Operation
PROPERTY DAMAGE

Have a HATLAPA mechanic undertake the initial operation!

If this is not possible, proceed as follows and send a report on the inspection to
HATLAPA.
Measuring equipment must be available for the initial operation.

5.1 Removing Preservation

HINT
TECTYL cures to a dark amber coloured, translucent film.
– Remove wax from blank surfaces. The following methods are suitable:
• wash off with mineral spirits or any similar petroleum solvent,
• wash off with hot alkaline wash,
• remove with low pressure steam.
– Do not remove the preservation of fasteners or fixings like screws, split pins and
bolts.

5.2 Checks Prior to Initial Operation

• Are the mechanical connection components firmly attached?
• Is the hydraulic system installed without tension?
• Are hydraulic lines correctly installed, and the connections screwed on tightly?
• Are the valves easily accessible?
• Have the electrical connections been installed correctly and attached tightly?
• Does the electrical connection correspond to the data on the type plate?
• Is the safety equipment complete?
• Are the filters in the pump units clean?
• Is the hydraulic tank clean?
• Has the entire hydraulic system been flushed?
• Has the steering gear been lubricated?
• Is the steering gear free from tools and external parts?
• Is the entire system clean?

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Steering Gear NEPTUNE 500–65°
Initial Operation

5.3 Fill Hydraulic System

5.3.1 Requirements of Hydraulic Oil

The hydraulic fluid was carefully selected when designing the system, in order to
guarantee flawless, abrasion-free, economic operation.
• Only use hydraulic oils produced by well-known manufacturers.
• Always adhere to the viscosity of the hydraulic oil, depending on the ambient
conditions.
• If you have any questions regarding hydraulic oils, contact the manufacturer.
The manufacturers are the experts.
• Select at least HLP oil, in accordance with DIN 51524 T2 and VDMA 24318.
• If hydraulic oils that do not comply with the requirements are used, the warranty
claim against HATLAPA becomes invalid.
The ambient conditions, under which the system will primarily be operated, are
decisive when selecting hydraulic fluid.

Viscosity Requirements
Climate Zone Arctic Temperate Tropical
Ambient Temperature -10…+30 °C 0…+40 °C +10…+50 °C
Average Ambient
10 °C (±5 °C) 20 °C (±5 °C) 30 °C (±5 °C)
Temperature
Mandatory Viscosity ISO VG 32 ISO VG 46 ISO VG 68

Contamination Class Requirements

Class, in accordance with
≤9
NAS 1638
Class, in accordance with
≤ 20/18/15
ISO 4406

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 Steering Gear NEPTUNE 500–65°
Initial Operation

5.3.2 Fill Hydraulic System

Figure 17: Cylinder

Item Description
1 Screw plug, vent screw
2 Fitting
1. Open all shut valves, see block diagram.
2. At the highest point of the cylinder, unscrew screw plug or fitting and fill the
cylinders with hydraulic oil through a hair sieve (maximum mesh width 10 µm).
3. Screw in the screw plug or fitting, but do not tighten.

HINT
For hydraulic unit see Figure 4: Hydraulic unit, p. 17.
4. Unscrew the cap of the oil filling air filter on the hydraulic unit. Fill with hydraulic
oil through a hair sieve (maximum mesh width 10 µm) until the oil level in the
hydraulic unit no longer falls. When hydraulic oil emerges without bubbles at
cylinder , tightly screw in the screw plug or fitting.

HINT
For storage tank see Storage Tank, p. 19.
5. Unscrew the cap of the oil filling air filter on the storage tank. Fill with hydraulic
oil through a hair sieve (maximum mesh width 10 µm) until the oil level in the
storage tank no longer falls.
6. Pump the hydraulic oil from storage tank into the hydraulic system until the
maximum oil level in the hydraulic unit is reached.
7. Fill the hydraulic oil through a hair sieve (maximum mesh width 10 µm) into the
storage tank until the oil level in the storage tank stops falling.
8. Screw the caps of the oil filling airs filters on storage tank and on hydraulic unit
onto the filters.
9. Open or close the shut valves for standard operation mode, see block diagram.

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Steering Gear NEPTUNE 500–65°
Initial Operation

PROPERTY DAMAGE

The entire hydraulic system must be completely free of air pockets. This is because
even smaller air pockets increase in size during operation, and air strokes in the
hydraulic system reduce the service life of hydraulic components.
Vent the hydraulic system after filling, see Venting the Hydraulic System, p. 74.

5.4 Start Up Pump Units

PROPERTY DAMAGE

If pumps are drawing in air during operation, the compression can cause the
hydraulic liquid to become hot. This causes the pump to become damaged after a
very short operating time.
If you hear a loud, persistent noise or the sound of air being pumped rather than oil,
then the pump is also drawing in air. In this case, if the pump does not become quiet
after a few minutes, switch the pump off and resolve the problem.

1. Set the shut valves for standard operation mode according block diagram.
2. Check at oil level indicators, that the hydraulic system is full.
3. Activate the MAIN SWITCH on the pump unit's contactor cabinet.
4. Switch the PUMP START LOCAL / BRIDGE selection switch on the pump unit's
contactor cabinet to the LOCAL position.
5. Use the START push button on the pump unit's contactor cabinet to start the
pump unit.

PROPERTY DAMAGE

If the rotational direction of the engine is incorrect, the hydraulic pump will be
destroyed within a short time.

6. Check the rotational direction of the engine, and compare it with the arrow
indicating the rotational direction. If the rotational direction is not correct, use the
STOP push button on the pump unit's contactor cabinet to stop the pump unit
immediately. In this case, reconnect the engine and repeat the check.
7. Repeat this procedure for the second pump unit.

5.5 Configure Hydraulic Controls

The steering gear control is influenced by the rudder's ship-specific reaction forces
and reaction torques. Causes of this include the elasticity of the ship's aft, piston
and rudder, play in the rudder stock bearing, and play in the transmission rod and
feedback unit.
For this reason, HATLAPA recommends controllers for which strength, threshold,
compensation time, minimum pump adjustment time and hysteresis can, to a
certain extent, be configured in order to control the rudder angle.
Precise configuration, in which a minimum target/deviation is achieved with a
stable control circuit, cannot be determined using theories, but based on
experience. The controller must be adjusted by authorised service personnel
during initial operation on a moving ship.

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 Steering Gear NEPTUNE 500–65°
Initial Operation

5.6 Start Up Steering Gear

HINT
Like the initial operation, the setup is always performed in normal mode. See
Operation of Steering Gear, p. 50.
Before starting operations, configure the shut valve as specified in the block
diagram.

PROPERTY DAMAGE

Only use one pump unit during the initial operation of the steering gear. Then use
the second, before finally using both pump units simultaneously.

During initial operation, continuously check the following:

− Rudder laying times from 35 ° to 30 ° with one and two pump units,
− Rudder angle and rudder angle indication on display devices,
− The turning angle transmitter is functioning properly,
− Oil level in all oil tanks,
− Pressure of hydraulic system on manometers,
− The entire hydraulic system for leakages,
− The entire hydraulic system for unusual noises,
− Temperature of pump casing and engine casing,
− Contamination of filters.
Then check that the steering gear also functions in emergency operation. See
Emergency Operation, p. 52.

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Steering Gear NEPTUNE 500–65°
Operation of Steering Gear

6 Operation of Steering Gear

PROPERTY DAMAGE

After damage or particular incidents, repair and maintenance work, have the safety
representative perform a visual and functional check.
Report any safety-related deficiencies and changes to the operational behaviour
immediately. Shut the steering gear down and ensure that it cannot be restarted
unintentionally.
Observe the inspection and maintenance intervals.
If the steering gear is not used for several months, or comprehensive repair work
has been carried out, perform an initial operation, in accordance with the Initial
Operation, p. 45.

HINT
In normal operations, work with one pump unit. However, to halve the rudder laying
time, you can also activate both pump units.

6.1 Steering Control

6.1.1 Follow-up mode (way control)
In follow-up mode the operator sets the rudder angle transmitter (e. g. the hand
wheel) to the rudder angle. The steering control moves the steering gear to the
preset rudder angle and adjusts it so that the rudder angle is kept constant.

Follow-up mode is the main operating mode.

6.1.2 Non-follow up-mode (time control)

In non-follow-up mode the operator moves the rudder angle transmitter (e. g. the
joystick) in one direction. The steering control moves the steering gear as long as
the rudder angle transmitter is deflected. The rudder angle is not readjusted.
Use the non-follow-up mode, for example, for quick reactions during port
operations.

HINT
In non-follow-up mode a steering action is normal due to internal leakage in the
system and is not a fault.

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 Steering Gear NEPTUNE 500–65°
Operation of Steering Gear

6.2 Activate Steering Gear

HINT
See the block diagram in the steering gear room for valve diagrams, the position of
the manometer, and notes on operating modes.
See the block diagram for the position of the shut valve.
For starting up the pump units see Initial Operation, p. 45.
1. Check that the safety equipment is complete, in accordance with chapter Safety
Equipment, p. 13.
2. On the steering gear:
• Open or close the shut valves for standard operation mode, see block
diagram.
• Close all cocks on the manometers.
3. On the pump units' contactor cabinets:
• Activate the MAIN SWITCH for the pump unit.
• Activate the main switch MAIN SWITCH HEATER for the anti-condensation
heating.
• Move the PUMP START selection switch to the BRIDGE position.
• Move the STEERING CONTROL selection switch to the BRIDGE position.
4. On the control panel:
• Use the LAMP TEST push button to check that the indicator lights are
working properly.

6.3 Normal Operation Mode

HINT
Normal operation mode is the operation from bridge control panel or from the bridge
wings.
1. Οn the pump unit's contactor cabinet move the PUMP START and the
STEERING CONTROL selection switch on the pump unit's contactor cabinet to
the BRIDGE position.
2. Press the START illuminated push button on the control panel for pump
selection.
3. If several control panels for steering control available: pre-select the active
control panel; see steering control manual. Check that the indicator lights at the
control panel are working properly.
4. If several steering gears available: pre-select, if the steering gears are
synchronously or independently driven; see steering control manual.
5. Pre-select the operating mode of steering control; see steering control manual.

6.3.1 Operation via Hand Wheel or Tiller

1. Take over the steering control for hand wheel or tiller, see steering control
manual.
2. Use hand wheel or tiller to adjust the rudder position.

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Steering Gear NEPTUNE 500–65°
Operation of Steering Gear

6.4 Checks During Operation

The steering gear doesn't have to be monitored during operation.
In case of malfunctions, an audible and visual alarm is triggered. Some
malfunctions are also displayed on the corresponding contactor cabinet.

HINT
For help on dealing with malfunction alarms, see Help in Case of Malfunctions, p.
54.

6.5 Emergency Operation

6.5.1 Operation from Contactor Cabinet for Pump Unit

PROPERTY DAMAGE

Only change the type of operation after consulting the bridge.

1. Move the PUMP START and the STEERING CONTROL selection switch on the
pump unit's contactor cabinet to the LOCAL position.
2. Press the START illuminated push button on the contactor cabinet.
3. Use the PORT or STARBOARD push buttons to set the rudder position in
accordance with the instructions from the bridge.

6.5.2 Emergency Control

PROPERTY DAMAGE

Only change the type of operation after consulting the bridge.

1. Move the PUMP START and the STEERING CONTROL selection switch on the
pump unit's switch cabinet to the LOCAL position.
2. Press the START illuminated push button on the switch cabinet.
3. Keep the mushroom button on the starboard or port side of the control plate
pressed in order to change the rudder position. See Emergency Control on
Pump Unit, p. 23.

6.5.3 Operation With One Hydraulic Cylinder

In the case of the damage of one hydraulic cylinder, is it possible to steer with the
other one. The defective cylinder has to be disconnected from the tiller.
It is suitable for low speed, small rudder angle and for a short time. The valves
have to be switched according to the block- diagram.

HINT
During the working with one cylinder additional radial load on the rudder shaft and
the rudder carrier appears!

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 Steering Gear NEPTUNE 500–65°
Operation of Steering Gear

6.6 Switch Active Pump Unit

PROPERTY DAMAGE

If you are operating the steering gear with one pump unit, switch the active pump
unit every 24 hours.

1. On the second pump unit's contactor cabinet:

• Activate the MAIN SWITCH for the pump unit.
• Activate the main switch MAIN SWITCH HEATER for the anti-condensation
heating.
2. For the second pump unit, press the START illuminated push button on the
control panel (in case of operation from the control panel) or on the pump unit's
contactor cabinet (in case of operation from the contactor cabinet).
3. For the first pump unit, press the STOP illuminated push button on the control
panel (in case of operation from the control panel) or on the pump unit's
contactor cabinet (in case of operation from the contactor cabinet).

6.7 Deactivate Steering Gear

HINT
The steering gear can be deactivated in any position. All valves stay in the operating
position. It is not necessary to take any special measures after deactivation.
1. On the control panel:
• In BRIDGE mode, use the STOP illuminated push button to deactivate the
pump unit.
2. On the pump units' contactor cabinets:
• In LOCAL mode, use the STOP illuminated push button to deactivate the
pump unit.

6.8 Stop Using Steering Gear

HINT
The steering gear is only stopped in order to work on the system.
1. On the pump units' contactor cabinets:
• Deactivate the MAIN SWITCH for the pump unit.
• Deactivate the main switch MAIN SWITCH HEATER for the anti-
condensation heating.

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Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7 Help in Case of Malfunctions

HINT
If malfunctions occur, first check the indicator lights on the alarm system.
− Attempt to remedy the malfunctions using the advice in the following sections.
− If the malfunctions cannot be remedied, contact the service department at
HATLAPA.

7.1 Malfunctions Indicated by the Steering Gear Alert System

The alert system consists of one contactor cabinet with a touch panel placed in
steering gear room (SGR) and two touch panels placed in engine control room
(ECR) and in bridge console.
Each touch panel shows 2 screens for the operator.

7.1.1 Touch Panel

Figure 18: Screen HOME (shown: touch panel in SGR)

Pos. Description
1 Status of pump 2 (shown: pump switched off)
2 Alert status
3 Change into the screen ALERT HISTORY
4 Current date and time
5 – Touch panel in SGR: change into the screen SETTINGS
(protected by password)
– Touch panel on bridge: adjust the display brightness
– Touch panel in ECR: no button
6 Status of pump 1 (shown: pump switched on)

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 Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.1.2 Incoming Alert

Figure 19: Incoming alert (alert status “red”)

Pos. Description
1 Stop the acoustic alarm and change into the screen ALERT
HISTORY
A malfunction of the steering gear is shown on the touch panels in SGR, in ECR as
well as on the bridge.
An acoustic signal is triggered. Stop the signal by pressing the alert area (20-1).
The signal only stops at the current touch panel.
The colour of the alert indicates how seriously the malfunction is:
Red
Indicates a serious malfunction which needs to solve immediately. In other cases
the steering gear could be damaged seriously.
Yellow
Indicates a problem that needs attention. The steering gear will not be damaged
immediately.
Blue
Indicates a note.
7.1.3 Acknowledge Alert
Acknowledge the alert on the touch panel in SGR:

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Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

Figure 20: Incoming alert in screen ALERT HISTORY

Pos. Description
1 New alert - marked but not acknowledged
2 Change into the screen HOME
3 Acknowledge the marked alert
1. Mark the new alert.
2. Press the ACKNOWLEDGE button (21-3):
• The acoustic alarm stops at all touch panels.
• When the alert has been confirmed, the alert status on the screen HOME
changes into “acknowledged”, see figure 4.
• When the malfunction has been remedied and no other alert is pending, the
alert status on the screen HOME changes into “no alarms”, see figure 19.
The alert is shown in screen ALERT HISTORY.

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 Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

Figure 21: Alert is acknowledged

7.1.4 Message SYSTEM ERROR

Malfunction Remedy
At one of the both other touch panels of the alert
system an error has occured
− Touch panel defective. • Check the touch panel, and replace it if
necessary. See electrical wiring diagrams.
− Connection broken. • Check the connection. See electrical wiring
diagrams.

7.1.5 Message HYDR. PUMP FAILURE

Malfunction Remedy
Selector switch PUMP START LOCAL / BRIDGE
is turned to LOCAL position (no malfunction)
Steering gear deactivated • Activate main switch on pump contactor
cabinet.
Hydraulic pump failed 1. Activate other pump unit, and deactivate the
defective pump unit.
2. Check system. See following points:
− Main contactor defective • Check the main contactor and replace it if
necessary. See electrical wiring diagrams.
− Auxiliary contactor defective • Check the auxiliary contactor, and replace it if
necessary. See electrical wiring diagrams.
– Hydraulic pump malfunction • Check the hydraulic pump. If necessary,
replace the whole pump and send for repair.
Selection switch LOCAL / BRIDGE on pump unit • Check the selection switch, and replace it if
contactor cabinet defective necessary. See electrical wiring diagrams.

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Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.1.6 Message RUDDER CONTROL FEEDER FAILURE

Malfunction Remedy
Selector switch STEERING CONTROL LOCAL /
BRIDGE is turned to LOCAL position (no
malfunction)
Supply to pump controls failed 1. Activate other pump, and deactivate the
defective pump unit.
2. Check the system. See following points.
− Control voltage failed • Check voltage supply, and correct any errors.
See electrical wiring diagrams.
− Auxiliary contractor defective • Check auxiliary contractor, and replace it if
necessary. See electrical wiring diagrams.
− Rectifier defective • Check rectifier, and replace it if necessary.
See electrical wiring diagrams.
− Transformer defective • Check transformer, and replace it if
necessary. See electrical wiring diagrams.
− Circuit breaker tripped 1. Rectify cause of short-circuit. See electrical
wiring diagrams.
2. Activate circuit breaker. See electrical wiring
diagrams.
− Circuit breaker defective • Check circuit breaker, and replace it if
necessary. See electrical wiring diagrams.

7.1.7 Message HYDR. PUMP OVERLOAD

Malfunction Remedy
Electric motor in pump unit is overloaded 1. Activate other pump unit, and deactivate the
(winding temperature of E-motor too high, at defective pump unit.
classification society LRS: too much current in 2. Check system while engine is idle. See
supply line). following points.
− Piston in distributing valve seized. • See Message HYDRAULIC LOCKING, p. 59
− Bearing of electric motor worn out. • Replace the bearing. See manufacturer's
delivery documents.
− Electric motor windings defective. • Replace the electric motor.
− Rudder / rudder stock blocked by foreign • Visually inspect rudder / rudder stock, and
body. remove any foreign bodies.
− Damage to rudder / rudder stock. • Visually inspect rudder / rudder stock, and
repair, if necessary.

7.1.8 Message PHASE FAILURE

Malfunction Remedy
A phase failed in the pump unit's drive. 1. Activate other pump unit, and deactivate the
defective pump unit.
2. Check system. See following points:
− Phase error in supply • Check the supply line, and repair it if
necessary. See electrical wiring diagrams.

58
 Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

Malfunction Remedy
− Phase error in engine supply • Check the engine supply line, and repair it if
necessary. See electrical wiring diagrams.
− Main contactor defective • Check the main contactor and replace it if
necessary. See electrical wiring diagrams.
− Phase failure relay defective • Check the relay, and replace it if necessary.
See electrical wiring diagrams.

7.1.9 Message HYDRAULIC LOCKING

Malfunction Remedy
The position of the piston in the distributing valve 1. Activate other pump unit, and deactivate the
does not correspond to the control command defective pump unit.
2. Check system. See following points:
− Main valve seizing due to dirty oil or 1. Clean main valve, or replace it if necessary.
malfunction 2. Change oil.
3. Clean or replace filter element.
− Pilot valve seizing due to dirty oil or 1. Clean pilot valve, and replace it if necessary.
malfunction 2. Change oil.
3. Clean or replace filter element.
− Magnetic coil of pilot valve is defective • Replace magnetic coil.
− Limit switch defective • Check limit switch, and replace it if
necessary.
− HLA unit (monitoring unit for Hydraulic • If necessary, have the HLA unit replaced by
Locking Alarm) defective authorized service personnel.

7.1.10 Message OIL FILTER CLOGGED

Malfunction Remedy
Filter differential pressure switch of running 1. Activate other pump unit, and deactivate the
pump unit longer than 5 minutes over default defective pump unit.
value 2. Check system. See following points:
− Filter dirty • Clean or replace filter element.
− Oil dirty • Change oil.

7.1.11 Message LOW OIL LEVEL

Malfunction Remedy
Oil level in oil expansion tank too low
− Leakages in hydraulic system 1. Check hydraulic circuit for loss of oil.
2. Isolate the leaking hydraulic circuit. See block
diagram.
3. Fix leaks.
4. Fill working tank until the oil level in the
working tank stops falling.
5. Check storage tank, and fill it if necessary.
False alarm at oil level switch • Check oil level switch, change if necessary.

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Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.2 Function Called Not Executed

Malfunction Remedy
Push button or selection switch defective • Check the push button or selection switch,
and replace them if necessary. See electrical
wiring diagrams.

7.3 No Rudder Movement Possible In One Direction

Malfunction Remedy
Valves not opened according block diagram. • Completely open the shut-valves according to
the block diagram.
Not possible to control main control valve due to • Check limit switch, change if necessary.
defective limit switch
Not possible to control main control valve due to • Check the auxiliary contactor, and replace it if
defective auxiliary contactor necessary. See electrical wiring diagrams.

7.4 Slow or No Movement of the Steering Gear

Malfunction Remedy
Malfunction of hydraulic pump 1. Activate other pump unit, and deactivate the
defective pump unit.
2. Check system. See following points:
− Pump damage caused by contaminated oil 1. Check the main pump. If necessary, exchange
it and send it to the manufacturer.
2. Change oil.
3. Clean or replace filter element.
− Hydraulic pump bearing worn out • Check the main pump. If necessary, exchange
it and send it to the manufacturer.
− Αuxiliary contractor K4 / K5 defective • Check the auxiliary contactor and replace as
necessary, see electrical wiring diagram.
Pressure relief valve on control plate jammed due 1. Check pressure relief valve, and clean it if
to contaminated oil. necessary.
2. Change oil.
3. Clean or replace filter element.
Counter balance valve in P channel jamming due 1. Check counter balance valve, and change the
to contaminated oil. entire control plate if necessary.
2. Change oil.
3. Clean or replace filter element.
Shut valve leaking. 1. Isolate the leaking hydraulic circuit.
2. Replace shut valve.
Cylinder seals worn out • Check the cylinder seals. If necessary,
exchange them.
Main contactor defective • Check the main contactor and replace it if
necessary. See electrical wiring diagrams.
Selection switch LOCAL / BRIDGE on pump unit • Check the selection switch, and replace it if
contactor cabinet defective necessary. See electrical wiring diagrams.

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 Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.5 Rudder Position Greater Than Nominal Rudder Angle

Malfunction Remedy
Turning angle transmitter defective 1. Do not specify a rudder position over nominal
rudder angle.
2. Check turning angle transmitter, change if
necessary.

7.6 Maximum Rudder Angle Not Achieved When Ship Travelling At High Speeds

Malfunction Remedy
Pressure relief valve on cylinder incorrectly • Check the pressure relief valve, and have it
configured reconfigured or exchanged by authorised
maintenance personnel if necessary.

7.7 Imprecise Control ("Hunting")

Malfunction Remedy
Wear on rudder carrier, transmission rod or angle • Have the three-step controller reconfigured by
transmitter authorised service personnel.
• Have the follow-up amplifier reconfigured by
authorised service personnel.
Malfunction of the autopilot system • Have the autopilot system re-adjusted or
replaced by the manufacturer.

7.8 The Steering Gear Operates Without a Steering Command

Fault Remedy
Rough sea (no malfunction)
In non-follow-up mode (time control via tiller) a • Switch to follow-up mode (control with hand
steering action of a few degrees is normal due to wheel).
internal leakage in the system and is not a fault. Follow-up mode is the main operating mode.
The pre-set rudder angle is set.
Non-follow-up mode is only intended for brief
operation as an auxiliary mode. The steering
gear only operates for as long as the tiller is
held. There is no follow-up control.
Malfunction of the autopilot system • Have the autopilot system re-adjusted or
replaced by the manufacturer.

7.9 Rudder Position Not Achieved

Malfunction Remedy
Non-return valve on hydraulic pump not closing 1. Check the non-return valve, and clean or
replace it if necessary.
2. Change oil.
3. Clean or replace filter element.

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Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.10 Main Pump Does Not Achieve Full Delivery Rate

Malfunction Remedy
Pressure relief valve incorrectly set on control • Check pressure relief valve, and reconfigure or
plate replace it if necessary.

7.11 Grating Noises from the Steering Gear

Fault Remedy
Lack of grease in the bearings • Re-lubricate the bearings

7.12 Pressure Increase on Movement of the Steering Gear

Fault Remedy
Rudder / rudder stock blocked by foreign body. • Visually inspect rudder / rudder stock, and
remove any foreign bodies.
Worn rudder carrier unit • Visually check rudder carrier unit, and repair,
if necessary.

7.13 Noises in Pump Unit

Malfunction Remedy
Hydraulic pump bearing worn out • Check the main pump. If necessary,
exchange it and send it to the manufacturer.
Non-return valve not opening 1. Check non-return valve, and change if
necessary.
2. Change oil.
3. Clean or replace filter element.
Switch time at throttle valve of pilot valve • Have HATLAPA service personnel
incorrectly configured reconfigure the switch time.
Flexible spider on motor coupling worn out • Exchange spider.
Bearing of electric motor worn out • Replace the bearing.
Electric motor windings defect • Replace the electric motor.

7.14 Oil Leaks on Cylinder

Fault Remedy
Cylinder sealing set worn • Replace cylinder sealing set.

7.15 Oil Level Too High

Fault Remedy
Air in the hydraulic system • Vent the entire hydraulic system.
• Tighten fittings.

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 Steering Gear NEPTUNE 500–65°
Help in Case of Malfunctions

7.16 Oil Temperature Too High

Malfunction Remedy
Hydraulic system dirty; heat emission reduced • Clean entire hydraulic system.
Pressure relief valve incorrectly configured • Check, reset or replace pressure relief valve.
Bearing damage to main pump • Check main pump. If necessary repair or
replace it.
Wa

63
Steering Gear NEPTUNE 500–65°
Maintenance

8 Maintenance
WARNING
Carry out inspections at regular intervals in order to reveal, at the earliest, any
possible damage which may also come from outside (e.g. rudder blade touching the
ground). The steering gear is vital for ship and crew!

PROPERTY DAMAGE

− Consider for determination of the inspection and maintenance rates apart from
the information in this documentation also the regulations of the classification
societies and Employer's Liability Insurance Associations.
− Exchange after a disassembly self-locking nuts and seals in principle. Do not use
it a second time.
− If leakages occur at the fittings, which are sealed with soft gaskets (O-rings,
moulded packing rings, or similar), the leakages cannot be remedied by
tightening the gaskets, because the soft gaskets are damaged or age-hardened.
Replace the soft gaskets.
− Look for scrupulous cleanliness. Cover openings in a way that no dirt can
penetrate.
− Make sure that tools, loose parts or clothes do not stay in or on the steering gear
ben.
− Care for proper disposal of waste oil and grease according to the national
regulations and beneficial to the environment.

8.1 Storing Spare Parts

PROPERTY DAMAGE

HATLAPA spare parts are provided with sufficient preservative measures for a
storage period of 5 years. The maximum storage times for individual component
parts (such as hoses and seals) may differ from this length.
In order for the spare parts to remain usable, they must be stored under the
following conditions, unless any special specifications exist:
− Storage temperature: +15 to +50 °C,
− Relative humidity 10 to 90 %, no condensation,
− Dry, under cover, and protected against dew,
− Protected against contamination,
− Protected against direct sunlight, UV radiation and ozone,
Leave the spare parts in their original packaging until required.
Store the spare parts horizontally and without tension. If several component parts
are stacked on top of each other, unacceptable tension can occur.

64
 Steering Gear NEPTUNE 500–65°
Maintenance

8.1.1 Storage and Shelf Life of Component Parts Made of Elastomers and Polyurethanes

HINT
The following standards must be observed when using component parts (e.g.
gaskets) made of elastomers and polyurethanes:
– DIN 7716 "Rubber products; requirements for storage, cleaning and
maintenance"
– ISO 2230 "Rubber products; guidelines for storage"
Storage
In order to store the component parts properly, observe the following:
– The maximum storage time for elastomers is 5 years; this can be extended by a
further 2 years after a thorough visual inspection,
– The maximum storage time for polyurethanes is 5 years; this can be extended
by a further 2 years after a thorough visual inspection,
– Store at a maximum storage temperature of 25 °C and protect from frost,
– Store at a maximum relative humidity of 65 %. In case of higher humidity, pack
the component part in dark air-tight PE foil,
– Protect from direct sunlight, UV radiation and ozone,
– Protect against sources of heat,
– Store in a dust-free environment,
– Do not store next to chemicals or acidic cleaning agents,
– Do not store next to metals such as copper or manganese,
– Store in a strain-free, horizontal position.
Visual Inspection
Before use, and in order to achieve the maximum storage time, check externally for
the following points and refrain from using any component parts should any of
these points occur:
– Permanent deformation, such as folds or flat spots,
– Mechanical damage, such as cuts, cracks, flat spots or loose plies,
– Crack formation on the surface, e.g. using a magnifying glass with 10 ×
magnification,
– Changes to the surface, e.g. hardening, softening, stickiness or discolouring.
Use
When using the component parts, observe the following:
– If the component parts were exposed to storage temperatures of over 25 °C, the
maximum storage time for elastomers is reduced to 4 years; this can be
extended by a further 2 years after a thorough visual inspection.
– If the maximum storage time is exceeded, the component part may no longer be
used. If the component part is used within this period, then the change interval
is reduced by the actual storage time.

PROPERTY DAMAGE

Under no circumstances use cleaning agents such as benzene, benzine or

turpentine to clean component parts.
Component parts made of elastomers and polyurethanes must not be painted.

– Before installing component parts, wipe them down with a clean, lint-free cloth.
If necessary, clean with hand-hot water.

65
Steering Gear NEPTUNE 500–65°
Maintenance

8.1.2 Storage and Service Life of Hoses

HINT
The operator is responsible for ensuring that all hoses are checked regularly to
ensure that they function flawlessly and reliably, even after the warranty has expired,
and that no damage occurs to persons or the environment.
The following standards must be observed when using hoses:
− DIN 7716 "Rubber products; requirements for storage, cleaning and
maintenance"
− DIN EN 982 "Safety of machinery - Safety requirements for fluid power systems
and their components: Hydraulics"
− DIN 20066 "Fluid power systems - Hose assemblies - Dimensions, requirements"
Storage of Hoses
Observe the following in order to correctly store hoses:
− maximum storage time for assembled hoses is 2 years,
− maximum storage time for tubular goods is 4 years,
− store in a dry, cool and dust-free location,
− protect from direct sunlight, UV radiation and ozone,
− protect against sources of heat,
− store in a strain-free, horizontal position.

Visual Inspection of Hoses

Before use, and in order to achieve the maximum storage time, check externally for
the following points and refrain from using hoses should any of these points occur:
− permanent deformation, such as folds or flat spots,
− mechanical damage, such as cuts, tears, flat spots or loose plies,
− crack formation on the surface, e.g. using a magnifying glass,
− changes to surface, e.g. hardening, softening, stickiness or discolouring.

Using Hoses
When using hoses, observe the following:
− Assembled hoses can be kept for a maximum 6 years, and must then be
exchanged.
− If the maximum storage time is exceeded, the hose may no longer be used.

66
 Steering Gear NEPTUNE 500–65°
Maintenance

8.2 Periodic Preventive Maintenance

8.2.1 Board Maintenance by Operating Personnel

Before departure of the ship, daily

Before departure of the ship

On commissioning or repair
during operation of the ship

Every 2500 operating hours

100 operating hours after

500 operating hours after

commissioning or repair

commissioning or repair
Task
Effort [man×h]

Six-monthly
Monthly
Weekly

Annual
Entire system
Check function of the steering gear 2×1 ×
Visual inspection: deformations,
cracks, missing mechanical
1×½ ×
connectors, defective mechanical or
electrical connections
Thorough inspection: deformations,
cracks, missing mechanical
1×8 ×
connectors, defective mechanical or
electrical connections
Mechanical parts
Check for unusual noises 1×½ ×
Check that all mechanical connections
which have been loosened are firmly 1×1 ×
seated
Grease the grease nipples at the
1×½ ×
cylinders with a grease gun
Grease the sliding surfaces on tiller
1×½ ×
and thrust block with a brush
Hydraulic system
Visual inspection for leaks in the
1×½ ×
hydraulic system
Check for unusual noises 1×½ ×
Check oil level on hydraulic unit 1×½ ×
Check oil level on oil storage tank 1×½ ×
Clean the outside of hydraulic system 1×8 ×
Check that hydraulic oil is clean, oil 1×½
×
change if necessary 1×8
Check that pressure gauges are
1×½ ×
functional and legible

67
Steering Gear NEPTUNE 500–65°
Maintenance

Before departure of the ship, daily

Before departure of the ship

On commissioning or repair
during operation of the ship

Every 2500 operating hours

100 operating hours after

500 operating hours after

commissioning or repair

commissioning or repair
Task

Effort [man×h]

Six-monthly
Monthly
Weekly

Annual
Check hoses 1×½ × ×
Clean the filter 1×2 × ×

8.2.2 Board Maintenance by Maintenance Personnel / Electrician

operating hours
Effort [man×h]

Every 2 years

Every 5 years

Every 6 years

Every 7 years

Every 10.000
Task
Monthly

Annual

Entire system
Check safety equipment and alarms are functioning
2×3 ×
properly, and provide proof
If steering gear equipped with HATLAPA steering control
Check rudder feedback units on steering gear, see
1×2 ×
steering control manual
Mechanical parts
Check for play in the hinge bearings of the hydraulic
1×½ ×
cylinders
Visual inspection of cylinder gaskets and dirt scraper 1×2 ×
Replace cylinder gaskets and dirt scraper 1×8 ×
Hydraulic system
Replace hoses 1×2 ×
Electrical system
Lubricate or replace the electric motor bearings 1×4 ×
Replace the auxiliary circuit breakers K4 and K5 in the
1×½ ×
pump contactor cabinets

68
 Steering Gear NEPTUNE 500–65°
Maintenance

8.2.3 Depot Maintenance

HINT
Depot maintenance (shipyard, dock) is not necessary.

8.3 Inspection

8.3.1 Checking the function of the steering gear

HINT
Due to the various conditions at sea, the function test may show different working
pressures. This makes the detection of faults more difficult.
Carry out the function test in port before the ship departs!
Adopt the target values for the table from the plates on the pressure relief valves.
Before functional check
• Switch on the MAIN SWITCH on the switch cabinets of both pump units.
• Set the selection switches PUMP START and STEERING CONTROL to
LOCAL.

Measurement of rudder laying times

HINT
Measure the following values:
− rudder laying times for pump unit 1, pump unit 2 as well as Pump units 1+2,
− in each case from PORT 35° to STARBOARD 30° as well as from STARBOARD
35° to PORT 30°.
Enter the values in the following table.
1. Press the illuminated START push button.
2. Set the rudder to the limit position with the STARBOARD push button.
3. Set the rudder to the limit position with the PORT push button and measure the
rudder laying time.
4. Set the rudder to the limit position with the STARBOARD push button and
measure the rudder laying time.
5. Press the illuminated STOP push button.

Measurement of working pressures

HINT
Measure the following values:
− working pressures "A" und "B" for pump unit 1 as well as pump unit 2.
For that purpose set the steering gear to the end positions.
Enter the values in the following table.
1. Connect the working circuit pressure gauge to the Minimess connector for the
working pressure, see Figure 4: Hydraulic unit, p. 17.
2. Press the illuminated START push button.
3. Hold STARBOARD push button pressed, until the steering gear has been
stopped and measure the working pressure in that moment.
4. Hold PORT push button pressed, until the steering gear has been stopped and
measure the working pressure in that moment.

69
Steering Gear NEPTUNE 500–65°
Maintenance

5. Press the illuminated STOP push button.

6. Connect the working circuit pressure gauge to the next Minimess connector for
working pressure and proceed with measuring.
7. Press the illuminated STOP push button.

After functional check

• Set the selection switches PUMP START and STEERING CONTROL to
BRIDGE.

HINT
Compare the rudder laying times and the system pressures with the previous
values. In case of increased rudder laying times or reduction in the system
pressures, first remedy the causes before using the steering gear or the pump unit,
see Help in Case of Malfunctions, p. 54.

70
 Steering Gear NEPTUNE 500–65°
Maintenance

Date:
Rudder laying time Rudder laying time
Pump unit PORTSTB STBPORT
Target Actual Target Actual
Pump 1
35° PORT  30° STB
Pump 2
35° STB  30° PORT
Pumps 1+2

Working pressure "A" Working pressure "B"

Pump unit 1
Target Actual Target Actual
STB end position
PORT end position

Working pressure "A" Working pressure "B"

Pump unit 2
Target Actual Target Actual
STB end position
PORT end position

Comments:

71
Steering Gear NEPTUNE 500–65°
Maintenance

8.3.2 Check the High Pressure Relief Valves

HINT
For pressure gauges see Figure 4: Hydraulic unit, p. 17.
1. Switch on the MAIN SWITCH on the switch cabinets of both pump units.
2. Set the selection switches PUMP START and STEERING CONTROL to
LOCAL.
3. Press the illuminated START push button.

HINT
Once the end position is reached, the hydraulic pressure should be the same as the
set pressure of high pressure relief valve (see the plate on the pressure relief valve).
4. Keep the emergency control on the starboard side pressed until the end
position stoppers stop the steering gear. See Figure 7, p. 23.
5. Keep the emergency control on the port side pressed until the end position
stoppers stop the steering gear.
6. Use the emergency control or the PORT push button to move the steering gear
into the midships rudder position.
7. Press the illuminated STOP push button.
8. Set the selection switches PUMP START and STEERING CONTROL to
BRIDGE.

8.3.3 Check Hydraulic Oil

PROPERTY DAMAGE

All equipment intended to be used must be clean in order to avoid contamination of

the oil supply tank and the sample.
There is special equipment available to take an oil sample. Such Kits include
sample tubes, sample hand pump and containers.

HINT
• Take the sample when the oil is circulating and at normal operation temperature.
• In the bottom of the tank might be an oil sump with sediment. Do not take the
sample from the bottom of the tank! Always take samples in the same manner, to
get comparable results.
• The container for the sample must be insensitive to hydraulic oil, transparent,
unbreakable, sealable and clean.

1. Unscrew the oil dip stick.

2. Take the oil sample.
3. Screw the oil dip stick back into the tank.
4. Examine the oil sample: If the oil is contaminated, thickened or emulsified with
water, or if it forms sediment after a longer quiet spell, replace the oil
completely.

HINT
We recommend, getting the oil sample analysed in a specialised laboratory.

72
 Steering Gear NEPTUNE 500–65°
Maintenance

8.3.4 Inspection of Hoses

CAUTION
Hoses are put under extreme pressure. If they are damaged, it can lead to persons
being injured or other machine parts being damaged.

Hoses must be checked visually before initial use, and once every year as a matter
of principle.
Pay attention to the following points during the inspection:

Figure 22: Damaged outer layer

Figure 23: Opened coil of outer layer

− Damage to outer layer

73
Steering Gear NEPTUNE 500–65°
Maintenance

Figure 24: Brittle outer layer

− Brittleness of outer layer
− Deformation of hose (change to geometry, separation of layers, blistering, etc.)
− Damage to or deformation of hose coupling
− Corrosion of coupling (restriction of functions and stability)
− Hose loosening from fastening
− Installation position (rubbing spots)
− Exceeding of permitted storage time and service life
If one or more of these points arise during the inspection, you must always
exchange the hose line.

8.4 Venting the Hydraulic System

For figures see Fill Hydraulic System, p. 46.
1. Loosen the caps of the oil filling air filters.
2. Loosen the vent screws on the steering gear.
3. Switch on the MAIN SWITCH on the switch cabinet of the pump unit.
4. Set the LOCAL / BRIDGE selection switch on the switch cabinet of the pump
unit to LOCAL.
5. Start the pump unit with the START button on the pump unit switch cabinet.
6. Move the steering gear two times to both end positions using the emergency
control.
7. Repeat the procedure for the second pump unit.

PROPERTY DAMAGE

The entire hydraulic system must be completely free of air pockets, as even small
air pockets expand during operation and cause shocks in the hydraulic system
which reduces the service life of the hydraulic components.
If hydraulic oil emerges from one of the vent holes without bubbles, close the vent
hole.

8. Tightly screw the caps onto the oil filling air filters.

74
 Steering Gear NEPTUNE 500–65°
Maintenance

8.5 Cleaning

PROPERTY DAMAGE

Only use solvents for cleaning if sufficient venting can be guaranteed.

All components must be free of solvent residue before being put into operation.
Protect electrical components during steam cleaning.
When using high-pressure steam cleaning systems, ensure that all components
can withstand the pressure.
Ensure that cleaning agents or solvents do not find their way into the hydraulic
system.
Under no circumstances use cleaning agents such as benzene, benzine or
turpentine to clean component parts (e.g. gaskets) made of elastomers and
polyurethanes.
Pay particular attention to cleanliness. Cover any openings, so that no dirt can find
its way in.
Ensure that tools, loose parts and cleaning cloths are not left in or on the steering
gear.
Dispose of cleaning material in an environmentally friendly manner, in accordance
with national regulations.

8.5.1 Clean Hydraulic System

Use a damp cloth to clean the outside of the entire hydraulic system. This is in
order to prevent
− leakages from not being recognised,
− dirt accessing the system when filling with hydraulic oil,
− dirt accessing the system when changing the filter element,
− grooves appearing on the cylinder rods,
− the heat emission from being insufficient.

8.5.2 Cleaning Hoses

CAUTION
Hoses may be under extreme pressure. If they are damaged, it can lead to persons
being injured or other machine parts being damaged.
Under no circumstances use sharp cleaning agents such as benzene, benzine or
turpentine, or use a pressure cleaner to clean hoses.

Wipe hoses with a clean cloth. If necessary, clean with hand-hot water.

75
Steering Gear NEPTUNE 500–65°
Maintenance

8.5.3 Clean Return Filter

1. Release the three retaining screws and remove the cover from the return filter.

Figure 25: Change filter element

2. Pull the filter element on the bracket upwards and out of the filter housing.
3. Wash the filter element with cleaning solvent.
CAUTION
The filter element must not contain any cuttings that could be blown out by the
compressed air.
• Do not aim compressed air at persons.
• Wear goggles to protect your eyes.

4. Blow out filter element with compressed air.

5. Place filter element in the filter housing.
6. Use retaining screws to attach cover.

76
 Steering Gear NEPTUNE 500–65°
Maintenance

8.6 Oil Change

8.6.1 Information for oil changing

Please refer to the hydraulic circuit diagram for the quantity of oil.
See Periodic Preventive Maintenance, p. 67 for the oil change intervals.
Special operating conditions, especially operation outside of the ambient
temperatures stated in Requirements of Hydraulic Oil, p. 46 may make earlier oil
changes necessary.
• Only use perfectly clean hydraulic oil according to Requirements of Hydraulic
Oil, p. 46.
• Fill the hydraulic oil through a fine filter mesh (mesh width max.10 µm).
• Do not mix different hydraulic oils.
• When changing the oil, always replace the entire oil.

8.6.2 Changing the oil

For figures see Fill Hydraulic System, p. 46 and Hydraulic Unit, p. 17.
1. Open all shut valves, see block diagram.
2. Unscrew the vent screws on the steering gear and pumps as far as the last
thread.
3. Place a container with an adequate capacity under the oil drain (oil drain
screws, oil drain valves) of the hydraulic tanks (working oil tanks, storage tank).
4. Unscrew the oil drains and drain off the warm hydraulic oil at operating
temperature.

PROPERTY DAMAGE

If the hydraulic oil is very dirty, clean the floor of the tank and the interior of the
pump before refilling the hydraulic system.

5. Close oil drain valves. Screw in oil drain screws with new sealing rings.

Figure 26: Steering gear

6. Place a container with an adequate capacity under the oil drain screws (27-1) of
the steering gear.

77
Steering Gear NEPTUNE 500–65°
Maintenance

7. Unscrew the oil drain screws and drain off the warm hydraulic oil at operating
temperature.
8. Screw in the oil drain screws with new packing rings.
9. Fill hydraulic system, see Fill Hydraulic System, p. 46.

8.7 Lubrication
8.7.1 Demands on Lubricant
The lubricant was carefully selected when designing the system, in order to
guarantee flawless, abrasion-free, economic operation.
• Only use lubricant produced by well-known manufacturers.
• Always observe the lubricant class.
• If you have any questions regarding lubricants, contact the manufacturer
directly. The manufacturers are the experts.
• If lubricants that do not correspond to the requirements, the warranty claim
against HATLAPA becomes invalid.
The following grease lubricants are permitted for HATLAPA steering gears:
− Li grease NLGI-2,
− Li grease NLGI-3.

8.7.2 Notes on Lubrication

− For lubrication intervals, see Periodic Preventive Maintenance, p. 67.

− Only use absolutely clean lubrication grease, in accordance with Lubrication,
p. 78.
− Do not mix different lubrication greases.

78
 Steering Gear NEPTUNE 500–65°
Maintenance

8.7.3 Manual Lubrication

Figure 27: Manual lubrication

Item Description
1 Sliding surface
• Grease the sliding surfaces on tiller and thrust block with a brush.

79
Steering Gear NEPTUNE 500–65°
Maintenance

8.8 Disassemble Rudder Shaft Using the Hydraulic Nut

PROPERTY DAMAGE

The lifting straps must be of sufficient strength: before starting work, determine the
weight of the rudder blade and the rudder stock. Only use tested lifting straps!

1. Drain the oil, see Oil Change, p. 77.

2. Install the measuring equipment, measure and note the installation dimension
from the upper edge of the rudder stock to the upper edge of the tiller.
3. Remove the securing plate, see Fig. 10: Hydraulic nut, installed, p. 29.
4. Loose the locknut by a few millimetres.
5. Remove the rudder stock securing device (provided by the shipyard).

Connect high-pressure hose if oil

grooves are in tiller

Hand pump
Secure rudder stock

Fig. 28: Disassemble rudder shaft

6. Connect the hand pump to the tiller's oil groove.

7. Fill the hydraulic system of the hydraulic nut / the tiller with ISO VG 15 hydraulic
oil and vent thoroughly.
8. With the hand pump, build up a pressure of approx. 60 % of the widening
pressure (see installation drawing).
The rudder stock slips down until it is held by the locknut.
If this attempt is not successful, the pressure can be increased up to the
widening pressure.
9. Secure the rudder blade and the rudder stock against falling, e.g. with chain
hoists.
10. Hoist rudder blade and rudder stock as far as the locknut is removable.
11. Remove the locknut.

80
 Steering Gear NEPTUNE 500–65°
Maintenance

8.9 When Decommissioning

PROPERTY DAMAGE

Run the following work, if the steering gear can't be maintained in regular intervals,
see Periodic Preventive Maintenance, p. 67.

HINT
The recommended preservatives can be obtained from HATLAPA. In this case,
please contact HATLAPA or our agents, see www.hatlapa.de.

Steering gear and hydraulic system (outside)

• Protect not painted fasteners or fixings as well as blank surfaces by TECTYL.
TECTYL is available as wax or wax-spray.
– Clean metal surfaces. They have to be clean, dry as well as free of rust, oil
and mill scale.

CAUTION
The partially cured film is flammable. Keep away from ignition sources and
excessive heat!
Process at ambient temperatures 10 ... 35 ° C. Ensure adequate ventilation!

– Stir wax before use. Do not thin! Apply by airless spray or brush (brush
lubrication).
– Recommended dry film thickness 50 µm.
– For wax-spray: spray one layer per pass, wait for 2 to 3 minutes and
continue until the required film thickness has been obtained.
• Apply anticorrosive grease RENOLIT by grease gun to all grease nipples until
the grease used has completely worn away from the points of lubrication.
RENOLIT is available as grease (brush lubrication) or spray.

81
Steering Gear NEPTUNE 500–65°
Maintenance

Hydraulic system (inside)

1. Drain hydraulic oil, see Oil Change, p. 77.

PROPERTY DAMAGE

Provide the space for oil expansion!

2. Fill the component with hydraulic oil HLP ISO VG 68 DIN 51524.
3. Set the rudder to each of the end positions, see Operation from Contactor
Cabinet for Pump Unit, p. 52.
4. Stop the steering gear.
5. If necessary, disassemble and store unit, for storage conditions see Storing
after Delivery , p. 24.
• The oil volume remains in the unit.
• Seal open pipe ends by plugs.
• Tightly screw the caps onto the oil filling air filters.
• Before recommissioning run oil change as well as initial commissioning,
see Initial Operation, p. 45.

82
Section 3 Rudder Carrier
 INSTALLATION INSTRUCTIONS FOR RUDDER CARRIER
The rudder carrier is delivered in pre-assembled condition. Prior to installation on board the rudder
carrier has to be dismounted completely. Make sure, that the grease pipes behind the grease
nipples are also dismounted.

INSTALLATION ON BOARD

Before mounting, it must be made sure that the recess of the base plate fits into the centring of the
fitting ring of the foundation prepared by the shipyard.
The sequence of works necessary for the installation is listed below:

1. Slide base plate over rudder stock head and insert the plate into the centring.

2. Insert shaft sealing rings into the spaces provided in the base plate for this purpose. Fill up the
hollow spaces of the sealing rings and the remaining space with grease.

3. Install the carrying plates on the base plate and secure them with fitting keys (picture 1).

4. Install the inner ring with fitting key to the rudder stock on top of the carrying plates (picture 2).

5. Add the bearing rings to the inner ring on top of the base plate.

6. Mount the halves of the housing and connect them with screws (picture 3).

7. Connect the housing with the base plate. Adjust the rudder carrier concentric to the rudder
stock. Check if the bearing clearance is constant through the circumference. Compare bearing
clearance with bearing clearance of the neck bearing.

8. Mount the casing cover on top of the housing. Mount the dirt scraper on top of the casing cover
and mount the grease pipes and grease nipples to the grease bores (picture 4).

9. Ream the bores in the foundation of the rudder carrier together with the rudder carrier to the
correct diameter for the fitting bolts.

10. Grease the rudder carrier bearing via the lubricating points.

1/4
picture 1

picture 2

2/4
picture 3

picture 4

3/4
 dirt scraper

casing cover

inner ring

housing

grease nipples
and pipes

bearing ring

carrying plate

sealing

base plate

picture 5

4/4
Section 4 Installation Drawings and Diagrams
 A-A
drawing shows condition after mounting
pressure relief valve
tiller

after mounting
hydraulic nut Tr260x4

5 mm space
scale pointer welded by shipyard

140
760

G 1/4

1121

760 length of cone

30
space between cylinder

760

220
568
and bearing
t = 20

30
5,5
256

103

50
support

603 500

20
stopper 15 15 thrust block
1585 180
rudder stock
B
3364 610

1100 3454
4362

67
°m
ec
h. cylinder2
st
op

30 440
V6 V5 B2

R925
13°

1800
700

630
U1 A2
connection to
2130

830
A A pump unit
ø30
B1
1000

welded with a10

welded with HV20

to sturdy foundation

V4 V3 A1

for further information see technical data sheet

zylinder1
3 drawing revision H0029 13.07.15 Groew
20 2 positions ball valves changed H0007 28.01.15 Kuech steering gear
603 1 drawing updated K0451 12.11.14 Lueh
rev. description mod.-no. date name

Netune 500-65° weight ( t ) drawing no. rev.

drawn 23.09.14 Groenwoldt

3,6 290203 3
scale: sheet
ch. 13.07.15 Kuechler 1:10 class no 43004 1/
app. 13.07.15 Groenwoldt origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
 oil level and thermo switch
filling and air filter
pipe 30 x 3 pump unit 2 2S8 temperature
2S0 oil level

B2 B
H1
Y M5
2Y1 L
2S3
T P2

M
P P1 2M1
V1
2Y2 2S4 EP1
manual pump
2S5

limit switches
1S11 V5 V6
2S11 Stb PS M4
B2 T1
A2 A
STORAGE
A2 pipe 30 x 3 pressure relief valve TANK
cylinder 2 oil level and thermo switch
pipe 30 x 3 1S8 temperature
cylinder 1 filling and air filter
U1 1S0 oil level
B1
pressure relief valve
B1 B
A1 H2
1S10 Y M5
2S10 PS Stb 1Y2 L
1S3
V4 V3
T P2

M
P P1 1M1
V2
1Y1 1S4 EP1

1S5

pipe lines, supplied and

installed by the shipyard
quality: E355+N
M4 T1 DIN 10305-4
A1 A
MX no.of hydraulik
meassure point
pressure relief valve 1X1 item-no.of
pipe 30 x 3 e-conection diagramm
pump unit 1 For operation advice see block diagramm

2 drawing revision H0029 13.07.15 Groew Hydraulikschaltplan

1
rev.
positions ball valves changed
description
H0007 28.01.15 Kuech
mod.-no. date name
hydraulic flow diagramm
weight ( kg ) drawing no. rev.

drawn 30.09.14 Groenwoldt

0 290216 2
scale: sheet
ch. 13.07.15 Kuechler % class no 43011 1/
app. 13.07.15 Groenwoldt origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
Section 5 Spare Parts Lists
 space for disassembly

e-motor

220
marks on dip stick
pump unit 1 pump unit 2

switch box emergency hand control max.

44
43
oil level and
thermo switch 45
42

1490
min.
filter alarm

18

197
80
max. oil level at 20° C

162
dual chamber tank min. oil level at 20° C
return flow filter
2 x 300 l

115
eyebolt for lifting

pipe connection Ø22 to storage tank

35
32
25

770 138
~950
for pipe Ø30 oil drain
~990
~1085

36

38
1480
40
41
34 35 30 31
37
foundation plan - 1:8
filling and air filter
35
35

28

22
15
350

24 14
770

6x 13
39
in pump unit for M12 in foundation

32
350

oil dipstick 7
8
9
33 10
11
84

1456
16 6
1480 5
13 1
29
229,5 162,5 597,5 162,5 19 12 26
27 25
740 20 4
3
~1520 2

17 18 21 2 technical upgrade H0008 29.01.15 Kuech Pumpenaggregat

1
rev.
check valve changed
description
K0450 11.11.14 Kuech
mod.-no. date name
pump unit
PK80/200L
H ATLAPA
weight ( kg ) drawing no. rev.

drawn 18.09.14 Kuechler

1102,4 290210 2
MARINE EQUIPMENT scale: sheet
ch. 10.02.15 Wonerow A MacGregor company 1:10 class no 43060 1/
app. 10.02.15 Kuechler origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290210 Index 2 Ersatzteilliste Spare Parts List
Pumpenaggregat Pump Unit

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Öltank oil tank 1

2 Dichtring packing ring 4

3 Verschlussschraube screw plug 2

4 Maschinenthermometer machine thermometer 2

5 Verschraubung fitting 2

6 Verschraubung fitting 2

7 Verschraubung fitting 2

8 Verschraubung fitting 2

9 Kugelhahn ball cock 2

10 Verschraubung fitting 2

11 Verschraubung fitting 2

13 Verschraubung fitting 1

14 Pumpeneinheit pump set 2

15 Sechskantschraube hexagon head screw 68

16 Verschraubung fitting 2

17 Verschraubung fitting 2

18 Verschraubung fitting 2

19 Verschraubung fitting 2

20 Schraubkupplung screw coupling 4

21 Verschraubung fitting 4

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

01a 290210-2 Pumepenaggregat de_en 12.02.2015 1/3

290210 Index 2 Ersatzteilliste Spare Parts List
Pumpenaggregat Pump Unit

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
22 HD-Schlauch hp-hose 4

24 Verschraubung fitting 4

25 Hinweisschild indicator plate 2

26 Schild label 2

27 Hinweisschild indicator plate 1

28 Schild plate 2

29 Firmenschild company label 1

30 Schild Schild 2

31 Schild label 2

32 Hinweisschild indicator plate 2

33 Hinweisschild indicator plate 2

34 Ventilschild valve plate 1

35 Ventilschild valve plate 1

36 Schilderhalterung plates bracket 2

37 Sechskantschraube hexagon head screw 4

38 Hinweisschild indicator plate 1

39 Hinweisschild indicator plate 1

40 Hinweisschild indicator plate 2

41 Hinweisschild indicator plate 2

42 Ventilschild valve plate 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

01a 290210-2 Pumepenaggregat de_en 12.02.2015 2/3

290210 Index 2 Ersatzteilliste Spare Parts List
Pumpenaggregat Pump Unit

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
43 Ventilschild valve plate 1

44 Ventilschild valve plate 1

45 Ventilschild valve plate 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

01a 290210-2 Pumepenaggregat de_en 12.02.2015 3/3

 929
A

A-A 1 : 7
9
63
e-motor
10

1220
42
48 41 8
13
5 47 40 12

20,5
71

22
6 39 25
37 3
11 26
69
23 70
68 27
15 hydraulic pump
24
20
21 65 66
remove drain plug
A
direct this component
always downwards 61, 62
67
30
64 2
31
29
38
39
16
33
34
51
60 17
35
59
41 18
54
50
53
36
19
49 55
44
57
45
58
52 56 22
28
43 ~738
38
1
2 technical upgrade H0008 10.02.15 Kuech Pumpeneinheit, vollst.
1
rev.
check valve changed
description
K0450 11.11.14 Kuech
mod.-no. date name
pump unit, compl.
PK80/200L
H ATLAPA
weight ( kg ) drawing no. rev.

4 drawn 17.09.14 Kuechler

469,8 290209 2
MARINE EQUIPMENT scale: sheet
ch. 12.02.15 Wonerow A MacGregor company 1:5 class no 42060 1/
14 app. 12.02.15 Kuechler origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290209 Index 2 Ersatzteilliste Spare Parts List
Pumpeneinheit, vollst. Pump Unit, compl.

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Deckel cover 1

2 Dichtung packing 1

3 Dichtung packing 1

4 Innenzahnradpumpe internal gear pump 1

5 Scheibe washer 4

6 Sechskantschraube hexagon head screw 4

8 Kupplung coupling 1

9 E-Motor E-motor 1

10 Sechskantschraube hexagon head screw 4

11 Flansch flange 2

12 Dichtung packing 1

13 Steuerplatte control plate 1

14 Zylinderschraube cylinder head screw 4

15 Verschraubung fitting 1

16 Verschraubung fitting 1

17 Verschraubung fitting 2

18 Verschraubung fitting 2

19 Rückschlagventil non-return valve 2

20 Verschraubung fitting 1

21 Verschraubung fitting 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

02a 290209-2 Pumpeneinheit de_en 13.02.2015 1/4

290209 Index 2 Ersatzteilliste Spare Parts List
Pumpeneinheit, vollst. Pump Unit, compl.

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
22 Verschraubung fitting 1

23 Rohr pipe 1

24 Rohr pipe 1

25 Verschraubung fitting 2

26 Rohr pipe 1

27 Verschraubung fitting 2

28 Ölpeilstab oil dip stick 1

29 Schwimmerschalter float switch 1

lowering brake holding valve
30 Senkbremshalteventilpatrone 1
cartridge
31 Sechskantschraube hexagon head screw 2

33 Verschraubung fitting 1

34 2/2-Wege-Kugelhahn 2/2-way-ball cock 1

35 Hahnschlüssel key 1

36 Verschraubung fitting 1

37 Verschraubung fitting 1

38 Verschraubung fitting 1

39 Verschraubung fitting 2

40 Rohr pipe 1

41 Verschraubung fitting 2

42 Verschlusskegel blanking plug 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

02a 290209-2 Pumpeneinheit de_en 13.02.2015 2/4

290209 Index 2 Ersatzteilliste Spare Parts List
Pumpeneinheit, vollst. Pump Unit, compl.

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
43 Verschraubung fitting 1

44 Verschraubung fitting 1

45 Verschraubung fitting 1

47 Rohr pipe 1

48 Verschraubung fitting 1

49 Rohr pipe 1

50 Rohr pipe 1

51 Rohr pipe 1

52 Rohr pipe 1

53 Verschraubung fitting 2

54 Rohr pipe 1

55 Rücklauffilter return filter 1

56 Druckschalter pressure switch 1

57 Stiftschraube stud screw 2

58 Sechskantmutter hexagon nut 2

59 Verschraubung fitting 1

60 Rohr pipe 1

61 Dichtring packing ring 1

62 Einfüll- und Belüftungsfilter filling - and vent filter 1

63 Manometer pressure gauge 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

02a 290209-2 Pumpeneinheit de_en 13.02.2015 3/4

290209 Index 2 Ersatzteilliste Spare Parts List
Pumpeneinheit, vollst. Pump Unit, compl.

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
64 Abstandhalter distance piece 1

65 Sechskantschraube hexagon head screw 4

66 Sechskantmutter hexagon nut 2

67 Klemmenkasten terminal box 1

68 Verschraubung fitting 1

69 Verschraubung fitting 1

70 Rohr pipe 1

71 Verschraubung fitting 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

02a 290209-2 Pumpeneinheit de_en 13.02.2015 4/4

 Rundstahl oben mit M5-
A A B Gewinde, Gewindelänge 17mm
round steel on top with
M5 thread, length
of thread 17mm

15
Metallkleber (ölfest)
M5 metal glue (oilproof)
A-A
B
010

020

Markierungen laut
Einbauzeichnung des
jeweiligen Auftrages
marks according to
installation drawing
of particular order
304,5
300

Kanten entgratet
edges broken
5
material: DIN:
raw part:

Ölpeilstab 300mm
rev. description mod.-no. date name
oil dip stick 300mm
G1" weight ( kg ) drawing no. rev.

drawn 11.03.14 Kuechler HATLAPA 0,2

scale:
722235 -
sheet
MARINE EQUIPMENT
ch. 11.03.14 Harder 1:1 class no 11095 1/
app. 11.03.14 Harder origin: rep. for: rep. by:

tol. ISO 2768-mH ISO 8015 surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
722235 Ersatzteilliste Spare Parts List
Ölpeilstab Oil Dip Stick

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
010 Verschlussschraube screw plug 1

020 Rundstahl round steel 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

03b 722235 Ölpeilstab de_en 12.02.2015 1/1

 630
430
830
1

453 620 3
683

Wiederlager Komplett
rev. description mod.-no. date name
thrust block complete
H ATLAPA
weight ( kg ) drawing no. rev.

drawn 19.09.14 Groenwoldt

302,7 290197 -
MARINE EQUIPMENT scale: sheet
ch. 29.10.14 Wonerow A MacGregor company 1:5 class no 43055 1/
app. 29.10.14 Wonerow origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290197 Ersatzteilliste Spare Parts List
Wiederlager, komplett Thrust Block, complete

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Widerlager thrust block 1

2 Lasche strap 2

3 Sechskantschraube hexagon head screw 4

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

05a 290197 Wiederlager, komplett 12.02.2015 1/1

3

2130
1
2

760 775

Pinne komplett
rev. description mod.-no. date name
tiller complete
H ATLAPA
weight ( kg ) drawing no. rev.

drawn 16.09.14 Groenwoldt

1947,3 290200 -
MARINE EQUIPMENT scale: sheet
ch. 25.09.14 Wonerow A MacGregor company 1:10 class no 42081 1/
app. 25.09.14 Wonerow origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290200 Ersatzteilliste Spare Parts List
Pinne, komplett Tiller, complete

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Pinne tiller 1

2 Lasche strap 2

3 Sechskantschraube hexagon head screw 4

4 Gradskala scale 1

5 Verschlußstopfen blanking plug 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

06a 290200 Pinne, komplett de_en 12.02.2015 1/1

K975601 Ersatzteilliste Spare Parts List
Hydraulikzylinder Hydraulic Cylinder

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Zylinderrohr cylinder tube 1

2 Kolbenstange cylinder rod 1

3 Kolben piston 1

4 Führung top nut 1

5 Hubbegrenzer stroke limiter 1

6 Zwischenring bushing 4

7 Druckschmierkopf grease nipple 2

8 Feststellschraube set screw 1

9 Lager bearing 2

10 Segerring lock ring 2

11 Kolbendichtung piston seal 1

12 Führungsring bearing ring 3

13 Abstreifer wiper 1

14 Stangendichtung rod seal 1

15 Stangendichtungen rod seal 1

16 Führungsring bearing ring 3

17 O-Ring o-ring 1

18 Tragring back-up ring 1

19 O-Ring o-ring 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

Ersatzteilliste de _en 09.02.2015 1/2

K975601 Ersatzteilliste Spare Parts List
Hydraulikzylinder Hydraulic Cylinder

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.

20 O-Ring o-ring 1

21 Diebel plug 4

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

Ersatzteilliste de _en 09.02.2015 2/2

 22 21 19 18
1 9 8 3 7
440

830 792

13 12 6 5 2 4

17 16 15 14

10

20

11

3 fitting changed H0019 06.03.15 Kuech

2 fittings changed H0018 02.03.15 Kuech Ventileinheit
1
rev.
positions ball valves changed
description
H0007 28.01.15 Kuech
mod.-no. date name
valve unit
Neptune
H ATLAPA
weight ( kg ) drawing no. rev.

drawn 09.10.14 Kuechler

90 290218 3
MARINE EQUIPMENT scale: sheet
ch. 06.03.15 Wonerow A MacGregor company 1:5 class no 42055 1/
app. 06.03.15 Kuechler origin: rep. for: rep. by:

general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290218 Index 3 Ersatzteilliste Spare Parts List
Ventileinheit Valve Unit

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Aufnahmeplatte supporte plate 1

2 Verschraubung fitting 4

3 Verschraubung fitting 6

4 Ger. Zwischenstutzen straight intermediate fitting 8

5 Verschraubung fitting 4

6 Kugelhahn ball cock 8

7 Verschraubung fitting 2

8 Verschraubung fitting 2

9 Ger. Zwischenstutzen straight intermediate fitting 2

10 Überdruck-Umlaufventil pressure relief 1

11 Rohr pipe 2

12 Verschraubung fitting 4

13 Verschraubung fitting 4

14 Ventilschild A 1 valve plate A 1 1

15 Ventilschild B 1 valve plate B 1 1

16 Ventilschild A 2 valve plate A 2 1

17 Ventilschild B 2 valve plate B 2 1

18 Ventilschild V 3 valve plate V 3 1

19 Ventilschild V 4 valve plate V 4 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

290218-3 Ventileinheit de_en 09.03.2015 1/2

290218 Index 3 Ersatzteilliste Spare Parts List
Ventileinheit Valve Unit

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.

20 Ventilschild U 1 valve plate U 1 1

21 Ventilschild V 5 valve plate V 5 1

22 Ventilschild V 6 valve plate V 6 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

290218-3 Ventileinheit de_en 09.03.2015 2/2

 060 050 040

010 020 030

Überdruck-Umlaufventil
rev. description mod.-no. date
pressure-and by-pass valve
name

weight ( kg ) drawing no. rev.

drawn 13.12.11 Burfeind HATLAPA 8

scale:
670806 -
sheet
MARINE EQUIPMENT
ch. 14.12.11 Loebel 1:2 class no 42719 1/
app. 14.12.11 Burfeind origin: rep. for: rep. by:

"Proprietary notice according to DIN ISO 16016 to be observed"

 Ersatzteilliste Zeichnung Nr.:
Drawing No.: 670806
List of Spare Parts

Zeichnung Nr. Teile Nr. Benennung

Drawing No. Part No. Designation

670806 Überdruck- Umlaufventil

pressure limiting and
by - pass valve
010 Kugelhahn
ball cock

020 Verschraubung
fitting

030 Verschraubung
fitting

040 Rohr
pipe

050 Verschraubung
fitting

060 Druckbegrenzungsventil
pressure relief valve
 A-A 340,8 H7
rudder stock 340,8 h6 10 9 11 17
1 x Key 50x28
Yards supply

disassembly measure
14 13

~100
B B

100
316

R1
5,6
2 7

80

60
30
55
15

rudder stock50 H7
R4

length for

2x45

2x45
1 4 bolts for fastening

8 B-B 1 : 2
12 J-J 1 : 3
connection variants for the fitting bolts /
320+0,1 all parts yard supply
rudder stock 320 k6
380 screw - in tap hole R2

,5
rudder stock 380 h6 ,5

R2
0
700 -0,1
880
housing
50 P9

+0,3
2 connections G1/4 for lubrication

352,1 0
each side base plate

deck
J
or
)

through bore - hole

60°
(= 3
30°

30°

J
12x

longitudinal direction

3
15°

±0 ,
of the ship

830

A A

2 bolt circle diameter added K0487 14.04.15 Lueh Ruderschaftstraglager

12xø24 for fitting bolt M24 (yards supply)
DIN610, Material 8.8
1
rev.
connection variants added
description
K0485 25.03.15 Lueh
mod.-no. date name
rudder carrier
RT 380/320
H ATLAPA
weight ( kg ) drawing no. rev.
Reaming has to be done by yard, together 712,7 2
with foundation. drawn 03.02.15 Lueckheide
MARINE EQUIPMENT scale:
290244 sheet
ch. 14.04.15 Wonerow A MacGregor company 1:5 class no 42830 1/
app. 14.04.15 Lueckheide origin: rep. for: rep. by:
3 16 15 general tol. ISO 2768-mH surface finish DIN ISO 1302 x Rz 100 y Rz 25 z Rz 6,3
"Proprietary notice according to DIN ISO 16016 to be observed"
290244 Index 2 Ersatzteilliste Spare Parts List
Ruderschaftstraglager Rudder Carrier

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Grundplatte base plate 1

2 Gehäuse housing 1

3 Sechskantschraube hexagon head screw 3

4 Gleitplatte carrying plate 1

5 Paßfeder parallel key 2

6 Zylinderschraube cylinder head screw 2

7 Gleitring bearing ring 1

8 Paßfeder parallel key 2

9 Innenring inner ring 1

10 Gehäusedeckel housing cover 1

11 Zylinderschraube cylinder head screw 12

12 Ruderschaftabdichtung rudder stock sealing 1

13 Schmierrohr lubricating tube 4

14 O-Ring o-ring 4

15 Firmenschild company label 1

16 Halbrundkerbnagel grooved pin 4

17 Dichtring packing ring 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

290244-2 Ruderschaftstraglager de_en 23.06.2015 1/1

 Ersatzteilliste Zeichnung Nr.:
List of Spare Parts Drawing No.: 114812-1

Zeichnung Nr. Teile Nr. Benennung

Drawing No. Part No. Designation

114812-1 Vorratstank vollst.

storage tank compl.

1 Vorratstank
storage tank

2 Flügelpumpe
vane pump size

3 Rohr
pipe

4 Verschraubung
fitting

5 Sechskantschraube
hexagon head bolt

6 Ölstandsanzeige
oil level indicator

7 Verschraubung
fitting

8 Deckel
cover

9 Dichtung
packing

10 Sechskantschraube
hexagon head bolt

11 Verschraubung
fitting

12 Verschraubung
fitting

13 Einfüllfilter mit Luftfilter

oil filling filter / air filter

Seite / page - 1 -
59.00-0423 Ersatzteilliste Spare Parts List
K393836 Hydraulikmutter Hydraulic Nut

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Mutter nut 1

2 Ringkolben ring piston 1

3 Verschlußstopfen blanking plug 1

5 O-Ring o-ring 1

6 O-Ring o-ring 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

14a K393836 Hydraulikmutter de_en 12.02.2015 1/1

Section 6 E-Equipment
• Wiring Diagrams
 APPROVAL DRAWINGS (ELECTRIC)
FOR STEERING GEAR
Shipyard Newbuilding Date Our ref.

HUANGHAI HCY-165 09.09.2014 14.6417

Shipbuilding HCY-166 14.6418
HCY-167 14.6419
HCY-168 14.6420
HCY-169 14.6421

ITEM DESCRIPTION DRAWING No.

1 Connection Diagram Steering Gear 722928-44009 1-4
2 Contactor Cabinet Hydr. Pump 1 722926-44000 1-8
3 Contactor Cabinet Hydr. Pump 2 722927-44000 1-8
4 Bridge Panel Hydr. Pumps 722160-44008 1-3
5 Contactor Cabinet SOTERIA Alert System 350600-44007 1-8
6 Alert Display Bridge 344678-44008 1-4
7 Alert Display ECR 344677-44008 1-4

1/1
Tel.: + 49-(0) 4122 / 711-0 Geschäftsführer / 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 Nürnberg Verwaltungsgesellschaft: HRB 1560
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 ELECTRICAL SPARE PARTS
FOR STEERING GEAR
Shipyard Newbuilding Date Our ref.

HUANGHAI HCY-165 09.09.2014 14.6417

Shipbuilding HCY-166 14.6418
HCY-167 14.6419
HCY-168 14.6420
HCY-169 14.6421

ITEM QUANTITY DESCRIPTION PART NO.

1 1 Main Contactor LC1-D50AP7 121496
2 1 Main Contactor LC1-D40AP7 121418
3 1 Aux. Contactor CAD-32P7 334545
4 1 Aux. Contactor RHK-412 B 339860
5 1 Aux. Relay 2CO; 24V DC 334712
6 1 Socket for Aux. Relay 334714
7 1 Rectifier SKB 046307
8 1 Ball Bearing for E-Motor 6312C3 006670
9 1 Ball Bearing for E-Motor 6212ZC3 082845
10 2 Aux. Contactor CAD-32BL 335724

1/1
Tel.: + 49-(0) 4122 / 711-0 Geschäftsführer / 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 Nürnberg Verwaltungsgesellschaft: HRB 1560
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 0 1 2 3 4 5 6 7 8 9

FEEDER FOR RUDDER CTRL.

BRIDGE PANEL
HYDRAULIC PUMPS
722160-44008

FLOATING CONTACT

FLOATING CONTACT
PUMP ON SERVICE

PUMP ON SERVICE
-X1 1 2 3 4 5 6
SHIP SUPPLY

SHIP SUPPLY
HP1/ALARM
440V 60 Hz

220V 60 Hz
3.0

(HEATING)

440V 60Hz
ST-BY 2.4

1.9
-X0 L1 L2 L3 1 2 3 4 11 12 -X2 1 2 3 4 5 6 -X5 1 2 3 4 -X9 1 2 3 4 -X10 + - 1 2 3 4 5 6 7 8 9 10

CONTACTOR CABINET
HYDRAULIC PUMP 1 722826 - 44000
-X1 U1 V1 W1 U2 V2 W2 1 2 9 10 -X3 1 2 3 4 5 6 7 8 9 10 11 12 13 -X4 1 2 3 4 11 12 13 14

C P S -

RUDDER CONTROL
-XK1 1 2 3 4 5 6 7 8 9 10 11 12 13 11 11
U1 V1 W1 U2 V2 W2 TP1 TP2 HE1 HE2

M
3 12 12
-1M1
HYDR. PUMP 1 THERMISTOR HEATING -1S10 -1S11
S6-25% 47kW PS SB

2 2 LIMIT SWITCHES
1 3 1 3 21 1 3 4 STEERING GEAR
P
1 1
22 2 5
4 4
-1Y1 -1Y2 -1S3 -1S4 -1S5 -1S0 -1S8
PORT STBD. PS SB

OIL FILTER
LIMIT SWITCHES

OIL LEVEL

OIL TEMP.
SOLENOID VALVES SOLENOID VALVES

Datum 05.09.14
Bearb. HAR CONNECTION DIAGRAM STEERING GEAR HATLAPA Gruppe : = 722924 - 44009
Gepr. har Uetersener Maschinenfabrik Blatt 1
D-25436 Uetersen Ort : +A
Zust. Änderung Datum Name Norm Urspr. 722888 Ers.f Ers.d von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

FEEDER FOR RUDDER CTRL.

BRIDGE PANEL
HYDRAULIC PUMPS
722160-44008

FLOATING CONTACT

FLOATING CONTACT
PUMP ON SERVICE

PUMP ON SERVICE
-X2 1 2 3 4 5 6
SHIP SUPPLY

SHIP SUPPLY
HP2/ALARM
440V 60 Hz

220V 60 Hz
3.4

(HEATING)

440V 60Hz
1.5 ST-BY

2.9
-X0 L1 L2 L3 1 2 3 4 11 12 -X2 1 2 3 4 5 6 -X5 1 2 3 4 -X9 1 2 3 4 -X10 + - 1 2 3 4 5 6 7 8 9 10

CONTACTOR CABINET
HYDRAULIC PUMP 2 722927 - 44000
-X1 U V W 1 2 9 10 -X3 1 2 3 4 5 6 7 8 9 10 11 12 13 -X4 1 2 3 4 11 12 13 14

C P S -

RUDDER CONTROL
V U W
-XK1 1 2 3 4 5 6 7 8 9 10 11 12 13 11 11
M
3
TP1 TP2 HE1 HE2

-2M1 12 12

HYDR. PUMP 2 HEATING -2S10 -2S11

S6-25% 47kW PS SB

2 2 LIMIT SWITCHES
1 3 1 3 21 1 3 4 STEERING GEAR
P
1 1
22 2 5
4 4
-2Y1 -2Y2 -2S3 -2S4 -2S5 -2S0 -2S8
PORT STBD. PS SB

OIL FILTER
LIMIT SWITCHES

OIL LEVEL

OIL TEMP.
SOLENOID VALVES SOLENOID VALVES

Datum 05.09.14
Bearb. HAR CONNECTION DIAGRAM STEERING GEAR HATLAPA Gruppe : = 722924 - 44009
Gepr. har Uetersener Maschinenfabrik Blatt 2
D-25436 Uetersen Ort : +A
Zust. Änderung Datum Name Norm Urspr. 722888 Ers.f Ers.d von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

1.9 HP1/ALARM HP2/ALARM

2.9
3.0

3.4
-X1 + - 1 2 3 4 5 6 7 8 9 10 -X2 + - 1 2 3 4 5 6 7 8 9 10 -X3 1 2 3 11 12 21 22 23 24 31 32 33 34

CONTACTOR CABINET
SOTERIA ALERT SYSTEM STEERING GEAR 350600-44007
9 pol SUB-D FEMALE
-X10 + - 1 2 3 S -X11 + - 1 2 3 S -X9 1 2 3 4 5 6 7 -COM2 1 2 3 4 5 6 7 8 9

Tx+ 0V Tx-

CAN-CONNECTOR CAN-CONNECTOR FLOATING CONTACTS NMEA-TELEGRAM

1C+ 1C- GND (349459)
SWITCH TO "ON" 1C+ 1C- GND (349459)
SWITCH TO "ON" DETAILS SEE LAST PAGE DETAILS SEE LAST PAGE

ALERT SYSTEM
-24VDC + - -CAN1 7 2 3 -24VDC + - -CAN1 7 2 3

(optional)
TO V.D.R.
TO SHIP
ALERT DISPLAY BRIDGE ALERT DISPLAY ECR
344678-44007 344677-44007
9 pol SUB-D FEMALE 9 pol SUB-D FEMALE
-COM2 1 2 3 4 5 6 7 8 9 -COM2 1 2 3 4 5 6 7 8 9

Tx+ 0V Tx- Tx+ 0V Tx-

NMEA-TELEGRAM NMEA-TELEGRAM
DETAILS SEE LAST PAGE DETAIL SEE LAST PAGE
(optional)

(optional)
TO V.D.R.

TO V.D.R.

Datum 05.09.14
Bearb. HAR CONNECTION DIAGRAM STEERING GEAR HATLAPA Gruppe : = 722924 - 44009
Gepr. har Uetersener Maschinenfabrik Blatt 3
D-25436 Uetersen Ort : +A
Zust. Änderung Datum Name Norm Urspr. 722888 Ers.f Ers.d von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

NMEA TELEGRAM DETAILS

PROTOCOL DETAILS:
TEXT TRANSMISSION (NMEA 0183 / VDR)
SERIAL RS-422 PORT
DATA-TRANSMISSION TO VDR

hydraulic pump X low servo oil pressure

talker identifier (P: Proprietary code)

hydraulic pump X high oil temperature

Baute rate: 4800

hydraulic pump X hydraulic locking

hydraulic pump X oilfilter clogged
HATLAPA Uetersener Maschinenfabrik
Data bits: 8

hydraulic pump X feeder failure

hydraulic pump X stand-by start

hydraulic pump X phase failure

hydraulic pump X low oil level

Parity: none

hydraulic pump X on service

Stop bit: 1

hydraulic pump identifier

hydraulic pump X overload

total number of sentences

hydraulic pump X failure

sentence terminator
COM2 SERIAL PORT ON DISPLAY (RS-422)

start of sentence

sentence number

checksum field
PIN NO. SIGNAL SIGNAL DIRECTION

STEERING GEAR
1
6
2
7 1 TxD+ OUTPUT

spare
spare
3
8 5 0V
4
9 6 TxD- OUTPUT
5
$PHUMSTG,2,1,1,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
D-SUB $PHUMSTG,2,2,2,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
9 PIN
FEMALE NOT ALL ALARMS HAVE TO BE SUPPORTED

FLOATING CONTACTS DETAILS

PRINCIPAL DRAWING 1: COMMON

2: NC - ALERT SYSTEM FAILURE
3: NC - AGGREGATED ALARM HYDR. PUMP 1
4: NC - LOW OIL LEVEL HYDR. PUMP 1
5: NC - AGGREGATED ALARM HYDR. PUMP 2
6: NC - LOW OIL LEVEL HYDR. PUMP 2
-X9 1 2 3 4 5 6 7
7: NC - SPARE

Datum 05.09.14
Bearb. HAR CONNECTION DIAGRAM STEERING GEAR HATLAPA Gruppe : = 722924 - 44009
Gepr. har Uetersener Maschinenfabrik Blatt 4
D-25436 Uetersen Ort : +A
Zust. Änderung Datum Name Norm Urspr. 722888 Ers.f Ers.d von 4 Bl.
 0 1 2 3 4 5 6 7 8 9
790

760 10 210

-3P1
-1P1

-3H1
-4S1 -3S1 -3H0
-4S2 -3S2 -1H1

-4S0 -3S0 -1Q2

760
702

-1Q1

ø 8,5 WEIGHT: appr. 75kg

PROTECTION: IP54
CABLE GLANDS

BACKGROUND/LETTERS
-1H1 (BU/BK) HEATING ON
-1P1 AMMETER
-1Q1 MAIN SWITCH (WITH INTERLOCKING DEVICE)
-1Q2 MAIN SWITCH HEATER
-3H0 (WH/BK) SOURCE ON
-3H1 (GN/BK) PUMP ON SERVICE
-3P1 RUNNING TIME METER
-3S0 SELECTOR SWITCH PUMP START LOCAL-BRIDGE
-3S1 (WH/GN) START PUSH BUTTON HYDR. PUMP
-3S2 (WH/RD) STOP PUSH BUTTON HYDR. PUMP
-4S0 SELECTOR SWITCH STEERING CONTROL LOCAL-BRIDGE
-4S1 (WH/RD) NFU PUSH BUTTON PORT
-4S2 (WH/GN) NFU PUSH BUTTON STARBOARD

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 1
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

0-100A
+ k -1P1 + A -
L -1T1
LED 100/1A l
-1H1 -1R1
- 70/30 W N

1 3 5 1 3 5 1 3 5 21 61
-2K1 -2K1.1 -2K1.2 -2K1
3.4 2 4 6 3.5 2 4 6 3.6 2 4 6 3.4 22 62
1 3
-1F4
2 4 6 2 4 6A 2 4

-1Q1 1 3 5 -1Q2 1 3
-1T2
2 4 1 3 1 3 5 220V 28V
11 400VA 150VA
-1F1 -1F2 -1F3 28V-L 5.0
4A 6A 14 2A 28V-N 5.0
1 3 2 4 2 4 6
7.2
L 3.0
L1 L2 L3 N 3.0
L1

L3 L2

RM17TA00 C 3.2
-1A1 D 3.2
7.4 14
7.4 12 11

-X0 L1 L2 L3 1 2 11 12 -X1 V1 U1 W1 V2 W2 U2 1 2 9 10 -X0 3 4

440V AC FOR RUDDER CTRL.

1 2 9 10
SHIP SUPPLY 440V 60Hz

SHIP SUPPLY 220V AC

V1 U1 W1 V2 W2 U2
M
3
38-59 kW
S6-25% HYDR. PUMP 1 THERMISTOR HEATING
HEATING

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
A -2F2 05.09.14 har Gepr. har Uetersener Maschinenfabrik Blatt 2
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

-2F1 6A
2.9 L L 4.0

2
1
N N
3

4
2.9 4.0

11
-3K1
4.4 12 14

16 18 26 28
83 13
-2K1 -2K1.2 -2K1.3
3.4 84 3.6 14 3.4 15 25

21 21 43 03
-2K1.2 -2K1.1 -2K2 -2K2
3.6 22 3.5 22 3.7 44 3.7 04

A1 2.6 C T1 A1 A1 A1 A1 A1
A1
-2K0 -2A1 -2K1 -2K1.3 -2K1.1 -2K1.2 -2K2
A2 2.6
D A2 50A A2 A2 50A A2 40A A2 A2 -X9 1 2 3 4
T2

FLOATING CONTACT

FLOATING CONTACT
PUMP ON SERVICE

PUMP ON SERVICE
7.1 13 14 7.2 14 2.4 1 2 3.5 18 2.5 1 2 2.6 1 2 4.3 13 14
7.5 21
22 12 11 3 4 16 15 3 4 3 4 21 22
31 32 7.2 2.4 5 6 3.5 28 2.5 5 6 2.6 5 6 7.3 31 32
2.4 13 3.6 2.5 2.6 7.4
7.2 43
03
44
04 6.1 21 14
22 3.6 26 25 13
21
14
22 3.4 13
21
14
22 3.8 43
03
44
04
2.7 53 54 3.6 3.5 3.8 53 54
7.1 61 62 7.0 61 62
2.7 71 72 7.6 71 72
8.2 83 84 7.8 83 84
3.4 4.7
Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 3
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
3.9 L
3.9 N

L N
2 Wago 787-1012
-3G1 24VDC/2,5A
+ -

Bridge
Local
2
-3S0
1 3 3S0 8.0

-X2 1 BRIDGE PANEL

PUMP CONTROL
(722160)
+PSP
-X1 1
13 13 13 13 +
13
-2K2 -3S1 -3S2 -1SH1 -1SH2 -1H1 LED
3.7 14 14 14 14 14
-
-X1 3 4 5 6 2

-3P1
h -X2 3 4 5 6 2
X1X2 3K1-A1 8.0
83
-2K2
A1 + + A1 B1 3.7 84
-3K0 -3H0 LED -3H1 LED -3K1 RHK-412B
-X10 + - A2 A2 B2
- - Start Stop
SOTERIA ALERT SYSTEM

7.2 14
12 11 3.3 14
12 11
7.2 24 3.3 24
22 21 7.1 22 21
SUPPLY FOR

7.1 34
(350600)

8.2 32 31
8.2 44
42 41

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 4
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
2.9 28V-L
2.9 28V-N

1 3
-4F0
6A 2 4
24V+ 6.0
+
-4V0 ~ ~
- 24V- 6.0

A1
+ -
-4K0
A2
E

12
7.5

7.2 14 Hydraulic Locking Alarm Logic

7.2 12 11
24 HLA951-V F

13
7.5
22 21

-A4 1 2 3 4 5 6

13 43 13 43 03 03
-4K1 -4K2 -4K1 -4K2
6.4 14 44 6.4 14 44 6.4 046.4 04
K

A
-4V1 -4V2

-X3 1 2 3 4 5 6 7 8

PUMP 1
-XK1 1 2 3 4 5 6 7 8
LIMIT SWITCH LIMIT SWITCH
1 SOLENID VALVE 1 SOLENID VALVE

-1Y1 -1S3 -1Y2 -1S4

PS 2 SB 2
1 3 4 1 3 4

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 5
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
5.9 24V+

13
-2K1 -X4
1
3.4 14

Bridge
Local RUDDER CONTROL C
2
-4S0
1 5 PS SB -

-X4 2 3 4

Bridge

Bridge
Local

Local
13 13 4 10
-4S1 -4S2 -4S0
14 14 3 7 9 13

-X4 11 13

LIMIT SWITCHES
-1S10 -1S11
PS SB

-X4 12 14
21 21
-4K2 -4K1
6.4 22 6.4 22
A1 A1
-4K1 -4K2
PS A2 SB A2

5.9 24V-
CAD-32BL CAD-32BL

5.2 13 14 5.4 13 14
6.4 21 22 6.4 21 22
31 32 31 32
5.2 43 44 5.5 43 44
5.6 03 04 5.6 03 04

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 6
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

OILFILTER CLOGGED
PUMP ON SERVICE

OIL TEMPERATURE
RUDDER CONTROL

STAND-BY START
PHASE FAILURE

HYDR. LOCKING
PUMP FAILURE

OIL LEVEL
OVERLOAD
FAILURE
Bridge

Bridge
Local

Local
6 12 E 25 71
5.9 -2K7 -2K2
5 7 11 15 8.4 3.7 72
-3S0 -4S0 -X3 9 26 28 11

Bridge
OIL LEVEL +

Local
TEMPERATURE
12 14 12 14 21 12 14 31 18 21 61 +XK1
-4K0 -2A1 -2K2 -1A1 -2K2 -2K0 -2K2 -XK1 9 11
5.1 11 3.3 11 3.7 22 2.4 11 3.7 32 17 19 3.1 22 3.7 62
-4S0 1 1 3 4
-1S5 P -1S0 -1S8
53 13 53 12 14 2 2 5
-2K2 -2K0 -2K1 -3K0 SHOWN WITH
EMPTY TANK
3.7 54 3.1 14 3.4 54 4.2 11
-XK1 10 12 13
F
5.9
22 24 43
-3K1 -2K0 -X3 10 12 13
4.4 21 3.1 44

11
-1F2
2.3 14

-X10 1 2 3 4 5 6 7 8 9 10 11 12

TO SOTERIA ALERT SYSTEM

(350600)

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : = 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 7
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
L
4.0

Bridge
Local
4.9 3S0

10

9 11
-3S0
-X5 3 1

PUMP STARTER 2
31
-3K1 -X5 1
4.4 32 34
15
-2K7
8.4
16 18
-3K1

71 -2K1
-2K1
3.4 72
-X5 2

-X5 4 2

4.9 3K1-A1

A1
-2K7
A2
N
4.0

8.0 18
16
8.0 28 15
7.7 26
7.7 25

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 1 HATLAPA Gruppe : 722926-44000
Gepr. har Uetersener Maschinenfabrik Blatt 8
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722886 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
790

760 10 210

-3P1
-1P1

-3H1
-4S1 -3S1 -3H0
-4S2 -3S2 -1H1

-4S0 -3S0 -1Q2

760
702

-1Q1

ø 8,5 WEIGHT: appr. 75kg

PROTECTION: IP54
CABLE GLANDS

BACKGROUND/LETTERS
-1H1 (BU/BK) HEATING ON
-1P1 AMMETER
-1Q1 MAIN SWITCH (WITH INTERLOCKING DEVICE)
-1Q2 MAIN SWITCH HEATER
-3H0 (WH/BK) SOURCE ON
-3H1 (GN/BK) PUMP ON SERVICE
-3P1 RUNNING TIME METER
-3S0 SELECTOR SWITCH PUMP START LOCAL-BRIDGE
-3S1 (WH/GN) START PUSH BUTTON HYDR. PUMP
-3S2 (WH/RD) STOP PUSH BUTTON HYDR. PUMP
-4S0 SELECTOR SWITCH STEERING CONTROL LOCAL-BRIDGE
-4S1 (WH/RD) NFU PUSH BUTTON PORT
-4S2 (WH/GN) NFU PUSH BUTTON STARBOARD

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 1
D-25436 Uetersen Ort :
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

0-100A
+ k -1P1 + A -
L -1T1
LED 100/1A l
-1H1 -1R1
- 70/30 W N

1 3 5 21 61
-2K1 -2K1
3.4 2 4 6 3.4 22 62
1 3
-1F4
2 4 6 2 4 6A 2 4

-1Q1 1 3 5 -1Q2 1 3
-1T2
2 4 1 3 1 3 5 220V 28V
11 400VA 150VA
-1F1 -1F2 -1F3 28V-L 5.0
4A 6A 14 2A 28V-N 5.0
1 3 2 4 2 4 6
7.2
L 3.0
L1 L2 L3 N 3.0
L1

L3 L2

RM17TA00 C 3.2
-1A1 D 3.2
7.4 14
7.4 12 11

-X0 L1 L2 L3 1 2 11 12 -X1 U V W 1 2 9 10 -X0 3 4

440V AC FOR RUDDER CTRL.

V U W 1 2 9 10
SHIP SUPPLY 440V 60Hz

SHIP SUPPLY 220V AC

3
M

38-59 kW
S6-25% HYDR. PUMP 2 THERMISTOR HEATING
HEATING

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
A -2F2 05.09.14 har Gepr. har Uetersener Maschinenfabrik Blatt 2
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

-2F1 6A
L L
2.9 4.0

2
1
N N
3

4
2.9 4.0

11
-3K1
4.4 12 14

43 03
-2K2 -2K2
3.7 44 3.7 04

A1 2.6 C T1 A1 A1
A1
-2K0 -2A1 -2K1 -2K2
A2 2.6
D A2 115A A2 A2 -X9 1 2 3 4
T2

FLOATING CONTACT

FLOATING CONTACT
PUMP ON SERVICE

PUMP ON SERVICE
7.1 13
21
14
22 7.2 14
12 11 2.4 1
3
2
4 4.3 13
21
14
22
7.5 31 32 7.2 2.4 5 6 7.3 31 32
2.4 13 7.4
7.2 43
03
44
04 6.1 21 14
22 3.8 43
03
44
04
2.7 53 54 3.8 53 54
7.1 61 62 7.0 61 62
2.7 71 72 7.6 71 72
8.2 83 84 7.8 83 84
4.7
Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 3
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
3.9 L
3.9 N

L N
2 Wago 787-1012
-3G1 24VDC/2,5A
+ -

Bridge
Local
2
-3S0
1 3 3S0 8.0

-X2 1 BRIDGE PANEL

PUMP CONTROL
(722160)
+PSP
-X2 1
13 13 13 13 +
13
-2K2 -3S1 -3S2 -2SH1 -2SH2 -2H1 LED
3.7 14 14 14 14 14
-
-X2 3 4 5 6 2

-3P1
h -X2 3 4 5 6 2
X1X2 83 3K1-A1 8.0

-2K2
+ + 3.7 84
A1 A1 B1
-3K0 -3H0 LED -3H1 LED -3K1 RHK-412B
-X10 + - A2 A2 B2
- - Start Stop
SOTERIA ALERT SYSTEM

7.2 14
12 11 3.3 14
12 11
7.2 24 3.3 24
22 21 7.1 22 21
SUPPLY FOR

7.1 34
(350600)

8.2 32 31
8.2 44
42 41

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 4
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
2.9 28V-L
2.9 28V-N

1 3
-4F0
6A 2 4
24V+ 6.0
+
-4V0 ~ ~
- 24V- 6.0

A1
+ -
-4K0
A2
E

12
7.5

7.2 14
12 11
Hydraulic Locking Alarm Logic
7.2 24
HLA951-V F

13
22 21 7.5

-A4 1 2 3 4 5 6

13 43 13 43 03 03
-4K1 -4K2 -4K1 -4K2
6.4 14 44 6.4 14 44 6.4 046.4 04
K

A
-4V1 -4V2

-X3 1 2 3 4 5 6 7 8

PUMP 2
-XK2 1 2 3 4 5 6 7 8
LIMIT SWITCH LIMIT SWITCH
1 SOLENID VALVE 1 SOLENID VALVE

-2Y1 -2S3 -2Y2 -2S4

PS 2 SB 2
1 3 4 1 3 4

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 5
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
24V+
5.9
13
-2K1 -X4
1
3.4 14

Bridge
Local RUDDER CONTROL C
2
-4S0
1 5 PS SB -

-X4 2 3 4

Bridge

Bridge
Local

Local
13 13 4 10
-4S1 -4S2 -4S0
14 14 3 7 9 13

-X4 11 13

LIMIT SWITCHES
-2S10 -2S11
PS SB

-X4 12 14
21 21
-4K2 -4K1
6.4 22 6.4 22
A1 A1
-4K1 -4K2
PS A2 SB A2

5.9 24V-
CAD-32BL CAD-32BL

5.2 13 14 5.4 13 14
6.4 21
31
22
32 6.4 21
31
22
32
43 44 43 44
5.2 03 04 5.5 03 04
5.6 5.6

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 6
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

OILFILTER CLOGGED
PUMP ON SERVICE

OIL TEMPERATURE
RUDDER CONTROL

STAND-BY START
PHASE FAILURE

HYDR. LOCKING
PUMP FAILURE

OIL LEVEL
OVERLOAD
FAILURE
Bridge

Bridge
Local

Local
6 12 E 25 71
5.9 -2K7 -2K2
5 7 11 15 8.4 3.7 72
-3S0 -4S0 -X3 9 26 28 11

Bridge
OIL LEVEL +

Local
TEMPERATURE
12 14 12 14 21 12 14 31 18 21 61
-4K0 -2A1 -2K2 -1A1 -2K2 -2K0 -2K2 -XK2 9 11
5.1 11 3.3 11 3.7 22 2.4 11 3.7 32 17 19 3.1 22 3.7 62
-4S0 1 1 3 4
-2S5 P -2S0 -2S8
53 13 53 12 14 2 2 5
-2K2 -2K0 -2K1 -3K0
3.7 54 3.1 14 3.4 54 4.2 11
-XK2 10 12 13
F
5.9
22 24 43
-3K1 -2K0 -X3 10 12 13
4.4 21 3.1 44

11
-1F2
2.3 14

-X10 1 2 3 4 5 6 7 8 9 10 11 12

TO SOTERIA ALERT SYSTEM

(350600)

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : = 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 7
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
L
4.0

Bridge
Local
4.9 3S0

10

9 11
-3S0
-X5 1 3

PUMP STARTER 1
31
-3K1 -X5 3
4.4 32 34
15
-2K7
8.4
16 18
-3K1

71 -2K1
-2K1
3.4 72
-X5 4

-X5 2 4

4.9 3K1-A1

A1
-2K7
A2
N
4.0

8.0 18
16
8.0 28 15
7.7 26
7.7 25

Datum 09.09.14
Bearb. HAR CONTACTOR CAB. HYDR. PUMP 2 HATLAPA Gruppe : 722927-44000
Gepr. har Uetersener Maschinenfabrik Blatt 8
D-25436 Uetersen Ort : +HP1
Zust. Änderung Datum Name Norm Urspr. 722923 Ers.f Ers.d von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

APPEARANCE

150

COLOUR: ALEXIT textured coating Z421

RAL 9005 Jet black satin gloss
ENCLOSURE: IP41

STEERING GEAR -1H1

-1SH1
(GN)
(WH)
HYDR. PUMP 1 ON SERVICE
HYDR. PUMP 1 START
-1SH2 (WH) HYDR. PUMP 1 STOP

HYDR. PUMP 1 HYDR. PUMP 2 -2H1 (GN) HYDR. PUMP 2 ON SERVICE

-2SH1 (WH) HYDR. PUMP 2 START
-2SH2 (WH) HYDR. PUMP 2 STOP
-1H1 -2H1

ON ON
SERVICE SERVICE -SH1 (WH) DIMMER / LAMP TEST

-1SH1 -2SH1
100

Hinweise:
START START -1SH2 und -2SH2 rote Schrift, mit Schutzklappe
-1SH1 und -2SH1 grüne Schrift

-1SH2 -SH1 -2SH2

DIMMER
STOP STOP
LAMP TEST

SCALE 1:1

Datum 30.06.10
Bearb. HSC
BRIDGE PANEL HYDR. PUMPS Gruppe : = 722160-44008
Gepr. har Blatt 1
Uetersener Maschinenfabrik Ort : +A
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 3 Bl.
 0 1 2 3 4 5 6 7 8 9

PATTERN OF DRILLING
150
135
120

ø5,5

32
PANEL CUT OUT

ø16,2

18
100
85
70

24
FLAT HEAD M5

32 43 43 SCALE 1:1

Datum 30.06.10
Bearb. HSC
BRIDGE PANEL HYDR. PUMPS Gruppe : = 722160-44008
Gepr. har Blatt 2
Uetersener Maschinenfabrik Ort : +A
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 3 Bl.
 0 1 2 3 4 5 6 7 8 9

PRINCIPAL WIRING
- - - - - - -

13 23 LED LED LED LED LED LED LED

-SH1 -1SH1 -1SH2 -1H1 -2SH1 -2SH2 -2H1
+ + + + + + +
14 24
-SH1

D1 L1 L2 D2 DIM1 DIM21 DIM22 DIM23

-x
DIMMER / LAMP TEST MODUL

+ - +24 IN1 IN2 IN3

K K
-V1 -V2
A A

13 13 13 13

-1SH1 14 -1SH2 14 -2SH1 14 -2SH2 14

-X1 1 2 3 4 5 6 -X2 1 2 3 4 5 6
24VDC

24VDC

+ - + -

CONTACTOR CABINET CONTACTOR CABINET

HYDR. PUMP 1 HYDR. PUMP 2

Datum 30.06.10
Bearb. HSC
BRIDGE PANEL HYDR. PUMPS Gruppe : = 722160-44008
Gepr. har Blatt 3
Uetersener Maschinenfabrik Ort : +A
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 3 Bl.
 0 1 2 3 4 5 6 7 8 9

430

400 210 354 mm

Ø9

SOTERIA alert system

steering gear
35

A12

A13
A14
A15
A16
A17
A18
A19
F1

F2

F3

F4
A11

Wago 750-1504
Wago 750-1504
Wago 750-837

Wago 750-626

Wago 750-517
Wago 750-517
Wago 750-517
Wago 750-600
475 mm
542,5

500
457,5

X1 X2 X3 X9 X10 X11

30 MOUNTING PLATE

25 25 CONTACTOR CABINET DETAILS:

350 CABLE GLANDS: 2x M30 13-21mm
THREAD M10
1x M25 9-17mm CABLE DIAMETER
9x M20 6-13mm CABLE DIAMETER
7x M20 closed with stopper
(optional using)
PROTECTION CLASS: IP 54
WEIGHT: 30kg
WIRES: HALOGEN FREE AND WITH MARKING

DATE 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 1
Uetersener Maschinenfabrik Ort : +A CONTACTOR CABINET LAYOUT
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

TOUCHPANEL

TOUCHPANEL

TOUCHPANEL
-F1 1 3 -F2 1 3 -F3 1 3 -F4 1 3

CABINET
BRIDGE

ECR

PLC
2A 2 4 2A 2 4 2A 2 4 2A 2 4

F1/24V /3.1
-A11

M
PE

USB
+24V

ETHERNET
Touch Panel
Beijer Electronics T7AM FreeCAN

CAN1 COM2

8
4
7
3
6
2
5
1
SUB-D male SUB-D female 750-837

24V 1
0V 5
+ 2
+ 6
- 3
- 7
PE 4
PE 8

0V SysOut
24V SysOut
0V
0V
24V
24V
0V In
24V In
SHLD
HIGH
LOW
GND

Tx+

GND
Tx-
Prog.-barer
123456789 123456789 Feldbus-
Controller CANopen
CAN-BUS PLUG DETAILS ON
SUBCON-PLUS-CAN PAGE 8 WAGO-I/O STOP
PHOENIX CONTACT
PART NO. 2744694 RUN
TX U U ~
K K 4CAN_H OVERFLOW
RX
-V1 -V2 3CAN_SHLD
A A
2CAN_L I/O
1CAN_GND USR

Versorgung
Interne
DIP SWITCH 1
ON

-X1 - -X2 -X10 -X11

12345678

ON
+ + - + - 1 2 3 S + - 1 2 3 S
750-626

Filtermodul
SUPPLY 24VDC FROM

SUPPLY 24VDC FROM

STARTER CABINET

STARTER CABINET
HYDR. PUMP 1

HYDR. PUMP 2

BRIDGEPANEL

BRIDGEPANEL

WAGO-I/O
SUPPLY FOR
(optional)

SUPPLY FOR
(optional)
ECR-PANEL

ECR-PANEL

-A12 -A13
CAN TO

CAN TO

SWITCH HAS TO BE IN UPPER POSITION

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 2
Uetersener Maschinenfabrik Ort : +A GENERAL
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0

Zust. Änderung
Datum
1

1 E0.0 /4.0 HP1 ON SERVICE

2 E0.1 /4.1 HP1 FAILURE

Name Norm
Gepr.
3 E0.2 /4.2 HP1 FEEDER FAILURE

-A14

Bearb.
4 E0.3 /4.3 HP1 OVERLOAD
5 E0.4 /4.4 HP1 PHASE FAILURE
6 E0.5 /4.5 HP1 HYDRAULIC LOCKING AL

har
HSC
7 E0.6 /4.5 HP1 OILFILTER CLOGGED
8 E0.7 /4.6 HP1 LOW SERVO OIL PRESSU

Datum 10.01.13
9 E0.8 /4.7 HP1 STAND-BY START
2

10 E0.9 /4.8 HP1 LOW OIL LEVEL

Digital

WAGO-I/O
750-1405

16-Kanal
11 E0.10/4.9 HP1 HIGH OIL TEMPERATURE
12 E0.11/6.0 SAFEMATIC FAILURE

Eingangsklemme

Urspr.
13 E0.12/6.2 RUDDER TORQUE REDUCED
14 E0.13/6.3 FAILURE GREASE PUMP
15 E0.14/6.5 LOW OIL LEVEL
16 E0.15/6.6 HIGH OILTEMPERATURE
1 E1.0 /5.0 HP2 ON SERVICE
2 E1.1 /5.1 HP2 FAILURE
3 E1.2 /5.2 HP2 FEEDER FAILURE

-A15
3

4 E1.3 /5.3 HP2 OVERLOAD

5 E1.4 /5.4 HP2 PHASE FAILURE

Ers.f
6 E1.5 /5.5 HP2 HYDRAULIC LOCKING AL
7 E1.6 /5.5 HP2 OILFILTER CLOGGED
8 E1.7 /5.6 HP2 LOW SERVO OIL PRESSU
9 E1.8 /5.7 HP2 STAND-BY START
10 E1.9 /5.8 HP2 LOW OIL LEVEL
Digital

WAGO-I/O
750-1405

16-Kanal

11 E1.10/5.9 HP2 HIGH OIL TEMPERATURE

12 E1.11/6.7 SPARE
Eingangsklemme

13 E1.12/6.9 SPARE

steering gear
contactor cabinet
14 E1.13
4

15 E1.14

Ers.d
16 E1.15

SOTERIA alert system

1 A0.0 /7.1 SHIP ALARM SYSTEM: WARNI
2 L
3 A

-A16
5 A0.1 /7.2 SHIP ALARM SYSTEM: HP1 C
6 L
750-517

2-Kanal
Digital

WAGO-I/O

7 A
5

1 A0.2 /7.4 SHIP ALARM SYSTEM: HP1 L

2 L
3 A

-A17
5 A0.3 /7.5 SHIP ALARM SYSTEM: HP2 C
6 L
750-517

2-Kanal
Digital

WAGO-I/O

7 A

1 A0.4 /7.7 SHIP ALARM SYSTEM: HP2 L

2 L
6

3 A
-A18

D-25436 Uetersen
5 A0.5 /7.8 SHIP ALARM SYSTEM: SPARE
6 L
750-517

2-Kanal
Digital

Uetersener Maschinenfabrik
WAGO-I/O

7 A
Ausgangsklemme Ausgangsklemme Ausgangsklemme

Ort
-A19

:
Gruppe :
7

+A
750-600

WAGO-I/O
Bus-Endklemme

PLC OVERWIEV
8

350600-44007

von 8
9

PAGE 3
Bl.
 0 1 2 3 4 5 6 7 8 9
/3.10 F1/24V F1/24V /5.1

-X1 1
NOT ALL ALARMS HAVE TO BE SUPPORTED

HYDR. PUMP 1
-XP1 1

-XP1 2 3 4 5 6 7 8 9 10 11 12

-X1 2 3 4 5 6 7 8 9 10 11 12

1 3 5 7 9 11

E0.0 /3.3 E0.2 /3.3 E0.4 /3.3 E0.6 /3.3 E0.8 /3.3 E0.10 /3.3

HP1 ON SERVICE HP1 FEEDER FAILURE HP1 PHASE FAILURE HP1 OILFILTER CLOGGED HP1 STAND-BY START HP1 HIGH OIL
TEMPERATURE

Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang

-A14 -A14 -A14 -A14 -A14 -A14

2 4 6 8 10

E0.1 /3.3 E0.3 /3.3 E0.5 /3.3 E0.7 /3.3 E0.9 /3.3

HP1 FAILURE HP1 OVERLOAD HP1 HYDRAULIC LOCKING HP1 LOW SERVO OIL HP1 LOW OIL LEVEL
ALARM PRESSURE

Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang

-A14 -A14 -A14 -A14 -A14

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 4
Uetersener Maschinenfabrik Ort : +A HYDRAULIC PUMP 1 INPUTS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
/4.10 F1/24V F1/24V /6.1

-X2 1
NOT ALL ALARMS HAVE TO BE SUPPORTED

HYDR. PUMP 2
-XP2 1

-XP2 2 3 4 5 6 7 8 9 10 11 12

-X2 2 3 4 5 6 7 8 9 10 11 12

1 3 5 7 9 11

E1.0 /3.4 E1.2 /3.4 E1.4 /3.4 E1.6 /3.4 E1.8 /3.4 E1.10 /3.4

HP2 ON SERVICE HP2 FEEDER FAILURE HP2 PHASE FAILURE HP2 OILFILTER CLOGGED HP2 STAND-BY START HP2 HIGH OIL
TEMPERATURE

Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang

-A15 -A15 -A15 -A15 -A15 -A15

2 4 6 8 10

E1.1 /3.4 E1.3 /3.4 E1.5 /3.4 E1.7 /3.4 E1.9 /3.4

HP2 FAILURE HP2 OVERLOAD HP2 HYDRAULIC LOCKING HP2 LOW SERVO OIL HP2 LOW OIL LEVEL
ALARM PRESSURE

Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang

-A15 -A15 -A15 -A15 -A15

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 5
Uetersener Maschinenfabrik Ort : +A HYDRAULIC PUMP 2 INPUTS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9
/5.10 F1/24V

-X3 1 11 21 23 31 33

SHOWN WITH EMPTY TANK

-XSM -XFP

GREASE PUMP
1 1

SAFEMATIC
ONLY IF AVAILABLE

ONLY IF AVAILABLE

ONLY IF AVAILABLE

ONLY IF AVAILABLE
BK 21

OIL TANK

OIL TANK
-S0 BN -S8 22

-XSM 2 3 -XFP 2

-X3 2 3 12 22 24 32 33

12 13 14 15 16 12 13

E0.11 /3.3 E0.12 /3.3 E0.13 /3.3 E0.14 /3.3 E0.15 /3.3 E1.11 /3.4 E1.12 /3.4

SAFEMATIC FAILURE RUDDER TORQUE REDUCED FAILURE GREASE PUMP LOW OIL LEVEL HIGH OILTEMPERATURE SPARE SPARE

Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang Digital Eingang

-A14 -A14 -A14 -A14 -A14 -A15 -A15

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 6
Uetersener Maschinenfabrik Ort : +A GENERAL INPUTS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

PRINCIPAL DRAWING OF RELAY OUTPUTS (WITH X9 JUMPER)

COMMON

-X9 1 2 3 4 5 6 7

PRINCIPAL DRAWING OF RELAY OUTPUTS (WITHOUT X9 JUMPER)

-X9 12 2 13 3 14 4 15 5 16 6 17 7

-A16 -A16 -A17 -A17 -A18 -A18

Digital Ausgang Digital Ausgang Digital Ausgang Digital Ausgang Digital Ausgang Digital Ausgang

SHIP ALARM SYSTEM: SHIP ALARM SYSTEM: HP1 SHIP ALARM SYSTEM: HP1 SHIP ALARM SYSTEM: HP2 SHIP ALARM SYSTEM: HP2 SHIP ALARM SYSTEM:
WARNING SYSTEM FAILURE COLLECTIVE ALARM LOW OIL LEVEL COLLECTIVE ALARM LOW OIL LEVEL SPARE

A0.0 /3.6 A0.1 /3.6 A0.2 /3.7 A0.3 /3.7 A0.4 /3.8 A0.5 /3.8
L
A

L
A

L
A

L
A

L
A

L
A
1 2 3 5 6 7 1 2 3 5 6 7 1 2 3 5 6 7

-X9 11 12 REMOVABLE JUMPER 13 14 15 16 17

-X9 1 2 3 4 5 6 7

SHIP ALARM SYSTEM

CONTACTS TO

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
A X9 JUMPER 27.08.14 HSC Gepr. har steering gear PAGE 7
Uetersener Maschinenfabrik Ort : +A SHIP ALARM SYSTEM
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

PARAMETERS:
SERIAL RS-422 PORT
FOR DATA-TRANSMISSION TO VDR
Baute rate: 4800
THE RS422-PORT IS AVAILABLE Data bits: 8
ON ALL TOUCH PANELS. Parity: none
(BRIDGE/ECR/CONTACTOR CABINET)
Stop bit: 1

HARDWARE DETAILS: PROTOCOL DETAILS:

RS-422-PORT (COM 2/4) TEXT TRANSMISSION (NMEA 0183 / VDR)

hydraulic pump X low servo oil pressure

talker identifier (P: Proprietary code)

hydraulic pump X high oil temperature

hydraulic pump X hydraulic locking
hydraulic pump X oilfilter clogged
HATLAPA Uetersener Maschinenfabrik

hydraulic pump X feeder failure

hydraulic pump X stand-by start

hydraulic pump X phase failure

hydraulic pump X low oil level

COM4 COM2

hydraulic pump X on service

hydraulic pump identifier

hydraulic pump X overload

total number of sentences

hydraulic pump X failure

sentence terminator
start of sentence

sentence number

checksum field
PIN NO. SIGNAL SIGNAL DIRECTION

STEERING GEAR
1
6
2
7 1 TxD+ OUTPUT

spare
spare
3
8 5 0V
4
9 6 TxD- OUTPUT
5
$PHUMSTG,2,1,1,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
D-SUB $PHUMSTG,2,2,2,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
9 PIN
FEMALE NOT ALL ALARMS HAVE TO BE SUPPORTED

Datum 10.01.13 contactor cabinet

Bearb. HSC SOTERIA alert system Gruppe : = 350600-44007
Gepr. har steering gear PAGE 8
Uetersener Maschinenfabrik Ort : +A VDR DATA TRANSMISSION
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 8 Bl.
 0 1 2 3 4 5 6 7 8 9

204

7
WEIGHT: 0,8kg
COM4 COM2 DC 24V PROTECTION CLASS: IP 65 (FRONT)
IP 20 (BACK)
65 CAN1

187
143

126
USB

DATE 03.03.14 alert display bridge

Bearb. HSC SOTERIA alert system Gruppe : = 344678-44007
Gepr. har steering gear PAGE 1
Uetersener Maschinenfabrik Ort : +A OUTER DIMENSIONS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

maximum thickness: 11mm

cut out 128 ±1

outline 143

cut out 189 ±1

55
space for plugs

outline 204

DATE 03.03.14 alert display bridge

Bearb. HSC SOTERIA alert system Gruppe : = 344678-44007
Gepr. har steering gear PAGE 2
Uetersener Maschinenfabrik Ort : +A CUT OUT DIMENSIONS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

CAN1-DETAILS
CONNECTOR DETAILS
CAN PORT
COMMUNICATION TO CONTACTOR CABINET
1
6
Baute rate: 125kbit/s 2
7
3
8
4
9 120 Ohm
5

D-SUB
CAN1 PORT ON DISPLAY 9 PIN
FEMALE

PIN NO. SIGNAL

5
9
4
8 2 CAN- SWITCH TO
3 "ON" POSITION
7 3 GND
2
6 7 CAN+
1 GND 1C- 1C+

D-SUB
9 PIN
MALE DON'T USE: 2C- AND 2C+

Datum 03.03.14 alert display bridge

Bearb. HSC SOTERIA alert system Gruppe : = 344678-44007
Gepr. har steering gear PAGE 3
Uetersener Maschinenfabrik Ort : +A CAN1 (COMMUNICATION)
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

COM2/4-DETAILS
PROTOCOL DETAILS:
TEXT TRANSMISSION (NMEA 0183 / VDR)
SERIAL RS-422 PORT
DATA-TRANSMISSION TO VDR

hydraulic pump X low servo oil pressure

talker identifier (P: Proprietary code)

hydraulic pump X high oil temperature

Baute rate: 4800

hydraulic pump X hydraulic locking

hydraulic pump X oilfilter clogged
HATLAPA Uetersener Maschinenfabrik
Data bits: 8

hydraulic pump X feeder failure

hydraulic pump X stand-by start

hydraulic pump X phase failure

hydraulic pump X low oil level

Parity: none

hydraulic pump X on service

Stop bit: 1

hydraulic pump identifier

hydraulic pump X overload

total number of sentences

hydraulic pump X failure

sentence terminator
COM2/4 SERIAL PORT ON DISPLAY (RS-422)

start of sentence

sentence number

checksum field
PIN NO. SIGNAL SIGNAL DIRECTION

STEERING GEAR
1
6
2
7 1 TxD+ OUTPUT

spare
spare
3
8 5 0V
4
9 6 TxD- OUTPUT
5
$PHUMSTG,2,1,1,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
D-SUB $PHUMSTG,2,2,2,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
9 PIN
FEMALE NOT ALL ALARMS HAVE TO BE SUPPORTED

Datum 03.03.14 alert display bridge

Bearb. HSC SOTERIA alert system Gruppe : = 344678-44007
Gepr. har steering gear PAGE 4
Uetersener Maschinenfabrik Ort : +A COM2 (VDR)
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

204

7
WEIGHT: 0,8kg
COM4 COM2 DC 24V PROTECTION CLASS: IP 65 (FRONT)
IP 20 (BACK)
65 CAN1

187
143

126
USB

DATE 03.03.14 alert display engine control room

Bearb. HSC SOTERIA alert system Gruppe : = 344677-44007
Gepr. har steering gear PAGE 1
Uetersener Maschinenfabrik Ort : +A OUTER DIMENSIONS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

maximum thickness: 11mm

cut out 128 ±1

outline 143

cut out 189 ±1

55
space for plugs

outline 204

DATE 03.03.14 alert display engine control room

Bearb. HSC SOTERIA alert system Gruppe : = 344677-44007
Gepr. har steering gear PAGE 2
Uetersener Maschinenfabrik Ort : +A CUT OUT DIMENSIONS
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

CAN1-DETAILS
CONNECTOR DETAILS
CAN PORT
COMMUNICATION TO CONTACTOR CABINET
1
6
Baute rate: 125kbit/s 2
7
3
8
4
9 120 Ohm
5

D-SUB
CAN1 PORT ON DISPLAY 9 PIN
FEMALE

PIN NO. SIGNAL

5
9
4
8 2 CAN- SWITCH TO
3 "ON" POSITION
7 3 GND
2
6 7 CAN+
1 GND 1C- 1C+

D-SUB
9 PIN
MALE DON'T USE: 2C- AND 2C+

Datum 03.03.14 alert display engine control room

Bearb. HSC SOTERIA alert system Gruppe : = 344677-44007
Gepr. har steering gear PAGE 3
Uetersener Maschinenfabrik Ort : +A CAN1 (COMMUNICATION)
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
 0 1 2 3 4 5 6 7 8 9

COM2/4-DETAILS
PROTOCOL DETAILS:
TEXT TRANSMISSION (NMEA 0183 / VDR)
SERIAL RS-422 PORT
DATA-TRANSMISSION TO VDR

hydraulic pump X low servo oil pressure

talker identifier (P: Proprietary code)

hydraulic pump X high oil temperature

Baute rate: 4800

hydraulic pump X hydraulic locking

hydraulic pump X oilfilter clogged
HATLAPA Uetersener Maschinenfabrik
Data bits: 8

hydraulic pump X feeder failure

hydraulic pump X stand-by start

hydraulic pump X phase failure

hydraulic pump X low oil level

Parity: none

hydraulic pump X on service

Stop bit: 1

hydraulic pump identifier

hydraulic pump X overload

total number of sentences

hydraulic pump X failure

sentence terminator
COM2/4 SERIAL PORT ON DISPLAY (RS-422)

start of sentence

sentence number

checksum field
PIN NO. SIGNAL SIGNAL DIRECTION

STEERING GEAR
1
6
2
7 1 TxD+ OUTPUT

spare
spare
3
8 5 0V
4
9 6 TxD- OUTPUT
5
$PHUMSTG,2,1,1,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
D-SUB $PHUMSTG,2,2,2,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>
9 PIN
FEMALE NOT ALL ALARMS HAVE TO BE SUPPORTED

Datum 03.03.14 alert display engine control room

Bearb. HSC SOTERIA alert system Gruppe : = 344677-44007
Gepr. har steering gear PAGE 4
Uetersener Maschinenfabrik Ort : +A COM2 (VDR)
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d D-25436 Uetersen von 4 Bl.
Section 7 Addition Information
• E-Motor

• High Pressure Hydraulic Pump

• Coupling

• Filter

• Wing Pump

• Alert System
 ADDITIONAL INFORMATION

Low and high voltage electric

motors
Edition: 50031142

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
1. FOREWORD
The installation, operation and maintenance of the motor must be always performed by qualified
personnel using proper tools and methods and following the instructions contained in the
documents supplied with the motor.

The instructions presented in this document are valid for WEG motors with the following characteristics:
Three-phase and single-phase induction motors (squirrel cage rotor);
J

Three-phase permanent magnet motors;

J

Three-phase hybrid motors (squirrel cage rotor + permanent magnets);

J

The objective of this manual is to provide important information, which must be considered during the
shipment, storage, installation, operation and maintenance of WEG motors. Therefore, we advise to make
a careful and detailed study of the instructions contained herein before performing any procedures on
the motor.

Electric motors have energized circuits and exposed rotating parts which may cause injuries to
people.

2. SHIPMENT, STORAGE AND HANDLING

Check the conditions of the motor immediately upon receipt. When any damage is noticed, this must be
reported in writing to the transportation company, and immediately communicated to the insurance company
and to WEG. In this case, no installation job can be started before the detected problem has been solved.
Check if the nameplate data matches the invoice data and the environmental conditions in which the motor
will be installed. If the motor is not immediately installed, it must be stored in a clean and dry room protected
against dust, vibrations, gases and corrosive agents, and with relative humidity not exceeding 60%.
In order to prevent water condensation within the motor during the storage period, it is recommended to
keep the space heater ON (where provided). In order to prevent oxidation of the bearings and ensure an even
distribution of the lubricant, rotate the motor shaft at least once a month (at least five turns), always leaving
it in a different position. For bearings with oil mist lubrication systems, the motor must be stored horizontally,
independently from the mounting configuration, with ISO VG 68 oil in the bearing, (the amount is indicated in
the motor manual available on the website www.weg.net) and the shaft must be turned weekly. If the motors
are stored for more than two years, it is recommended to change the bearings, or to remove, wash, inspect
and relubricate them before the motor is started. After this storage period, it is also recommended to change
the start capacitors of single-phase motors since they loss their operating characteristics.

Handle the motor always carefully in order to prevent impacts and damages to the bearings and
always install the shaft transportation/locking device (if supplied) when transporting the motor.
Use only the eyebolts to lift the motor. However these eyebolts are designed for the motor
weight only. Thus never use these eyebolts to lift the motor with additional loads coupled to it. The
lifting eyebolts of the terminal box, fan cover, etc., are intended to handle only these parts when
disassembled from the motor. Additional information regarding the maximum allowable angle-of-
inclination is indicated in the general manual available on the website www.weg.net.
3. INSTALLATION
During the installation, the motors must be protected against accidental energization.
Check the motor direction of rotation, turning it without load before it is coupled to the
load.

Motors must be only installed in places compatible with their mounting features and in applications and
environments for which they are intended.
Those motors with feet must be installed on bases duly planned in order to prevent vibrations and assure
perfect alignment. The motor shaft must be properly aligned with the shaft of the driven machine. Incorrect
alignment, as well as improper belt tension, will certainly damage the bearings, resulting in excessive
vibrations and even causing the shaft to rupture. The admissible shaft radial and axial loads indicated in the
general manual of the website must be respected. Use flexible coupling whenever possible.
When motors are fitted with oil lubricated bearings or oil mist lubrication systems, connect the cooling and
lubrication tubes (where provided). Only remove the corrosion protection grease from the shaft end and
flange immediately before the motor installation.
Unless specified otherwise in the purchase order, WEG motors are dynamically balanced with “half key” and
without load (uncoupled). The driving elements, such as pulleys, couplings, etc., must be balanced with
“half key” before they are mounted on the shaft of the motors.

Do not cover and block the motor ventilation openings. Ensure a minimum clearance of
¼ (25%) of the diameter of the air intake of the fan cover from the walls. The air used for
cooling the motor must be at ambient temperature, limited to the temperature indicated on
the motor nameplate.
Motors installed outdoors or in the vertical position require the use of additional shelter to protect
them from water; for instance, use of a drip cover.
To prevent accidents, ensure that the grounding connection has been performed according to the
applicable standards and that the shaft key has been securely fastened before the motor is started.
Connect the motor properly to the power supply by means of safe and permanent contacts, always
considering the data informed on the nameplate, such as rated voltage, wiring diagram, etc.

For power cables, switching and protection devices dimensioning, consider the rated motor current, the
service factor, and the cable length, among others. For motors without terminal block, insulate the motor
terminal cables by using insulating materials that are compatible with the insulation class informed on the
nameplate. The minimum insulation distance between the non-insulated live parts themselves and between
live parts and the grounding must be: 5.5 mm for rated voltage up to 690V; 8 mm for voltages up to 1.1kV;
45 mm for voltages up to 6.9kV; 70 mm for voltages up to 11kV and 105 mm for voltages up to 16.5kV.
In order to assure the degree of protection, unused cable inlet holes in the terminal
box must be properly closed with branking plugs having and equal or higher degree of
protection to that indicated on the motor nameplate.
The motor must be installed with overload protection devices. When motor is fitted with temperature-
monitoring devices, they must be connected during the operation and even during tests.
Ensure the correct operation of the accessories (brake, encoder, thermal protection, forced ventilation, etc.)
installed on the motor before it is started.

Motors fitted with Automatic Thermal Protectors will reset automatically as soon as
the motor cools down. Thus, do not use motors with Automatic Thermal Protection in
applications where the auto-reseting of this device may cause injuries to people or damage
to equipment. Motors fitted with Manual Thermal Protectors require manual reset after they trip. If
the Automatic Thermal Protector or the Manual Thermal Protector trip, disconnect the motor from
the power supply and investigate the cause of the thermal protector tripping. Wmagnet motors must
be driven by WEG variable frequency drives only.
4. OPERATION
During operation, do not touch the non-insulated energized parts and never touch or stay
too close to rotating parts.
Ensure that the space heater is always OFF during the motor operation.

The rated performance values and the operating conditions are specified on the motor nameplate. The
voltage and frequency variations of the power supply should never exceed the limits established in the
applicable standards.
Occasional different behavior during the normal operation (actuation of thermal protections, noise level,
vibration level, temperature and current increase) must always be assessed by qualified personnel. In case
of doubt, turn off the motor immediately and contact the nearest WEG service center.
Do not use roller bearings for direct coupling. Motors fitted with roller bearings require radial load to ensure
their proper operation.
For motors fitted with oil lubrication or oil mist systems, the cooling system must be ON even after the
machine is OFF and until the machine is at complete standstill.
After complete standstill, the cooling and lubrication systems (if any exist) must be switched OFF and the
space heaters must be switched ON.
 SPARE PARTS

Electric Motor
Type: SW22-132-200

Edition: 10.07.2012

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
     
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 Additional Information

High Pressure Pump

Type: QXM
Edition: 07.2005

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
Table of contents

Table of contents
1 Layout ...................................................................................................................................................... 2
2 About this document ............................................................................................................................. 3
2.1 Valid scope ............................................................................................................................................... 3
2.2 Warning labels and symbols .................................................................................................................... 3
3 Security ................................................................................................................................................... 4
3.1 Intended use............................................................................................................................................. 4
3.2 General safety instructions ....................................................................................................................... 4
4 Transport, storage and disposal .......................................................................................................... 6
4.1 Transport .................................................................................................................................................. 6
4.2 Preservation ............................................................................................................................................. 7
4.3 Storage ..................................................................................................................................................... 7
4.4 Remove the preservative ......................................................................................................................... 7
4.5 Disposal .................................................................................................................................................... 7
5 Setup and connection ............................................................................................................................ 8
5.1 Assembly .................................................................................................................................................. 8
5.2 Connecting the pipes ............................................................................................................................... 8
5.3 Install connection for leaking oil ............................................................................................................... 9
5.4 Connect the electrics ................................................................................................................................ 9
6 Operation ................................................................................................................................................ 9
6.1 Preparations for the initial start-up ........................................................................................................... 9
6.2 Start-up ..................................................................................................................................................... 9
6.3 Interrupting operation ............................................................................................................................. 10
6.4 Returning to operation ............................................................................................................................ 10
7 Maintenance.......................................................................................................................................... 11
7.1 Inspections ............................................................................................................................................. 11
7.2 Maintenance ........................................................................................................................................... 11
7.3 Returning the pump to the manufacturer ............................................................................................... 12
7.4 Assembly ................................................................................................................................................ 12
7.5 Ordering spare parts .............................................................................................................................. 12
8 Disturbance recovery........................................................................................................................... 12
8.1 QXM (drive) ............................................................................................................................................ 12
9 Run in cycle .......................................................................................................................................... 14

410.10.00.00 / VPZ / 07.2005 1

 Layout

1 Layout

Fig. QXM – high pressure pump

1 Pump shaft 4 Gear wheels 7 Plain bearing

2 Flange with radial shaft seal rings 5 Connection for leaking oil (optional) 8 Gear wheel housing 1
3 Antifriction bearing 6 Gear wheel housing 2 9 Housing

2 410.10.00.00 / VPZ / 07.2005

About this document

2 About this document

2.1 Valid scope

In this manual, all series, even the QXM

drive, will be generally called pumps.

This manual

x is part of the pump,

x applies to all of the pump series
mentioned above.
x describes safe and appropriate operation
during all operating phases.

2.2 Warning labels and symbols

Warninglabel Risk level Consequences of disregard
Immediate acute risk Fatal injury, grievous bodily
DANGER harm
Potential acute risk Fatal injury, grievous bodily
WARNING harm
Potentially hazardous situation Minor bodily harm, material
CAUTION damage
Tab. Warning labels and consequences of disregarding them

Symbol Meaning

Safety warning sign

¾ Take note of all information highlighted by the safety
warning sign and follow the instructions to avoid injury
or death.
¾ Instruction
1. , 2. , ... Multiple step instructions
9 Precondition
Ö Cross reference
Information, note
Tab. Symbols and their meaning

410.10.00.00 / VPZ / 07.2005 3

 Security

3 Security
3.2 General safety instructions
The manufacturer does not accept any
liability for damage resulting from disregard
of the entire documentation. Take note of the following instructions before
carrying out any work.

3.1 Intended use

3.2.1 Product safety

Ö Only use the pump to pump the agreed

liquids. The pump has been constructed using the latest
Ö Maintain operating limits and size- technology and accepted technical safety rules.
GHSHQGHQWPLQLPXPÀRZUDWH Nevertheless, operation of the pump can involve
Ö Do not allow to run dry. risk to life and health of the user or of third parties,
Damage occurs within a few seconds. or risk of damage to the pump and other property.
x Make certain that the pump is never
commissioned and never operated
without a pumped liquid. Ö The pump has been constructed using the
Ö Avoid cavitation: latest technology and accepted technical
x Maintain minimum pressure at pump safety rules. Nevertheless, operation of
input. the pump can involve risk to life and
Ö Avoid overheating: health of the user or of third parties, or
x Maintain permissible values of risk of damage to the pump and other
pressure, temperature, speed of property.
rotation and on-time. Ö Keep this manual and all other applicable
Ö Avoid damage to motor: documents complete, legible and
accessible to staff at all times.
x Do not open the pressure release
Ö Refrain from any procedures that would
valve beyond the agreed operating
endanger staff or third parties.
point.
Ö Should there be any safety-relevant fault,
Ö Consult with the manufacturer about any
deactivate the pump immediately and
other use of the pump.
have the fault corrected by responsible
personnel.
Ö In addition to the entire documentation for
the product, always comply with statutory
or other safety and accident- prevention
rules as well as with the applicable
standards and guidelines in the country
where the pump is operated.

4 410.10.00.00 / VPZ / 07.2005

Security

3.2.2 Operator´s obligations Safety installations

Safety-conscious operation Ö Provide the following safety installations

and verify their integrity:
Ö Only operate the pump if it is in perfect x for hot and moving parts: on-site
technical condition; only use it as protection against accidental contact
intended, staying aware of safety and with the pump,
risks, and adhering to the instructions in x LIHOHFWURVWDWLFFKDUJLQJLVSRVVLEOH¿W
this manual. appropriate earthing.
Ö Ensure that the following are observed
and monitored: Warranty
x adherence to intended use,
x statutory or other safety and Ö Obtain the manufacturer's approval prior
accident-prevention rules, WRFDUU\LQJRXWDQ\PRGL¿FDWLRQUHSDLURU
alterations during the warranty period.
x safety regulations governing the
Ö Only use original parts or parts that have
handling of hazardous substances,
been approved by the manufacturer.
x applicable standards and guidelines
in the country where the pump is
operated.
3.2.3 Duties of the operating staff
Ö Make protective equipment available.

Ö Observe and keep legible all instructions

Staff qualifications given on the pump, e.g. the arrow
indicating the direction of rotation and the
Ö Make certain that all personnel tasked PDUNLQJVIRUÀXLGFRQQHFWLRQV
with work on the pump have read and Ö Do not remove the protection against
understood this manual and all other accidental contact for hot, cold and
applicable documents, especially the moving parts during operation.
safety, maintenance and repair Ö Use protective equipment if necessary.
instructions, before they begin the job. Ö Carry out work on the pump only while the
Ö Organize responsibilities, who is in pump is not running.
FKDUJHRIDQ\VSHFL¿FGXW\DQGKRZ Ö Isolate the motor from its supply voltage
personnel is supervised. and keep it locked in that state while
Ö Ensure that all work is carried out by FDUU\LQJRXWDQ\¿WWLQJRUPDLQWHQDQFH
specialist technicians only: work.
x ¿tting, repair and maintenance work, Ö Mount the safety installations on the
x work on the pump electrical system. pump according to regulations after
Ö Make certain that trainee personnel may completion of work on the pump.
only work on the pump when supervised
by a specialist technician.

410.10.00.00 / VPZ / 07.2005 5

 Transport, storage and disposal

4 Transport, storage and

disposal
4.1 Transport
4.1.1 Unpacking and inspection on delivery

1. Unpack the pump on delivery and inspect

for transport damage.
2. Report any transport damage to the
manufacturer without delay.
3. Dispose of packaging material according
to local regulations.

4.1.2 Lifting

DANGER
Death or crushed limbs caused by falling
loads!
¾ Use lifting gear appropriate for the total
weight to be lifted.
¾ Fasten the lifting gear as shown in the
illustrations below.
¾ Do not stand under suspended loads.

Fig. Fastening the lifting gear to the pump

1. If only one thread is available for eye bolt,

put the second sling around the end of the
pump.
2. Lift the pump properly.

6 410.10.00.00 / VPZ / 07.2005

Transport, storage and disposal

4.2 Preservation
4.4 Remove the preservative
Only necessary when storing.
CAUTION
CAUTION Damage to seals through incorrect cleaning
Material damage due to improper agent!
preservation! ¾ Ensure that the cleaning agent does not
¾ Preserve the pump properly inside and out attack the seals.
for storage.
1. Select the cleaning agent according to the
1. Select preservative according to the type area of use.
and duration of storage. 2. Dispose of preservative according to local
2. 8VHWKHSUHVHUYDWLYHDVVSHFL¿HGE\WKH regulations.
manufacturer.
3. Apply the preservative to all bare metal
surfaces inside and out. 4.5 Disposal

4.3 Storage WARNING

Risk of poisoning and environmental damage
caused by pumped liquid or oil!
CAUTION ¾ Use protective equipment when carrying out
Material damage due to inappropriate any work on the pump.
storage! ¾ Prior to disposal of the pump:
¾ Preserve and store the pump properly. x Collect pumped liquid and oil or grease
which drain out and dispose of
separately according to local
1. 6HDODOORSHQLQJVZLWKEODQNÀDQJHVEOLQG regulations.
plugs or plastic covers. x Neutralise residues of pumped liquid in
2. Make certain that the storage room meets the pump.
the following conditions: x Remove the preservative.
x dry ¾ Dismount plastic parts and dispose of the
x frost-free parts according to local regulations.
x vibrationfree
3. Turn shaft once a month.
4. Make certain that the shaft and the Ö Dispose of pump according to local
bearing change their rotational position in regulations.
the process.

410.10.00.00 / VPZ / 07.2005 7

 Setup and connection

5 Setup and connection 5.2 Connecting the pipes

5.1 Assembly CAUTION

Damage due to impurities in the pump!
¾ Ensure that no impurities can get into the
CAUTION pump.
Material damage caused by knocks and
blows!
¾ Do not cant the coupling halves when
sliding on. 5.2.1 Install the suction pipe
¾ Do not knock or hit any component of the
pump.
1. Remove transport and sealing covers
Material damage by recoil force of the from the pump.
coupling! 2. Avoid air pockets: Run pipes with a
¾ Connect the shaft and the motor with continuous slope up to the pump.
< 0.2 mm misalignment. 3. Ensure that no gaskets protrude inwards.
4. For hydraulic systems: Connect the
Material damage due to axial forces! suction pipe to the tank a few cm below
¾ Only operate the pump with direct drive and the minimum liquid level.
elastic coupling.
5.2.2 Install the pressure pipe
1. Use coupling with H7 tolerance on the
coupling bore. 1. Remove transport and sealing covers
2. Apply DYHU\WKLQ¿OPRI molybdenum from the pump.
disulphide. 2. Fit the pressure pipe.
(e.g. Molykote) on the pump and motor 3. Ensure that no gaskets protrude inwards.
shaft ends.
3. ,QVHUW¿WWLQJNH\V
4. Without mounting device: Remove rubber 5.2.3 Check that pipe connections are stress-
buffers and heat coupling halves to free
approx. 100 °C.
9 Pipe installed and cooled down
5. Slide on the pump-side and motor-side
coupling halves until the shaft ends and
1. 6HSDUDWHWKHFRQQHFWLQJÀDQJHVRIWKH
WKHFRXSOLQJFHQWUHDUHÀXVKZLWKHDFK
pipes from the pump.
other. Keep the VSHFL¿HGGLVWDQFH
2. Check that pipes can move freely in all
between the coupling halves.
directions they might be expected to
6. Tighten the grub screws on both coupling
expand.
halves.
3. 0DNHFHUWDLQWKDWWKHÀDQJHVXUIDFHVDUH
parallel.
4. 5HFRQQHFWWKHSLSHÀDQJHVWRWKHSXPS

8 410.10.00.00 / VPZ / 07.2005

Operation

5.3 Install connection for leaking oil

6 Operation
¾ Install connection for leaking oil with
VFUHZLQ¿WWLQJRQWKHSXPS 6.1 Preparations for the initial start-
up
5.4 Connect the electrics 6.1.1 Fill the system

DANGER CAUTION
Risk of fatal injury through electric shock! Damage caused by running dry!
¾ Have all electrical work carried out by ¾ 0DNHFHUWDLQWKDWWKHSXPSLVSURSHUO\¿OOHG
TXDOL¿HGelectricians only. ¾ When operating pump: Ensure minimum
liquid level in tank.
Risk of fatal injury due to rotating parts!
¾ When carrying RXWDQ\¿WWLQJRU
maintenance work, isolate the motor from its 1. Fill the pump and the suction pipe with
supply voltage and keep it locked in that pumped liquid.
state.
Fill the pump and suction pipe with pumped
liquid by turning the pump by hand or by
DANGER pulsing the drive (recommended).

2. Switch motor on and pressurise pumped

OLTXLGZLWK”EDU (consult manufacturer
5.4.1 Connect the motor for higher pressure).
3. Ensure that no joints or connections leak.

Follow the manufacturer's instructions. 6.1.2 Check the connection for leaking oil
¾ Collect leaking oil with < 1,5 bar absolute
1. Connect the motor according to the circuit in tank.
diagram.
2. Ensure that the electrical energy does not
present any risk. 6.2 Start-up
3. Install an EMERGENCY OFF switch.
6.2.1 Switch on

5.4.2 Check the direction of rotation 9 The pump is correctly installed and
connected
9 The motor is correctly installed and
CAUTION 9
connected
All connections are stress-free and leak-
Damage caused by running dry!
free
¾ Decouple the motor from the pump.
9 $OOVDIHW\LQVWDOODWLRQVKDYHEHHQ¿WWHG
and tested for integrity
9 The pump has been correctly prepared,
As default setting, the pump rotates
clockwise. Anti-clockwise is also possible. ¿lled and bled

1. Switch motor on and immediately off

again.
2. Check that the motor's direction of
rotation corresponds to the arrow showing
the direction of rotation on the pump.
3. If the direction of rotation is different:
swap two phases.
4. Recouple the motor to the pump.

410.10.00.00 / VPZ / 07.2005 9

 Operation

CAUTION 6.3 Interrupting operation

Damage caused by running dry!
¾ Make FHUWDLQWKDWWKHSXPSLVSURSHUO\¿OOHG
¾ Ensure minimum liquid level in tank.
WARNING
Damage through cavitation! Risk of injury and poisoning due to
¾ To bleed the pump operate pressure free. hazardous pumped liquids!
¾ Only pressurise pumped liquid that has ¾ Safely collect any leaking pumped liquid
been completely bled. and dispose of it in accordance with
environmental rules and requirements.
Damage caused by temperature shock!
¾ Ensure that the temperature difference
between the pump and the pumped liquid is ¾ Carry out the following measures when
< 25 °C. operation is interrupted:

Pump is Action
1. Note run-in cycle … emptied ¾ Close stop valves on
2. Switch on the motor and check that it runs both sides of pump.
smoothly. … disassembled ¾ Isolate the motor from
3. $IWHUWKH¿UVWVWDUWVZLWFKWKHSXPSRII its power supply and
and wait until there are no more air … put into Pump
pockets in the pumped liquid. storage ¾ preserve
4. Switch motor on and pressurise pumped ¾ store
OLTXLGZLWK”EDU Tab. Action to be taken for operational
(consult manufacturer for higher interruptions
pressure).
5. After the initial stress caused by pressure
and operating temperature, check that the 6.4 Returning to operation
pump is not leaking.
6. ,QFUHDVHWKHSUHVVXUHDVVSHFL¿HGLn the 1. After shutdowns, take the following
run-in cycle. actions before restarting the pump:
7. After the initial stress caused by pressure
and operating temperature, check that the Shutdown Action
pump is not leaking. duration
> 6 month ¾ Other pumps: Replace
6.2.2 Switch off shaft seal with repair
> 2 years ¾ Return pumps to
manufacturer.
WARNING Tab. Actions to be taken after prolonged
Risk of injury caused by hot pump parts! shutdown periods
¾ Use protective equipment when carrying out
any work on the pump. 2. Carry out all steps as for the initial start-
up.

1. Switch the control to circulate to the tank.

2. Switch off the motor.
3. &KHFNDOO¿[LQJEROWVDQGWLJKWHQLI
necessary.

10 410.10.00.00 / VPZ / 07.2005

Maintenance

7 Maintenance 7.2 Maintenance

Trained service technicians are available for DANGER

¿WWLQJDQGUHSDLUMREV Risk of fatal injury through electric shock!
¾ Have all electrical work carried out by TXDOL¿HG
electricians only.
7.1 Inspections
The inspection intervals depend on the load
placed on the pump. WARNING
Risk of injury and poisoning due to
hazardous or hot pumped liquids!
WARNING ¾ Use protective equipment when carrying out
Risk of injury and poisoning due to any work on the pump.
hazardous pumped liquids! ¾ Allow the pump to cool down completely
Use protective equipment when carrying before commencing any work.
out any work on the pump. ¾ Make certain that the pump is
unpressurised.
¾ Empty the pump, safely collect the pumped
1. Check at appropriate intervals: liquid and dis- pose of it in accordance with
¾ FRPSOLDQFHZLWKPLQLPXPÀRZUDWH environmental rules and requirements.
¾ normal operating conditions
unchanged
¾ for hydraulic systems: check liquid
level in tank and check hydraulic
CAUTION
liquid for viscosity, ageing and conta- Damage due to disassembly of the pump!
mination ¾ Do not take the pump to pieces.
¾ coupling alignment and condition of ¾ Return faulty pumps to the manufacturer.
elastic elements
2. For trouble-free operation, always ensure
the following: For QXM pump, only the repair set can be
¾ no dry running replaced
¾ no leaks
¾ no cavitation
7.2.1 Antifriction bearing
¾ suction-side gate valves open
¾ XQREVWUXFWHGDQGFOHDQ¿OWHUV Faulty antifriction bearings increase noise
¾ VXI¿FLHQWVXSSO\SUHVVXUH levels, torque or temperature.
¾ no unusual running noises and
vibrations ¾ Return pumps with faulty bearings to the
¾ proper functioning of auxiliary manufacturer
operating systems
¾ proper functioning of auxiliary
operating systems

410.10.00.00 / VPZ / 07.2005 11

 Disturbance recovery

7.2.2 Replace radial shaft seal ring 7.4 Assembly

5HSODFHFRYHUÀDQJHZLWKIDXOW\UDGLDOVKDIW 1. .HHSWRVSHFL¿HGWRUTXH
seal ring with repair set. 2. Fit the pump into the system.

1. Remove pump from system.

2. 5HPRYH¿WWLQJNH\IURPSXPSVKDIW 7.5 Ordering spare parts
3. Remove cheese head bolts from
FRYHUÀDQJH For trouble-free replacement in case of any
4. 3XOORIIFRYHUÀDQJHZLWKROGUDGLDOVKDIW damage we recommend keeping
seal ring from shaft. replacement pumps or spare parts available
5. Grease pump shaft. on site
6. 6OLGHUHSDLUVHWRQWRVKDIWDQG¿[LQSODFH
with cheese head bolts. ¾ To order spare parts keep the pump type
7. )LW¿WWLQJNH\LQWRSXPSVKDIW ready.

7.3 Returning the pump to the 8 Disturbance recovery

manufacturer
9 Pump is unpressurised
9 Pump is completely empty
9 Electrical connections are isolated and
8.1 QXM (drive)
the motor is secured against switch-on For faults that do not appear in the following table
9 Pump has cooled down or faults that cannot be traced back to the
9 Coupling guard has been removed suggested causes, please consult with the
9 For couplings with a spacer: Spacer has manufacturer.
been removed
9 Auxiliary operating systems are shut 3RVVLEOHIDXOWVDUHLGHQWL¿HGE\DIDXOWQXPEHULQ
down, unpressurised and emptied WKHWDEOHEHORZ8VHWKLVQXPEHUWR¿QGWKHFDXVH
9 Manometer connections, manometer and and remedy in the troubleshooting list.
¿[WXUHVKDYHEHHQUHPRYHG
 Fault Number
1. Flush the pump and decontaminate if Drive does not start 1
hazardous liquid has been pumped. Drive rotates too slowly 2
2. Return the complete pump (not
disassembled) to the manufacturer. Drive rotates too quickly 3
,QVXI¿FLHQWWRUTXH 4
,QVXI¿FLHQWSRZHUGHOLYHUHG 5
Drive is leaking 6
Tab. Assignment of fault numbers QXM (drive)

12 410.10.00.00 / VPZ / 07.2005

Disturbance recovery

Fault number Cause Remedy

1 2 3 4 5 6
X – – – – – Transport and sealing cover not ¾ Remove transport and sealing cover.
removed ¾ If damage caused by running dry,
return to the manufacturer.
X – – – – – Supply and/or pressure line closed by ¾ Open valve.
valve
X – – – – – Coupling destroyed ¾ Replace coupling.
X X – X – – Rotational speed too low or start up ¾ Compare required rotational speed of
torque too high drive with type plate. Replace motor if
necessary.
¾ Increase motor speed, if speed control
available.
– X – X – – Supply/drain pipe not fully opened ¾ Open armature.
– X – X – – Faulty control ¾ Repair control.
X X – X – X Supply/drain pipe, drive blocked or ¾ Clean supply/drain pipe, drive.
encrusted
– X – X – X Supply/drain pipe cross-section too ¾ Increase cross-section.
narrow
– X – X – X Hydraulic components of the pump ¾ Return drive to manufacturer.
dirty, clotted or encrusted
X X – X – X Excessive amount of gas ¾ Consult with manufacturer.
– X – X – – Viscosity or density of the pumped ¾ Consult with manufacturer.
OLTXLGRXWVLGHWKHVSHFL¿HGUDQJHIRU
the drive
– X – X – X Temperature of pumped liquid too high ¾ Lower temperature.
¾ Inquire with manufacturer.
X X – X – X Drive rotates in wrong direction ¾ Exchange connections for supply and
drain pipes.
– X – X – X Pump components worn ¾ Return pump to manufacturer.
– – X – X X Excessive supply ¾ Compare required rotational speed of
drive with type plate. Replace motor if
necessary.
¾ Reduce supply.
¾ Reduce motor speed with speed
control, if available.
– – – – – X Drive distorted ¾ Check pipe connections and drive
¿[LQJV
– – – – – X Worn coupling ¾ Replace coupling.
Tab. Fault table – QXM (drive)

410.10.00.00 / VPZ / 07.2005 13

 Run in cycle

9 Run in cycle

Fig. Run-in cycle QXM – overall run-in time 10 minutes

x time [min]
y working pressure [%]

14 410.10.00.00 / VPZ / 07.2005

 SPARE PARTS

Internal Gear Pump

Type: QXM63-080N66, QXM63-100N66

Article: 670463, 118825

Edition: 03.2012

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
670463, 118825 Ersatzteilliste Spare Parts List
Innenzahnradpumpe Internal Gear Pump

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1. Reparatursatz shaft seal repare kit 1

1.01. Anbauflansch mounting flange 1

1.02. Wellendichtring shaft seal repare kit 2

1.03. Stützring thrust ring 1

1.04. O-Ring o-ring 1

2. Passfeder key 1

3. Lagersatz ball bearing kit 1

3.01. Kugellager ball bearing 1

3.02. Stützscheibe thrust washer 1

3.03. Sicherungsring circlip 1

4. O-Ring o-ring 2

5. O-Ring o-ring 1

6. Zylinderstift cylindrical pin 4

7. Scheibe washer 4

8. Zylinderschraube hexagon socket head cap screw 4

9. Zylinderschraube hexagon socket head cap screw 4

10. Zylinderschraube hexagon socket head cap screw 2

670463+118825 12.12.2014 1/1

 Repair kit complete

Internal Gear Pump

Type: QXM
Edition: 04.2011

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 Motor type
Pos. QTY Description
QXM23-…N66 QXM33-…N66 QXM43-…N66 QXM53-…N66 QXM63-…N66
Best-Nr.
- 1 Repair kit complete
100747683 100747684 100747685 100747686 100747689
contain Best-Nr.
1. 1 Repair kit 100116673 100116674 100116209 100116675 100116676
1.1 1 Flange
1.2 2 Shaft seal
1.3 1 O-ring
1.4 1 Spacer
2. 1 O-ring set 1001330861 1001330371 1001330381 1001330391 1001330401
2.1 1 O-ring
2.2 2 O-ring
2.3 1 O-ring
 ADDITIONAL INFORMATION

Torsionally Flexible Jaw-Type

Coupling
Design: No.001 shaft coupling
Edition: 18

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 1 Technical data

®
Illustration 3: ROTEX (material: steel)

Table 3: Material steel

1) 3)
Spider (component 2) Dimensions [mm]
Com- rated torque [Nm] 2) General
Size Finish bore
ponent 4)
92 Sh A 98 Sh A 64 Sh D d (min-max) L l1; l2 E b s DH DZ DZ1 dH D N
1a 35 11
14 7.5 12.5 16 0 - 16 13 10 1.5 30 - - 10 30 -
1b 50 18.5
1a 66 25
19 10 17 21 0 - 25 16 12 2.0 40 - - 18 40 -
1b 90 37
1a 78 30
24 35 60 75 0 - 35 18 14 2.0 55 - - 27 55 -
1b 118 50
1a 90 35
28 95 160 200 0 - 40 20 15 2.5 65 - - 30 65 -
1b 140 60
1 114 45 70 27
38 190 325 405 0 - 48 24 18 3.0 80 - - 38
1b 164 70 80 -
1 126 50 85 28
42 265 450 560 0 - 55 26 20 3.0 95 - - 46
1b 176 75 95 -
1 140 56 95 32
48 310 525 655 0 - 62 28 21 3.5 105 - - 51
1b 188 80 105 -
1 160 65 110 37
55 410 685 825 0 - 74 30 22 4.0 120 - - 60
1b 210 90 120 -
1 185 75 115 47
65 625 940 1175 0 - 80 35 26 4.5 135 - - 68
1b 235 100 135 -
1 210 85 135 53
75 1280 1920 2400 0 - 95 40 30 5.0 160 - - 80
1b 260 110 160 -
1 245 100 160 62
90 2400 3600 4500 0 - 110 45 34 5.5 200 218 230 100
1b 295 125 200 -

1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and thread for setscrew
3) For dimensions G and t see table 6; threads for setscrews are located opposite the keyway with material Al-D and on the keyway with
material EN-GJL-250/EN-GJS-400-15
4) DZ1 = internal diameter of housing
2 Advice

2.4 General hazard warnings

DANGER!
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by ro-
tating parts. Please make absolutely sure to read through and observe the following safety
indications.
All operations on and with the coupling have to be performed taking into account "safety first".
Please make sure to switch off the power pack before you perform your work on the coupling.
Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
Do not touch the operation area of the coupling as long as it is in operation.
Please secure the coupling against accidental contact. Please provide for the necessary protection devices
and covers.

2.5 Intended use

You may only assemble, operate and maintain the coupling if you
have carefully read through the assembly instructions and understood them
had technical training
are authorized by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1). Unauthorized
modifications on the coupling design are not admissible. We will not assume liability for any damage that may
arise. In the interest of further development we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these assembly in-
structions.

3 Storage

The coupling hubs are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable stock con-
ditions.

CAUTION!
! The storage rooms may not include any ozone-generating devices like e. g. fluorescent light
sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.

4 Assembly

Generally the coupling is supplied in individual parts. Before assembly the coupling has to be inspected for com-
pleteness.
4 Assembly

4.1 Components of the couplings

Components of ROTEX®, shaft coupling type No. 001

Compo- Quantity Description
nent
1 2 Hub
2 1 Spider 1)
3 5 2) DZ elements 1)
Setscrews
4 2
DIN EN ISO 4029
1) Optionally spider or DZ elements
2) With size 180 the quantity is 6.

Illustration
®
6: ROTEX

Features of the standard spiders

92 Shore-A 95/98 Shore-A 64 Shore-D
Spider hardness ® ® ®
T-PUR PUR T-PUR PUR T-PUR PUR
(Shore) 1)
(orange) (yellow) (purple) (red) (light green) (natural white )

Marking
(colour)

1) Natural white with green marking of teeth

4 Assembly

4.2 Advice for finish bore

DANGER!
STOP The maximum permissible bore diameters d (see table 1
to 5 in chapter 1 - technical data) must not be exceeded. If
these figures are disregarded, the coupling may tear. Ro-
tating particles may cause danger to life.

Hub bores machined by the customer have to observe

concentricity or axial runout, respectively (see illustration
9).
Please make absolutely sure to observe the figures for
Ø dmax.
Carefully align the hubs when the finish bores are drilled.
Please provide for a setscrew according to
DIN EN ISO 4029 with a cup point or an end plate to fasten
the hubs axially. Illustration 9: Concentricity and axial runout

Table 6: Setscrews DIN EN ISO 4029

Size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Dimension G M4 M5 M5 M8 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20
Dimension t 5 10 10 15 15 20 20 20 20 25 30 30 35 40 45 50 50
Tightening
1.5 2 2 10 10 10 10 17 17 17 40 40 80 80 140 140 140
torque TA [Nm]

Table 7: Recommended fit pairs acc. to DIN 748/1

Bore [mm]
Shaft tolerance Bore tolerance
above up to
50 k6 H7
50 m6 (KTR standard)

If a feather key is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR standard)
with normal operating conditions or ISO P9 with difficult operating conditions (frequently alternating torsional di-
rection, shock loads, etc.). The keyway should preferably be located between the cams. For the axial fastening by
setscrews the tapping should be located on the keyway with the exception of Al-D which should be located oppo-
site to the keyway.

The transmittable torque of the shaft/hub connection must be reviewed by the customer and is subject to his re-
sponsibility.
4 Assembly

4.3 Assembly of the hubs

ATTENTION!
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.

Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.

WARNING!
Please pay attention to the ignition risk in hazardous locations!

DANGER!
STOP Touching the heated hubs causes burns.
Please wear safety gloves.

CAUTION!
! With the assembly please make sure that the distance dimension E (see table 1 to 5) is ob-
served to allow for axial clearance of the spider when in operation.
Disregarding this advice may cause damage to the coupling.

Mount the hubs on the shaft of driving and driven side (see illustration 10).
Insert the spider or DZ elements into the cam section of the hub on the driving or driven side.
Shift the power packs in axial direction until the distance dimension E is achieved (see illustration 11).
If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting the
distance dimension E.
Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see table 6).

ATTENTION!
If the shaft diameters with inserted feather key are smaller than the dimension dH (see table
1 to 5) of the spider, one or two shaft ends may protude into the spider.

Illustration 10: Assembly of the hubs Illustration 11: Coupling assembly

4 Assembly

4.5 Displacements - alignment of the couplings

Table 9: Displacement figures for 92 and 95/98 Shore-A

®
ROTEX size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Max. axial displacement Ka -0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5 -3.0
[mm] +1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4
Max. radial 1500 rpm 0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48 0.50 0.52 0.55 0.60 0.62 0.64 0.68
displacement
Kr [mm] with 3000 rpm 0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32 0.34 0.36 0.38 - - - -
Kw [degree] 1.2 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.2 1.2 1.3 1.3 1.2 1.2 1.2
max. angular displacement
with n=1500 rpm
0.67 0.82 0.85 1.05 1.35 1.70 2.00 2.30 2.70 3.30 4.30 4.80 5.60 6.50 6.60 7.60 9.00
Kw [mm]
Kw [degree] 1.1 1.1 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2 - - - -
max. angular displacement
with n=3000 rpm
0.60 0.70 0.75 0.85 1.10 1.40 1.60 2.00 2.30 2.90 3.80 4.20 5.00 - - - -
Kw [mm]

Table 10: Displacement figures for 64 Shore-D

®
ROTEX size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Max. axial displacement Ka -0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5 -3.0
[mm] +1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4
Max. radial 1500 rpm 0.11 0.13 0.15 0.18 0.21 0.23 0.25 0.27 0.30 0.34 0.36 0.37 0.40 0.43 0.45 0.46 0.49
displacement
Kr [mm] with 3000 rpm 0.08 0.09 0.10 0.13 0.15 0.16 0.18 0.19 0.21 0.24 0.25 0.26 0.28 - - - -
Kw [degree] 1.1 1.1 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2 1.2 1.1 1.1 1.1
max. angular displacement
with n=1500 rpm
0.57 0.77 0.77 0.90 1.25 1.40 1.80 2.00 2.50 3.00 3.80 4.30 5.30 6.00 6.10 7.10 8.00
Kw [mm]
Kw [degree] 1.0 1.0 0.7 0.7 0.8 0.8 0.9 0.9 1.0 1.0 1.0 1.0 1.1 - - - -
max. angular displacement
with n=3000 rpm
0.52 0.70 0.67 0.80 1.00 1.30 1.60 1.80 2.20 2.70 3.50 4.00 4.90 - - - -
Kw [mm]
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

Type Hub design Sizes Material

1.0, 1.1, 1.3 38 - 90 Cast iron (GJL)
Standard 1a (large hub) 100 - 180 Nodular iron (GJS)
001
clamping set 4.1, 4.2, 4.3 14 - 180

Clamping hub 2.0, 2.1, 2.3 19 - 180 Steel

WARNING!
Clamping hubs without feather key may be used in category 3 only.

5.1 Intended use in hazardous locations

Conditions of operation in hazardous locations

ROTEX® couplings are suitable for the use according to EC directive 94/9/EC.

1. Industry (with the exception of mining)

Equipment group II of category 2 and 3 (coupling is not approved for equipment group 1)

Media class G (gases, fogs, steams), zone 1 and 2 (coupling is not approved for zone 0)

Media class D (dusts), zone 21 and 22 (coupling is not approved for zone 20)

Explosion group IIC (explosion class IIA and IIB are included in IIC)

Temperature class:
T-PUR® PUR
Ambient or operat- Max. surface tem- Ambient or operat- Max. surface tem-
Temperature class Temperature class
ing temperature Ta perature ing temperature Ta perature
- 50 °C to 2) - 30 °C to 2)
T3, T2, T1 1) + 140 °C T4, T3, T2, T1 1) + 110 °C
+ 120 °C + 90 °C
T4 - 50 °C to + 115 °C + 135 °C T5 - 30 °C to + 80 °C + 100 °C
T5 - 50 °C to + 80 °C + 100 °C T6 - 30 °C to + 65 °C + 85 °C
T6 - 50 °C to + 65 °C + 85 °C
Explanation:
The maximum surface temperatures result from each the maximum permissible ambient or operating temperature Ta plus the maximum tem-
perature increase T of 20 K which has to be taken into account.
®
1) The ambient or operating temperature Ta is limited to + 90 °C (valid for T-PUR only: + 120 °C) due to the permissible permanent operat-
ing temperature of the elastomers used.
®
2) The maximum surface temperature of + 110 °C (valid for T-PUR only: + 140 °C) applies for the use in locations which are potentially
subject to dust explosion, too.

2. Mining
Equipment group I of category M2 (coupling is not approved for equipment group M1).
Permissible ambient temperature - 30 °C to + 90 °C (valid for T-PUR® only: - 50 °C to + 120 °C).
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.2 Inspection intervals for couplings in hazardous locations

Explosion group Inspection intervals

For couplings which are classified in category 3G or 3D the operating and assembly instructions
that are usual for standard operation apply. During the standard operation which has to be sub-
3G ject to the ignition risk analysis the couplings are free from any ignition source. Merely the tem-
3D perature increase produced by self-heating and depending on the coupling type has to be con-
sidered: for ROTEX®: T = 20 K
An inspection of the torsional backlash and a visual inspection of the flexible spider/DZ ele-
ments must performed after 3,000 operating hours for the first time, at the latest after 6 months
after start-up of the coupling.
If you note insignificant or no wear on the spider/DZ elements upon this initial inspection, further
II 2GD c IIB inspections can each be performed after 6,000 operating hours or at the latest after 18 months,
T4, T5, T6 provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable to
replace the spider/DZ elements, please find out the cause according to the table „Breakdowns“,
if possible.
The maintenance intervals must be adjusted to the modified operating parameters without fail.
An inspection of the torsional backlash and a visual inspection of the flexible spider/DZ ele-
ments must performed after 2,000 operating hours for the first time, at the latest after 3 months
after start-up of the coupling.
If you note insignificant or no wear on the spider/DZ elements upon this initial inspection, further
II 2GD c IIC inspections can each be performed after 4,000 operating hours or at the latest after 12 months,
T4, T5, T6 provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable to
replace the spider/DZ elements, please find out the cause according to the table „Breakdowns“,
if possible.
The maintenance intervals must be adjusted to the modified operating parameters without fail.

ROTEX® coupling
Illustration 17.1:
®
ROTEX DZ
elements

Illustration 17.2:
®
ROTEX spider

®
Illustration 16: ROTEX coupling

Here the backlash between the cams of the coupling and the flexible spider/DZ element must be inspected by
means of a feeler gauge.
When reaching the wear limit maximum friction, the spider/DZ element must be replaced immediately, irrespec-
tive of the inspection intervals.
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.3 Standard values of wear

In case of a backlash > X mm, the flexible spider/DZ elements must be replaced.

Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.

CAUTION!
! In order to ensure a long service life of the coupling and avoid dangers with the use in haz-
ardous locations, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 9 to 11). If the fig-
ures are exceeded, the coupling will be damaged.

Illustration 18: Inspection of the limit of wear Illustration 19: Wear of spider

Table 12:
Limits of wear (friction) Limits of wear (friction)
ROTEX® size ROTEX® size
Xmax. [mm] Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.5 marking of coupling for hazardous locations

Couplings for the use in hazardous locations are marked on at least one component completely and on the re-
maining components by an label on the outside diameter of the hub or on the front side each for the operating
conditions permitted. The flexible spider or DZ element is excluded. For reason of the limited space only the sym-
bol is stamped up to size 19.

Short labelling:
II 2GD c IIC T X/I M2 c X
(standard)

Complete labelling: II 2G c IIC T6, T5, T4 resp. T3 - 50 °C Ta + 65 °C, + 80 °C, + 115 °C

(valid for T-PUR® only) resp. + 120 °C
II 2D c T 140 °C/I M2 c - 50 °C Ta + 120 °C

Complete labelling: II 2G c IIC T6, T5 resp. T4 - 30 °C Ta + 65 °C, + 80 °C resp. + 90 °C

(valid for PUR only) II 2D c T 110 °C/I M2 c - 30 °C Ta + 90 °C

The labelling with explosion group llC includes the explosion groups llA and llB.

5.6 Start-up

Before start-up of the coupling, please inspect the tightening of the setscrews in the hubs, the alignment and the
distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques
specified, dependent on the type of coupling.

If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections
must be secured against working loose additionally, e. g. conglutinating with Loctite (average
strength).

Finally, the coupling protection against accidental contact must be fitted.

The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off after having stopped the unit.

During operation of the coupling, please pay attention to

different operating noise

vibrations occurring.

If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there
is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not
operate in an accumulation of dust.

For covers with unlocked openings on the top face no light metals may be used if the couplings are used as
equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition,
it must be resistant to higher mechanical loads than if it is used as equipment of equipment group ll.
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.6 Start-up

The minimum distance „Sr“ between the protection device and the rotating parts must at least correspond to the
figures mentioned below.

If the protection device is used as cover, regular openings complying with the explosion protection demands can
be made that must not exceed the following dimensions:

Cover [mm]
Openings
Top side Lateral components Distance „Sr“
Circular - max. diameter 4 8 10
Rectangular - max. lateral length 4 8 10
Straight or curved slot - max. lateral
not permissible 8 20
length/height

CAUTION!
! If you note any irregularities with the coupling during operation, the drive unit must be
switched off immediately. The cause of the breakdown must be found out by means of the
table „Breakdowns“ and if possible, be eliminated according to the proposals. The potential
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.

Coupling coating:
If coated (priming, painting etc.) couplings are used in hazardous locations, the requirements on
conductibility and coating thickness must be considered. In case of paintings up to 200 µm electro-
static load does not have to be expected. Multiple coatings that are thicker than 200 µm are prohib-
ited for explosion group llC.

5.7 Breakdowns, causes and elimination

The below-mentioned failures can lead to a use of the ROTEX® coupling other than intended. In addition to the
specifications given in these operating and assembly instructions please make sure to avoid these failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent compo-
nents must generally be included.

If used other than intended the coupling can become a source of ignition.
EC directive 94/9/EC requires special care from the manufacturer and the user.

General failures with use other than intended:

Important data for the coupling selection were not forwarded.

The calculation of the shaft/hub connection was not considered.

Coupling components with damage occurred during transport are assembled.

If the heated hubs are assembled, the permissible temperature is exceeded.

The clearance of the components to be assembled is not coordinated with each other.

Tightening torques have been fallen below/exceeded.

Components are exchanged by mistake/assembled incorrectly.

A wrong or no spider/DZ elements are inserted in the coupling.

No original KTR parts (purchased parts) are used.

Old/already worn out spiders/DZ elements or spiders/DZ elements stored for too long are used.
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.7 Breakdowns, causes and elimination

Continuation:

The coupling used/the coupling protection used is not suitable for the operation in hazardous areas and does
not correspond to EC directive 94/9/EC, respectively.
Maintenance intervals are not observed.

Hazard notes for haz-

Breakdowns Causes Elimination
ardous locations
1) Set the unit out of operation
2) Eliminate the reason for the misalign-
increased temperature ment (e. g. loose foundation bolts,
on the spider surface; breaking of the engine mount, heat ex-
Misalignment
ignition risk by hot sur- pansion of unit components, modifica-
faces tion of the mounting dimension E of the
coupling)
3) Inspection of wear see item inspection
1) Set the unit out of operation
2) Disassemble the coupling and remove
Different operating
remainders of the spider
noise and/or vibra- Wear of spider,
3) Inspect coupling components and re-
tions occurring short-term torque Ignition risk due to
place coupling components that are
transmission due to sparking
damaged
metal contact
4) Insert spider, assemble coupling com-
ponents
5) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Screws for axial 2) Inspect alignment of coupling
Ignition risk due to hot
fastening of hubs 3) Tighten the screws to secure the hubs
surfaces and sparking
working loose and secure against working loose
4) Inspection of wear see item inspection
Wear of spider, 1) Set the unit out of operation
torque transmission 2) Replace complete coupling
due to metal contact 3) Inspect alignment
Breaking of the 1) Set the unit out of operation
cams due to high 2) Replace complete coupling
impact ener- 3) Inspect alignment
gy/overload 4) Find out the reason for overload
1) Set the unit out of operation
Operating parame- Ignition risk due to
Breaking of cam 2) Review the operating parameters and
ters do not corre- sparking
select a bigger coupling (consider
spond to the per-
mounting space)
formance of the
3) Assemble new coupling size
coupling
4) Inspect alignment
1) Set the unit out of operation
Operating error of 2) Replace complete coupling
the unit 3) Inspect alignment
4) Instruct and train the service staff
5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.7 Breakdowns, causes and elimination

Hazard notes for haz-

Breakdowns Causes Elimination
ardous locations
1) Set the unit out of operation
2) Eliminate the reason for the misalign-
Increased temperature ment (e. g. loose foundation bolts,
on the spider surface; breaking of the engine mount, heat ex-
Misalignment
ignition risk by hot sur- pansion of unit components, modifica-
faces tion of the mounting dimension E of the
coupling)
3) Inspection of wear see item inspection
1) Set the unit out of operation
2) Disassemble the coupling and remove
e. g. contact with
remainders of the spider
aggressive liq-
3) Inspect coupling components and re-
uids/oils, ozone
place coupling components that are
influence, too
damaged
high/low ambient
4) Insert spider, assemble coupling com-
temperatures etc.
Early wear of spider ponents
causing a physical
5) Inspect alignment, adjust if necessary
change of the spider
6) Make sure that further physical modifi-
cations of the spider are excluded
1) Set the unit out of operation
2) Disassemble the coupling and remove
Ambient/contact remainders of the spider
temperatures which 3) Inspect coupling components and re-
are too high for the place coupling components that are
Ignition risk due to
spider, max. permis- damaged
sparking in case of
sible 4) Insert spider, assemble coupling com-
metallic contact of the
e. g. with T-PUR® ponents
cams
T4 = - 50 °C/ 5) Inspect alignment, adjust if necessary
+ 120 °C 6) Inspect and adjust ambient/contact
temperature (possibly remedy by using
different spider materials)
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the spider
3) Inspect coupling components and re-
Early wear of spider place coupling components that are
(liquefaction of damaged
Vibrations of drive
material inside the 4) Insert spider, assemble coupling com-
spider cam) ponents
5) Inspect alignment, adjust if necessary
6) Find out the reason for the vibrations
(possibly remedy by spider with lower
or higher shore hardness)

If you operate with a worn spider/DZ elements (see item 5.2) and with the subsequent contact of
metal parts a proper operation meeting the explosion protection requirements and acc. to directive
94/9/EC is not ensured.
 ERSATZTEILE

SPARE PARTS

Filter
Type: MPF

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
 Ersatzteilliste Spare Parts List
Rücklauffilter Return Filter

Teil-Nr./ Menge/
Benennung Designation
Part No Qty.
1 Komplettfilter filter assembly 1

2 Filterelement filter element 1

3 Dichtsatz seal kit 1

3a Dichtung, Deckel seal, cover 1

3b Dichtung, Filtertopf seal, bowl 1

3c Dichtung, Filterkopf seal, head 1

3d Dichtung, Filterelement seal, filter element 1

Hinweis: Nur die Teile aus dieser Liste sind als Ersatzteile bestellbar.
Note: Only parts of this list can be ordered as spare parts.

ERT 19.01.2015 1/1

 ADDITIONAL INFORMATION

Wing Pump
Design A, Size 1
Article-No. 060928

Edition: 07. 05. 1999

Tel.: + 49 4122 711-0 Geschäftsführer / Amtsgericht Pinneberg:

Uetersener Maschinenfabrik GmbH & Co. KG Fax: + 49 4122 711-104 Managing Directors: HRA 0499 EL
Tornescher Weg 5-7 info@hatlapa.de Dr.-Ing. Alexander Nürnberg Verwaltungsgesellschaft: HRB 1560 EL
25436 Uetersen / Germany www.hatlapa.de Jörg Tollmien UST.ID-Nr. DE 134527127
1. Genelal
During the installationthe pumps haveto betreated carefully.You. therefore, haveto observelhat there is no
tension in the pump or that thev are defo.med by hämmerblows A tension in the casingmav occur when the
red is .ot plain or the fixing screwshsvebeenfastend unsymm€tricäly.lt is advantngeouslv whilo screwingto
movethewing to and fro. Should a tension haveoccuredyou would notice it right_away.The tension can be
avoidedby fasteningthe nuts accordingly.
In order to avoid a tension,discsof leatheror other soft materialmay be put behind the fixing sttapc
Thewinqs may evenjamwhen the pipingshavenot b€en placedwithout tension.
As the valvesare not splinq-loaded,the pumpscän operateverticallyonly.
Tl"resuction piping hasto be placedin sucha waythat it constantlyascendstothe pump. The suction piping
which will b€ used.must havethe sam€connectionas the pump flange.Th€ manometricsuction laft must not
exceed7,5 m - 24feet and th€ total manometic h€admust not be more than 20 m = 65 feet.
For suction lifts of more than 2 m = 6l/2 feet a foot valvehasto be provided For bendsin suction pipesno
right anglebendsmust be used.

2. Operation
During operation.the pumpsare insensibleand needoo maintenance.Onlv pure liquids lnav be händled.

Troubles
3 Operaring
Th€ nuts of the flange stuffing box haveto be tightenedfrom timsto time lf the gland hasbeen pressed
againstthe{lange of the stuffing box, a neu/stuffing box p€ckinghasto befixed
Scbnltt C·D
cwnsaltu c..D
1---

SchnittA-B
a--t-- crw wdQu A1l
Part No./Teile Nr. Denomination Benennung

1 Pump casing Pumpengehäuse

2 Driving shaft incl. Wing Antr. Welle m. Flügel
3 Lever Hebel
10 Cover Deckel
11 Gland Stopfbuchsbrille
12 Flange Zweischr.-Fiansch
13 Gland packing Stopfbuchs-Packung
14 Gasket Dichtung
23 Stud bolt Stiftschraube
24 Hexagon screw Sechs,kantschraube
25 Hexagon screw Sechskantschraube
31 Hexagonnut Sechskantmutter
32 Hexagonnut Sechskantmutter
34 Hexagonnut Sechs,kantmutter
61 Fixing pin Fixierstift
63 Valve seat Ventilsitz
64 Valve flap Ventilklappe
66 Spit pin Splint
69 Sealing strip Dichtleiste
101 Valve flap Ventilklappe
103 Spit pin Splint
SOTERIA alert system
for steering gears
SOTERIA alert system for steering gears

Index of contents

I. Overview of system
1. General
2. Alerts
3. Control inputs
4. Control outputs
5. Bus-system
6. Displays (touch panel)
II. Functional description
1. General
2. Alert display handling
3. Floating contacts to ship alert system
5. Settings
6. Fail safe operation
III. Technical Data
1. Touch Panel “iX Panel T7AM”

page 1
SOTERIA alert system for steering gears

I. Overview of system

1. General
The system consists of one control cabinet with a touch panel placed in steering
gear room (SGR) and 2 touch panels placed in engine control room (ECR) and in
bridge console.

Touch panel Touch panel

placed in ECR placed on bridge

RS485 - NMEA
RS485 - NMEA

supply 24VDC

supply 24VDC
CAN Bus

Control Cabinet

CAN Bus
placed in steering gear room
Contacts to s.a.s.

alert inputs HP1

alert inputs HP2

RS485 - NMEA
supply 24VDC

The system will not affect the function of steering gear. It is indicating the status of
steering gear.

2. Alerts
The system supports 3 kinds of alerts:
• “Alarm”: is shown in red and is a serious problem that needs to solve
immediately, because the steering gear could be damaged seriously!
Following alarms can be indicated (for each pump):
o FAILURE
o FEEDER FAILURE
o HYDRAULIC LOCKING
o LOW SERVO OIL PRESSURE
o OVERLOAD
o HIGH OIL TEMPERATURE
o SAFEMATIC FAILURE
o SYSTEM ERROR
o GREASE PUMPE FAILURE

page 2
SOTERIA alert system for steering gears

• “Warning”: is shown in yellow and is a problem that needs attention. The

steering gear will not be damaged immediately.
o OIL FILTER CLOGGED
o PHASE FAILURE
o LOW OIL LEVEL
o RUDDER TORQUE REDUCED
• “Caution”: is shown in blue and is only for standby-start of one pump. The
alerts for the reason of starting are shown too.
o STAND-BY START
Not all alerts need to be activated. They can be selected to the steering gear
configuration.

3. Control inputs
The alert inputs are connected to the hydraulic pump starter cabinets of steering
gear. The inputs are designed as fail safe inputs (no alert = 24V active signal).

4. Control outputs
The system is providing following floating contacts for central ship alert system:
• Warning system failure
• Hydraulic pump 1 aggregated alert
• Hydraulic pump 1 low oil level
• Hydraulic pump 2 aggregated alert
• Hydraulic pump 2 low oil level
Outputs are normally closed (closed = no alert/failure).

5. Bus-system
The new system is a based on CAN Bus. CAN-Bus is a very robust bus-system
with a large range depends on bit rate (see table below).

Bit rate Cable-length

10 kbits/s 6,7 km
20 kbits/s 3,3 km
50 kbits/s 1,3 km
125 kbits/s 530 m
250 kbits/s 270 m
500 kbits/s 130 m
1 Mbits/s 40 m

The HATLAPA steering gear warning system works with a bit rate of 125kbits/s
and has got a range of 530m. This is for the most configurations applicable.

The wiring of CAN is very easy and you can use standard cables. This will avoid
troubles in commissioning and operating the system.

6. Displays (touch panel)

Status of hydraulic pump 1 and 2 are shown on display. Alerts are indicated by
visual and acoustic signal. The alert messages are stored in a list with alert text,
status and date/time.
Date and time are synchronized on all panels. Master time can be set on bridge
touch panel.
Alert-Settings can adjust only in SGR by service personnel.
Every touch panel is generating a NMEA telegram for voyage data recorder based
on RS422.

page 3
SOTERIA alert system for steering gears

II. Functional description

1. General
All touch panels have 2 screens for the operator. Start screen is an overview. 2nd
Screen is the Alert History. The touch panel in Steering Gear Room has more
Screens for Settings. These settings are only available for service personnel.
Without any alert the display shows the pump state, actual date and time.

Steering Gear Room start screen

Pump state
On Service / Off

Go to screen Go to screen
Settings (protected) Alert History

On Bridge is an additional dimmer via slider on the touch panel available.

Bridge start screen

Brightness 0% Brightness 100%

page 4
SOTERIA alert system for steering gears

2. Alert display handling

If an alert occurs, the three displays are showing the class of alert (alert, warning
or note) and the corresponding text. An acoustic signal sounds at the panels.

Alert is displayed on screen (with acoustic signal)

Go to screen
Alert History
and
Buzzer Off

A transparent Button on the red area opens the detailed alert list and the buzzer
gets off.

Alert in alert list with state, date/time and text

Marked alert

Acknowledge Go back to
marked alarm Start screen

page 5
SOTERIA alert system for steering gears

Alert can be acknowledged only at Steering Gear Room. Then all displays
changes to acknowledge-status. The buzzers on all panels get off.

Acknowledge status (without acoustic signal)

Acknowledge status in Alert History.

The alert is pending until acknowledgement is done on SGR and input signal is
back.
If in acknowledge-status a new alert occurs the display changes to alert status and
acoustic signal is coming back until acknowledge again.

3. Floating contacts to ship alert system

Whenever an alert occurs the according floating contact to ship alert system is
open.
The contact to ship alert system is closing short time and opening again, if a new
alert occurs.

page 6
SOTERIA alert system for steering gears

4. NMEA-String to VDR
The string to VDR has this style:

HP Low Servooil P.
Hydr. Pump ident.

HP Hydr. Locking

HP Low Oillevel
Talker identifier

Checksum field
HP Overload
Total no. of

HP Failure.
sentences

Line Feed
Spare
$PHUMSTG,2,1,1,0,0,0,0,0,0,0,0,0,0,0,0,0*32<CR><LF>

HP Feeder Failure

HP Stand-By Start
HP Phase Failure
Present sentence

HP High Oiltemp.
Start of sentence

HP Oilfilter Clog.

Carriage Return
Company code

HP On Service

Spare
The transmission is only for state changing (alert, pump start)

5. Settings
Settings can adjust only on SGR. It is possible to activate and deactivate the alert
and adjust the delay time. This section is protected by a password and is only for
service personnel.

Furthermore the language can set. Following languages are supported:

• English
• German
• French
• Portuguese
• Russian
• Chinese

Time adjustments can be done on bridge display. All other displays are
synchronized by the bridge panel.

Set Date and Time

page 7
SOTERIA alert system for steering gears

6. Fail safe operation

All displays are sending life signals to controller. If one display fails or the
connection is broken, an alert “system error” is shown on the other displays. In
addition the contact “system failure” to the ship alert system is open.
III. Technical Data

1. Touch Panel “iX Panel T7A”

Front panel, W x H x D 204 x 143 x 7 mm

Mounting depth 43 mm (143 mm including clearance)
Standalone mounting VESA 50x50 / 75x75
Note: Maximum screw length for VESA mounting is
4 mm. Usage of longer screws may lead to damage.
Front panel seal IP 65
Rear panel seal IP 20
Touch screen material Polyester on glass, resistive.
Overlay: Autotex F157 or F207*.
Touch screen Operations 1 million finger touch operations
Reverse side Material Powder-coated aluminium
Frame material Powder-coated aluminium
Weight 0.8 kg
Serial port for COM1 RS232 and 9-pin D-sub contact with RS232 RTS/CTS, chassis-
COM2 RS422/RS485 mounted
female with standard locking screws 4-40 UNC
Serial port for COM3 RS232 and 9-pin D-sub contact with RS232 RTS/CTS, chassis-
COM4 RS422/RS485 mounted
female with standard locking screws 4-40 UNC
Ethernet 1 x 10 Base-T / 100 Base-T (shielded RJ 45)
USB 1 x USB Host 2.0, max output current 500 mA
Processor 400 MHz ARM9
External storage media 1 x SD card (optional)
Flash memory 128 MB SSD (Nand Flash)
Memory RAM 64 MB (DDR2)
LED 1 x blue/red
Real time clock Yes (on chip)
Power consumption at rated Normal: 250 mA
voltage
Fuse Internal DC fuse, 2.0 AT, 5 x 20 mm
Power supply +24 V DC (16 – 36 V DC), max. 2 A. CE: The power
supply must conform to the requirements according
to IEC 60950 and IEC 61558-2-4.
UL and cUL: The power supply must conform to the
requirements for class II power supplies.
Display TFT-LCD. 800 x 480 pixels, 262 K colors
LED backlight
Active area of display, W x H 152.4 x 91.4 mm
Operating temperature -10 ° to +60 ° C

page 8
Section 8 Instructions for Correctly Ordering
Spare Parts
Instructions for Correctly Ordering Spare Parts

When ordering spare parts, the following details must be given:

1. Serial No. and type designation (see name plate).
2. Part No. from the spare parts list.
3. Method of the required dispatch, as well as consignee and address for the
invoice.
4. Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get directly in touch
with

Uetersener Maschinenfabrik GmbH & Co. KG

Tornescher Weg 5-7
D-25436 Uetersen
Germany
Phone: (+49) 4122 / 711- 0
Fax: (+49) 4122 / 711 - 330
E-mail: info@hatlapa.de
Internet: http://www.hatlapa.de

or with our subsidiaries or representatives. For a current list of our subsidiaries

and representatives, please see our homepage http://www.hatlapa.de.