Kongsberg SR Series User manual

Maintenance Manual
Kongsberg Steering Gear type SR and SV
2020.09.24 13:41 [CET] RELEASED

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 2 |
Doc.no DMN000278736
Rev.
Date
Reason for
issue
Author, dept. and name
Authorizing dept.
name, sign
A
15 April 2020
First issue
SU, EM, GB, EK, OM,
Motion Control
JA
B_01
22 April 2020
Minor changes
SU - Motion Control
C_01
24 Sept 2020
Minor changes
SU- Motion Control

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 3 |
TABLE OF CONTENTS
Safety .....................................................................................................................................4
General statement..............................................................................................................4
Safety annotations .............................................................................................................5
1. Introduction .....................................................................................................................6
2. Maintenance overview....................................................................................................6
3. Docking related service and maintenance tasks ...........................................................7
4. Regular maintenance tasks............................................................................................9
5. Steering gear actuator..................................................................................................12
6. Steering gear electrical motor, pump and valve block.................................................13
6.1 Steering gear with frequency controlled pumps ............................................................ 13
6.2 Steering gear with conventional pumps......................................................................... 14
7. Maintenance task procedures ......................................................................................15
7.1 Frequency converter error log....................................................................................... 15
7.2 Oil recommendations .................................................................................................... 16
7.3 System oil volume ......................................................................................................... 18
7.4 Inspection of oil level and condition............................................................................... 19
7.5 Oil level ......................................................................................................................... 19
7.6 Oil sampling .................................................................................................................. 20
7.7 Internal leakage test - with frequency controlled pumps................................................ 21
7.8 Manoeuvring time test - with frequency controlled pumps............................................. 23
7.9 Feedback form .............................................................................................................. 24
7.10 Internal leakage test – with conventional pumps........................................................... 25
7.11 Manoeuvring time test – with conventional pumps ........................................................ 26
7.12 Visual inspection ........................................................................................................... 27
7.13 Test of emergency steering........................................................................................... 28
7.14 Function test of alarm system ....................................................................................... 29
7.15 Check for proper earth connection ................................................................................ 31
7.16 Check for system temperature ...................................................................................... 31
7.17 Replacement of filter ..................................................................................................... 32
7.18 Cleaning of air oil cooler type B10/M10-30.................................................................... 34
7.19 Log files submission procedure..................................................................................... 37
8. Self - Assessment or Maintenance Inspection.............................................................39
9. Spare parts ...................................................................................................................40
10. Contact..........................................................................................................................41

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 4 |
Safety
Please take the time to read this chapter carefully, as it concerns your safety.
General statement
"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR INDIRECTLY
CREATE RISKS TO:
[1] THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR,
[2] THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS
ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY THIS DOCUMENT IN
ACCORDANCE WITH RELEVANT STATUTORY, LEGAL AND INDUSTRY REQUIREMENTS TO PROTECT THE
HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE WORK.
IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS
ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED BY THIS DOCUMENT TO PROTECT
AGAINST RISKS TO THE KONGSBERG STEERING GEAR AND/OR ITS COMPONENTS WHILST THE WORK IS
BEING UNDERTAKEN.
NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR RESPONSIBILITY
TO ENSURE THAT THE CONTROLS AND PRECAUTION REFERRED TO ABOVE ARE IMPLEMENTED.
IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME AWARE OF ANY
KONGSBERG MARITIME PRODUCT DESIGN RELATED FEATURE WHICH COULD CREATE RISK TO A
PERSON UNDERTAKING WORK OR TO THE PRODUCT AND/OR ITS COMPONENTS PLEASE CONTACT THE
RESPECTIVE TECHNICAL PRODUCT MANAGER AT KONGSBERG MARITIME IMMEDIATELY."

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 5 |
Safety annotations
All safety directions must be respected in order to avoid damage to personnel, environment and
equipment. In this document the following annotations are used with belonging significance:
WARNING
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or
severe personnel injuries or substantial product or property damage, if the required
precautions are not taken.
Note!
Draws attention to specific information of technical significance which might not be obvious
to specialist personnel, or points at important remarks in the procedures to follow.

Maintenance manual
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information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
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1. Introduction
This manual provides the Kongsberg Maritime maintenance recommendations and instructions for the
SR and SV type steering gears. All recommendations are provided in relation to general Class
requirements and guidelines.
2. Maintenance overview
Kongsberg Maritime (KM) steering gears are designed for safe operation with a minimum
maintenance. To prevent unexpected problems or downtime, it is recommended that the users
maintain the steering gear system at regular intervals.
For scheduled class survey and general service or repair, it is recommended to use Kongsberg
Maritime service engineers. This will decrease the time of repair to a minimum and ensure
continuous safe operation.
This document describes all relevant maintenance procedures and activities to be carried out by the
crew, in addition to the maintenance recommended to be performed by Kongsberg Maritime
engineers. Any other information may be found in the steering gear OPERATING AND MAINTENANCE
MANUAL (USER MANUAL) or by contacting [e-mail]
After a certain number of years in operation it is, however, necessary to service the equipment and
replace internal and external wear parts in order to achieve a predictable and safe life-cycle for the
steering gear equipment. The service intervals are depending on factors such as:
•Alignment of rudderstock and steering gear
•Radial forces from rudder and the operation profile of the steering gear
•Oil temperature, pressure and oil condition
•Duty cycles and degrees travelled
•Other conditions such as DP operations
•General maintenance
It is important to monitor the condition and performance of the equipment and take notice of any
changes. This might be important to reveal any problem about to develop before a breakdown
occur.
Note!
It is requested that any failures or maintenance work on the equipment, no matter how small,
should be reported to Kongsberg Maritime at; [e-mail]
By reporting, any failures and maintenance work, an accurate equipment history can be maintained.
This history will be continuously monitored and compared to other vessels with similar equipment.
With this information, we can provide better service, faster delivery of spare parts, and guidance for
preventive maintenance.

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 7 |
3. Docking related service and maintenance tasks
Please see below intervals for service and maintenance recommended in relation to scheduled class
surveys or docking.
Service and maintenance 5 YEAR 10 YEAR 15 YEAR 20 YEAR 25 YEAR
Change of actuator seals and
bearings*
(x) x (x) x (x)
Change Oil*
(x)
x
(x)
x
(x)
(x)
Service of distribution valve* x
(x)
x
(x)
Change flexible coupling hydraulic
pump No 1 and 2*
x (x) x (x)
Replace vibration dampers (if
applicable)
x (x) x (x)
Replace hydraulic pump No 1 and 2* x
(x)
x
(x)
Replace frequency converters x (x) x (x)
Replace coolers (if applicable) x (x) x (x)
Replace rubber hoses x
(x)
x
(x)
Replace or overhaul electric motors x
(x)
x
(x)
Condition based recommendation
x
(x)
x
(x)
x
*Recommended to be carried out in dry dock/port, by Kongsberg Maritime service engineers.
(X) - Service or maintenance recommendation dependent on equipment condition and service history.
X -Recommendation based on number of years in service (minimum every 10 years).
X - Condition based recommendatation:
The Condition based recommendation is based on several condition values reported through a mobile
application provided by KM to the customer to perform inspection of the steering gear equipment
themselves. The Mobile application contains a Self - Assessment, leakage and manoeuvre time test
and loading of SG PMS Log files by using our dedicated application – customer sync result back to KM
for recommendations, ideally six months in advance of the vessels planned class surveys or docking.
Steering Gear Performance Monitoring System (SG PMS):
The purpose of the performance monitoring system is to continuously monitor the performance and
operation of the steering gear, and provide an alarm when degraded or irregular performance is
detected. The SG PMS Amplifier card is part of the standard delivery for all new steering gears type
SR/SV - FCP, as of early 2019. The SG PMS solution is also available as an upgrade on all steering gear
installations completed in 2005 or later.
Service and maintenance intervals:
5 years:
Service and maintenance recommendations based on current equipment performance and
conditions reported through the Kongsberg Mobile application including:
•Self – Assessment or Maintenance Inspection report (ref. chapter 8)
•Leakage and manoeuvring time test

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 8 |
•Steering gear PMS log files for the last 12 months (if SG PMS amplifier card is
available)
10 years:
Recommended service and maintenance according to above table, and previous service
history.
15 years:
Recommendations will be based on previous service and maintenance completed, current
equipment performance and condition reported through the Kongsberg Mobile application
including:
•Self – Assessment or Maintenance Inspection report (ref. chapter 8)
•Leakage and manoeuvring time test
•Steering gear PMS log files for the last 12 months (if SG PMS amplifier card is
available)
20 years:
Recommended service and maintenance according to above table, and previous service
history.
25 years:
Recommendations will be based on previous service and maintenance completed, current
equipment performance and condition reported through the Kongsberg Mobile application
including:
•Self – Assessment or Maintenance Inspection report (ref. chapter 8)
•Leakage and manoeuvring time test
•Steering gear PMS log files for the last 12 months (if SG PMS amplifier card is
available)

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 9 |
4. Regular maintenance tasks
The Maintenance instructions below details all preventative maintenance activities to be carried out by
the Crew on a regular basis. Please add below tasks to applicable vessel maintenance system.
System (a) Sub-System (b) Part (c) Maintenance Task (d) Maint (e) Freq (f) Type (g) Skill Level (h) Facility (I)
Steering Gear
system Actuator Check for any leakage around the steering gears inboard part. Prev 1 day CHK A A
Steering Gear
system Actuator
Check surface temperatur of the
equipment( pipes from pumps) Prev 1 day CHK A A
Steering Gear
system Actuator Check for abnormal vibrations/noises on the equipment. Pre 1 day CHK A A
Steering Gear
system Controls System Frequency Converter
Check Frequency Converter display for error
message. Prev 1 wk CHK A A
Steering Gear
system Hydraulic System Oil Tank Check oil level in the expansion tank and top up if necessary Prev 1 wk CHK A A
Steering Gear
system
Hydraulic System
Standby
Pump
Start/stop standby pump Prev 1 wk TST A A
Steering Gear
system
Cleaning of Steering Gear unit and
surroundings Prev 1 mth CL A A
Steering Gear
system Actuator Actuator
Perform test of Steering Gear modes,
Emergency Steering and normal steering
from all stations.
Prev 1 mth TST A A
Steering Gear
system Actuator
Check manoeuvring time according to
SOLAS Prev 1 mth CHK A A
Steering Gear
system Hydraulic System Duplex Filter
Check filter blockage indicators, change
filter element if necessary. Prev 1 mth CHK A A
Steering Gear
system Controls System Controll Panels
Make sure that all electrical indications push
buttons back light bulbs are ok Prev 1 mth CHK A A
Steering Gear
system Hydraulic Pumps Actuator Perform visual check of pump and motor coupling Prev 1 mth CHK A A
Steering Gear
system
Alarm System Alarms
Function test of alarm system according to
manual.
Prev 3 mth CHK A A
Steering Gear
system Coolers Visual inspection of coolers Prev 6 mth CHK A A
Steering Gear
system Actuator Internal leakage test Prev 6 mth TST A A
Steering Gear
system
Hydraulic System
Collect sample of hydraulic oil from the
actuator
Prev 6 mth SAM A A
Steering Gear
system Hydraulic System Change filter Prev 6 mth FC A A
Steering Gear
system
Controls System
Frequency
Converter
Check of alarm log Prev 1 yr CHK C A
Steering Gear
system
Intercom system
Steering
gear room
Check communication system between
Steering Gear room and the bridge.
Prev 1 yr CHK A A
Steering Gear
system Controls System
Electric
Motor Megger test electric motors Prev 1 yr MEG A A
Steering Gear
system
Control System
Motor
Controller
Freq Converter (small starters), Annual
Check
Prev 1 yr CHK C A
Steering Gear
system Control System El system
Perform a visual check of all Electrical
components, eartings, cable conetctions. Prev 1 yr INSP A A
Steering Gear
system
El system El system Replace vibration dampers (Freq converters) Prev 5 yr REP A A

Maintenance manual
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information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 10 |
The table below illustrates the inetrvals for service and maintenance recommended in relation to scheduled
class surveys or docking, recommended to be carried out in dry dock/port, by Kongsberg Maritime service
engineers, (also described under section 3. of this manual). Please add below tasks to applicable vessel
maintenance system.
System (a) Sub-System (b) Part (c) Maintenance Task (d) Maint (e) Freq (f) Type (g) Skill Level (h) Facility (I)
Steering Gear
system
Steering Gear
system Actuator Change of seals and bearings Prev 10 yr REP C A
Steering Gear
system
Steering Gear
system Actuator Change Oil Prev 10 yr OC C A
Steering Gear
system
Steering Gear
system
Valve Overhaul distribution valve Prev 10 yr INSP C A
Steering Gear
system
Steering Gear
system
Hydraulic
Pump No1 Change flexible coupling prev 10 yr REP C A
Steering Gear
system
Steering Gear
system
Hydraulic
Pump No2
Change flexible coupling prev 10 yr REP C A
Steering Gear
system Controls System
Frequency
Converter
No1
Replace frequency converter Prev 10 yr REP C A
Steering Gear
system Controls System
Frequency
Converter
No2
Replace frequency converter Prev 10 yr REP C A
Steering Gear
system
Hydraulic System
Hydraulic
Pump No1
Replace Pump Prev 10 yr REP C A
Steering Gear
system Hydraulic System Hydraulic Pump No2 Replace Pump Prev 10 yr REP C A
Steering Gear
system Controls System
Electric
Motor No 1
and No2
Replace or overhaul electric motor Prev 10 yr OVH B A/D
Steering Gear
system Coolers Replace coolers Prev 10 yr REP A A
Steering gear
system
Hydraulic system Replace rubber hoses Prev 10 yr REP A A
Column description:
•Columns a, b& cillustrate the hierarchical relationship between the components/sub-
assemblies (column c) on which maintenance is performed and the high level module
(columna).
•Column ddescribes the maintenance activity.
•Column eidentifies the maintenance activity as either Preventative or Corrective.
•Column fdetails the frequency of the maintenance activity.
•Column ggroups the maintenance activity into a category which facilitates the rapid analysis of
the maintenance data, eg one can search on OC to identify when the equipment underwent an
oil change.
•Column hidentifies which skill level is required for the maintenance activity.
•Column iidentifies what facility is required for the maintenance activity.

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 11 |
Maintenece categories:
Abreviation
Description
BC
Bearing Change
CHK
Check
CL
Clean
FC
Filter Change
FLU
Flush
INSP
Inspect
LUB
Lubricate
MEA
Measure
MEG
Megger
OC
Oil Change
OVH
Overhaul
REP
Replace
KM OVH
Kongsberg Maritime Overhaul
SAM
Sample
TST
Test
Skill level and facilities:
The skill levels indicate the skill level of the person responsible for the maintenance task, the facility
indicates the physical location of the vessel during the maintenance procedure. The skill and facility
codes are:
•Maintenance Level A is general operational maintenance carried out by the ships crew on
board, with no additional support or facilities.
•Maintenance Level B is maintenance carried out in port, using ships crew and local port supplied
support and facilities.
•Maintenance Level C is maintenance carried out in port, requiring specialist Kongsberg Maritime
support.
•Maintenance Level D is repair and overhaul activities undertaken in a Kongsberg Maritime
specialist workshop.
The facility indicates the physical location of the vessel during the maintenance procedure.
The codes for facility are:
•A – Onboard
•B – Harbour
•C – In dry dock
•D – In Workshop (Kongsberg Maritime or port workshop facilities)

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 12 |
5. Steering gear actuator
The function of the hydro-mechanical steering gear unit is to provide the rotational power to operate
the rudder unit. The steering gear has a compact and unique design with cylindrical rudderstock.
The vanes/pistons work in a spherical shaped rotor with the rudder stock as the centre. The vane/pistons
are fastened to the rotor in a manner; which allows them to absorb and adjust to the spherical deflection
of the rotor due to misalignment in installation or deflection of the rudder stock.
The housing has a cast spherical shape with oil channels leading the oil to the different chambers. The
housing is divided with an upper and lower part which are connected by several bolts.
The synthetic bearing pads maintain hundred percent surface contact at all times, even as the rudder
stock flexes. It will also absorb and suppress vibrations and shock pulses. The bearing surface is
continuously lubricated by the hydraulic oil.
Note!
In order to access the lower seals and bearing pads the rotor will need to be lifted up, prior to this operation
the rudder unit will need to be blocked and secured, and lifting gear made available.
Kongsberg Maritime is not responsible for the securing of the rudder. It is the customer responsibility to engage
a yard or a suitable third party to undertake this task. If there is less than 1.5 meter free height above the steering
gear, arrangements to cut the deck above the steering gear room and/or lower the rudder stock will be required.
After service, KM will document the actual condition of the steering gear in a separate report with picture, and
it is the customer’s responsibility to notify the class society in order for them to survey the completed service.
Rotor
Piston bolts
Upper housing
Lower housing
Actuator seals
Bearing pads
Feedback unit

Maintenance manual
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information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 13 |
6. Steering gear electrical motor, pump and valve block
The SR and SV steering gears can be installed with either a conventional pump unit (PU) or a frequency
controlled pump (FCP) system.
6.1 Steering gear with frequency controlled pumps
The frequency driven steering gears have a compact design with two frequency controlled reversible
pump units, valve block and electrical feedback units fitted to the steering gear.
The electrical motor for each pump unit starts when a rudder command signal is given and stops when
the rudder has reached the desired position. The power for operating control and steering systems are
both hydraulically and electrically separated and independent. The normal running condition is achieved
when one pump is running, when both pump units are running the steering gear will run twice as fast.
The pump units consist of four main parts which are; reversible pump, electrical motor, and bell house
with a flexible coupling inside.
The integrated valve block with filter units has fewer and less complex valves due to the reversible
pumps. The distributing valve housing is flanged to the housing of the Steering gear containing the non-
return valves (not illustrated), load control valves (1), solenoid operated isolating valves and coil (2),
relief valve (3), and return filter units.
Electrical motor
Flexible coupling
Reversible pump
Return filters
Valve block

Maintenance manual
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information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 14 |
6.2 Steering gear with conventional pumps
The steering gears fitted with a conventional pump system have separate pump units, the pumps are
constantly running and the oil is controlled by a manoeuvring valve. The pump unit consists of a tank
with foundation, manoeuvring valve (on steering gear for PU50 andFV2 or FV10 valve), return filter and
vane pump (PU30 uses gear pumps) with flexible coupling. The electric motor is flanged to the top plate
(flanged to the side on PU30).
The pump runs submerged in oil and an arrow on the pump flange indicates the direction of rotation.
The pump unit is to be connected by three pipes; two to the distributing valve on the actuator and one
to the oil reservoir. (Different types of installations will have individual variances).
Electrical motor
Filter assembly
Flexible coupling
Vane pump
Electrical motor
Flexible coupling
Filter assembly
Relief valve
Emergency Steering

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 15 |
7. Maintenance task procedures
Please see below maintenance support procedure and guidelines required for maintaining the steering
gear system in a safe and correctly manner.
7.1 Frequency converter error log
1. Check that there are no obstructions to the flow of cooling air over the cooling ribs of the FC and
that the FC is not covered by dust.
2. Check that the cover is properly secured
3. Press the alarm log push button on the frequency converter's local control panel. All incidents in the
alarm log are time stamped with running hours as reference.
4. Use the up and down push buttons to navigate in the alarm log.
5. Press the Status push button to finish reading the alarm log.
Frequency Converter

Maintenance manual
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information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 16 |
7.2 Oil recommendations
.
WARNING
•
Using oil other than that specified by Kongsberg Maritime CM may cause malfunctions when
manoeuvring the vessel. This may cause personal injury and equipment damage.
•Before using other brands, please contact Kongsberg Maritime CM.
Note!
The oil is one of the main components in a hydraulic steering gear, and must therefore be
selected and handled with this in mind.
Do not mix hydraulic oil with other types of oil. Even very small amounts of other oil in the
hydraulic oil, will considerably lower the quality of these oils.
The performance of the unit is highly depended on the viscosity of the oil. The surrounding
temperatures of the hydraulic components when operating at extreme temperature conditions, tropic
or arctic waters, shall be taken into account when selecting type of oil.
General requirement to the hydraulic fluids used on Kongsberg steering gear should meet DIN 51524.
The viscosity index improve must not be broken down and effect flow and lubrication properties
Pour point should be below -30ocentigrade.
The oil must contain the following additives.
Performance qualities:
a. Anti-wear properties
b. Water and foaming resistance
The following hydraulic oils are approved and recommended by Kongsberg Maritime:
Manufacturer Type Bio-degradable type
AGIP AGIP ARNICA 32
BEVEROL HV-ISO32
BP BARTRAN HV32
CALTEX RANDO HDZ32
CASTROL HYSPIN AWH-M 32 Biobar 32
CENTURY NEVIS 7

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 17 |
Manufacturer Type Bio-degradable type
CEPSA CEPSA HV 32
CHEVRON RANDO HDZ32
SHELL TELLUS S2 VX 32
STATOIL HYDRAWAY HVXA 32
TEXACO RANDO HD Z32
YUKONG ZIC SUPERVIS X32
EXXON MOBIL DTE10 EXCEL 32
NYNÄS HYDOL 32
ESSO (Exxon) UNIVIS N 32
HISPANO QUIMICA, S.A HYDRO DRIVE HP150
LUB MARINE (TOTAL) VISGA 32
MOBIL SYNTHETIC MOBIL SHC 524
Change the oil when laboratory tests show:
•High neutralizing number
•Low remaining amount of EP-additives
•High amounts of insoluble particles in the oil
•Oil cleanliness no longer is within 17/14 or better according to ISO standard 4406, class 8 or better
according to NAS 1638
•If components of the hydraulic system have been broken down.

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 18 |
7.3 System oil volume
Oil volume for steering gears with frequency controlled pumps:
Model type SR Oil volume
SR 562 Approx. 35 litre
SR 622 Approx. 45 litre
SR 642 Approx. 50 litre
SR 662 Approx. 65 litre
SR 722 Approx. 125 litre
SR 723 Approx. 120 litre
SR 742 Approx. 160 litre
SR 743 Approx. 160 litre
Model type SV Oil volume
SV 430 Approx. 145 litre
SV 650 Approx. 135 litre
SV 570 Approx. 250 litre
SV 850 Approx. 230 litre
Oil volume for steering gears with conventional driven pumps:
Actuator type Pump unit type Oil volume
SR 562 PU30 Approx. 60 litre
SR 622 PU30
Approx. 70 litre
PU45
Approx. 205 litre
SR 642 PU30
Approx. 80 litre
PU45
Approx. 215 litre
SR 662 PU45
Approx. 230 litre
SR 722 PU50
Approx. 455 litre
SR 723 PU50
Approx. 450 litre
SR 742 PU50
Approx. 485 litre
SR 743 PU50
Approx. 485 litre
SV 570 PU50
Approx. 570 litre

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 19 |
7.4 Inspection of oil level and condition
WARNING
•IT IS EXTREMELY IMPORTANT THAT OIL BOTTLE USED FOR OIL SAMPLING
IS CHEMICALLY PURE, AND THAT THE PROCEDURE IS PERFORMED WITH A
HIGH DEGREE OF CLEANLINESS.
7.5 Oil level
Examine the oil level in the expansion tank. When oil is visible in the upper level gauge glass the tank is
properly filled up. Unchanged oil level for a long time indicates no leakage.
If the oil level in the expansion tank is low, refill with the oil from the storage tank.
Do visual inspections of all components including pipes and connectors on a regular basis to identify
leakages. Repair the oil leak immediately.

Maintenance manual
KONGSBERG PROPRIETARY. This document and its accompanying elements contain KONGSBERG
information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2020 KONGSBERG - All rights reserved.
Page 20 |
7.6 Oil sampling
Note!
•The hydraulic system must be operated for a while before the oil sampling procedure is carried
out.
•The oil must at all times meet the specification for actual type of oil used in the system. Take
oil samples regularly.
•Follow the instructions regarding oil change intervals or the recommendations based on an oil
sample test.
The oil sampling points [1] can be located either on the upper housing port and stbd, upper
rear side of the valve block or on the filter housing, as illustrated in the picture.
1. Locate the sampling point.
2. Remove the protecting cap [2], as illustrated in the picture below. (The sampling plug
contain a non-return valve to prevent oil spill prior to connection of sampling hose.)
3. Connect the sampling hose [3] to the sampling point.
4. While the Steering gear is operated flush the hose by letting some of the oil run
through the hose and in to a bucket.
5. Fill a clean sample bottle [4] with oil.
6. Close the sample bottle and attach label to sample bottle indicating oil type, date,
sample taken by and oil used for how long.
7. Compare sample with new oil by visual examination. If the oil colour has clearly
changed or impurities are present in the oil consider replacing the oil.
8. Send the oil sample to be examined immediately.