YOOWON-MITSUBISHI

ELEC. HYDR. STEERING GEAR

MODEL : YDFT-200-2
SHIPBUILDER : Jiangsu New Yangzi Shipbuilding Co.,Ltd
SHIP No. : YZJ2015-2022/23/24/2223
OWNER : SITC
KIND OF VESSEL : 2,700TEU Containe Vessel

2 FOR FINISHED (YZJ2015-2223) 172 K.D.H C.Y.S 21.06.02

1 FOR WORKING 124 K.D.H C.Y.S 20.12.14
No. DESCRIPTION PAGE CHECKED APPROVED DATE

APPROVED B.G.KIM
CHECKED H.D.H YDFT-200-2
DRAWN K.J.G ELEC. HYDR. STEERING GEAR
CLASS SCALE

YZJ2015- SERIAL No.: YS-13545/46/47 DRAWING No. REV. NO.

2022/23/24 : YS-14181 YS-ZDT2022-00001-1
DNVGL
YZJ2015-2223 :
NK YOOWON INDUSTRIES LTD.
DATE 18.JAN.2019 ISSUED
 INDEX FOR FINISHED
No. NAME DRAWING No. REV No. PAGE
1 PARTICULARS OF STEERING GEAR YS-ZDT2022-00100-0 1
2 IN CASE OF USING EMERGENCY GENERATOR YS-ZKH2022-AP200-0 2
3 MATERIALS FOR PRINCIPAL PARTS YS-ZMP0000-00104-0 3
4 GENERAL ----- 4
5 RECOMMEND OILS FOR HYDR. & LUBRICATION ----- 7
6 HYDRAULIC DIAGRAM YS-DDT0620-MS001-2 8
OPERATING INSTRUCTION PLATE &
7 YS-ODT2022-MS0F0-1 9
EXPOSITIVE NAME PLATE
8 GENERAL ARRANGEMENT YS-ADT2022-TMP20-1 10
9 INSTALLATION YS-FCZ2022-TP001-3 11
10 TILLER YS-CCZ2022-00301-0 12
11 HYDR. NUT YS-CCZ2022-00900-0 13
12 ARRANGEMENT OF LIMIT SWITCH YS-EDT2022-LS000-1 14
13 LEVEL SWITCH DX005S-L-1 15
14 55kW & 55/11kW ELEC. MOTOR YS-MHS2022-00500-2 16
MITSUBISHI JANNEY PUMP TYPE 3V-FH2B-MK
15 RA3300-111-1 21
EXTERNAL VIEW
MITSUBISHI JANNEY PUMP TYPE 3V-FH2B-MK
16 RA3300-211-0 22
ARRANGEMENT
MITSUBISHI JANNEY PUMP TYPE 3V-FH2B-MK
17 RA3300-221-0 23
PARTS LIST
18 LIST OF SPARE AND TOOL YS-RDT2022-MS000-0 28
19 CABLE ARRANGEMENT YS-ECZ2022-TMS00-2 41
20 CONTROL MOTOR UNIT N76-90T-2530 42
21 INSPECTION & TEST REPORT - 45
22 PARTICULARS OF SHOP TEST YS-ZD00000-MS000-0 54
PARTICULARS OF SHOP TEST
23 YS-ZKD2022-30202-0 58
FOR TYPE 3V-FH2B-MK JANNEY PUMP
24 STARTER & ALARM PANEL YS-EDT2022-00300-1 61
25 HYDR.LOCK ALARM SYSTEM YS-EH00000-00001-0 74
26 SPARE LIST OF ELECTRICAL EQUIPMENT YS-EDT2022-00400-1 79
27 PIPING METHOD FOR STORAGE TANK YS-HPM2022-HWP00-1 81
28 GREASE LUBE SYSTEM FOR RUDDER CARRIER YS-EGP0000-0P800-0 82
29 INSTRUCTION BOOK YS-ZT30020-MP200-0 92
DATE 15.MAY.2020 ISSUED.
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PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD NO. DESCRIPTION(DATE)

PARTICULARS OF STEERING GEAR

NOMINAL TYPE NUMBER YDFT-200-2
RULE DIA. OF RUDDER STOCK BY DNVGL mm Ф 405
ACTUAL DIA. OF RUDDER STOCK IN TILLER BOTTOM mm Ф 540 (TAPER 1/15)
TORQUE OF THE STEERING GEAR kN-m 2,030
AT MAX. WORKING PRESSURE AT 35 DEGREE tf-m 207
DESIGN TORQUE OF THE STEERING GEAR kN-m 2,538
AT DESIGN PRESSURE AT 35 DEGREE tf-m 259
MPa 21.6
MAX. WORKING PRESSURE
kgf/㎠ 220
MPa 27
SAFETY VALVE ADJUSTING PRESSURE(DESIGN PRESS.)
kgf/㎠ 275
RUDDER TURNING SPEED (BY ONE PUMP) deg/sec 65/28
DIA. OF RAM mm 250
NORMAL TILLER RADIUS mm 715
MAX. WORKING RUDDER ANGLE deg 35
LIMIT RUDDER ANGLE deg 37.5
OUTPUT kW No.1 : 55 No.2 : 55/11
THEORETICAL NUMBER OF REVOLUTION rpm 1,200 1,200/600
POWER SOURCE V AC 440V, 3Ф, 60Hz
MOTOR
25% - Cont.
RATING 100% - 1 Hr.
200% - 60 sec.
TYPE x NUMBER 3V-FH2B-MK×2
PUMP DESIGN TILTING ANGLE % 58
THEORETICAL DELIVERY OIL QUANTITY ℓ/min 228
TOTAL OIL QUANTITY ℓ abt. 1,800
TOTAL WEIGHT(EXCEPT FEED BACK UNIT) kgf abt. 13,440
MAIN PRESSURE PIPE (OUTDIA. x THICKNESS) mm 63.5 × 9.0
STORAGE TANK MINIMUM CAPACITY ℓ abt. 1,050

SHIPBUILDER : Jiangzu New Yangzi Shipbuiulding Co.,Ltd

2,700TEU Containe Vessel
SHIP No. : YZJ2015-2022/23/24/2223
APPROVED B.G.KIM
CHECKED H.D.H
YDFT-200-2
ELECTRO-HYDRAULIC STEERING GEAR
DRAWN K.J.G
PARTICULARS OF STEERING GEAR
CLASS SCALE
YZJ2015- SERIAL No.: YS-13545/46/47 DRAWING No. REV. NO.
2022/23/24 : YS-14181 YS-ZDT2022-00100-1
DNVGL
YZJ2015-2223
: NK YOOWON INDUSTRIES LTD.
DATE 18.JAN.2019 ISSUED
 2
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD NO. DESCRIPTION(DATE)

PARTICULARS OF STEERING GEAR

(IN CASE OF USING EMERGENCY GENERATOR)

RUDDER TURNING SPEED (BY No.2 PUMP) deg/sec 15˚~15˚/60

RECOMMENDED MAX. WORKING RUDDER ANGLE deg 15˚
OUTPUT kW 11
THEORETICAL NUMBER OF REVOLUTION rpm 600
No.2
VOLTAGE V AC 440
MOTOR
100%-CONT
RATING
200%-60sec
TYPE 3V-FH2B-MK
No.2
DESIGN TILTING ANGLE % 58
MOTOR
THEORETICAL DELIVERY OIL QUANTITY ℓ/min 114

* No.2 MOTOR POLE CHANGE

SHIPBUILDER : Jiangzu New Yangzi Shipbuiulding Co.,Ltd
2,700TEU Containe Vessel
SHIP No. : YZJ2015-2022/23/24/2223
APPROVED B.G.KIM
YDFT-200-2
CHECKED H.D.H ELECTRO-HYDRAULIC STEERING GEAR
DRAWN K.J.G PARTICULARS OF STEERING GEAR
CLASS SCALE (IN CASE OF USING EMERGENCY GENERATOR)

YZJ2015- SERIAL No.: YS-13545/46/47 DRAWING No. REV. NO.

2022/23/24 : YS-14181 YS-ZKH2022-AP200-1
DNVGL
YZJ2015-2223
: NK YOOWON INDUSTRIES LTD.
DATE 18.JAN.2019 ISSUED
 3
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD NO. DESCRIPTION(DATE)

MATERIALS FOR PRINCIPAL PARTS

MARKS NAME MATERIAL

1 CYLINDER SPHEROIDAL GRAPHITE CAST IRON

2 CYLINDER BUSH BRONZE CASTINGS

3 TILLER CARBON STEEL CASTINGS

5 RAM CARBON STEEL

6 RAM PIN CHROMIUM MOLYBDENUM STEELS

7 RAM PIN BUSH SPECIAL COPPER ALLOY

8 HIGH PRESS. PIPE SEAMLESS CARBON STEEL PIPES

NOTE : MARKS NO. TO BE SEEN THE "GENERAL ARRANGEMENT"

APPROVED K. H. LEE
CHECKED B. G. KIM ELECTRO-HYDRAULIC STEERING GEAR
DRAWN C.M.G MATERIALS FOR PRINCIPAL PARTS
CLASS SCALE
DRAWING No. REV. NO.
YS-ZMP0000-00104-0

YOOWON INDUSTRIES LTD.

DATE 27.DEC.2006 ISSUED
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GENERAL
A. MANUFACTURING
Made under "TECHNICAL LICENSE" agreement with Mitsubishi Heavy Industries,
LTD in japan.

B. CONSTRUCTION OF STEERING GEAR

1. YOOWON - MITSUBISHI - ELECTRO - HYDRAULIC STEERING GEAR
is compact in construction and high in reliability and practical applicability, and comprises the
following components.
2. THIS STEERING GEAR
is 2-Ram, 4-Cylinders, Rapson-slide type and constructed by two variable displacement pumps,
one of which is stand-by.
3. THIS STEERING GEAR
is operated as follows.
a) Auto. pilot(to be supplied by the shipyard)
(Maker & Model : TOKYO KEIKI, PR-9370A-DW-SS2 )
b) Follow-up control.
c) Non follow-up control.
d) Emergency control in steering gear room.
4. CLASSIFICATION AND REGULATION
Yoowon-Mitsubishi steering gear is designed and manufactured so as to meet the latest shipping
classification rule requirements as follow according to MOU.

1) Design
DNVGL
2) Certification
Hno. YZJ2015-2022/23/24 : DNVGL
Hno. YZJ2015-2223 : NK

5. MAXIMUM RUDDER ANGLE

Yoowon-Mitsubishi steering gear is designed so that the ram stops at 37.5° for maximum
rudder angle of 35° to each side.

C. SIMPLE - FORMED SOLID TILLER IS FORK TYPE TILLER WHICH IS COMPLIED

FOR DF(DOUBLE FORK)TYPE STEERING GEAR.
The tiller would be of solid boss keyless type and have ample sectional are based on the rudder stock
diameter and tiller taper fitted to rudder stock by wet-fit.
The tiller is furnished with 0.4mm scraping allowance in diameter of bore.

D. RIGID RAM AND HYDRAULIC CYLINDERS HAVING ADEQUATE WALL THICKNESS

are designed at the design pressure of 1.25 times the maximum working pressure which is expected
under the operational conditions specified in classification society's requirements.

E. RAM-PIN BUSH
The bushes are equipped with a grease nipple for sufficient lubrication between the ram-pin
and pin bush & between the ram-pin bush and tiller fork.

F. SEPARATE AND INDEPENDENT PIPING AND VALVE BOX SYSTEM

Permits any single failure to be easily isolated when such a failure should occur.
Also each valve box contains the transfer valve for non-reverse locking of the stand-by pump.
The relief valves are adjusted at the range of 25% above max. working pressure.
-1-
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G. PUMP CONTROL AND HUNTING MECHANISM

Mitsubishi janney pump, equipped with hydraulic servo mechanism, is low in pump control
force required. The subject steering gear employs the torque motor control system which are
the product of TOKYO-KEIKI

H. SEPARATE AND INDEPENDENT OIL TANKS

are located at the outside of pump for efficient cooling and also compact in size and rigid in
construction.

I. Electric Motor
The three phase induction motor would be designed and manufactured in accordance with the
classification society.
1) Type : Marine T. E. F. C
2) Out put : No.1 : 55kW x 6P
: No.2 : 55/11kW x 6/12P
3) Power source : AC440V, 3Φ, 60Hz
4) Theoretical number of revolution : No.1 : 1,200rpm
: No.2 : 1,200/600rpm
5) Starting method : No.1 : Y-D
: No.2 : D.O.L(High), Y-D(Low)
6) Insulation : "F" class
7) Bearing : No.1 & No.2 : Open sealed type bearing
8) Rating : 25%- Continuous
100%- 1 Hour
200%- 60sec
9) Winding heater : No.1 & No.2 : 1Φ, 18A, 16V `
10) IP grade : IP44

J. ISOLATION SYSTEM WHEN SINGLE FAILURE SHOULD OCCUR

For application to ship other than oil tankers, manual isolation valves are provided for separation
of hydraulic system(I.e disconnecting the failed system) to recover the steering capability speedily
according to the rule requirements part of the steering gear.

K. PAINTING COLOR
1) Steering gear : MUNSELL No. 7.5 BG 7/2
2) Starter panel : MUNSELL No. 7.5 BG 7/2
3) Alarm panel in W/H and ECR: Black with MUNSELL NO. 7.5 BG 7/2

-2-
 6

L. SCOPE OF SUPPLY
QUANTIT YOOWON SHIPBUILDER'S
ITEM NAME
Y SUPPLY SUPPLY
STEERING GEAR
1 1 set 0
1) Tiller (keyless type)
2) Tiller bore scraping - 0
3) Hydraulic cylinder w/oil tray 4 set 0
4) Installation work and fittings
- 0
(Steel liner, stopper & cotter)/ All foundation bolts/nuts
5) Ram 2 sets 0
6) Ram pin & slide bearing 2 sets 0
7) Guide bar 2 sets 0
8) Rudder angle indicator plate 2 sets 0
9) Hydraulic janney pump w/auxiliary pump,
2 sets 0
filter and flexible shaft coupling
10) Electric motor w/element heater 2 sets 0
11) Supply oil tank with thermometer, and
2 sets 0
low level alarm switch and self closing type level gauge
12) Valve block(safety valve, non-reverse locking transfer
2 sets 0
valve, by-pass valve and manual isolation valve)
13) High press. piping formed preset style 1 set 0
14) Press. gauge with gauge valve 6 sets 0
2 Storage tank ass'y w/hand wing pump 1 set 0
Piping and pipe fittings between supply oil tank to
3 - 0
storage tank.
4 Operating instruction plate 2 sets 0
5 Spare parts and tools. 1 set 0
1)Elec. motor driven grease pump for rudder carrier. 1 set 0
6
2)Control box for grease pump. 1 set 0
7 Auto pilot system. 1 set 0
8 Torque motor. 2 sets 0
9 Feed back unit for auto pilot system. 2 sets 0
10 Seat for feed back unit. 1 set 0
11 Rudder angle transmitter and indicator. 1 set 0
12 Seat for rudder angle transmitter. 1 set 0
13 Linkage between feed back unit and tiller. 2 sets 0
14 Linkage between rudder angle transmitter and tiller. 1 set 0
15 All installation work. - 0
16 Working fluid and lubricant. 1 set 0
17 Pipe support.(Plastic clamp/Nuts) 6 sets 0
18 Test operation onboard and sea trial. 1 set 0
19 All cable wiring work for onboard. 1 set 0
20 Hydr. Nut w/ring piston 1 set 0
21 Rudder carrier and bearing 1 set 0
22 Starter panels for S/G electric motor 2 sets 0
23 Audible and visual alarm panel(W/H & E.C.R) 2 sets 0
24 Hydr. Lock alarm system w/proximity sensor and relay box. 2 sets 0
25 Elec. Limit switches 1 sets 0
DATE 18.JAN.2019 ISSUED
 7

RECOMMEND OILS FOR HYDR. & LUBRICATION

(FOR SFM/DFM, SFT/DFT TYPE)
Maker Hydr. Oil for Supply tank Grease for Ram Pin Bush Grease for
Name & Storage tank & Chain Coupling Grease pump / Rudder carrier

Idemitsu Daphne Super Hydro A46, A68 Daphne Eponex Grease No. 2 Daphne Eponex Grease No. 0
Kosan Daphne Super Hydro HF46, HF68 Daphne Eponex EP No. 2 Daphne Eponex EP No. 0
Co., Ltd. Daphne Super Hydro 46X, 68X Daphne Eponex SR No. 2 Daphne Eponex SR No. 0

JK Nippon
Oil FBK Turbine 46, 68 Multinoc Grease 2 Multinoc Grease 0
& Energy Super Hyrando 46, 68 Epnoc Grease AP2 Epnoc Grease AP0
Corp.

Cosmo Oil Cosmo Grease Dynamax No. 2 Cosmo Grease Dynamax No. 0
Super Epoch ES46, ES68
Co., Ltd. Cosmo Grease Dynamax EP No. 2 Cosmo Grease Dynamax EP No. 0

NATURELLE
GREASE S5
Sunlight Grease No.2 Sunlight Grease
V120P 2(VGP2013)
Alvania Grease 2 No.0
Shell Tellues S3 V46, V68
Alvania EP Grease 2 Alvania Grease 0
NATURELLE S2
Gadus S2 V220 2 Alvania EP Grease 0
WIRE ROPE
(VGP2013)

Beacon 2, Lithtan 2 Beacon 0, Lithtan 0

Esso Nuto H46, H68
Nebula EP2 Nebula EP 0

Mobil SHC Aware

Exxon- Mobil DTE 10 Excel 46 Mobilgrease XHP222 Mobilgrease
Grease EP2
Mobil Mobil DTE 10 Excel 68 Mobilith SHC 460 XHP220
(VGP2013)

Caltex Regal R&O 46, 68 Multifak EP2 Multifak EP0

Regal R&O 46, 68

LANOPRO EP
Chevron Turbine Oil GST 46, 68
Multifak EP2 Multifak EP0 GREASE 53
(FAMM) Rando HD Ashless 46, 68
(VGP2013)
Clarity Hydraulic Oil AW46, AW68

Biobar 46,68(VGP2013) Castrol Spheerol AP2, SX2 BIOTAC OG

Castrol Spheerol EPL 0
Perfecto T 68 Biotac MP (EP1) (VGP2013)
BIOMULTIS
Preslia 68 EP2(VGP2013)
Total MULTIS EP2
AZOLLA AF46, AF68 MULTIS EP0 BIOADHESIVE
Lubmarine CERAN XM220
EQUIVIS AF46, AF68 PULS (EP1)
(VGP2013)

Gulf Oil GulfSea Turbine Oil 46, 68 GulfSea HyperBar GulfSea BD EP0
GulfSea HyperBar CS2
Marine Ltd. GulfSea Hydraulic HVI ZF 46,68 Super CS GREASE (VGP2013)

FUCHS PLANTOGEL 2S
RENOLIT CXI2 RENOLIT CX-EP0
(LUK OIL) (VGP 2013)

BIOMULTIS EP2
AEGEAN ALFATURBO 68 ALFAGREASE LI 2 ALFAGREASE LI 0
(VGP2013)

NOTE) Selected oils according to voyage area. FOR J. P REV. 46 06.NOV.2018

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S . .
15
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PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

5 sheets with cover

APPROVED

CHECKED H.D.H
YDFT-200-2
ELECTRO-HYDRAULIC STEERING GEAR
DRAWN K.J.G 55kW & 55/11kW ELEC. MOTOR
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-MHS2022-00500-2

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
17
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PLAN RECORD REVISIONS AP- CHECK-

No. DESCRIPTION (DATE) PROVED ED
2
06.11.16
符号160.ORIFICE 追記 北村 玉島 上原

5 SHEET(S) WITH COVER

PRODUCTION DESIGNING GROUP
MACHINERY DEPARTMENT

APPROVED
K.Morita ＭＩＴＳＵＢＩＳＨＩ ＪＡＮＮＥＹ ＰＵＭＰ
CHECKED S.Takayama ＴＹＰＥ ３Ｖ－ＦＨ２Ｂ－ＭＫ
DRAWN T.Sumiyoshi
SCALE ＰＡＲＴＳ ＬＩＳＴ
ORDER DRAWING No.
STANDARD ＲＡ３３００－２２１－０ 4
DRAWN APR.9.1985
 24
SYNTHETIC
42 O RING RA3300-211-0 42 RUBBER 1 361-031-085-1
SPECIAL
41 KEY 41 STEEL 1 200-118-072-1
SPRING
40 E RING 40 STEEL 4 YA3902-001-0
SPRING
39 RETAINING RING 39 STEEL 1 YA3904-004-0
SPRING
38 SNAP RING 38 STEEL 1 YA3901-003-0
SPRING
37 SNAP RING 37 STEEL 1 250-000-070-1
SPECIAL
36 SOCKET CAP SCREW 36 STEEL 8 YA9201-049-0
SPECIAL
35 SOCKET CAP SCREW 35 STEEL 4 YA9201-054-0
SPECIAL
34 SOCKET CAP SCREW 34 STEEL 4 YA9201-108-0
SPRING
33 SPRING PIN 33 STEEL 4 189-050-014-3
SPRING
32 SPRING PIN 32 STEEL 1 189-080-022-3
SYNTHETIC
31 OIL SEAL 31 RUBBER 1 YA9101-012-0

SPRING
29 SPRING - PILOT RELIEF VALVE 29 STEEL 1 JT0300-833
SPRING
28 SPRING - BOOST RELIEF VALVE 28 STEEL 1 JT0300-807
SPRING
27 SPRING - CYLINDER BARREL 27 STEEL 9 DA3300-803-0
SPECIAL
26 ADAPTER - PILOT RELIEF VALVE 26 STEEL 1 DV3300-402-0
SPECIAL
25 SPOOL - PILOT RELIEF VALVE 25 STEEL 1 JT0300-831
SPECIAL
24 CAP - PILOT RELIEF VALVE 24 STEEL 1 DV3300-404-0
SPECIAL
23 SPOOL - BOOST RELIEF VALVE 23 STEEL 1 JT0300-805
SPECIAL
22 CAP - BOOST RELIEF VALVE 22 STEEL 1 DV3300-405-0
SPECIAL
21 LINK PIN 21 STEEL 2 DA3300-411-1
SPECIAL
20 LINK 20 STEEL 2 DA3300-410-1
19 SUB PLATE 19 STEEL 1 DZ3300-411-0

SPECIAL
17 PISTON ASS'Y 17 STEEL
9SETS DB3300-321-0
SPECIAL
16 SOLID CAM 16 STEEL 1 DB3300-402-0
15 CAM BEARING 15 CU ALLOY 2 DB3300-431-0
SPECIAL
14 FRONT PLATE 14 CAST IRON 1 DB3300-603-0
SPECIAL
13 CASING 13 CAST IRON 1 DB3300-601-1
SPECIAL
12 ADAPTER 12 STEEL 1 DZ3300-402-0
SPECIAL
11 END PLATE 11 CAST IRON 1 DB3300-612-0
SPECIAL
10 VALVE PLATE 10 CAST IRON 1 DB3300-511-0
BEARING
9 PIN 9 STEEL 1 NT0150-808-0
8 CYLINDER BARREL 8 CU ALLOY 1 DB3300-501-1
SPECIAL
7 OLDHAM'S COUPLING 7 STEEL 1 DZ3300-401-0
BEARING
6 ROLLER BEARING 6 STEEL 1 YA3206-029-0
BEARING
5 ROLLER BEARING 5 STEEL 1 YA3206-023-0
SPECIAL
4 SEAL BOX 4 STEEL 1 DA3300-604-0
SPECIAL
3 RETAINER 3 STEEL 1 DA3300-502-1
2 RETAINER BALL 2 BRONZE 1 DA3300-503-1
SPECIAL
1 DRIVE SHAFT RA3300-211-0 1 STEEL 1 DB3300-451-0
DRW
MARKS DESCRIPTION DRAWING NO. PART MATERIALS WORK PART NO.
NO.
 25

SPECIAL
60 BEARING PIN RA3300-211-0 60 STEEL 2 DB3300-432-0
SPECIAL
59 PLUG 59 STEEL 2 YA4501-003-0
SPECIAL
58 PLUG 58 STEEL 2 352-201-802-3
SPECIAL
57 PLUG 57 STEEL 4 352-201-803-3
SPECIAL
56 SUCTION VALVE ASS'Y 56 STEEL
2SETS GA0400-301-0
55 HEXAGON NUT 55 STEEL 1 150-012-510-1
SPECIAL
54 SET SCREW 54 STEEL 1 178-451-032-3
SYNTHETIC
53 O RING 53 RUBBER 1 YA9107-116-0
SYNTHETIC
52 O RING 52 RUBBER 1 363-204-026-1
SYNTHETIC
51 O RING 51 RUBBER 2 361-031-035-1
SYNTHETIC
50 O RING 50 RUBBER 1 361-057-150-1
SYNTHETIC
49 O RING 49 RUBBER 1 363-204-040-1
SYNTHETIC
48 O RING 48 RUBBER 1 363-204-047-1
SYNTHETIC
47 O RING 47 RUBBER 7 360-019-010-2
SYNTHETIC
46 O RING 46 RUBBER 1 360-024-018-1
SYNTHETIC
45 O RING 45 RUBBER 1 360-024-021-1
SYNTHETIC
44 O RING 44 RUBBER 1 360-024-022-1
SYNTHETIC
43 O RING RA3300-211-0 43 RUBBER 2 360-031-030-1
DRW
MARKS DESCRIPTION DRAWING NO. PART MATERIALS WORK PART NO.
NO.
 26
142 HEXAGON NUT RA3300-211-0 142 STEEL 1 YA9203-013-0
SPRING
141 SET SCREW 141 STEEL 1 178-450-404-3
SPRING
140 SPRING PIN 140 STEEL 1 189-060-020-3
SPRING
139 SNAP RING 139 STEEL 1 YA3901-014-0
SPRING
138 SNAP RING 138 STEEL 1 251-000-030-1
SPRING
137 SPRING PIN 137 STEEL 1 189-025-018-3
136 BEARING LOCK WASHER 136 STEEL 1 168-700-007-0
135 BEARING LOCK NUT 135 STEEL 1 161-006-035-1
134 HEXAGON NUT 134 STEEL 2 152-012-508-1
133 HEXAGON BOLT 133 STEEL 2 YA9201-112-0

SPECIAL
131 SOCKET CAP SCREW 131 STEEL 1 141-506-020-3
SPECIAL
130 SOCKET CAP SCREW 130 STEEL 8 141-516-035-3
SPECIAL
129 SOCKET CAP SCREW 129 STEEL 4 YA9201-150-0
SPECIAL
128 SOCKET CAP SCREW 128 STEEL 6 141-512-030-3

SPECIAL
126 ADAPTER 126 STEEL 2 DR3300-424-0
SPRING
125 SPRING 125 STEEL 1 DR3300-802-0
SPRING
124 SPRING 124 STEEL 1 DR0600-801-0
SPECIAL
123 SCALE PLATE 123 BRONZE 1 DR0600-423-0
SPECIAL
122 INDICATOR 122 BRONZE 1 DR0600-422-0

SPECIAL
120 PIN 120 STEEL 1 DR0600-421-0
SPECIAL
119 SPACER 119 STEEL 1 DR0600-420-0
SPECIAL
118 SHAFT 118 STEEL 1 DR0600-419-0
SPECIAL
117 ROD 117 STEEL 1 DR3300-418-0
SPECIAL
116 PLUG 116 STEEL 1 DR0600-417-0
SPECIAL
115 ADJUST SCREW 115 STEEL 1 DR3300-416-0
114 LOCK NUT 114 STEEL 1 DR3300-415-0
SPECIAL
113 SPRING SEAT 113 STEEL 2 DR3300-414-0
SPECIAL
112 SPRING HOLDER 112 STEEL 1 DR3300-412-0
SPECIAL
111 VALVE 111 STEEL 1 DR3300-411-0
SPECIAL
110 SLEEVE 110 STEEL 1 DR3300-410-0
SPECIAL
109 ARM 109 STEEL 1 DR0600-409-0
SPECIAL
108 PIN 108 STEEL 1 DR3300-408-0
SPECIAL
107 LINK 107 STEEL 1 DR3300-407-0
SPECIAL
106 HINGE 106 STEEL 1 DR3300-413-0
SPECIAL
105 SLEEVE 105 STEEL 1 DR3300-405-0
SPECIAL
104 PISTON 104 STEEL 1 DR3300-404-0
SPECIAL
103 VALVE CASE 103 CAST IRON 1 DR3300-403-0
SPECIAL
102 COVER 102 CAST IRON 2 DR3300-402-0
SPECIAL
101 CASING RA3300-211-0 101 CAST IRON 1 DR3300-401-0
DRW
MARKS DESCRIPTION DRAWING NO. PART MATERIALS WORK PART NO.
NO.
 27

160 ORIFICE RA3300-211-0 160 STEEL 2 YA4504-050-0

SYNTHETIC
159 V RING 159 RUBBER 1 YA9105-003-0
158 LOCK NUT 158 STEEL 1 DR0600-425-0
SPECIAL
157 PLUG 157 STEEL 10 352-201-801-3
SYNTHETIC
156 O RING 156 RUBBER 1 360-019-008-1
SPRING
155 SPRING PIN 155 STEEL 2 189-060-014-3
SPRING
154 SPRING PIN 154 STEEL 1 189-060-012-3
153 UNION ASS'Y 153 STEEL 1SET YB4211-001-0
152 AIR VENT PLUG 152 STEEL 1 YA4501-006-0
SYNTHETIC
151 O RING 151 RUBBER 1 360-019-006-1
SYNTHETIC
150 O RING 150 RUBBER 4 360-019-010-1
SYNTHETIC
149 O RING 149 RUBBER 2 360-024-014-1
SYNTHETIC
148 O RING 148 RUBBER 1 YA9107-115-0
SYNTHETIC
147 O RING 147 RUBBER 1 360-035-025-1
SYNTHETIC
146 O RING 146 RUBBER 1 360-035-032-1
SYNTHETIC
145 O RING 145 RUBBER 2 361-031-085-1
SYNTHETIC
144 O RING 144 RUBBER 1 361-031-075-1
SPECIAL
143 SCREW RIVET RA3300-211-0 143 BRONZE 4 174-200-004-1
DRW
MARKS DESCRIPTION DRAWING NO. PART MATERIALS WORK PART NO.
NO.
 28
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

13 sheets with cover

APPROVED
CHECKED H.D.H
YDFT-200-2
ELECTRO-HYDRAULIC STEERING GEAR
DRAWN K.J.G LIST OF SPARE AND TOOL
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.: YS-RDT2022-MS000-0

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
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PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

4 sheets with cover

APPROVED

CHECKED ELECTRO-HYDRAULIC STEERING GEAR

DRAWN K.J.G PARTICULARS OF SHOP TEST
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-ZD00000-MS000-0

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
 55

TESTING ITEM

Ⅰ PURPOSE

The purpose of this test is to determine the function of electro-hydraulic ram type
steering gear made by YOOWON and to check propriety of this gear for various
sorts of use.
We do not carry out the load test of electric motors, because they are tested by their
maker. The load test of hydraulic pump is carried out individually.

Ⅱ METHOD OF TEST

In this test, load is not applied to the rudder stock but we simply set the ram in
motion for various method of use. Function of this gear, and propriety of
maneuvering and hunting gear are examined.

Ⅲ ARRANGEMENT

The gear is fitted to the surface plate in our fitting shop as shown in the
“GENERAL ARRANGEMENT”, and the gauges and instruments are fitted suitably.
The tiller is made temporarily.

Ⅳ DETAILS OF TEST

The voltage is held at about AC 440V and the revolution of the motor at about
1200 rpm.
Operating the mechanical handle, three kinds of the test shown on (B) are carried
out by steering as shown on (A).
At the test, necessary items such as time required, oil pressure, and motor input
are recorded.

-1
 56

(A) Steering Test Mode

Above operating mode is carried out for each case 1,2 and 3.
The turning time for each operation ①, ②, ③ and ④ are recorded.

(B) Classifications of Equipments in working

WORKING WORKING BY-PASS VALVE STOP VALVE

CASE
PUMP CYLINDER
A B No.1 No.2
1 1 X X ○ ○
2 2 1,2,3,4 X X ○ ○
3 1 & 2 X X ○ ○

Valve conditions 0 : open , X : closed

(C) Motions for emergency operation shall be confirmed after above mentioned normal
operation test as follows.

WORKING WORKING BY-PASS VALVE STOP VALVE

CASE
PUMP CYLINDER
A B No.1 No.2
4 1 1 & 2 X X X ○
5 2 3 & 4 X X ○ X

V. Requirements of the rudder turning speed

(1) Normal condition : 65 deg / 28 sec. with 1 pump running.

(2) Emergency test : 30 deg / 60 sec. with 1 pump running.

-2
57
 58
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

3 sheets with cover

APPROVED

CHECKED H.D.H
ELECTRO-HYDRAULIC STEERING GEAR
PARTICULARS OF SHOP TEST
DRAWN K.J.G FOR TYPE 3V-FH2B-MK JANNEY PUMP
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-ZKD2022-30202-0

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
 59

1. HYDRAULIC CIRCUIT OF THE TESTING FACILITY

SERVO
2

M 1

PACKAGED PUMP UNIT

FOR TESTING

2. SPECIFICATION

SPECIFICATION

MODEL 3V-FH2B-MK
THEORETICAL NUMBER OF REVOLUTION N 1,200 rpm
RATED TILTING ANGLE ΦD 58 %
THEORETICAL DELIVERY OIL QUANTITY Qd 228 ℓ/min
220 kgf/㎠
RATED PRESSURE Pd
(21.6) (Mpa)
275 kgf/㎠
MAX. PRESSURE Pmax.
(27) (Mpa)
2 kgf/㎠
BOOST PRESSURE Pb
(0.20) (Mpa)
55 kW
ELEC. MOTOR 25% cont.
Ni
100% 1hr
200% 60sec

-1
 60

3. ADJUSTMENT
1) Set the boost relief valve at ( 2 )kgf/㎠. 1
2) Set the servo relief valve at ( 14 )kgf/㎠. 2

4. PERFORMANCE TEST
1) Set the tilting angle at(ΦD)%maintaining boost pressure at (2) kgf/㎠
and continue this condition for 15min.
2) Reverse the tilting angle at (ΦD)% with same condition and interval.
3) Operate the pump with the condition as shown in table 1.
4) The test number 3,4 as shown in table 1 shall be operated for 30 seconds.

Table 1
TEST NUMBER 1 2 3 4
TILTING ANGLE +ΦD -ΦD +ΦD -ΦD
PRESSURE Pd/2 Pd/2 Pd Pd

5. OVER PRESSURE TEST

1) Increase the system pressure up to (Pmax.) kgf/㎠ at the tilting angle
of (ΦD)% for 5 sec.

6. ENDURANCE TEST
1) Operate the pump for 30 min, keeping the tilting angle at (ΦD)%
and at pressure of (Pd/2) kgf/㎠, Reverse the tilting angle at (ΦD)%
with same condition and interval.

7. NOTE
1) In any condition the temperature must not exceed 80℃.
2) A temporary electric motor provided in the shop will be used in
the shop test.

-2
 61
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

12 sheets with cover

APPROVED

CHECKED H.D.H STARTER & ALARM PANEL

DRAWN K.J.G FOR STEERING GEAR
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-EDT2022-00300-1

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
62
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 YOOWON

2 3 24 2 3

4 5 4 5

6 7 15 6 7

8 9 8 9

10 19 16 10 19

20 21 20 21

22 23 17 22 23

11 25 14 12 13 14
18
MOTOR MOTOR MOTOR MOTOR MOTOR
RUN STOP R UN(HIGH) R UN(LOW) STOP

BUZZER

FUSE 1

DC SOURCE
YOOWON ELECTRIC
70
71
 YOOWON

2 3 24 2 3

4 5 4 5
6 7 13 6 7

8 9 8 9
10 19 14 10 19

20 21 20 21

22 23 15 22 23

11 25 14 12 13 14
16
MOTOR MOTOR MOTOR MOTOR MOTOR
RUN STOP RUN(HIGH) RUN(LOW) STOP

B UZZER

FUSE 1
DIMMER DC SO URCE
YOOWON ELECTRIC
72
73
 74
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

5 sheets with cover

APPROVED

CHECKED H.D.H
HYDR. LOCK ALARM SYSTEM
DRAWN K.J.G
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-EH00000-00001-0

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
75
76
77
78
 79
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

2 sheets with cover

APPROVED

CHECKED H.D.H SPARE PART LIST

DRAWN K.J.G FOR ELECTRICAL EQUIPMENT
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-EDT2022-00400-1

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
80
81
 82
PLAN RECORD REVISIONS
APPROVED CHECKED
ISO METRIC SCREW THREAD No. DESCRIPTION(DATE)

10 sheets with cover

APPROVED

CHECKED H.D.H GREASE LUBE SYSTEM

DRAWN K.J.G FOR RUDDER CARRIER
CLASS SCALE
DRAWING No. REV. NO.
SERIAL No.:
YS-EGP0000-0P800-0

YOOWON INDUSTRIES LTD.

DATE 18.JAN.2019 ISSUED
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1 3 5

2 4 6

1 3 5 31 43

2 4 6 32 44

1 3 5 95 97

2 4 6 96 98
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 OPERATING & MAINTENANCE INSTRUCTION FOR

GREASE LUBRICATION SYSTEM

Customer : YOOWON INDUSTRIES CO., LTD.

Project Name : YZJ2015-2223

Equipment : 1) Motor Driven Grease Pump

( TYPE : EGP4S-MLA )
2) Manual Grease Pump
( TYPE : HS-115 )
3) Filling Pump
( TYPE : FP-1 )
4) Distributor
(TYPE : M-7)
5) Control Panel
(TYPE : HCMP-HSO1)

Advanced Technology In Centralized Lubrication

TEL +82-31-491-8251, FAX +82-31-491-8226 ANSAN, KOREA
 CONTENTS

1. Gemeral ------------------------------------------------------------------------------------------ 1

1.1. Structure ------------------------------------------------------------------------------------ 1

2. Motor driven grease pump --------------------------------------------------------------------- 2

2.1. Specification -------------------------------------------------------------------------------- 3

2.2. Relief valve --------------------------------------------------------------------------------- 3

2.3. Tank ---------------------------------------------------------------------------------------- 3

3. Manual grease pump --------------------------------------------------------------------------- 4

3.1. Specification -------------------------------------------------------------------------------- 4

3.2. Operation ----------------------------------------------------------------------------------- 5

3.3. Caution of filling grease ------------------------------------------------------------------ 5

3.4. Adjustment of discharge volume --------------------------------------------------------- 5

3.5. Repair and check -------------------------------------------------------------------------- 6

4. Filling pump -------------------------------------------------------------------------------------- 8

4.1. Specification -------------------------------------------------------------------------------- 8

4.2. Out of order ------------------------------------------------------------------------------- 8

4.3. Parts exchange ---------------------------------------------------------------------------- 8

4.4. Caution of filling pump disassembly ---------------------------------------------------- 8

5. Distributor ---------------------------------------------------------------------------------------- 10

4.1. Repair --------------------------------------------------------------------------------------- 10

4.2. Operation ----------------------------------------------------------------------------------- 10

6. Control Panel ------------------------------------------------------------------------------------ 11

6.1. Dimension ---------------------------------------------------------------------------------- 11

6.2. Terminal Block ----------------------------------------------------------------------------- 12

6.3. Control circuit ----------------------------------------------------------------------------- 13

6.4. Technical Data ----------------------------------------------------------------------------- 13

6.5. Control modes ----------------------------------------------------------------------------- 15

6.6. Displays of Time values and Faults on LEDs ------------------------------------------- 16

6.7. Trouble shooting --------------------------------------------------------------------------- 17

7. Troubleshooting and Remedy ------------------------------------------------------------------ 17

1. General
The system operates automatically according to the settings of the pause and operation
interval of electric control panel as single line lubrication system, which supplies specific
volume of grease to the lubrication points through distributor, And manual grease pump is
used on the occasion of trouble occurrence of motor driven grease pump.

1-1. Structure
This system is composed of motor driven grease pump which supplies oil or grease in
pressure, manual grease pump, piping, distributor, filling pump, and electric control
panel which is required to operate system as shown in Fig. 1.

Fig. 1

Motor driven grease pump is mounted on metal base with main pump, motor, and
pressure gauge which shows discharge pressure, and the indicating rod installed at
upper part of the tank of the pump shows the amount of grease.
Distributor should be selected to appropriate type according to the lubrication necessary
as point number and required volume, which should be located in the smallest distance
with lubrication points.
The electric control panel automatically optimizes lubrication system and the filling
pump is provided to send clean grease to reservoir tank of pump.
 2. Motor driven grease pump (Type : EGP4S-MLA)
The geared motor of pump lets the cam turn, and the pump sucks and discharges the
grease by means of reciprocation of piston.
The tank at higher part of pump reservoirs grease. The lower plate and indicating rod is
installed inside the tank in order to show the grease level, whick prevents the grease
from over-flow.
If the low level switch is actuated as the grease level in tank becomes lower, grease
pump will stop and alarm will be informed.

fig. 2

2.1. Specification
DESCRIPTION ITEM TYPE AND SIZE REMARK
TYPE EGP4S-MLA
DISCHARGE CAPACITY 25
(㏄/min.)
MOTOR DRIVEN
DISCHARGE 210
GREASE PUMP PRESSURE(㎏f/㎠)
TANK VOLUME(L) 4
40w, 4P, 3Φ
MOTOR
AC440V, 60Hz

2.2. RELIEF VALVE

Relief valve is installed at pump body and opened when excessive pressure acts above set
ting pressure, which protects the pump
 MAX. RELIEF VALVE SETTING
PUMP TYPE DISCHARGE PRESSURE
PRESSURE
EGP4S-MLA 210㎏f/㎠ 150㎏f/㎠

Because these limits are adjusted properly at factory, do not try to change them.

2.3 TANK
2.3.1 TANK
Lower plate lets grease surface flat as a barrier against air contact. Level indicating rod p
asses through the cover. And air vent plug which is used to eliminate the remaining air at fi
rst is located at the end part of the indicating rod, where valve seat functions as a cam to
operate the switch.

fig. 3
 2.3.2 LOW LEVEL SWITCH
The air could be inhaled from outside while the tank is getting empty in proportion of
grease consumtion. If air trap exists in pipng, lubricatiom becames disorder eminently. And
all grease in piping should be replaced by new one in order to expel the air inside the pipe.
In this reason, low level switch is equipped to stop pump with alarm, which is actuated
when the grease in tank is consumed by some specific amount.
As grease is consumed, lower plate goes down and the indicating rod assembled together
moves simultaneously, where the cam is attached and it operates the low level switch. This
signal is transmitted to the electric control panel to inform alarm and pump stops in series.

3. Manual grease pump (HS115)

This pump is manual type used in single line lubrication system and operated by handle
work, which supplies specific amount of grease.

fig. 4
3.1. Specification
DESCRIPTION ITEM TYPE AND SIZE REMARK
TYPE HS115
DISCHARGE CAPACITY 1.5
MANUAL (cc/min.)
GREASE PUMP DISCHARGE 100
PRESSURE(㎏f/㎠)
TANK VOLUME(L) 1

3.2. Operation
The pump structure is separated into pump body and handle, which is operated by
moving the handle front and back and the pinion assembled at the handle axis
operates the rack of piston, which pressurizes the grease out with pushing the check
piston. Additionally, indicating rod shows the grease level with upper and lower limit
marking. If the indicating rod of tank which shows the grease level reaches the lower
limit, fill the grease until the indicating rod reaches the upper limit.
3.3. Caution of filling grease
3.3.1 To fill grease to the grease tank, use the filling pump (TYPE : FP-1(U)), which fills
grease through the filling port equipped at pump. In case of pouring grease in with
opening the cover, air and dust may be mixed, which induces suction fail and the
other malfunction.
3.3.2. The using grease is NLGI #0(penetration No. above 350), or NLGI #1(penetration
No. 310340)
3.3.3. If the pump is used after long period, the grease discharged out at start time with
handle work should be wasted.

3.4. Adjustment of discharge volume

Adjustment lock washers as shown in Fig. 5 appear when cover plugs at both side of
pump are loosed off. There are the lock washers in front of piston sleeves shown in Fig.
6.
3.4.1. Put the projection located at outside perimeter of adjustment lock washer into the
groove which is so
prepared to fix the washer.
3.4.2. Washer has the 1-2-3-4 prints stamped with four projection at the inside of the ring,
which should be
assembled to with the number stamped side to external
3.4.3. To adjust the maximum discharge volume, align the groove of piston sleeve to the
direction of No. 1 projection with bending it.
 Fig. 5 Fig. 6
3.3.4. The groove direction of piston sleeve is able to be aligned to the each 2-3-4
projection for volume
adjustment.
The pump is adjusted to deliver the maximum discharge volume (groove is fit to
No.1 projection) at factory.

3.5. Repair and check

3.5.1. Safety sheet
Safety sheet(BLOW OUT) is auxiliary method such as electric fuse in order to protect
pump from damage at excessive pressure.
SIZE BREAKING PRESSURE REMARK

0.60mm 210㎏f/㎠ GREASE

0.30mm 105㎏f/㎠ OIL

1) The case of safety sheet breaking

① The safety sheet broken from the use for a long time shall be replaced.
② If the safety sheet is broken by the use of the grease of low temp.-heavy, grease
should be replaced by new one.
③ Do not use thick sheet without particular purpose.
④ The safety sheet installed improperly causes the leakage with pushing the side
edge, which spoils the safety sheet.

2) The case of continual safety sheet breaking

① From Brg. growth
② When the passage of line or piping is enclosed.
③ The breakdown of lubrication system occurs from the use of improper filter. (line
or check valve is closed with rigid matters)
④ Malfunction of check valve ( item ③. and 3.5.2. 4) )
a. Do not use the similar plate different in sort or the thing such as coin to the
alternative.
3.5.2. Low pressure of pump
If the pump doesn't support the sufficient pressure for the lubrication system, the
condition of low pressure has occurred, The causes and repair steps are explained in
followings.
1) If air occurs in pump body, open the air cock to take the air out, and operate the
pump until the grease comes out continuously.
2) At empty tank, fill the tank with clean grease.
3) Get the 3 nuts of tie bolt loose (Take care of not loosing the nut completely at
this time), and extrude the air out with the strength of spring.
4) The valve lack in quality induces feed back to premier piston of pump body.
① The causes of feed back
a. Valve is fixed tightly in open position.
b. Foreign matter is nuit up at O-ring seal.
c. Piston is located at one place without operation.
5) Cleaning is needed at the occurrence of feed back.
① Disassemble step for check valve

Fig. 7
a. Take the two bolt(HEX. BOLT) off, and the check valve body apart from pump body.
b. Release the 2 plug③ with gasket②.
c. Take piston① out (confirm whether the piston in cylinder moves smoothly well in
cylinder
at reassemble)
d. Release the plug⑦ and take the spring⑥ out.
e. Take the valve⑤ out with o-ring④.
f. To assemble, reverse this order.
6) If the pressure of pump is still low even after the air is vented and the check valve is
cleaned, the pump body may have the problem.
4. Filling pump
The one filling pump may fill several grease pumps with ease.
After the socket at the end of rubber hose is connected with the filling port of the pump
and if handle is operated manually by moving front and back, the spindle lets the piston
move up and down in cycle and the grease is filled to the tank.
In condition that suction is not performed well at start time, use a little oil instead of the
grease in suction part for operation.

4.1. Specification
DESCRIPTION ITEM TYPE AND SIZE REMARK
TYPE FP-1
DISCHARGE CAPACITY 30
(㏄/min.)
FILLING PUMP
DISCHARGE 30
PRESSURE(㎏f/㎠)
TANK VOLUME(L) 18Liter/Pail

4.2. Out of order

4.2.1 If leakage occurs at gland, the o-ring or back up-ring should be checked and
replaced.
4.2.2 In case that discharge volume decreases, some matters may close the suction valve,
so disassembly and cleaning is needed.

4.3. Parts exchange

The O-ring such as that of valve piston may be spoiled to decrease the discharge
volume.

4.4. Caution of filling pump disassembly

4.4.1 Do not use vise or pipe wrench to disassemble or assemble the suction pipe in
which the valve piston moves up and down in cycle.
4.4.2 To take the valve cap of suction apart, use the screw driver.
Fig. 10
5. Distributor
The distributor is of the progressive-operating type and send grease to each supplication
point in series, if one cycle is over, the indicating pole acts. Check the indicator often,
because a distributor in malfunction causes for all distributors not to operate in this system.
5.1. Repair
The wrong assembled gasket causes malfunction of operation in case, so the precise
caution is needed for this at assembling, and the piston shall be put together again
with good cleaning.
Cf.) ① The distributor marked "T" shall utilize the both side in symmetry and the
other marked "S" only one side with holes of the different side all plugged.
② The discharge volume of the distributor marked "S" is twice as much as that of
the one marked "T", which has two discharge ports in contrast with the
previous one.

5.2. Operation

Fig. 11

5.2.1. The grease pressurized by pump goes into the center of the cylinder of distributor
unit through supply line(inlet flow).
5.2.2. The grease goes into A1, B1, C1 chamber when the piston A, B, C is located at
right, and C2 chamber is filled with the grease supplied through slender path, which
pushes the piston to the left direction.
5.2.3. As piston moves in the left direction, the grease filled in C1 chamber is sent to the
discharge port No. 1.
5.2.4. Simultaneously the grease pressurized by pump goes into the B2 chamber.
5.2.5. After operation has been performed by the way of progressive-operating by No. 3
discharge port, the piston gets to move to the opposite direction, and grease is
discharged in series by No. 6, which is performed continuously to discharge grease as
progressive operation system.
6. Control panel
This control panel is used for automatic operation of HEP type grease pump. This can
start motor pump automatically by timer setting and the operation stops automatically
after one process of lubrication. A inter-lock functions are provided to realize unmanned
operation of this system.

6.1. Dimension

Fig. 12

NP1 Grease control board : plaque

NP2 LED for Power(Green) : The electricity will come if power(DC 24V or 12V) is supplied.
When the word LED is flashed, it means the time you have to wait. if you fix the
waiting time, it will disappear.
NP3 LED for Rest(Green) : The green lamp, which signals the pump is not working because
its cycle is fixed.
NP4 LED for Run(Red) : When the motor operates, it ignites, which means the pump is
working. if you fix the time. it will disappear.
NP5 LED for Cycle(Red) : When you operate by the Count mode, it will ignite, if the count
mode is fixed, it will disappear.
NP6 Button for Value Increase( ▲ ) : When you press the button switch as a way of
increasing the time fixed, it will increase. Pressed for a short time, It will increase by
one unit, but pressed for a long time, It will increase quickly.
NP7 Button for Value Decrease( ▼ ) : When you press the button to reduce the time fixed,
 it will be reduced. pressed for a short time, It will be reduced by one unit, But pressed
for a long time, it will be reduced quickly.
NP8 Button for Move/Confirm( ↵ ) : It is used to select some categories, or put in the
time fixed or select the mode lf operating.
NP9 Button for Reset(RES) : It is the press Button that is used to turn back to the
lubrication system, the original system at the beginning of the stage where the
electricity control board is provided with the power. Before pressing the button, if there
is some warning sound, you should turn it off.
NP10 LED for Local(Red) : If there is Local mode, you should turn it on.
NP11 LED for Remote(Red) : If there is Remote mode, you should turn it on.
NP12 Button for mode(Local/Remote) : It is the press Button that is used to select Local
mode or Remote mode.
NP13 Button for Start : It is the press Button that is used to operate the Grease Pump.
NP14 Button for Stop(Emergency) : It is the press Button that is used to stop operating the
PUMP.

6.2. Terminal Block

Fig. 14
 6.3. Control circuit

1 3 5

2 4 6

1 3 5 31 4 3

2 4 6 32 44

1 3 5 95 97

2 4 6 96 98

Fig. 13
6.4 Basic Functions
HCMP control panel is a micom type control PCB which automatically drives and stops of
motor pumps. It provides 2 kinds of operating modes. Timer mode and counter mode. and
an add up function.
1) Operating modes
A. Timer Mode In this mode. the pump runs for a programmed run lime and pauses for a
programmed rest lime. The controller repeats rest stage and run stage continually.

Pump On(=Run)

PumpOff(=Rest)
Rest Run Rest Run Rest

B. Counter Mode This operating mode makes the pump run until the numbers of contacts
from a cycle switch reaches the programmed count number. As the rest lime ends. the
controller provides electric power to pump motor. then the pump makes the distributor work
and the cycle switch on the distributor gives contact signal to PCB. When the contact signals
reaches programmed numbers. the controller cuts oft electric current to the pump. If the
contact signals do not reach the programmed numbers. an over-time alarm is raised.
 Pump on(=Run)

PumpOff(=Rest)
Rest Run&Count Rest Run&Count Rest
Protection time off on off on off

2) Add-up tunction
If power source to the controller is cut off during a certain stage. For example. under the
conditions at 8 hours rest time and 5 minutes run time. it power source is cut off after 2
hours since rest time has started and the controller gets turned on again in some hours
thereafter, the controller will go on remaining 6 hours of the 8 hrs rest time. If power
source is cut off again after 3 hours since remaining rest time has started. the controller
will go on remaining 3 hours of the rest time as it is turned on again and then will enter
to run time.

Example) Rest time : 8 hours. Run time 5 minutes

Power
On Pump On(Run)

Pump Off(Rest)
Power Rest Run Rest Run
Power On,
Off Rest o ff Rest o ff
3hrs 3hrs Accumulated
2hrs 3hrs 3hrs 5min 8hrs 5min
Rest Time: 5hrs
Accumulated Rest Time: 5hrs

3) Display of Set value and Elapsed value on FND

Index value Elapsed value
Item Set value
Display Unit of increase Display Unit of increas
0.0 - 9.9 0.0 - 9.9 0.1 hrs(-6 min) 0.0 - 9.9 .1 hrs(=6 min)
Rest time(hrs)
10 - 99 10 - 99 1 hrs 1 - 99 1 hrs
0.1 - 9.9 0.1 - 9.9 0.1 min( 6sec) 0.1 - 9.9 0.1 min( 6sec)
Run time(Protection time)(min)
10 - 99 10 - 99 1 min 1 - 99 1 min

4) Display of Faults (3 LEDs blink fast at the same time)

Item Over-time running Low Level in reservoir

In count mode, when cycle
When low level is detected
Display contacts does not reach the set
by level switch(Level switch
value within protection time, this
is an optional item)
fault is raised.

Item Abnormal High Pressure Overload of motor

When abnormal high pressure is

When overload of motor is
detected by a pressure
Display detected by overload
switch(Press. switch is an optional
switch
item)
6.5 To check the programmed values
Control PCB shows current status by means of the FND and LEDs. The numberss
appeared on the FND are elapsed values.
Programmed values are displayed by depressing button. In any operating process,
the firstly depressing of button shows the programmed rest time.
1) Factory settings
*Operating Mode : Timer
*Rest time : 6hrs *Run time(Protection time in Counter mode) : 2min *Count : 5times
2) How to check the programmed values.
Example 1. In timer mode In counter mode(optional item)
Status Status
Butt Butt-
Step Display LEDs Step Display LEDs
-on on
FND & Meaning FND & Meaning
REST RUN
LED for REST is on. LEDs for RUN and Cycle
POWER

1. - *Elapsed REST time 1 - are on.

*Number of cycle ontacts
*2.4hrs(=2hrs and 24min) POWER CYCLE

elapsed. *Cycle contacts counted 3.

REST RUN
POWER

LED for REST blinks. LED for Cycle is on and

2 Programmed REST time 2 LED for REST blinks.
6.8hrs(= 6hrs 48min). POWER CYCLE
Programmed REST time
REST is 6hrs
POWER

LED for RUN blinks RUN

3 Programmed RUN time LED for Cycle is on and
3 LED for RUN blinks.
5.3min (= 5min 18sec)
Programmed Protection
POWER CYCLE

REST
time is 10min
LED for REST is on.
POWER

*Elapsed REST time RUN

4 -
LED for Cycle blinks.
*2.4hrs(=2hrs and 24min) 4
elapsed. POWER CYCLE Programmed COUNT is 8
times.
RUN
Note)
1. To leave an LED blinking for 10 seconds LEDs for RUN and CNT
without no button input makes the displays are on.
return to show current status. 5 - *Numbers of cycle
2. At the step 4 above, the displayed number POWER CYCLE
contacts
of elapsed rest time is may be more than
2.4 because timer in the PCB keeps going *Cycle contacts counted 3.
during the steps above.
Note)
Legend - LED lights At the step 5 above, the displayed number of
cycle count is may be more than 3 because the
unlit being lit blinking pump is still running and the counter in the PCB
keeps going during the steps above.
6.6 Programming (Time Setting)
Firstly, select one of 2 operating modes then input the values required for the selected mode.
Check the programmed values by depressing the button then input new data with the ,
button.
1) Shift between 2 operating modes: To depress the button for 5 seconds makes shift
between modes. Although change from a mode to the other one, the values programmed at
former mode will be kept before users change the values. Operating mode and programmed
values can be changed at any time during the PCB is on.
2) How to programme the values
A. To change values(at current mode) B. To change mode and values
Action Action
Ste Butt-on
Step Butt-on Display LEDs p Display LEDs
FND & Meaning FND & Meaning
Current status displayed Current status displayed
*REST stage goes on *RUN stage goes on
1 - *LED for REST is on. 1 - under timer mode
*Elapsed REST time *LED for REST is on
*Elapsed run time
POWER CYCLE

0hrs.
0.7min
To check programmed REST *Mode change :Timer
time mode → Counter mode
2 *LED for REST blinks *LED for CYCLE is on
2
*Programmed REST time long *LED for REST blinks
POWER CYCLE
*Programmed REST time
6hrs(Factory setting)
8.5hrs
To change current rest *To keep current REST
time(=To input new one) time and move to next
3 *Programmed Protection
REST time time
8.5hrs 3 *LED for CYCLE is on
POWER CYCLE *LED for run blinks
*To check the programmed *Programmed Protection
RUN time confirming the time
changed value 4min
4 *LED for RUN blinks To change the current
*Programmed RUN time value
2min(Factory setting) *LED for cycle is on
4 *LED for RUN blinks
To change current run time POWER CYCLE
*Changed Protection time
5 RUN time is changed 2.5min
To move to next,
4min confirming the new
*To confirm the changed value Protection time.
5
and be back to current status POWER CYCLE *LED for CYCLE blinks
*REST stage goes on under *Changed Cycle count
6 timer mode 5times
*LED for REST is on To change the current
*Elapsed REST time value
0hrs 6 *LED for CYCLE blinks
POWER CYCLE *Changed Cycle count
3times
Note) *To confirm the changed
1. No action at step 3 or step 5 keeps the current Cycle count
value.
2. The displayed number of the REST time at step 6 *LED for CNT is on,
may be 0.1 hrs (=6min) because the REST time elapsed 7 *LED for RUN blinks
before step 2 has been close to 0,1 hrs. *Cycle switch contacted
3. No depressing the button for 10 seconds
POWER CYCLE

once
afterchanging value makes the new value
confirmed. 1time
4. New values will take effective when the motor starts
after the current stage ends. Note)
Depressing M/S button makes the changed value Number of cycle contacts at step 7 may be "0" or
effective immediately. more than "1".
6.7. Trouble shooting
Trouble Causes Action
*Check if main power source connected
Power is not connected
*Check if the NFB in the HCMP-HS01 is switched on.
No connection to PCB *Check if cables properly connected
No LED is lit
*Check no load ampere of the pump motor.
Motor overload
*Check if any short circuit along the cable
PCB broken down *Contact Hanil Lubtec
*Check the magnetic switch and replace it if
Magnetic switch broken
damaged
*Check no load ampere of the pump motor.
Motor does not run Motor overload
*Check if any short circuit along the cable
Relay for magnetic switch on
*Check the relay and contact Hanil Lubtec
the PCB broken

7. Troubleshooting and Remedy

No Trouble Causes Remedy

1.Examine the supply lines and branch lines,especially

a.Leakage along pipe lines joints.
2.Check if any plugs on distributors are removed.
Prolong
b.Leakage in distributor Examine the movements of distributors.
1 pumping c.Empty pail Replace the empty one with new one.
alarm 1.Check if grease is solidified.
d.No suction of grease
2.Check if grease is too sticky to suck into
e.Lower setting of relief Check if grease is discharged through the relief valve.
valve Adjust the pressure setting higher
Low level
2 a. Empty pail Replace the empty one with new one.
alarm
a.Piston clogged (by Check if the pistons in the pumping unit move. If they
intrusion of dust or dirt) do not move
Motor over b.Wire breakage in motor
3 Check if there is any cut-off along the wires.
load alarm circuit
Check if the geared motor revolve. If not, repair or
c.Breakage in gear box
replace.
1.Turn on the main power switch and push the optional
Motor does a.Power is not supplied drive button
4 2.Check the voltage of source power.
not run
b.Wire breakage Check and repair wiring.
1.Examine the supply lines and branch lines, especially
a.Leakage along pipe lines
joints.
2.Check if any plugs on distributors are removed.
Remove the measuring chamber plug and check if the
b.Measuring piston clogged
piston is clogged in the chamber.
Indicator
Disconnect the line from distributor and check if rease
5 pin(s) not comes out. Connect the line back to the stributor and
move c.Feed line blockage
disconnect the line from its point and check if ease
comes out from the line.
d.Lubrication point lockage
Examine the bearing
e. Lower setting of relief 1. Check the pressure gauge.
valve or reversing valve 2. Adjust the pressure settings
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(1L-9B) BANWOUL-GONGDAN 649-4, CHOJI-DONG, ANSAN-SI,

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TEL +82-31-491-8251, FAX +82-31-491-8226