INSTRUCTION MANUALFOR FRYDENBÖ STEERING GEAR RV1350-3 Chengxi Shipyard P. R. China Hull No. CX4204/05/06/07/08/09 Frydenbö Order No: 7474-7479 Classification: DnV Type of vessel: 53.000 DWT Bulk Carrier ROLLS-ROYCE MARINE Dep.: Steering Gears - Frydenbö N-5217 Hagavik, Norway Switchboard + 47 56 57 16 00. Telefax + 47 56 30 82 41 0 CONTENTS PAGE: SECTION 1 GENERAL INFORMATION 1.0 Introduction 1.1 General description 1.2 Technical data 1.3 Weight list 1.4 Oil specification 1.5 The actuator 1.6 The pump unit 1.7 Functioning of the pump/control unit 1.8 Functioning of the actuator 1.9 Storing of the equipment and filling of oil 3 4 5 6 7 8 11 12 16 17 SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL 2.0 Installation 2.1 Mounting/dismounting rudderstock 2.2 Filling of oil and venting procedure 2.3 Procedure for start-up and sea-trial 19 21 24 25 SECTION 3 MAINTENANCE INSTRUCTION 3.0 Service locations 3.1 Maintenance reporting 3.2 Maintenance 3.3 Periodical maintenance 3.4 Cleaning the strainer/filter of the pump unit 28 30 31 32 33 SECTION 4 REPAIR INSTRUCTION 4.0 Fault finding chart 4.1 Replacement of the actuator seals 4.2 Control and replacement of the trustbearing 4.3 Control and replacement of the liners 4.4 Pump unit 35 36 38 39 40 SECTION 5 DRAWINGS 5.0 Drawing list 43 SECTION 6 PARTS CATALOGUE 6.0 Parts list - Actuator and Pump unit 45 SECTION 7 ELECTRICAL PART 46- 1 SECTION 1 GENERAL INFORMATION 2 SECTION 1.0 INTRODUCTION This instruction manual, issued for Frydenbö rotary vane rudder actuator, is prepared for use of the operating personnel. The operators should familiarise themselves with the working principles of the equipment and with the instructions and precautions contained herein. The manual should be kept handy for reference at all times so that the proper and correct operating instructions can be observed and followed. No dismantling or adjusting work should be started unless the pertinent instructions have been carefully studied so that the work sequence is clear and all of the necessary tools are available. It is of paramount importance that extreme cleanliness is observed during all work on the equipment. Sand, dust, or other impurities are detrimental to the hydraulic equipment and will most likely impair the proper operations. Keep hands and tools clean. Use only clean linen rags, - never cotton waste. Ulstein Frydenbö is ready to be of assistance and service at all times and will appreciate the operator's comments on any phase of the equipment's operation and it's maintenance. 3 with one low level alarm-switch in each of the pump unit chambers. From top of the steering gear leakage oil will run through pipe to the oiltank.1 GENERAL DESCRIPTION (See general arrangement dwg. When cruising at sea. served by two pump units delivering the necessary oil pressure for operating the rudder. STEERING GEAR The FRYDENBØ steering gear on this vessel is composed of one hydraulic rotary vane actuator mounted directly on the rudder stock. 4 . only one pump unit is normally in operation while the other is acting as a standby unit. During manoeuvre of the vessel. The pump is submerged in the oiltank. The pump units are equipped with solenoid valves.SECTION 1. one for each pump unit and one for the integrated storage tank. when the shortest possible steering time is required. The tank is divided into three chambers. Each pump unit will provide oil with sufficient pressure to develop the specified rudder torque. it is possible to run both pump units simultaneously whereby the rudder rate will be doubled. which are normally operated by means of signals from the bridge steering controls. The two pump units may be operated together or separately.) PPSI A. 0 degr.P.C. Vickers 24 V DC ELECTRIC MOTOR Type Rating Revolution Voltage Current Frequency Protection degree Heating element 4) ABB M3AA 200 MLB2 43 kW 3500 R.P. mechanical Maximum rudder angle. 2 x 36. storage tank . electrical Design torque Displacement (35-0-30) = 65 degr. with two pumps running 2) RV 1350-3 428 mm 70.5 degr.1 bar 70 degr.2 1) TECHNICAL DATA RUDDER ACTUATOR Type Rudderstock diameter Maximum working pressure Maximum design pressure Maximum rudder angle.14 seconds PUMP UNIT Type Screw pump "Leistritz " type Revolution Capacity at 3500 R.P.28 seconds max.7 bar 2 x 46.M. with one pump running Steering time (35-0-30) degr. 3 x 440 V AC In= 68A. 1438 kNm 186 liters max.M. 430 l/min 70.SECTION 1.1 bar 87. yard supply 270 Liters 50 Liters 1000 Liters 1000 Liters* Total oil volume 2320 Liters * Volume to be verified by shipyard 5 . Relief valve setting Maximum temperature system Solenoid valve 3) PPSM 2" L3MF 52-104 3500 R.M. Steering time (35-0-30) degr. Is=442 S1 100% 60 Hz IP 54 220 V AC OIL CAPACITY Rudder actuator Pipe lines / hoses Pump units 2x500 ltrs Min. 3 WEIGHT LIST STEERING GEAR TYPE RV 1350-3 EQUIPMENT: WEIGHT DRY: W/OIL: Rudder Actuator Pump Unit EL-motors 6000 kg 1000 kg 400 kg ------- 6320 kg 1500 kg 400 kg ------- TOTAL 7400 kg ------- 8220 kg ------- 6 .SECTION 1. The oil should have antifoam.SECTION 1. anti-oxidant and anti-rust additives. OIL SPECIFICATION Viscosity: ISO 68 Oil temperatures should be limited to 70 °C. and the oil companies' recommendation for change of oil to be followed. The oil to be checked regularly for contamination.4 OIL SPECIFICATION HYDRAULIC OIL TYPE FOR FRYDENBØ ROTARY VANE STEERING GEAR Use only a high quality hydraulic oil with a viscosity index of approximate 100. Oil level should be checked daily with new oil added as necessary. 7 . 2.SECTION 1. 6. 3.5 THE ACTUATOR The actuator consists of these main components: 1. 5. Housing Cover Rotor Stoppers Vanes Safety relief valve 8 1 . 4. SECTION 1. CASE 2 THE ACTUATOR CLOSEDRUDDER BLOCKED 9 . Between inlet and outlet there is a pilot-piston which operates the two spring-loaded valves. CASE 1 STEERING TAKES PLACE Oil pressure from the pump unit opens both the inlet and the outlet side of the valve. where both pipes from the pump unit are connected.5 (Continued) THE ACTUATOR LOCK VALVE The automatic lock valve mounted on the actuator consists of a housing. (Oil pressure inside the actuator will increase the closing force). 10 . the valves are kept closed by spring load.When there is no oil supply. will be pushed over and the maximum pressure will be relieved over to the suction side. 3. NORMAL RUNNING CONDITION: CASE 1: The working pressure. 3. 4. Pilot piston. 5. and will keep the safety valve in closed position. P1. SAFETY VALVE OPENS: CASE 2: If the pressure increases to maximum. 1. Pilot relief valve. Check valve. Adjusting screw for relief pressure.SECTION 1. 4. 11 . the springloaded main valve. Spring loaded main valve. which is the opening pressure for the pilot relief valve. P2. opens the check valve.5 (Continued) THE ACTUATOR SAFETY VALVE There is one safety valve-block on the actuator consisting of: 1. 2. 12 . with emergency push-button steering controls. Pressure gauge. 2. 7.SECTION 1. Gear pump.6 THE PUMP UNIT PPSM-2 The pump unit consists of following components mounted on a common bedplate: 1. 6. Solenoid operated control valve for connection to steering controls. Safety relief valve. Flexible coupling between motor and pump. Filter. 5. 3. Oil tank with two chambers. 4. Electric motor. 8. IDLING: Fig. the pilot valves are equipped with push button controls that make it possible to operate the steering gear manually from the steering gear compartment. 1. and the solenoid valve. are kept in center position by spring load when no steering signal is given.1 shows the pump unit when idling. Safety relief valve. CONTROL UNIT: 1.Pilot valve. 1. Solenoid . 3. Control valve. By-pass valve. 13 . 3. FIG. The control valve. For emergency operation.7-1 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2 The steering gear is normally operated from the steering controls initiating the pilot valve solenoids. 4.SECTION 1. 2. The smaller oil volume being directed gradually to the actuator will give a soft start. The control valve (3) is now at the beginning of its stroke.7-2 (Continued) FUNCTIONING OF THE PUMP/CONTROL UNIT PME2 FIG. Some of the oil flows through the throttling slots to the actuator. 14 . 2. The control valve (3) will be pushed over to the right side. BEGINNING OF STEERING (MODULATED FLOW): Steering is carried out by operating the solenoid valve (1).2 on the diagram shows the beginning of the steering process when the right solenoid is operated. and overflow is by-passed at the by-pass valve (4) back to the suction side of the pump. by the oil pressure in the left chamber.SECTION 1. Fig. 7-3 (Continued) FUNCTIONING OF THE PUMP/CONTROL UNIT PME2 FIG. STEERING: After approximately one second. 15 . 3. The oil-flow from the pump has now free passage from channel (1) into pipe (B) leading to the actuator. 3. The return oil from the actuator flows through pipe (A) and has free passage to channel (2) and back to the suction side of the pump. the control valve (3) is moved over to it's end position.SECTION 1. see fig. clockwise. EMERGENCY OPERATION During emergency operation the solenoid valves (1) can be manually operated by means of manual controls on the solenoid valves. Safety valve opening pressure has been set during assembly by the suppliers and possible adjustment should only be carried out by a competent person. Now the by-pass valve will open. SETTING THE RELIEF VALVE. allowing the oil (D) to flow to the return channel (2). turn adjusting screw. has to be in local position during emergency operation. The pressure oil will flow to channel (2) and the pressure behind the by-pass valve (7) will drop. the valve.switch. S3. 5. on starter cabinets. NOTE: "Local/Remote". 6. (Item 2) Opening pressure for relief valve.SECTION 1. exceeds the preset value of the valve spring load. RELIEF VALVE (Item 2) When the oil pressure.7-4 (Continued) FUNCTIONING OF THE PUMP/CONTROL UNIT PME2 FIG. 4. C. will open (fig 4). see technical data sheet. To increase the pressure. 16 . Use push buttons on solenoid valve to operate the manual controls SECTION 1. The rotor. The stoppers also act as mechanical rudder stops in hard-over position. AUTOMATIC LOCK VALVE The actuator is equipped with automatic lock valves. eliminating the need for a separate rudder carrier bearing. SAFETY VALVE The actuator is equipped with a safety valve. preventing effectively internal leakages. a rotor and a boltedon cover. the lock valve will close immediately and keep the actuator intact for operation by means of the stand-by pump. of actuator) The actuator consists of three main components: A cylindrical housing with stoppers. the actuator is equipped with electrical limit switches stopping the turning movement at the predetermined angle.8 FUNCTIONING OF THE ACTUATOR (See assembly dwg. The turning movement is limited by stoppers fixed to the housing. limiting the pressure to the specified value. The axial bearing thrustring of the actuator is of sufficient capacity to carry the full weight of rudder. and gland seals preventing external leakage. The bearings of the actuator are lubricated by means of the system oil. rudderstock and rotor. is equipped with vanes upon which the oil pressure is acting and thereby developing the turning torque. 17 . The sealing system consists of synthetic oil resistant material resting in seal grooves. In addition to the stoppers. turning in bearings at top and bottom. If there should be loss of oil pressure due to possible external failures. a special corrosion retarding ingredient is added to the hydraulic oil used during final testing of the steering gear. In order to protect the inside of the steering gears. Locations of filling. Open all bleeding plugs on top of the rudder actuator and the pump unit (See venting procedure section 2. to protect the equipment. (See sketch). 1. PROCEDURE FOR FILLING THE ACTUATOR AND THE PUMP UNIT WITH OIL.9 STORING OF THE EQUIPMENT AND FILLING OF OIL.SECTION 1. Use pump or gravity connected to the filling holes. NOTE: Fill oil through all filling plugs in order to fill all chambers of the actuator.2). 2. 18 . The steering gear should be filled with oil immediately after received at yard. This is a short time protection only.and drain plugs are marked on the arrangement drawing. to fillthe actuator and the pump. SECTION 2 INSTALLATION COMMISSIONING SEA TRIAL 19 . 20 .1. Tackle bracket should be arranged.PP SECTION 2.0 INSTALLATION RUDDER ACTUATOR Sufficient space for inspection and service of the gland seals must be provided (see arr. For fastening of the rudderstock to the rudder actuator. a hatchway in deck may be provided. If this cannot be arranged. There should be sufficient space between top of the rudder actuator and the deck above to permit the cover and the rotor to be lifted. Do not open the rudder actuator during installation. See arrangement drawing. see "Procedure for hydraulic mounting/dismounting of the rudder actuator on the rudderstock". dwg). 0position of rotor is marked on top of the actuator. Make sure that rudderstock and actuator are aligned. section 2. Forward position is marked on the actuator flange. PIPES Sharp vertical bends on the pipe lines should be avoided. 21 .0 (Continued) INSTALLATION PUMP UNIT The pump unit should be installed close to the rudder actuator with good access for inspection and maintenance.PP SECTION 2. as air pockets may occur. Mount pump 1 for oil pressure to the nut.1-1 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK. 1. min 1000 bar.SECTION 2. 4. 5. To find a correct starting position for the pull up length. Note! No anti-friction additives allowed in oil. 10 bar). 6. 1 Dial gauge. 2. 3. See drawing and table "HYDR.) This is the starting position. 22 . MOUNTING. Put the rudder actuator on the rudderstock with its full weight on the taper area. Relieve the pressure and tighten the nut until contact between nut and actuator is obtained. until sufficient contact between the rudderstock and the rotor has been obtained (according to classification requirements). fig. NECESSARY EQUIPMENT: 2 High-pressure oil pumps with pressure gauges.MOUNTING / DISMOUNTING OF RUDDERSTOCK". Mount the hydraulic nut and tighten by hand. Clean and lubricate the taper area of the rudderstock and the rotor using hydraulic oil. This to avoid that the o-ring on piston in the nut should break if too long stroke. see arrangement drawing.1. use blue color. OIL SPECIFICATION: Hydraulic oil: 100 mm2/s at 40°C. (For permissible length of stroke. start to pump oil into the nut with pump1 until the pressure starts to increase (max. The taper area of the rudderstock should be adapted to the rudder actuator. and pump 2 for oil pressure to the taper. Mount the dial gauge and adjust to zero. NOTE: When pulling up. 7. 2. and pump 2 for oil-pressure to the taper. 8.SECTION 2. Pump oil (pump 2) to the taper fitting until the oil leaks out at the lower part of the taper. 4. Increase the oil-pressure from pump 1 to about 50 bar. 11. See the table. Relieve the pressure from pump 2. 6. This indicates that the taper is "floating". 12. 3. Increase the pressure on the taper (pump 2) gradually until the pressure in the nut (pump 1) is rising. 9. 13. DISMOUNTING 1. Dismount the pumps and the dial gauge. Check the length "L". (Until the oil leaks out at the lower or upper part of the taper). 10. Dismount the lockplate. keep pressure as high as possible on pump 2.1-2 (Continued) PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK. Wait about 30 minutes. Increase slowly the pressure from both pumps 1 and 2 until the rudderstock is pulled up the length "L". specified in the table. 5. Secure the rudderstock nut. 14. Tighten the nut to contact with the actuator. and then relieve the pressure from pump 1. 23 . Mount pump 1 for oil pressure to the nut. Unscrew the nut to the length (L + 2) mm. Reduce the pressure from pump 1 gradually without reducing the taper pressure (from pump 2). and the rudderstock will be released from rudder actuator. RRM-Frydenbö Order No. CALCULATION NO.: PULL UP LENGTH MIN: PULL UP LENGTH MAX: PISTON AREA: PISTON STROKE: 7474-7479 2804 428 mm 10.SECTION 2.12 mm 10.44 mm 940 cm2 15 mm 24 . FIG 1.1-3 (Continued) PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.: RUDDERSTOCK DIA. Stop the pumps and vent the system.9. open all vent plugs on the actuator. To fill actuator and pump unit with oil. Oil specification. Fill oil into the oiltank of the power pack. If still noisy. Operate the solenoid valves manually to move the rudder. The system should now operate smoothly without noise. 25 . and vent the system. Repeat this procedure until the actuator is filled up with oil. ALL AIR MUST BE REMOVED FROM THE SYSTEM.2 FILLING OF OIL AND VENTING PROCEDURE. Actuator Start the pump units (check the correct rotation). Start again and move the rudder hard-over to hard-over. repeat the venting. see section 1.SECTION 2.4. to move the rudder. Operate the solenoid valves manually for a few seconds. Do the same operation on the second pump unit. IF A HYDRAULIC SYSTEM IS TO BE RELIABLE AND FUNCTION SATISFACTORILY. Venting procedure Start the pump units. Before starting to fill oil. see section 1. .Control that the electric motor is rotating in the correct direction. . START-UP: Fill oil into the actuator and the pump unit according to instruction.SECTION 2. Control that the steering handles and the rudder indicators both show correct direction. .Test the alarm panels (See instructions).Steering time 35 .30 deg. using both one and two pumps. . if necessary.0 .Check that the relief valve opens at maximum specified pressure. Adjust both the mechanical and the electrical rudder indicators according to this 0-point.Test the start and stop switches. Control that the rudder moves without any obstructions and that maximum rudder angle is obtained. . To obtain correct pressure. . Adjust electrical end stoppers. and bleed the system. adjust relief valve (See instructions).Half the total rudder angle is the correct center position.3 PROCEDURE FOR START-UP AND SEA TRIAL. Please fill in the form on the next page.Check that these items are within the limits of the specification for the supplied steering gear. 26 . .Max. by pushing the emergency push-buttons on the solenoid valve until the rudder is in hard-over position. . SEA TRIAL: .Run the rudder hard over to both sides. working pressure. .... Max pressure during steering: (bar) ... Address: ROLLS-ROYCE MARINE DEP.…. Port Pump pump ------...... Both pumps ------ ............... Comments: .….......................... .. Hull no:...... Max amps on el...... Shipyard:.........................…....................SEATRIAL DATA Please fill in this form during the sea trial and send it to our head office for later reference...…………………………………………………………… 27 .…...................................................: STEERING GEARS .......... …........... ........FRYDENBÖ N-5217 HAGAVIK NORWAY Name of ship:.............................knots Stb.…. ….....….... Owner:..------Steering time 35-0-30 degrees: (seconds) ..... ….. Speed:......................motor during steering: (amp) .. SECTION 3 MAINTENANCE INSTRUCTION 28 . thrusters) Tel: +358 2 83 791 Fax: +358 2 8379 4804 FRANCE ROLLS-ROYCE Rungis Tel: +33 1 468 62811 Fax: +33 1 468 79398 GERMANY ROLLS-ROYCE Hamburg Tel: +49 40 381 277 Fax: +49 40 389 2177 Hamburg (Service) Tel: +49 40 78091910 Fax: +49 40 78091919 THE NETHERLANDS ROLLS-ROYCE Groningen Tel: +31 50 54 25 425 Fax: +31 50 54 25 588 Purmerend (Service) Tel: +31 299 641 118 Fax: +31 299 644 999 Rotterdam (Service) Tel: +31 10 42 61 227 Fax: +31 10 42 64 298 Aalesund (Ship design) Tel: +47 70 10 37 00 Fax: +47 70 10 37 01 POLAND ROLLS-ROYCE Gniew (Deck machinery) Tel: +48 69 135 22 71 Fax: +48 69 135 22 18 Bergen (Frydenbö steering gear) Tel: +47 56 57 16 00 Fax: +47 56 30 82 41 RUSSIA ROLLS-ROYCE Moscow Tel: +7 095 230 6441 Fax: +7 095 230 6441 Bergen (Turbines) Tel: +47 55 53 64 50 Fax: +47 55 53 60 60 St.) Tel: +47 70 01 40 05 Fax: +47 70 01 40 01 Dartford Tel: +44 1322 394 300 Fax: +44 1322 394 301 Ulsteinvik (Ship design) Tel: +47 70 01 40 00 Fax: +47 70 01 40 13 Dunfermline (Propulsion) Tel: +44 1383 82 31 88 Fax: +44 1383 82 40 38 Ulsteinvik (Propulsion) Tel: +47 70 01 40 00 Fax: +47 70 01 40 17 Edinburgh (Stabilisers) Tel: +44 131 556 2440 Fax: +44 131 556 3253 Volda (Propulsion) Tel: +47 70 07 39 00 Fax: +47 70 07 39 50 Newcastle (Bearings) Tel: +44 191 273 0291 Fax: +44 191 272 2787 Oslo (Repr. office) Tewkesbury (Service) 29 .0 SERVICE LOCATIONS: NOTHERN EUROPE Tel: +47 23 31 04 80 Fax: +47 23 31 04 99 DENMARK ROLLS-ROYCE Aalborg (Service) Tel: +45 98 114 955 Fax: +45 98 114 945 NORWAY ROLLS-ROYCE Bergen (Cast Iron) Tel: +47 55 53 65 00 Fax: +47 55 53 65 05 Esbjerg Tel: +45 75 14 15 22 Fax: +45 75 14 41 02 Bergen (Engines) Tel: +47 55 53 65 00 Fax: +47 55 19 04 05 FINLAND ROLLS-ROYCE Helsinki Tel: +358 96866330 Fax: +358 968663339 Bergen (Service) Tel: +47 56 57 16 00 Fax: +47 56 30 82 41 Kokkola (Water jets) Tel: +358 68324500 Fax: +358 68324511 Rauma (Winches.SECTION 3. Petersburg Tel: +7 812 960 4627 Fax: +7 812 325 5604 Brattvaag (Deck machinery) Tel: +47 70 20 85 00 Fax: +47 70 20 86 00 SWEDEN ROLLS-ROYCE Gøteborg Tel: +46 31 492 202 Fax: +46 31 497 531 Hareid (Rudders) Tel: +47 70 09 55 00 Fax: +47 70 09 55 55 Longva (Automation) Tel: +47 70 20 82 00 Fax: +47 70 20 83 51 Kristinehamn (Propulsion) Tel: +46 550 84000 Fax: +46 550 18190 Tennfjord (Steering gear) Tel: +47 70 20 88 00 Fax: +47 70 20 89 00 UNITED KINGDOM ROLLS-ROYCE Aberdeen Tel: +44 1224 58 1722 Fax: +44 1224 58 1723 Ulsteinvik (Adm. Tel: +44 1684 290 781 Fax: +44 1684 290 786 Tel: +86 411 281 5791 Fax: +86 411 263 1573 Tel: +55 21 507 4992 Fax: +55 21 509 5610 SOUTHERN EUROPE Hong Kong Tel: +852 2526 6937 Fax: +852 2868 5344 CANADA ROLLS-ROYCE Halifax Tel: +1 902 468 2883 Fax: +1 902 468 2759 ITALY ROLLS-ROYCE Genova (Marine Sales & Service) Tel: +39 010 839 1561 Fax: +39 010 839 3663 CROATIA ROLLS-ROYCE Rijeka Tel: +38 5512 54882 Fax: +38 5512 55154 Shanghai Tel: +86 21 6387 8808 Fax: +86 21 5382 5793 INDIA ROLLS-ROYCE Mumbai Tel: +91 22 820 45 41 Fax: +91 22 820 45 42 NORTH EAST ASIA St. Johns Tel: +1 709 364 3053 Fax: +1 709 364 3054 Vancouver (Propulsion) Tel: +1 604 942 1100 Fax: +1 604 942 1125 USA ROLLS-ROYCE Annapolis (Propulsion) Tel: +1 410 224 2130 Fax: +1 410 266 6721 MALTA ROLLS-ROYCE Valletta Tel: +356 805 497 Fax. +356 677 747 JAPAN ROLLS-ROYCE Tokyo Tel: +81 3 3237 6861 Fax: +81 3 3237 6846 SPAIN ROLLS-ROYCE Madrid Tel: +34 91 372 81 42 Fax: +34 91 372 87 28 REPUBLIC OF KOREA ROLLS-ROYCE Inchon Tel: +82 32 888 4576 Fax: +82 32 888 4579 Tarragona Tel: +34 977 296 444 Fax: +34 977 296 450 Pusan (Deck machinery) Tel: +82 51 266 0170 Fax: +82 51 266 0175 New Orleans Tel: +1 504 464 4561 Fax: +1 504 464 4565 ASIA PACIFIC Pusan Tel: +82 51 205 0236 Fax: +82 51 205 0235 Pascagoula (Cast Iron) Tel: +1 228 762 0728 Fax: +1 228 769 7048 RUSSIA ROLLS-ROYCE Vladivostok Tel: +7 5232 495 484 Fax: +7 5232 495 484 Seattle Tel: +1 206 782 9190 Fax: +1 206 782 0176 AUSTRALIA ROLLS-ROYCE Melbourne Tel: +61 3 9848 6061 Fax: +61 3 9848 6078 Perth Tel: +61 8 9336 7910 Fax: +61 8 9336 7920 CHINA ROLLS-ROYCE Dalian (Purchasing Office) AMERICAS BRAZIL ROLLS-ROYCE Rio de Janeiro 30 Fort Lauderdale Tel: +1 954 581 2757 Fax: +1 954 581 2785 Houston Tel: +1 281 497 5220 Fax: +1 281 497 4903 Walpole (Propulsion) Tel: +1 508 668 9610 Fax: +1 508 660 6152 . we can provide better service. the following additional information is requested in addition to items 1-8 above. faster delivery of spare parts.1 MAINTENANCE REPORTING It is requested that any failures or maintenance work on the equipment. no matter how small.order number 4) Operating hours (if available) 5) Description of problem 6) Did the problem impair vessel's operation 7) Corrective action taken 8) How many man-hours were required to repair it In reporting a failure or request for service.SECTION 3. should be reported to Frydenbö. the following information should be included: 1) Date 2) Vessel name 3) Date of installation . With this information. When reporting. 35-0-30 degrees. an accurate machinery history can be maintained. This history will be continuously monitored and compared to other vessels with similar equipment. 9) Working and idling pressures 10) Steering time. 31 . This will insure more efficient service. By reporting any failures and maintenance work. and guidance for preventive maintenance. SECTION 3. CALL IN A SERVICE ENGINEER. The service personnel of Frydenbö AS has long experience in the service and maintenance of hydraulic steering gears. IF THE PROBLEM CANNOT BE SOLVED BY YOUR MAINTENANCE MEN. as this will facilitate the faultfinding. or. it is essential to find the cause and put it right as quickly as possible. it will have a long life and run reliably. ask for a service engineer to be sent. If problems do occur. This experience in the maintenance and service sectors is at the disposal of our customers. if necessary. Contact our service department for guidance.2 MAINTENANCE If a hydraulic system is properly installed. The FAULTFINDING CHART must be seen as a general fault finding guide only. Also use the hydraulic diagram if problems occur. however. 32 . USE THE FAULTFINDING CHART. IF PROBLEMS OCCUR. started up and maintained. A continuous undisturbed functioning of the steering gear is dependent on two simple points: 1. C. A. the oil filter should be opened for inspection and changed if necessary. Oil filters in the pump unit to be changed. If these points are adhered to the preventive maintenance will be limited to following: Yearly. If you find impurities. The hydraulic pump. Change hydraulic oil. damages etc. Every second year. B. A worn pump means reduced pumping capacity indicated by slower steering speed. 33 . Stuffing glands on the actuator to be checked.3 PERIODICAL MAINTENANCE PP The actuator should regularly be visually inspected for external leakage. the normal life time of the rotor seals is 5 to 10 years. indicates wear on the rotor seals. Keep the hydraulic system clean The hydraulic oil and the interior of the installation should be kept absolutely free from any impurities and air. After the first 200 hours running.SECTION 3. Unintended movement (creeping) of the rudder at sea. see instructions. A. This indicates that the hydraulic system is clean and the filter should now be left for the yearly change. The hydraulic pump will normally last more than 10 years. A worn pump should be replaced or repaired. B. The actuator. A clean actuator will facilitate the inspection work. Oil filter. The rotor seals and the gland seals are practically the only wearing parts. For change of rotor seals. change of the filter must be repeated at short intervals until it stays clean. paintwork. Based on experience. Use the specified hydraulic oil 2. and remove the rod. 3. top and spring. magnet (N/A on all filters).PP SECTION 3. Loosen the Allen screw at the bottom of the filter cartridge. magnet.4 CHANGE THE FILTER OF THE PUMP UNIT (See assembly dwg. and insert it into the filter housing. 34 . lift out the filter cartridge 2. Open the cover of the filter. top and spring on the new filter cartridge. Mount the rod.) 1. Reassemble the cover and tighten up the nuts. 4. SECTION 4 REPAIR INSTRUCTION 35 . 36 . ) GLAND SEALS. (Item 5). Remove the upper gland ring. before they are inserted. 2. The seals to be cut apart for inserting around rudderstock and to be glued together (Use LOCKTITE superglue no. Remove the old gland seals. (Item 6). To facilitate reassembling of the lower gland ring. 1. 495). Upper gland seals. Same procedure as for the upper seals. we recommend lowering the gland ring by means of two lengthened screws. The correct way of inserting the gland seals is shown in fig. 1. IMPORTANT All seals are supplied in correct lengths and must NOT be shortened.SECTION 4. Grease new seals. 37 . FIG. Lower gland seals. and also apply grease before replacing gland ring.1 REPLACEMENT OF THE ACTUATOR SEALS (See fig. 38 .2.FIG. . .item 3 . Bottom ring seal 2. When rotor is still attached to rudderstock: 1. Replace seals in this order: A.Drain the actuator for hydraulic oil through the bottom drain holes.item 2 . Vertical vane seals with springs 4.1.item 1 .) INTERNAL SEALS: The following seals may be replaced without disconnecting the rotor from the rudderstock: Cover ring seal Vertical stopper seals with springs Vertical vane seals with springs Top vane seals . Cover ring seal B.item 4 Bottom ring seal .Inspect actuator and cover.item 1 .SECTION 4. Clean. Vertical vane seals with springs 3. Lower vane seal After the rotor has been lowered in to the housing: 3. . Cover ring seal 2. use rags. Top vane seals Note! Grease all new seals before assembly. Assemble the actuator and fill up with oil. 39 . Top vane seals 6.1 (Continued) REPLACEMENT OF ACTUATOR SEALS.Make sure that the vent plugs are open. (See fig. When rotor has been dismounted from rudderstock and lifted out of the housing: 1. Vertical segment seals with springs 4.item 4 The following seals can be replaced only when the rotor has been dismounted from the rudderstock: Lower vane seals . Vertical segment seals with springs 5.Remove the actuator cover. (See oil filling procedure). Remove the old bearing (splitted in 4) and mount the new ones. Important! Secure rudderstock. 3.1). clearance is 0. Remove the gland ring and gland seals. Remove the cover of the actuator. Attach the rotor to the rudderstock again. 4. The actuator is now ready for trial. Min. 6. Assemble cover. 2. 40 . Use feeler gauge and check the clearance between rotor-vanes and bottom of housing. Drain oil from the actuator.) CONTROL OF THE THRUST BEARING: 1.2). Fill the actuator with oil and vent.10 mm. Remove the cover of the actuator.2 CONTROL AND REPLACEMENT OF THE THRUST BEARINGS (See assembly dwg. (see section 2. 5. 2. 7. 9. 4. (see section 2. (see section 2. 6. 5. Dismount the rotor from the rudderstock. gland seals and gland ring. 3. 8. Close the shut off valves for the expansion pipes.1).SECTION 4. Drain oil from the actuator Remove the gland ring and the gland seals. Be sure that the rudder shaft is aligned and is not bending. CHANGE OF THE THRUST BEARING: 1. glandseals and glandrings.SECTION 4.3 CONTROL AND REPLACEMENT OF THE LINERS (See assembly dwg. The clearances in the liners can be checked by removing the cover. (see arr. Be sure that the rotor is in center.1). 14 Close the shut off valves for the exp. 11. Remove the gland ring and the gland seals. 5. It can also indicate that the actuator and rudderstock are out of line. grind the inner surfaces of the liners. This should be checked. 41 . Press out the old liners. Fit cover.1).) CONTROL OF THE LINERS: 1. A and B. and the outer diameter of the "rotorneck" to control that the clearances. 13. Remove the cover.dwg). are within limits. 7. Lower the rudderstock or loosen the foundation bolts and lift the actuator off the rudderstock. Use feeler gauge and control that clearances between the rotor and the liners. 3. A and B. Dismount the rotor from the rudderstock (see section 2. 12. Fill actuator with oil and vent (See section 2. pipes. 2. Put the rudderstock and/or the actuator back in position. 6. REPLACEMENT OF THE LINERS: 1. 8. 10. Check the inner diameter of the replaced liners. Attach the rotor to the rudderstock again (See section 2. 2. (Freeze if necessary). are within limits. If not. Remove the upper and lower gland rings and gland seals. Fit the new liners. indicates too big clearances. cover or stoppers. Drain oil from the actuator. 3. 4. 9.2) The steering gear is now ready for sea trial. Mechanical contact between the rotor and the housing. Disconnect the coupling from the pump shaft. 3.CHANGE OF THE PUMP (See assembly dwg. 42 .PP SECTION 4. 4. 6. Unscrew the bolts and lift the cover off the tank. Reassemble in opposite order. 5.) 1. Unscrew the bolts and change the pump. Loosen the bolts and disconnect the electric motor from the pump. 2.4 THE PUMP UNIT . Change the elastic part of coupling if necessary. Disconnect SAE flanges and pipes. THE PUMP CARTRIDGE -CHANGE OF THE BALL BEARING (See dwg. 3. Unscrew the hexagon screw. 5. 2. Circlips and washers. to be removed. to be withdrawn after the fixing bolts have been unscrewed. and the el. The ball bearing.) 1. 2. 3. motor. to be withdrawn from the shaft. and tighten the bolts. Insert supporting washers and the circlips. 14702) 1. 5. Remove the old elastic ring.CHANGE OF THE ELASTIC RINGS (See assembly dwg. The old shaft seal rings.4-3 THE PUMP CARTRIDGE-CHANGE OF THE SHAFT SEAL RING (See dwg. Insert the new shaft seal rings. SECTION 4. 14702) Unscrew the hexagon screw. 6.4-2 1. 4. Insert the new ball bearing on the shaft. in correct position. motor to be remounted. Lift off the el.4-1 THE PUMP UNIT . and remove the seal cover. and tighten the bolts. Assemble the shaft sealing-housing/bearing-housing and the seal cover. 4. to be withdrawn after the fixing bolts have been unscrewed. and remove the seal cover. Important: Do not forget to insert the supporting ring.no. 4. The shaft sealing-housing/bearing-housing. 2.no. 3. The shaft sealing-housing/bearing-housing. to be removed.PPS SECTION 4. Unscrew the hexagon head screws which fasten the electric motor to the bellhousing. The new elastic ring to be inserted. 43 . Assemble the shaft sealing-housing/bearing-housing and seal cover. SECTION 4. SECTION 5 DRAWINGS 44 . 0 DRAWING LIST Drawing no. 24122 45 .SECTION 5.: General arrangement 15402 Rudder actuator – assembly 14471 Part list P81457 Safety relief valve 23317 3" Automatic Lock valve 45333 Pump unit type PPSM 2 " 13883 Part list P81458 Control valve for pump unit Part list 23710 P80536 Top end of rudderstock 13350 Steering Loss and Recovery 32897 Hydraulic Diagram 44896 Transmitter Arr. SECTION 6 PARTS CATALOGUE 46 . 4 KG 04 05 06 07 08 09 10 11 12 13 47 ORDER NO: 7474-7479 . PART DESCRIPTION 01 33034-7 1 SEALING RING 02 70105 2 FILTER ELEMENT 03 P80674 1 GLAND SEAL SET 03-01 45009 4 GLAND SEAL XNBR 03-02 45009 2 O-RING FOR GLAND 03-03 45009 1 MOUNTING OF GLAND SEAL 03-04 45009 1 GREASE TUBE 0.Rolls Royce Marine . China DATE: March 2004 Steering gear type: Hull no: RV 1350-3 CX4204-CX4209 Page 1 of 1 POS Part No. QTY.R.Frydenbö SPARE PARTS FOR STEERING GEARACTUATOR AND PUMP UNIT P80503 YARD: Chengxi Shipyard P. SECTION 7 ELECTRICAL PART 48 .