INSTRUCTION MANUAL

FOR
FRYDENBÖ
STEERING GEAR RV 1350-3

Chengxi Shipyard P. R. China

Hull No. CX4219, 4216, 4217

Frydenbö Order No: 8233, 8236 and 8237
Classification: DNV

Hull No. CX4214, 4215, 4220

Frydenbö Order No: 8234, 8235 and 8238
Classification: BV

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
1
CONTENTS
PAGE:
SECTION 1 GENERAL INFORMATION
1.0 Introduction 3
1.1 General description 4
1.2 Technical data 5
1.3 Weight list 6
1.4 Oil specification 7
1.5 The actuator 8
1.6 The pump unit 11
1.7 Functioning of the pump/control unit 12
1.8 Functioning of the actuator 16
1.9 Storing of the equipment and filling of oil 17

SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL

2.0 Installation 19
2.1 Mounting/dismounting rudderstock 21
2.2 Filling of oil and venting procedure 24
2.3 Procedure for start-up and sea-trial 25

SECTION 3 MAINTENANCE INSTRUCTION

3.0 Service locations 28
3.1 Maintenance reporting 30
3.2 Maintenance 31
3.3 Periodical maintenance 32
3.4 Cleaning the strainer/filter of the pump unit 33

SECTION 4 REPAIR INSTRUCTION

4.0 Fault finding chart 35
4.1 Replacement of the actuator seals 36
4.2 Control and replacement of the trustbearing 38
4.3 Control and replacement of the liners 39
4.4 Pump unit 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-

2
 SECTION 1

GENERAL INFORMATION

3
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.

4
SECTION 1.1 GENERAL DESCRIPTION PPSI
(See general arrangement dwg.)

A. STEERING GEAR

The FRYDENBØ steering gear on this vessel is composed of one hydraulic rotary vane actuator
mounted directly on the rudder stock, served by two pump units delivering the necessary oil pressure
for operating the rudder.
The two pump units may be operated together or separately. Each pump unit will provide oil with
sufficient pressure to develop
the specified rudder torque.

When cruising at sea, only one pump unit is normally in operation while the other is acting as a stand-
by unit. During manoeuvre of the vessel, when the shortest possible steering time is required, it is
possible to run both pump units simultaneously whereby the rudder rate will be doubled.

The pump units are equipped with solenoid valves, which are normally operated by means of signals
from the bridge steering controls.

The pump is submerged in the oiltank. The tank is divided into three chambers, one for each pump
unit and one for the integrated storage tank, 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.

5
 SECTION 1.2 TECHNICAL DATA

1) RUDDER ACTUATOR

Type RV 1350-3
Rudderstock diameter 428 mm
Maximum working pressure 70,1 bar
Maximum design pressure 87,7 bar
Maximum rudder angle, mechanical 2 x 46,5 degr.
Maximum rudder angle, electrical 2 x 36,0 degr.
Design torque 1438 kNm
Working torque 1150 kNm
Displacement (35-0-30) = 65 degr. 186 liters
Steering time (35-0-30) degr.
with one pump running max.28 seconds
Steering time (35-0-30) degr.
with two pumps running max.14 seconds

2) PUMP UNIT

Type PPSM 2"

Screw pump "Leistritz " type L3MF 52/104
Revolution 3500 R.P.M.
Capacity at 3500 R.P.M. 431 l/min
Relief valve setting 70,1 bar
Maximum temperature system 70 degr.C.
Solenoid valve Vickers 24 V DC

3) ELECTRIC MOTOR

Type ABB M3AA 200 MLB-2

Rating 43 kW
Revolution 3500 R.P.M.
Voltage 3 x 440 V AC
Current In= 68A, Is=442 S1 100%
Frequency 60 Hz
Protection degree IP 55
Heating element 240 V AC

4) OIL CAPACITY

Rudder actuator 270 Liters

Pipe lines / hoses 50 Liters
Pump units 2x500 ltrs 1000 Liters

Total oil volume 1320 Liters

6
SECTION 1.3 WEIGHT LIST

STEERING GEAR TYPE RV 1350-3

EQUIPMENT: WEIGHT

DRY: W/OIL:

Rudder Actuator 6000 kg 6320 kg

Pump Unit 1500 kg 2500 kg
EL-motors 400 kg 400 kg
------- -------

TOTAL 7900 kg 9220 kg

------- -------

7
SECTION 1.4 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. The oil should have anti-
foam, anti-oxidant and anti-rust additives.

OIL SPECIFICATION

Viscosity: ISO 68

Oil temperatures should be limited to 70 °C.

The oil to be checked regularly for contamination, and the oil companies' recommendation for change of
oil to be followed.

Oil level should be checked daily with new oil added as necessary.

8
SECTION 1.5 THE ACTUATOR 1

The actuator consists of these main components:

1. Housing
2. Cover
3. Rotor
4. Stoppers
5. Vanes
6. Safety relief valve

9
SECTION 1.5 THE ACTUATOR
(Continued)

LOCK VALVE
The automatic lock valve mounted on the actuator consists of a housing, where both pipes from the pump
unit are connected. 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.

CASE 2

THE ACTUATOR CLOSED-

RUDDER BLOCKED

When there is no oil

supply, the valves are kept closed by
spring load.
(Oil pressure inside
the actuator will
increase the closing force).

10
SECTION 1.5 THE ACTUATOR
(Continued)

SAFETY VALVE

There is one safety valve-block on the actuator consisting of:

1. Pilot relief valve.
2. Pilot piston.
3. Check valve.
4. Spring loaded main valve.
5. Adjusting screw for relief pressure.

NORMAL RUNNING CONDITION:

CASE 1: The working pressure, P1, opens the check valve, 3, and will keep the safety valve in closed
position.

SAFETY VALVE OPENS:

CASE 2: If the pressure increases to maximum, P2, which is the opening pressure for the pilot relief
valve, 1, the springloaded main valve, 4, will be pushed over and the maximum pressure will be relieved
over to the suction side.

11
SECTION 1.6 THE PUMP UNIT PPSM-2

The pump unit consists of following components mounted on a common bedplate:

1. Gear pump.
2. Oil tank with two chambers.
3. Flexible coupling between motor and pump.
4. Solenoid operated control valve for connection to steering controls, with emergency
push-button steering controls.
5. Electric motor.
6. Pressure gauge.
7. Safety relief valve.
8. Filter.

12
SECTION 1.7-1 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2

The steering gear is normally operated from the steering controls initiating the pilot valve solenoids.

For emergency operation, the pilot valves are equipped with push button controls that make it possible to
operate the steering gear manually from the steering gear compartment.

CONTROL UNIT:
1. Solenoid - Pilot valve.
2. Safety relief valve.
3. Control valve.
4. By-pass valve.

FIG. 1.

IDLING:
Fig.1 shows the pump unit when idling. The control valve, 3, and the solenoid valve, 1, are kept in center
position by spring load when no steering signal is given.

13
SECTION 1.7-2 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2
(Continued)

FIG. 2.

BEGINNING OF STEERING (MODULATED FLOW):

Steering is carried out by operating the solenoid valve (1). Fig.2 on the diagram shows the beginning of
the steering process when the right solenoid is operated. The control valve (3) will be pushed over to the
right side, by the oil pressure in the left chamber.

The control valve (3) is now at the beginning of its stroke. Some of the oil flows through the throttling
slots to the actuator, and overflow is by-passed at the by-pass valve (4) back to the suction side of the
pump. The smaller oil volume being directed gradually to the actuator will give a soft start.

14
SECTION 1.7-3 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2
(Continued)

FIG. 3.

STEERING:

After approximately one second, the control valve (3) is moved over to it's end position, see fig. 3.
The oil-flow from the pump has now free passage from channel (1) into pipe (B) leading to the actuator.
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.

15
SECTION 1.7-4 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2
(Continued)

FIG. 4.
RELIEF VALVE (Item 2)
When the oil pressure, C, exceeds the preset value of the valve spring load, the valve, 5, will open (fig 4).
The pressure oil will flow to channel (2) and the pressure behind the by-pass valve (7) will drop.
Now the by-pass valve will open, allowing the oil (D) to flow to the return channel (2).

SETTING THE RELIEF VALVE. (Item 2)

Opening pressure for relief valve, see technical data sheet.
To increase the pressure, turn adjusting screw, 6, clockwise.
Safety valve opening pressure has been set during assembly by the suppliers and possible adjustment
should only be carried out by a competent person.

EMERGENCY OPERATION
During emergency operation the solenoid valves (1) can be manually operated by means of manual
controls on the solenoid valves.
NOTE: "Local/Remote"- switch, S3, on starter cabinets, has to be in local position during emergency
operation.

Use push buttons on solenoid valve to operate the manual controls

16
SECTION 1.8 FUNCTIONING OF THE ACTUATOR
(See assembly dwg. of actuator)

The actuator consists of three main components: A cylindrical housing with stoppers, a rotor and a
bolted-on cover.

The rotor, turning in bearings at top and bottom, is equipped with vanes upon which the oil pressure is
acting and thereby developing the turning torque. The turning movement is limited by stoppers fixed to
the housing.

The stoppers also act as mechanical rudder stops in hard-over position.

The axial bearing thrustring of the actuator is of sufficient capacity to carry the full weight of rudder,
rudderstock and rotor, eliminating the need for a separate rudder carrier bearing.

In addition to the stoppers, the actuator is equipped with electrical limit switches stopping the turning
movement at the predetermined angle.

The sealing system consists of synthetic oil resistant material resting in seal grooves, preventing
effectively internal leakages, and gland seals preventing external leakage.

The bearings of the actuator are lubricated by means of the system oil.

AUTOMATIC LOCK VALVE

The actuator is equipped with automatic lock valves. If there should be loss of oil pressure due to possible
external failures, the lock valve will close immediately and keep the actuator intact for operation by
means of the stand-by pump.

SAFETY VALVE

The actuator is equipped with a safety valve, limiting the pressure to the specified value.

17
SECTION 1.9 STORING OF THE EQUIPMENT AND FILLING OF OIL.

In order to protect the inside of the steering gears, a special corrosion retarding ingredient is added to
the hydraulic oil used during final testing of the steering gear. This is a short time protection only. The
steering gear should be filled with oil immediately after received at yard, to protect the equipment.

PROCEDURE FOR FILLING THE ACTUATOR AND THE PUMP UNIT WITH OIL.

Locations of filling- and drain plugs are marked on the arrangement drawing.

1. Open all bleeding plugs on top of the rudder actuator

and the pump unit (See venting procedure section 2.2).
2. Use pump or gravity connected to the filling holes, to
fillthe actuator and the pump. (See sketch).

NOTE: Fill oil through all filling plugs in order to fill all chambers of the actuator.

18
 SECTION 2

INSTALLATION
COMMISSIONING
SEA TRIAL

19
 PP
SECTION 2.0 INSTALLATION

RUDDER ACTUATOR

Sufficient space for inspection and service of the gland seals must be provided (see arr. dwg). 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. If this cannot be arranged, a hatchway in deck may be provided. Tackle bracket
should be arranged.

Do not open the rudder actuator during installation. Forward position is marked on the actuator flange. 0-
position of rotor is marked on top of the actuator. See arrangement drawing.

Make sure that rudderstock and actuator are aligned.

For fastening of the rudderstock to the rudder actuator, see "Procedure for hydraulic
mounting/dismounting of the rudder actuator on the rudderstock", section 2.1.

20
 PP
SECTION 2.0 INSTALLATION
(Continued)

PUMP UNIT
The pump unit should be installed close to the rudder actuator with good access for inspection and
maintenance.

PIPES
Sharp vertical bends on the pipe lines should be avoided, as air pockets may occur.

21
SECTION 2.1-1 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

The taper area of the rudderstock should be adapted to the rudder actuator, use blue color, until sufficient
contact between the rudderstock and the rotor has been obtained (according to classification
requirements).

See drawing and table "[Link] / DISMOUNTING OF RUDDERSTOCK", fig.1.

NECESSARY EQUIPMENT:

2 High-pressure oil pumps with pressure gauges, min 1000 bar.

1 Dial gauge.

OIL SPECIFICATION:

Hydraulic oil: 100 mm2/s at 40°C.

Note! No anti-friction additives allowed in oil.

MOUNTING.

1. Clean and lubricate the taper area of the rudderstock and the rotor using hydraulic oil.

2. Put the rudder actuator on the rudderstock with its full weight on the taper area.

3. Mount the hydraulic nut and tighten by hand.

4. Mount pump 1 for oil pressure to the nut, and pump 2 for oil pressure to the taper.

5. To find a correct starting position for the pull up length, start to pump oil into the nut
with pump1 until the pressure starts to increase (max. 10 bar). Relieve the pressure and
tighten the nut until contact between nut and actuator is obtained. This to avoid that the
o-ring on piston in the nut should break if too long stroke. (For permissible length of
stroke, see arrangement drawing.)
This is the starting position.

6. Mount the dial gauge and adjust to zero.

22
SECTION 2.1-2 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
(Continued) OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

7. Pump oil (pump 2) to the taper fitting until the oil leaks out at the lower part of the taper.

8. Increase slowly the pressure from both pumps 1 and 2 until the rudderstock is pulled up
the length "L", specified in the table.

NOTE:
When pulling up, keep pressure as high as possible on pump 2. (Until the oil leaks out at
the lower or upper part of the taper).

9. Relieve the pressure from pump 2.

10. Wait about 30 minutes, and then relieve the pressure from pump 1.

11. Check the length "L".

12. Dismount the pumps and the dial gauge.

13. Tighten the nut to contact with the actuator.

14. Secure the rudderstock nut.

DISMOUNTING

1. Dismount the lockplate.

2. Unscrew the nut to the length (L + 2) mm. See the table.

3. Mount pump 1 for oil pressure to the nut, and pump 2 for oil-pressure to the taper.

4. Increase the oil-pressure from pump 1 to about 50 bar.

5. Increase the pressure on the taper (pump 2) gradually until the pressure in the nut (pump
1) is rising.
This indicates that the taper is "floating".

6. Reduce the pressure from pump 1 gradually without reducing the taper pressure (from
pump 2), and the rudderstock will be released from rudder actuator.

23
SECTION 2.1-3 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
(Continued) OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

FIG 1.

RRM-Frydenbö Order No. 8233, 8236 and 8237 8234, 8235 and 8238
Hull No.: CX4219-CX4216-CX4217 CX4214-CX4215-CX4220
CALCULATION NO.: 3040DNV 3040BV
RUDDERSTOCK DIA.: 428 mm 428 mm
PULL UP LENGTH MIN: 10,12 mm 10,03 mm
PULL UP LENGTH MAX: 10,44 mm 10,58 mm
PISTON AREA: 940 cm2 940 cm2
PISTON STROKE: 14 mm 14 mm

24
SECTION 2.2 FILLING OF OIL AND VENTING PROCEDURE.

To fill actuator and pump unit with oil, see section 1.9.

Oil specification, see section 1.4.

Before starting to fill oil, open all vent plugs on the actuator.

Fill oil into the oiltank of the power pack.

Actuator
Start the pump units (check the correct rotation). Operate the solenoid valves manually for a few seconds,
to move the rudder. Repeat this procedure until the actuator is filled up with oil, and vent the system.
Do the same operation on the second pump unit.

Venting procedure
Start the pump units.
Operate the solenoid valves manually to move the rudder. Stop the pumps and vent the system.
Start again and move the rudder hard-over to hard-over.

The system should now operate smoothly without noise. If still noisy, repeat the venting.

IF A HYDRAULIC SYSTEM IS TO BE RELIABLE AND FUNCTION SATISFACTORILY, ALL AIR

MUST BE REMOVED FROM THE SYSTEM.

25
SECTION 2.3 PROCEDURE FOR START-UP AND SEA TRIAL.

START-UP:

Fill oil into the actuator and the pump unit according to instruction, and bleed the system.

- Control that the electric motor is rotating in the correct direction.

- Run the rudder hard over to both sides. Control that the rudder moves without any obstructions and that
maximum rudder angle is obtained. Adjust electrical end stoppers, if necessary.

- Half the total rudder angle is the correct center position. Adjust both the mechanical and the electrical
rudder indicators according to this 0-point. Control that the steering handles and the rudder indicators both
show correct direction.

- Check that the relief valve opens at maximum specified pressure, by pushing the emergency push-buttons
on the solenoid valve until the rudder is in hard-over position. To obtain correct pressure, adjust relief valve
(See instructions).

- Test the start and stop switches.

- Test the alarm panels (See instructions).

SEA TRIAL:

- Check that these items are within the limits of the specification for the supplied steering gear, using both
one and two pumps;
- Steering time 35 - 0 - 30 deg.
- Max. working pressure.

Please fill in the form on the next page.

26
SEATRIAL DATA

Please fill in this form during the sea trial and send it to our head office for later reference.

Address: ROLLS-ROYCE MARINE

DEP.: STEERING GEARS - FRYDENBÖ
N-5217 HAGAVIK
NORWAY

Name of ship:....................................
Shipyard:........................................
Hull no:.........................................
Owner:...........................................

Speed:.........knots

Stb. Port Both

Pump pump pumps
------- ------- ------

Steering time 35-0-30 degrees: (seconds) ...…. ...…. …....

Max pressure during steering: (bar) ...…. ...…. …....

Max amps on [Link] during steering: (amp) ...…. ...…. …....

Comments:

.............................................................……………………………………………………………

27
 SECTION 3

MAINTENANCE
INSTRUCTION

28
SECTION 3.0 SERVICE LOCATIONS:

NOTHERN EUROPE NORWAY

ROLLS-ROYCE Aalesund (Ship design)
DENMARK Bergen (Cast Iron) Tel: +47 70 10 37 00
ROLLS-ROYCE Tel: +47 55 53 65 00 Fax: +47 70 10 37 01
Aalborg (Service) Fax: +47 55 53 65 05
Tel: +45 98 114 955 POLAND
Fax: +45 98 114 945 Bergen (Engines) ROLLS-ROYCE
Tel: +47 55 53 65 00 Gniew (Deck machinery)
Esbjerg Fax: +47 55 19 04 05 Tel: +48 69 135 22 71
Tel: +45 75 14 15 22 Fax: +48 69 135 22 18
Fax: +45 75 14 41 02 Bergen (Service)
Tel: +47 56 57 16 00 RUSSIA
FINLAND Fax: +47 56 30 82 41 ROLLS-ROYCE
ROLLS-ROYCE Moscow
Helsinki Bergen Tel: +7 095 230 6441
Tel: +358 96866330 (Frydenbö steering gear) Fax: +7 095 230 6441
Fax: +358 968663339 Tel: +47 56 57 16 00
Fax: +47 56 30 82 41 St. Petersburg
Kokkola (Water jets) Tel: +7 812 960 4627
Tel: +358 68324500 Bergen (Turbines) Fax: +7 812 325 5604
Fax: +358 68324511 Tel: +47 55 53 64 50
Fax: +47 55 53 60 60 SWEDEN
Rauma (Winches, thrusters) ROLLS-ROYCE
Tel: +358 2 83 791 Brattvaag (Deck machinery) Gøteborg
Fax: +358 2 8379 4804 Tel: +47 70 20 85 00 Tel: +46 31 492 202
Fax: +47 70 20 86 00 Fax: +46 31 497 531
FRANCE
ROLLS-ROYCE Hareid (Rudders) Kristinehamn (Propulsion)
Rungis Tel: +47 70 09 55 00 Tel: +46 550 84000
Tel: +33 1 468 62811 Fax: +47 70 09 55 55 Fax: +46 550 18190
Fax: +33 1 468 79398
Longva (Automation) UNITED KINGDOM
GERMANY Tel: +47 70 20 82 00 ROLLS-ROYCE
ROLLS-ROYCE Fax: +47 70 20 83 51 Aberdeen
Hamburg Tel: +44 1224 58 1722
Tel: +49 40 381 277 Tennfjord (Steering gear) Fax: +44 1224 58 1723
Fax: +49 40 389 2177 Tel: +47 70 20 88 00
Fax: +47 70 20 89 00 Dartford
Hamburg (Service) Tel: +44 1322 394 300
Tel: +49 40 78091910 Ulsteinvik (Adm.) Fax: +44 1322 394 301
Fax: +49 40 78091919 Tel: +47 70 01 40 05
Fax: +47 70 01 40 01 Dunfermline (Propulsion)
THE NETHERLANDS Tel: +44 1383 82 31 88
ROLLS-ROYCE Ulsteinvik (Ship design) Fax: +44 1383 82 40 38
Groningen Tel: +47 70 01 40 00
Tel: +31 50 54 25 425 Fax: +47 70 01 40 13 Edinburgh (Stabilisers)
Fax: +31 50 54 25 588 Tel: +44 131 556 2440
Ulsteinvik (Propulsion) Fax: +44 131 556 3253
Purmerend (Service) Tel: +47 70 01 40 00
Tel: +31 299 641 118 Fax: +47 70 01 40 17 Newcastle (Bearings)
Fax: +31 299 644 999 Tel: +44 191 273 0291
Volda (Propulsion) Fax: +44 191 272 2787
Rotterdam (Service) Tel: +47 70 07 39 00
Tel: +31 10 42 61 227 Fax: +47 70 07 39 50 Tewkesbury (Service)
Fax: +31 10 42 64 298 Tel: +44 1684 290 781
Oslo (Repr. office) Fax: +44 1684 290 786
Tel: +47 23 31 04 80
Fax: +47 23 31 04 99

29
SOUTHERN EUROPE AMERICAS

ITALY Hong Kong BRAZIL

ROLLS-ROYCE Tel: +852 2526 6937 ROLLS-ROYCE
Genova (Marine Sales & Fax: +852 2868 5344 Rio de Janeiro
Service) Tel: +55 21 507 4992
Tel: +39 010 839 1561 Shanghai Fax: +55 21 509 5610
Fax: +39 010 839 3663 Tel: +86 21 5818 8899
Fax: +86 21 5818 9388 CANADA
CROATIA ROLLS-ROYCE
ROLLS-ROYCE INDIA Halifax
Rijeka ROLLS-ROYCE Tel: +1 902 468 2883
Tel: +38 5512 54882 Mumbai Fax: +1 902 468 2759
Fax: +38 5512 55154 Tel: +91 22 820 45 41
Fax: +91 22 820 45 42 St. Johns
MALTA Tel: +1 709 364 3053
ROLLS-ROYCE SINGAPORE Fax: +1 709 364 3054
Valletta ROLLS-ROYCE
Tel: +356 805 497 Singapore Vancouver (Propulsion)
Fax. +356 677 747 Tel: +65 686 21 901 Tel: +1 604 942 1100
Fax: +65 686 22 477 Fax: +1 604 942 1125
SPAIN
ROLLS-ROYCE NORTH EAST ASIA USA
Madrid ROLLS-ROYCE
Tel: +34 91 372 81 42 JAPAN Annapolis (Propulsion)
Fax: +34 91 372 87 28 ROLLS-ROYCE Tel: +1 410 224 2130
Tokyo Fax: +1 410 266 6721
Tarragona Tel: +81 3 3237 6861
Tel: +34 977 296 444 Fax: +81 3 3237 6846 Fort Lauderdale
Fax: +34 977 296 450 Tel: +1 954 581 2757
REPUBLIC OF KOREA Fax: +1 954 581 2785
ASIA PACIFIC ROLLS-ROYCE
Inchon Houston
AUSTRALIA Tel: +82 32 888 4576 Tel: +1 281 497 5220
ROLLS-ROYCE Fax: +82 32 888 4579 Fax: +1 281 497 4903
Melbourne
Tel: +61 3 9848 6061 Pusan (Deck machinery) New Orleans
Fax: +61 3 9848 6078 Tel: +82 51 266 0170 Tel: +1 504 464 4561
Fax: +82 51 266 0175 Fax: +1 504 464 4565
Perth
Tel: +61 8 9336 7910 Pusan Pascagoula (Cast Iron)
Fax: +61 8 9336 7920 Tel: +82 51 205 0236 Tel: +1 228 762 0728
Fax: +82 51 205 0235 Fax: +1 228 769 7048
CHINA
ROLLS-ROYCE RUSSIA Seattle
Dalian (Purchasing Office) ROLLS-ROYCE Tel: +1 206 782 9190
Tel: +86 411 281 5791 Vladivostok Fax: +1 206 782 0176
Fax: +86 411 263 1573 Tel: +7 5232 495 484
Fax: +7 5232 495 484 Walpole (Propulsion)
Tel: +1 508 668 9610
Fax: +1 508 660 6152

30
SECTION 3.1 MAINTENANCE REPORTING

It is requested that any failures or maintenance work on the equipment, no matter how small, should be
reported to Frydenbö. By reporting any failures and maintenance work, an accurate machinery 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.

When reporting, the following information should be included:

1) Date

2) Vessel name

3) Date of installation - 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, the following additional information is requested in addition
to items 1-8 above. This will insure more efficient service.

9) Working and idling pressures

10) Steering time, 35-0-30 degrees.

31
SECTION 3.2 MAINTENANCE

If a hydraulic system is properly installed, started up and maintained, it will have a long life and run
reliably.
If problems do occur, however, it is essential to find the cause and put it right as quickly as possible. The
FAULTFINDING CHART must be seen as a general fault finding guide only. Also use the hydraulic
diagram if problems occur, as this will facilitate the faultfinding.

The service personnel of Frydenbö AS has long experience in the service and maintenance of hydraulic
steering gears. This experience in the maintenance and service sectors is at the disposal of our customers.
Contact our service department for guidance, or, if necessary, ask for a service engineer to be sent.

IF PROBLEMS OCCUR, USE THE FAULTFINDING CHART.

IF THE PROBLEM CANNOT BE SOLVED BY YOUR MAINTENANCE MEN,

CALL IN A SERVICE ENGINEER.

32
SECTION 3.3 PERIODICAL MAINTENANCE PP

The actuator should regularly be visually inspected for external leakage, paintwork, damages etc.
A clean actuator will facilitate the inspection work.

A continuous undisturbed functioning of the steering gear is dependent on two simple points:
1. Use the specified hydraulic oil
2. Keep the hydraulic system clean

The hydraulic oil and the interior of the installation should be kept absolutely free from any impurities
and air.
If these points are adhered to the preventive maintenance will be limited to following:

Yearly.

A. Oil filters in the pump unit to be changed.

Stuffing glands on the actuator to be checked.

Every second year.

B. Change hydraulic oil.

A. Oil filter.
After the first 200 hours running, the oil filter should be opened for inspection and changed if
necessary. If you find impurities, change of the filter must be repeated at short intervals until it
stays clean. This indicates that the hydraulic system is clean and the filter should now be left for
the yearly change.

B. The hydraulic pump.

The hydraulic pump will normally last more than 10 years. A worn pump should be replaced or
repaired. A worn pump means reduced pumping capacity indicated by slower steering speed.

C. The actuator.
The rotor seals and the gland seals are practically the only wearing parts. Unintended movement
(creeping) of the rudder at sea, indicates wear on the rotor seals. Based on experience, the normal
life time of the rotor seals is 5 to 10 years. For change of rotor seals, see instructions.

33
 PP
SECTION 3.4 CHANGE THE FILTER OF THE PUMP UNIT
(See assembly dwg.)

1. Open the cover of the filter, lift out the filter cartridge

2. Loosen the Allen screw at the bottom of the filter cartridge, and remove the rod, magnet (N/A on
all filters), top and spring.

3. Mount the rod, magnet, top and spring on the new filter cartridge, and insert it into the filter
housing.

4. Reassemble the cover and tighten up the nuts.

34
 SECTION 4
REPAIR INSTRUCTION

35
36
SECTION 4.1 REPLACEMENT OF THE ACTUATOR SEALS
(See fig. 1.)
GLAND SEALS.

Upper gland seals. (Item 5).

Remove the upper gland ring. Remove the old gland seals.
Grease new seals, before they are inserted, and also apply grease before replacing gland ring.

Lower gland seals, (Item 6).

Same procedure as for the upper seals.
To facilitate reassembling of the lower gland ring, we recommend lowering the gland ring by means of
two lengthened screws.

The seals to be cut apart for inserting around rudderstock and to be glued together (Use LOCKTITE
superglue no. 495).

FIG. 1.

IMPORTANT
All seals are supplied in correct lengths and must NOT be shortened.
The correct way of inserting the gland seals is shown in fig. 2.

FIG.2.

37
SECTION 4.1 REPLACEMENT OF ACTUATOR SEALS.
(Continued) (See fig.1.)

INTERNAL SEALS:

The following seals may be replaced without disconnecting the rotor from the rudderstock:

Cover ring seal - item 1

Vertical stopper seals with springs - item 2
Vertical vane seals with springs - item 3
Top vane seals - item 4

The following seals can be replaced only when the rotor has been dismounted from the rudderstock:
Lower vane seals - item 4
Bottom ring seal - item 1

- Drain the actuator for hydraulic oil through the bottom drain holes.
- Make sure that the vent plugs are open.
- Remove the actuator cover.
- Inspect actuator and cover. Clean, use rags.

Replace seals in this order:

A. When rotor has been dismounted from rudderstock and lifted out of the housing:
1. Bottom ring seal
2. Lower vane seal
After the rotor has been lowered in to the housing:
3. Vertical vane seals with springs
4. Vertical segment seals with springs
5. Top vane seals
6. Cover ring seal

B. When rotor is still attached to rudderstock:

1. Cover ring seal
2. Vertical vane seals with springs
3. Vertical segment seals with springs
4. Top vane seals

Note! Grease or oil all new seals before assembly, see drawing 33637E

Assemble the actuator and fill up with oil. (See oil filling procedure).

38
SECTION 4.2 CONTROL AND REPLACEMENT OF THE
THRUST BEARINGS (See assembly dwg.)

CONTROL OF THE THRUST BEARING:

1. Close the shut off valves for the expansion pipes.

2. Drain oil from the actuator.
3. Remove the gland ring and gland seals.
4. Remove the cover of the actuator.
5. Be sure that the rudder shaft is aligned and is not bending.
6. Use feeler gauge and check the clearance between rotor-vanes and bottom of housing; Min.
clearance is 0,10 mm.

CHANGE OF THE THRUST BEARING:

1. Drain oil from the actuator

2. Remove the gland ring and the gland seals.
3. Remove the cover of the actuator.
4. Dismount the rotor from the rudderstock, (see section 2.1). Important! Secure rudderstock.
5. Remove the old bearing (splitted in 4) and mount the new ones.
6. Attach the rotor to the rudderstock again, (see section 2.1).
7. Assemble cover, gland seals and gland ring.
8. Fill the actuator with oil and vent, (see section 2.2).
9. The actuator is now ready for trial.

39
SECTION 4.3 CONTROL AND REPLACEMENT OF THE LINERS
(See assembly dwg.)

CONTROL OF THE LINERS:

1. Remove the upper and lower gland rings and gland seals.
2. Use feeler gauge and control that clearances between the rotor and the liners, A and B, are within
limits. Be sure that the rotor is in center.
3. The clearances in the liners can be checked by removing the cover. Mechanical contact between the
rotor and the housing, cover or stoppers, indicates too big clearances. It can also indicate that the
actuator and rudderstock are out of line. This should be checked.

REPLACEMENT OF THE LINERS:

1. Close the shut off valves for the exp. pipes, (see [Link]).
2. Drain oil from the actuator.
3. Remove the gland ring and the gland seals.
4. Remove the cover.
5. Dismount the rotor from the rudderstock (see section 2.1).
6. Lower the rudderstock or loosen the foundation bolts and lift the actuator off the rudderstock.
7. Press out the old liners.
8. Fit the new liners. (Freeze if necessary).
9. Check the inner diameter of the replaced liners, and the outer diameter of the "rotorneck" to control
that the clearances, A and B, are within limits. If not, grind the inner surfaces of the liners.
10. Put the rudderstock and/or the actuator back in position.
11. Attach the rotor to the rudderstock again (See section 2.1).
12. Fit cover, glandseals and glandrings.
13. Fill actuator with oil and vent (See section 2.2)
14 The steering gear is now ready for sea trial.

40
 PP
SECTION 4.4 THE PUMP UNIT - CHANGE OF THE PUMP
(See assembly dwg.)

1. Unscrew the bolts and lift the cover off the tank.

2. Disconnect SAE flanges and pipes.

3. Loosen the bolts and disconnect the electric motor from the pump.

4. Disconnect the coupling from the pump shaft.

Change the elastic part of coupling if necessary.

5. Unscrew the bolts and change the pump.

6. Reassemble in opposite order.

41
 PPS
SECTION 4.4-1 THE PUMP UNIT - CHANGE OF THE ELASTIC RINGS
(See assembly dwg.)

1. Unscrew the hexagon head screws which fasten the electric motor to the bellhousing.
2. Lift off the el. motor.
3. Remove the old elastic ring.
4. The new elastic ring to be inserted, and the el. motor to be remounted.

SECTION 4.4-2 THE PUMP CARTRIDGE -CHANGE OF THE BALL BEARING

(See [Link]. 14702)

1. Unscrew the hexagon screw, and remove the seal cover.

2. The shaft sealing-housing/bearing-housing, to be withdrawn after the fixing bolts have been
unscrewed.
3. Circlips and washers, to be removed.
4. The ball bearing, to be withdrawn from the shaft.
5. Insert the new ball bearing on the shaft. Insert supporting washers and the circlips.
6. Assemble the shaft sealing-housing/bearing-housing and the seal cover, and tighten the bolts.

SECTION 4.4-3 THE PUMP CARTRIDGE-CHANGE OF THE SHAFT SEAL RING

(See [Link]. 14702)

1. Unscrew the hexagon screw, and remove the seal cover.

2. The shaft sealing-housing/bearing-housing, to be withdrawn after the fixing bolts have been
unscrewed.
3. The old shaft seal rings, to be removed.
4. Insert the new shaft seal rings.
Important: Do not forget to insert the supporting ring, in correct position.
5. Assemble the shaft sealing-housing/bearing-housing and seal cover, and tighten the bolts.

42
SECTION 5

DRAWINGS

43
SECTION 5.0 DRAWING LIST

Drawing no.:

General arrangement 15929

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 23710
Part list P80536
Top end of rudderstock 13350
Steering Loss and Recovery 32897
Hydraulic Diagram 44896
Transmitter Arr FB40 with Limit Switches 24122
Lubrication Chart for Actuator Assembly 33637E
Spare Part List P80503

44
 SECTION 6

PARTS CATALOGUE

45
 Rolls Royce Marine - Frydenbö
SPARE PARTS FOR STEERING GEAR- P80503
ACTUATOR AND PUMP UNIT

YARD: Chengxi Shipyard P.R. China DATE: 14 March 2006

Steering gear type: Hull no:

RV 1350-3 CX4219, CX4216, CX4217 Page 1 of 1 ORDER NO: 8233, 8236, 8237
CX4214, CX4215, CX4220 ORDER NO: 8234, 8235, 8238

POS Part No. QTY. 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 0,4 KG

04

05

06

07

08

09

10

11

12

13

46
 SECTION 7

ELECTRICAL PART
(See Separate Manual)

47