INSTRUCTION MANUAL

FOR
FRYDENBÖ

STEERING GEAR
RV 900-2
FRYDENBÖ ORDER No: 7512-7513-7514-7515

Jiangsu Yangzijiang Shipbuilding Co. Ltd.

Hull No YZJ2003-667C/668C/669C/6670C
Type of vessel: 1574 TEU Container Vessel

Rolls-Royce Marine AS
Dep. Steering Gears - Frydenbö
N-5217 Hagavik, Norway
Switchboard + 47 56 57 16 00. Telefax + 47 56 30 82 41
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 15
1.9 Storing of the equipment and filling of oil 16

SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL

2.0 Installation 18
2.1 Mounting/dismounting rudderstock 20
2.2 Filling of oil and venting procedure 23
2.3 Procedure for start-up and sea-trial 24

SECTION 3 MAINTENANCE INSTRUCTION

3.0 Service locations 27
3.1 Maintenance reporting 29
3.2 Maintenance 30
3.3 Periodical maintenance 31
3.4 Cleaning the strainer/filter of the pump unit 32

SECTION 4 REPAIR INSTRUCTION

4.0 Fault finding chart 34
4.1 Renewal of the actuator seals 35
4.2 Control and renewal of the trustbearing 37
4.3 Control and renewal of the liners 38
4.4 Pump unit 39

SECTION 5 DRAWINGS
5.0 Drawing list 42

SECTION 6 PARTS CATALOGUE

6.0 Parts list - Actuator and Pump unit 44

SECTION 7 ELECTRICAL PART

46-

1
 SECTION 1

GENERAL INFORMATION

2
SECTION 1.0 INTRODUCTION

This instruction manual, issued for Rolls-Royce 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.

Rolls-Royce 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
SECTION 1.1 GENERAL DESCRIPTION PPS
(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 oil tank. The tank is divided into two chambers, one for each
pump unit, 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 oil tank.

4
SECTION 1.2 TECHNICAL DATA

1) RUDDER ACTUATOR

Type RV 900-2
Rudderstock diameter 400 mm
Maximum rudder angle 2 x 71,5 degr.
Maximum oil pressure 82,4 BAR
Relief valve setting 103 BAR
Design torque 1125 kNm
Displacement (35-0-30) = 65 degr. 124 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 PPSMI 2"

Screw pump "Leistritz" type L3MF 45-90
Revolution 3500 R.P.M.
Capacity at 3500 R.P.M. 278 l/min
Relief valve setting 82,4 Bar
Maximum temperature system 70 degr.C.
Solenoid valve Vickers 24V DC

3) ELECTRIC MOTOR

Type ABB M3AA 180 LB2

Revolution 3500 R.P.M.
Rating S1 35,6 kW
Voltage 3 x 440 V AC
Current 56A/420 A
Frequency 60 Hz
Protection degree IP 54

4) OIL CAPACITY

Rudder actuator 280 Liters

Pump units 2x300 litres = 600 Liters
Int. storage tank 550 Liters
Pipe lines / hoses 50 Liters

Total oil volume 1480 Liters

5
SECTION 1.3 WEIGHT LIST

STEERING GEAR TYPE RV 900-2

EQUIPMENT: WEIGHT

DRY: With OIL:

Rudder actuator 6000 kg 6280 kg

Pump unit 1250 kg 2450 kg
------- -------

TOTAL 7250 kg 8730 kg

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

6
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.

7
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

8
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

9
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 PPSMI-2

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

1. Gear pump.
2. Oil tank with two chambers and one integrated storage tank.
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.
9. Hand pump for pumping oil from storage chamber to pump chamber.

11
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 centre position by
spring load when no steering signal is given.

12
SECTION 1.7-2 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2
(Continued)

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

FIG. 2.

13
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.

FIG. 3.

SECTION 1.7-3 FUNCTIONING OF THE PUMP/CONTROL UNIT PME2

14
 (Continued)

FIG. 4.
RELIEF VALVE (Item 2)
When the oil pressure, C, exceeds the pre-set 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.

15
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.

16
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
fill the actuator and the pump. (See sketch).

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

17
18
 SECTION 2

INSTALLATION
COMMISSIONING
SEA TRIAL

17
 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.

18
 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.

19
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 colour, until
sufficient contact between the rudderstock and the rotor has been obtained (according to
classification requirements).

See drawing and table "HYDR.MOUNTING / 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.

20
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.

21
SECTION 2.1-3 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
(Continued) OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

FIG 1.

Frydenbö Order.: 7512-7513-7514-7515

Hull No. : JLZ2003-667C/668C/669C/6670C
CALCULATION NO.: 2811GL
PULL UP LENGTH MIN: 8,94 mm
PULL UP LENGTH MAX: 9,26 mm
PISTON AREA: 940 cm²
PISTON STROKE: 19 mm
RUDDERSTOCK DIA.: 400 mm
 PP
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 oil tank 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.
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 centre 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.

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 AS

Dep. Steering Gear - Frydenbö
N-5217 HAGAVIK
NORWAY

Fax: +47 56 30 82 41

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 el.motor during steering: (amp) ...…. ...…. …....

Comments:

.............................................................……………………………………………………………
 SECTION 3

MAINTENANCE
INSTRUCTION
SECTION 3.0 SERVICE LOCATIONS:

NOTHERN EUROPE Tel: +47 70 07 39 00

Fax: +47 70 07 39 50
DENMARK
ROLLS-ROYCE Oslo (Repr. office)
Aalborg (Service) Tel: +47 23 31 04 80
Tel: +45 98 114 955 NORWAY Fax: +47 23 31 04 99
Fax: +45 98 114 945 ROLLS-ROYCE
Bergen (Cast Iron)
Esbjerg Tel: +47 55 53 65 00
Tel: +45 75 14 15 22 Fax: +47 55 53 65 05 Aalesund (Ship design)
Fax: +45 75 14 41 02 Tel: +47 70 10 37 00
Bergen (Engines) Fax: +47 70 10 37 01
FINLAND Tel: +47 55 53 65 00
ROLLS-ROYCE Fax: +47 55 19 04 05 POLAND
Helsinki ROLLS-ROYCE
Tel: +358 96866330 Bergen (Service) Gniew (Deck machinery)
Fax: +358 968663339 Tel: +47 56 57 16 00 Tel: +48 69 135 22 71
Fax: +47 56 30 82 41 Fax: +48 69 135 22 18
Kokkola (Water jets)
Tel: +358 68324500 Bergen RUSSIA
Fax: +358 68324511 (Frydenbö steering gear) ROLLS-ROYCE
Tel: +47 56 57 16 00 Moscow
Rauma (Winches, thrusters) Fax: +47 56 30 82 41 Tel: +7 095 230 6441
Tel: +358 2 83 791 Fax: +7 095 230 6441
Fax: +358 2 8379 4804 Bergen (Turbines)
Tel: +47 55 53 64 50 St. Petersburg
FRANCE Fax: +47 55 53 60 60 Tel: +7 812 960 4627
ROLLS-ROYCE Fax: +7 812 325 5604
Rungis Brattvaag (Deck machinery)
Tel: +33 1 468 62811 Tel: +47 70 20 85 00 SWEDEN
Fax: +33 1 468 79398 Fax: +47 70 20 86 00 ROLLS-ROYCE
Gøteborg
GERMANY Hareid (Rudders) Tel: +46 31 492 202
ROLLS-ROYCE Tel: +47 70 09 55 00 Fax: +46 31 497 531
Hamburg Fax: +47 70 09 55 55
Tel: +49 40 381 277 Kristinehamn (Propulsion)
Fax: +49 40 389 2177 Longva (Automation) Tel: +46 550 84000
Tel: +47 70 20 82 00 Fax: +46 550 18190
Hamburg (Service) Fax: +47 70 20 83 51
Tel: +49 40 78091910 UNITED KINGDOM
Fax: +49 40 78091919 Tennfjord (Steering gear) ROLLS-ROYCE
Tel: +47 70 20 88 00 Aberdeen
THE NETHERLANDS Fax: +47 70 20 89 00 Tel: +44 1224 58 1722
ROLLS-ROYCE Fax: +44 1224 58 1723
Groningen Ulsteinvik (Adm.)
Tel: +31 50 54 25 425 Tel: +47 70 01 40 05 Dartford
Fax: +31 50 54 25 588 Fax: +47 70 01 40 01 Tel: +44 1322 394 300
Fax: +44 1322 394 301
Purmerend (Service) Ulsteinvik (Ship design)
Tel: +31 299 641 118 Tel: +47 70 01 40 00 Dunfermline (Propulsion)
Fax: +31 299 644 999 Fax: +47 70 01 40 13 Tel: +44 1383 82 31 88
Fax: +44 1383 82 40 38
Rotterdam (Service) Ulsteinvik (Propulsion)
Tel: +31 10 42 61 227 Tel: +47 70 01 40 00 Edinburgh (Stabilisers)
Fax: +31 10 42 64 298 Fax: +47 70 01 40 17 Tel: +44 131 556 2440
Fax: +44 131 556 3253
Volda (Propulsion)
Newcastle (Bearings) Shanghai Fax: +1 709 364 3054
Tel: +44 191 273 0291 Tel: +86 21 6387 8808
Fax: +44 191 272 2787 Fax: +86 21 5382 5793 Vancouver (Propulsion)
Tel: +1 604 942 1100
Tewkesbury (Service) INDIA Fax: +1 604 942 1125
Tel: +44 1684 290 781 ROLLS-ROYCE
Fax: +44 1684 290 786 Mumbai USA
Tel: +91 22 820 45 41 ROLLS-ROYCE
Fax: +91 22 820 45 42 Annapolis (Propulsion)
SOUTHERN EUROPE Tel: +1 410 224 2130
Fax: +1 410 266 6721
ITALY
ROLLS-ROYCE SINGAPORE Fort Lauderdale
Genova (Marine Sales & ROLLS-ROYCE Tel: +1 954 581 2757
Service) Singapore Fax: +1 954 581 2785
Tel: +39 010 839 1561 Tel: +65 686 21 901
Fax: +39 010 839 3663 Fax: +65 686 22 477 Houston
Tel: +1 281 497 5220
CROATIA NORTH EAST ASIA Fax: +1 281 497 4903
ROLLS-ROYCE
Rijeka JAPAN New Orleans
Tel: +38 5512 54882 ROLLS-ROYCE Tel: +1 504 464 4561
Fax: +38 5512 55154 Tokyo Fax: +1 504 464 4565
Tel: +81 3 3237 6861
MALTA Fax: +81 3 3237 6846 Pascagoula (Cast Iron)
ROLLS-ROYCE Tel: +1 228 762 0728
Valletta REPUBLIC OF KOREA Fax: +1 228 769 7048
Tel: +356 805 497 ROLLS-ROYCE
Fax. +356 677 747 Inchon Seattle
Tel: +82 32 888 4576 Tel: +1 206 782 9190
SPAIN Fax: +82 32 888 4579 Fax: +1 206 782 0176
ROLLS-ROYCE
Madrid Pusan (Deck machinery) Walpole (Propulsion)
Tel: +34 91 372 81 42 Tel: +82 51 266 0170 Tel: +1 508 668 9610
Fax: +34 91 372 87 28 Fax: +82 51 266 0175 Fax: +1 508 660 6152

Tarragona Pusan
Tel: +34 977 296 444 Tel: +82 51 205 0236
Fax: +34 977 296 450 Fax: +82 51 205 0235

ASIA PACIFIC RUSSIA

ROLLS-ROYCE
AUSTRALIA Vladivostok
ROLLS-ROYCE Tel: +7 5232 495 484
Melbourne Fax: +7 5232 495 484
Tel: +61 3 9848 6061
Fax: +61 3 9848 6078 AMERICAS

Perth BRAZIL
Tel: +61 8 9336 7910 ROLLS-ROYCE
Fax: +61 8 9336 7920 Rio de Janeiro
Tel: +55 21 507 4992
CHINA Fax: +55 21 509 5610
ROLLS-ROYCE
Dalian (Purchasing Office) CANADA
Tel: +86 411 281 5791 ROLLS-ROYCE
Fax: +86 411 263 1573 Halifax
Tel: +1 902 468 2883
Hong Kong Fax: +1 902 468 2759
Tel: +852 2526 6937
Fax: +852 2868 5344 St. Johns
Tel: +1 709 364 3053
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 Rolls-Royce 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.

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 Rolls-Royce Frydenbö have 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 Rolls-Royce Frydenbö SERVICE ENGINEER.

SECTION 3.3 PERIODICAL MAINTENANCE PP

The actuator should regularly be visually inspected for external leakage, paint work, 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.
 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.

 SECTION 4
REPAIR INSTRUCTION
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.
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 all new seals before assembly.

Assemble the actuator and fill up with oil. (See oil filling procedure).
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. 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.
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 centre.
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 arr.dwg).
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 "rotor neck" 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, gland seals and gland rings.
13. Fill actuator with oil and vent (See section 2.2)
14 The steering gear is now ready for sea trial.
 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.

 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 assembly dwg.)

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 assembly dwg.)

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.
SECTION 5

DRAWINGS
SECTION 5.0 DRAWING LIST

Description Drawing no.:

General arrangement.............................................................15419
Rudder actuator - assembly...................................................14470
Part list actuator ....................................................................P81466
Safety relief valve .................................................................23317
2" Automatic Lock valve .....................................................44299
Pump unit type PPSMI 2 " – assembly .................................13887
Part list Pump unit ................................................................P81467
Pump insert, Leistritz ............................................................44702
Control valve for pump unit .................................................23710
Part list control valve ............................................................P80536
Top end of rudderstock .........................................................13350
Transmitter Arr .....................................................................24122
Hydraulic Nut .......................................................................23637
Stuffing Box 430 mm ...........................................................32890
Steering loss and recovery ....................................................32897
 SECTION 6

PARTS CATALOGUE
Rolls-Royce Frydenbö
Type: ACTUATOR RV 900-2 Wrt. by: MM

List no.: P80460 Date: 20.10.04

Shipyard: Jiangsu Yangzijiang Shipbuilding Rev.:

Item no. Part no. Part Name No. off Unit

01 P80674 GLAND SEAL SET 1 PCS

01-01 45009 GLAND SEAL XNBR 4 PCS
01-02 44821 O-RING FOR GLAND HS 360-03 2 PCS
01-03 42888 MOUNTING OF GLAND SEALS 1 PAT
01-04 N34285 GREASE TUBE 0,4KG 1 PCS
02 70105 FILTER CARTRIDGE 2 PCS
03 33034-7 COVER SEAL HS 240- RV 1350 1 PCS

43
 SECTION 7

ELECTRICAL PART

44