INSTRUCTION MANUAL

FOR
FRYDENB
STEERING GEAR RV1350-3
Chengxi Shipyard P. R. China
Hull No. CX4204/05/06/07/08/09
Frydenb Order No: 7474-7479
Classification: DnV
Type of vessel: 53.000 DWT Bulk Carrier

ROLLS-ROYCE MARINE
Dep.: Steering Gears - Frydenb
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
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-

SECTION 1
GENERAL INFORMATION

SECTION 1.0

INTRODUCTION

This instruction manual, issued for Frydenb 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 Frydenb 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.

SECTION 1.1

GENERAL DESCRIPTION
(See general arrangement dwg.)

PPSI

A. STEERING GEAR
The FRYDENB 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 standby 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.

SECTION 1.2
1)

TECHNICAL DATA

RUDDER ACTUATOR
Type
Rudderstock diameter
Maximum working pressure
Maximum design pressure
Maximum rudder angle, mechanical
Maximum rudder angle, electrical
Design torque
Displacement (35-0-30) = 65 degr.
Steering time (35-0-30) degr.
with one pump running
Steering time (35-0-30) degr.
with two pumps running

2)

RV 1350-3
428 mm
70,1 bar
87,7 bar
2 x 46,5 degr.
2 x 36,0 degr.
1438 kNm
186 liters
max.28 seconds
max.14 seconds

PUMP UNIT
Type
Screw pump "Leistritz " type
Revolution
Capacity at 3500 R.P.M.
Relief valve setting
Maximum temperature system
Solenoid valve

3)

PPSM 2"
L3MF 52-104
3500 R.P.M.
430 l/min
70,1 bar
70 degr.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.M.
3 x 440 V AC

In= 68A, Is=442 S1 100%

60 Hz
IP 54
220 V AC

OIL CAPACITY
Rudder actuator
Pipe lines / hoses
Pump units 2x500 ltrs
Min. storage tank , yard supply

270 Liters
50 Liters
1000 Liters
1000 Liters*

Total oil volume

2320 Liters

* Volume to be verified by shipyard

SECTION 1.3

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
-------

SECTION 1.4

OIL SPECIFICATION

HYDRAULIC OIL TYPE

FOR
FRYDENB ROTARY VANE STEERING GEAR
Use only a high quality hydraulic oil with a viscosity index of approximate 100. The oil should have antifoam, 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.

SECTION 1.5

THE ACTUATOR

The actuator consists of these main components:

1.
2.
3.
4.
5.
6.

Housing
Cover
Rotor
Stoppers
Vanes
Safety relief valve

SECTION 1.5
(Continued)

THE ACTUATOR

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 CLOSEDRUDDER 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
(Continued)

THE ACTUATOR

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.
2.
3.
4.
5.
6.
7.
8.

Gear pump.
Oil tank with two chambers.
Flexible coupling between motor and pump.
Solenoid operated control valve for connection to steering controls, with emergency
push-button steering controls.
Electric motor.
Pressure gauge.
Safety relief valve.
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
(Continued)

FUNCTIONING OF THE PUMP/CONTROL UNIT

PME2

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
(Continued)

FUNCTIONING OF THE PUMP/CONTROL UNIT

PME2

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
(Continued)

FUNCTIONING OF THE PUMP/CONTROL UNIT

PME2

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.

16

Use push buttons on solenoid valve to operate the manual controls

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 boltedon 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.
2.

Open all bleeding plugs on top of the rudder actuator

and the pump unit (See venting procedure section 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. 0position 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
(Continued)

INSTALLATION

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 "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 40C.
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
(Continued)

PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING

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
(Continued)

PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING

OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

FIG 1.

RRM-Frydenb Order No.

CALCULATION NO.:
RUDDERSTOCK DIA.:
PULL UP LENGTH MIN:
PULL UP LENGTH MAX:
PISTON AREA:
PISTON STROKE:

7474-7479
2804
428 mm
10,12 mm
10,44 mm
940 cm2
15 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 - FRYDENB
N-5217 HAGAVIK
NORWAY

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

Stb.
Port
Pump pump
------- ------Steering time 35-0-30 degrees: (seconds)

....

Both
pumps
------

....

....

Max pressure during steering: (bar)

....

....

....

Max amps on el.motor during steering: (amp)

....

....

....

Comments:
.............................................................

27

SECTION 3
MAINTENANCE
INSTRUCTION

28

SECTION 3.0

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, 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
(Frydenb 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. 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
Gteborg
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: +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

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

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 Frydenb. 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 Frydenb 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.

37

FIG.2.

38

SECTION 4.1
(Continued)

REPLACEMENT OF ACTUATOR SEALS.

(See fig.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

- item 1
- item 2
- item 3
- 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).

39

SECTION 4.2 CONTROL AND REPLACEMENT OF THE

THRUST BEARINGS (See assembly dwg.)

CONTROL OF THE THRUST BEARING:

1.
2.
3.
4.
5.
6.

Close the shut off valves for the expansion pipes.

Drain oil from the actuator.
Remove the gland ring and gland seals.
Remove the cover of the actuator.
Be sure that the rudder shaft is aligned and is not bending.
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.
2.
3.
4.
5.
6.
7.
8.
9.

Drain oil from the actuator

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

40

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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14

Close the shut off valves for the exp. pipes, (see arr.dwg).
Drain oil from the actuator.
Remove the gland ring and the gland seals.
Remove the cover.
Dismount the rotor from the rudderstock (see section 2.1).
Lower the rudderstock or loosen the foundation bolts and lift the actuator off the rudderstock.
Press out the old liners.
Fit the new liners. (Freeze if necessary).
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.
Put the rudderstock and/or the actuator back in position.
Attach the rotor to the rudderstock again (See section 2.1).
Fit cover, glandseals and glandrings.
Fill actuator with oil and vent (See section 2.2)
The steering gear is now ready for sea trial.

41

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.

42

PPS
SECTION 4.4-1 THE PUMP UNIT - CHANGE OF THE ELASTIC RINGS
(See assembly dwg.)
1.
2.
3.
4.

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

SECTION 4.4-2
1.
2.
3.
4.
5.
6.

THE PUMP CARTRIDGE -CHANGE OF THE BALL BEARING

(See dwg.no. 14702)

Unscrew the hexagon screw, and remove the seal cover.

The shaft sealing-housing/bearing-housing, to be withdrawn after the fixing bolts have been
unscrewed.
Circlips and washers, to be removed.
The ball bearing, to be withdrawn from the shaft.
Insert the new ball bearing on the shaft. Insert supporting washers and the circlips.
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 dwg.no. 14702)
1.
2.
3.
4.
5.

Unscrew the hexagon screw, and remove the seal cover.

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

43

SECTION 5
DRAWINGS

44

SECTION 5.0

DRAWING LIST

Drawing no.:
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.

24122

45

SECTION 6
PARTS CATALOGUE

46

Rolls Royce Marine - Frydenb

SPARE PARTS FOR STEERING GEARACTUATOR AND PUMP UNIT

P80503

YARD: Chengxi Shipyard P.R. China

DATE: March 2004

Steering gear type:

Hull no:

RV 1350-3

CX4204-CX4209

Page 1 of 1

POS

Part No.

QTY.

PART DESCRIPTION

01

33034-7

SEALING RING

02

70105

FILTER ELEMENT

03

P80674

GLAND SEAL SET

03-01

45009

GLAND SEAL XNBR

03-02

45009

O-RING FOR GLAND

03-03

45009

MOUNTING OF GLAND SEAL

03-04

45009

GREASE TUBE 0,4 KG

04
05
06
07
08
09
10
11
12
13

47

ORDER NO: 7474-7479

SECTION 7
ELECTRICAL PART

48