INSTRUCTION MANUAL

FOR

FRYDENBÖ

STEERING GEAR

FRYDENBÖ ORDER NO: 8662 - 8663

Brodosplit Shipyard: Hull no. 460 - 461

ROLLS-ROYCE MARINE

1
 Dep.: Steering Gears - Frydenbö
N-5217 Hagavik, Norway
Switchboard + 47 81 52 00 70. Telefax + 47 56 30 82 41
CONTENTS
PAGE:
SECTION 1 GENERAL INFORMATION
1.0 Introduction 4
1.1 General description 5
1.2 Technical data 6
1.3 Weight list 7
1.4 Oil specification 8
1.5 The actuator 9
1.6 The pump unit 12
1.7 Functioning of the pump/control unit 13
1.8 Functioning of the actuator 17
1.9 Storing of the equipment and filling of oil 18
1.10 Oil cooler 19

SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL

2.0 Installation 27
2.1 Mounting/dismounting rudderstock 30
2.2 Filling of oil and venting procedure 33
2.3 Procedure for start-up and sea-trial 34

SECTION 3 MAINTENANCE INSTRUCTION

3.0 Service locations 37
3.1 Maintenance reporting 40
3.2 Maintenance 41
3.3 Periodical maintenance 42
3.4 Cleaning the strainer/filter of the pump unit 43

SECTION 4 REPAIR INSTRUCTION

4.0 Fault finding chart 45
4.1 Renewal of the actuator seals 46
4.2 Control and renewal of the trustbearing 48
4.3 Control and renewal of the liners 49
4.4 Pump unit 50

SECTION 5 DRAWINGS
5.0 Drawing list 53

SECTION 6 PARTS CATALOGUE

6.0 Parts list - Actuator and Pump unit 55

SECTION 7 ELECTRICAL PART

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.

Rolls-Royce Marine dep. 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 PPS
(See general arrangement dwg.)

A. STEERING GEAR

The FRYDENBÖ steering gear on this vessel is composed of one hydraulic rotary vane
“IMO-type” actuator. The actuator is mounted directly on the rudder stock and is 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 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 oiltank.

NOTE! When operating in IMO-mode (emergency steering) the steering gear torque will
be reduced by 50% as only one vane (half the steering gear) is activated. For actual
capacity, please refer to SECTION 1.2, Technical Data. Further description can be found
in SECTION 1.8, Functioning of the Actuator.

5
SECTION 1.2 TECHNICAL DATA

1) RUDDER ACTUATOR

Type IRV 2700-2

Rudderstock diameter 500 mm
Maximum rudder angle 37,5 deg
Maximum working pressure 80,0 BAR
Relief valve setting 100,0 BAR
Working torque 2666 KNm
Design torque 3333 KNm
Displacement (35-0-30) = 65 degr. 379 liters
With one pump running max. 28 seconds
Steering time (35-0-30) degr.
With two pumps running max. 14 seconds
Limit switches 35 deg.

2) PUMP UNIT

Type PPSMI 3
Screw pump Leistriz type L3MF 70/112
Revolution 3500 RPM
Capacity at 3500 RPM 880 liters
Relief valve setting 80,0 BAR
Meximum temperature system 70 degr. C
Selenoid valve Vickers 24V DC

3) ELECTRIC MOTOR
No. 1 Starbord No. 2 Port
Type ABB M3AA 250 SMB-2 ABB M3AA 250 SMB-2
Speed 3500 RPM 3500 RPM
Rating output 86 kW S1 = 86 kW
Current In / Is 134 / 992 A 134 / 992 A
Voltage 440V 60Hz 440V 60Hz
Protection class IP55 IP55
Temp rise F F
Isolation class F F
Heating element 240V - kode 451 240V - kode 451

4) OIL CAPACITY

Rudder actuator 880Litres

Pump tanks (total volume) 2000Litres
Integrated storage tank 1950Litres
Pipe line / hoses (aprox.) 120Litres
Total volume 4950Litres

6
SECTION 1.3 WEIGHT LIST

STEERING GEAR TYPE IRV 2700-2

EQUIPMENT: WEIGHT

DRY: W/OIL:

Rudder actuator 15000 kg 16000 kg

Pump unit. 3500 kg 7400 kg
------- -------

TOTAL 18500 kg 23400 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. IMO valve including 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

10
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).

11
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.

12
SECTION 1.6 THE PUMP UNIT PPSM-3

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.

SECTION 1.7-1 FUNCTIONING OF THE PUMP/CONTROL UNIT PME-3

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 which 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.
SECTION 1.7-2 FUNCTIONING OF THE PUMP/CONTROL UNIT PME-3
(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 left 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
SECTION 1.7-3 FUNCTIONING OF THE PUMP/CONTROL UNIT PME-3
(Continued)

FIG. 3.

STEERING:

After approximately one second, the control valve (3) is moved over to its 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.
SECTION 1.7-4 FUNCTIONING OF THE PUMP/CONTROL UNIT PME-3
(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.

17
18
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.

INTERCONNECTING/ISOLATING VALVE

The steering gear is designed with isolating valve system for emergency steering. (IMO
requirement for tankers above 100’ tdwt).
The actuator is fitted with an isolating valve system interconnecting the two independent and
separate power actuating system for the steering gear. In case of a single failure in one of the
power actuating system the isolating valve system will detect and automatically isolate the
defect system, and the intact system will continue operating with reduced steering torque.

19
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 recieved 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.

20
SECTION 1.10 OIL COOLER

Water/Oil Cooler.

1
General
The cooler is mounted to the hydraulic power pack as shown in both the power pack assembly drawing and
picture above. It is designed to work as an in-line cooling circuit, as shown in the main hydraulic diagram.
The cooler assembly is fitted with both an open/shut valve (1) on the water inlet side and a non-return valve (2)
on the water outlet side. These provide protection for the cooler as well as control of the water flow rate and
therefore cooling capacity of the cooler.

Connection of oil/water inlets and outlets.

Oil connection diameters should always be larger than water connection diameters.
Connect inlet oil to lower left connection (F3)
Connect oil outlet to upper left connection (F1)
Connect water inlet to upper right connection (F2)
Connect water outlet to lower right connection (F4)

21
 Water Cooler Operation
PWO provides an oil temperature very close to the cooling water temperature, eliminating the need for an active
cooling system in certain applications.

The unique PWO design features result in a turbulent oil and cooling water flow, the key to high cooling
capacity. This turbulent flow prevents clogging, a frequent cause of reduced heat transfer efficiency. The PWO
cooler privides reliable temperature control of oils, a condition for maximum performance.

How to avoid material stresses

All units – without support – should be fitted with a clamp around the cooler.

Signs of clogging
To establish clogging, check water inlet and outlet temperatures. Clogging will reduce the heat transfer capacity,
causing increased water consumption, reduced difference in water inlet and outlet temperatures and a rise in oil
temperature. Another method is to check pressure drop across the cooler. Clogged and narrow passages will
cause acceleration in flow rate and increased pressure drop.

Cleaning
In general, all minor deposits can be removed by back flushing the cooler with water. Fouling can be dealt with
using a light acid. Use 5% phosphoric acid or, when cleaned frequently, 5% oxalic acid or similar light organic
acid. Rinse the cooler with a large quantity of water. Remove all acids before restarting the system. Always
clean the cooler before it becomes completely clogged.

Technical Data
Max working pressure = 15 Bar (water side)
Inlet water – Temperature = 32°C
At ΔT Water – Oil = 23°C
Water flow rate approx = 25l/min
Max cooling capacity approx = 13kw

22
23
 SECTION 2

INSTALLATION
COMMISSIONING
SEA TRIAL

24
 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.

25
 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.

26
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.

27
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.

28
SECTION 2.1-3 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
(Continued) OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.

FIG 1.

PULL UP LENGTH : Min: 10,24 mm, max: 11,05 mm

PISTON AREA : 2022 cm²
PISTON STROKE : 19 mm
RUDDERSTOCK DIA. : 500 mm
CALCULATION NO. : 3157
FRYDENBÖ ORDER : 8662-8663

29
 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 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.

30
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.

31
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 el.motor during steering: (amp) ...…. ...…. …....

Comments:

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

32
 SECTION 3

MAINTENANCE
INSTRUCTION

33
SECTION 3.0 SERVICE LOCATIONS:

NOTHERN EUROPE THE NETHERLANDS Longva (Automation)

ROLLS-ROYCE Tel: +47 70 20 82 00
DENMARK Groningen Fax: +47 70 20 83 51
ROLLS-ROYCE Tel: +31 50 54 25 425
Aalborg (Service) Fax: +31 50 54 25 588 Tennfjord (Steering gear)
Tel: +45 98 114 955 Tel: +47 70 20 88 00
Fax: +45 98 114 945 Purmerend (Service) Fax: +47 70 20 89 00
Tel: +31 299 641 118
Esbjerg Fax: +31 299 644 999 Ulsteinvik (Adm.)
Tel: +45 75 14 15 22 Tel: +47 70 01 40 05
Fax: +45 75 14 41 02 Rotterdam (Service) Fax: +47 70 01 40 01
Tel: +31 10 42 61 227
FINLAND Fax: +31 10 42 64 298 Ulsteinvik (Ship design)
ROLLS-ROYCE Tel: +47 70 01 40 00
Helsinki NORWAY Fax: +47 70 01 40 13
Tel: +358 96866330 ROLLS-ROYCE
Fax: +358 968663339 Bergen (Cast Iron) Ulsteinvik (Propulsion)
Tel: +47 55 53 65 00 Tel: +47 70 01 40 00
Kokkola (Water jets) Fax: +47 55 53 65 05 Fax: +47 70 01 40 17
Tel: +358 68324500
Fax: +358 68324511 Bergen (Engines) Volda (Propulsion)
Tel: +47 55 53 65 00 Tel: +47 70 07 39 00
Rauma (Winches, thrusters) Fax: +47 55 19 04 05 Fax: +47 70 07 39 50
Tel: +358 2 83 791
Fax: +358 2 8379 4804 Bergen (Service) Oslo (Repr. office)
Tel: +47 56 57 16 00 Tel: +47 23 31 04 80
FRANCE Fax: +47 56 30 82 41 Fax: +47 23 31 04 99
ROLLS-ROYCE
Rungis Bergen (Steering gear) Aalesund (Ship design)
Tel: +33 1 468 62811 Tel: +47 81 52 00 70 Tel: +47 70 10 37 00
Fax: +33 1 468 79398 Fax: +47 56 30 82 41 Fax: +47 70 10 37 01

GERMANY Bergen (Turbines) POLAND

ROLLS-ROYCE Tel: +47 55 53 64 50 ROLLS-ROYCE
Hamburg Fax: +47 55 53 60 60 Gniew (Deck machinery)
Tel: +49 40 381 277 Tel: +48 69 135 22 71
Fax: +49 40 389 2177 Brattvaag (Deck machinery) Fax: +48 69 135 22 18
Tel: +47 70 20 85 00
Hamburg (Service) Fax: +47 70 20 86 00
Tel: +49 40 78091910
Fax: +49 40 78091919 Hareid (Rudders)
Tel: +47 70 09 55 00
Fax: +47 70 09 55 55

34
SECTION 3.0 SERVICE LOCATIONS:
(continued)

RUSSIA SOUTHERN EUROPE CHINA

ROLLS-ROYCE ROLLS-ROYCE
Moscow ITALY Dalian (Purchasing Office)
Tel: +7 095 230 6441 ROLLS-ROYCE Tel: +86 411 281 5791
Fax: +7 095 230 6441 Genova (Marine Sales & Fax: +86 411 263 1573
Service)
St. Petersburg Tel: +39 010 839 1561 Hong Kong
Tel: +7 812 960 4627 Fax: +39 010 839 3663 Tel: +852 2526 6937
Fax: +7 812 325 5604 Fax: +852 2868 5344
CROATIA
SWEDEN ROLLS-ROYCE Shanghai
ROLLS-ROYCE Rijeka Tel: +86 21 6387 8808
Gøteborg Tel: +38 5512 54882 Fax: +86 21 5382 5793
Tel: +46 31 492 202 Fax: +38 5512 55154
Fax: +46 31 497 531 INDIA
MALTA ROLLS-ROYCE
Kristinehamn (Propulsion) ROLLS-ROYCE Mumbai
Tel: +46 550 84000 Valletta Tel: +91 22 820 45 41
Fax: +46 550 18190 Tel: +356 805 497 Fax: +91 22 820 45 42
Fax. +356 677 747
UNITED KINGDOM SINGAPORE
ROLLS-ROYCE SPAIN ROLLS-ROYCE
Aberdeen ROLLS-ROYCE Singapore
Tel: +44 1224 58 1722 Madrid Tel: +65 686 21 901
Fax: +44 1224 58 1723 Tel: +34 91 372 81 42 Fax: +65 686 22 477
Fax: +34 91 372 87 28
Dartford NORTH EAST ASIA
Tel: +44 1322 394 300 Tarragona
Fax: +44 1322 394 301 Tel: +34 977 296 444 JAPAN
Fax: +34 977 296 450 ROLLS-ROYCE
Dunfermline (Propulsion) Tokyo
Tel: +44 1383 82 31 88 Tel: +81 3 3237 6861
Fax: +44 1383 82 40 38 ASIA PACIFIC Fax: +81 3 3237 6846

Edinburgh (Stabilisers) AUSTRALIA REPUBLIC OF KOREA

Tel: +44 131 556 2440 ROLLS-ROYCE ROLLS-ROYCE
Fax: +44 131 556 3253 Melbourne Inchon
Tel: +61 3 9848 6061 Tel: +82 32 888 4576
Newcastle (Bearings) Fax: +61 3 9848 6078 Fax: +82 32 888 4579
Tel: +44 191 273 0291
Fax: +44 191 272 2787 Perth Pusan (Deck machinery)
Tel: +61 8 9336 7910 Tel: +82 51 266 0170
Tewkesbury (Service) Fax: +61 8 9336 7920 Fax: +82 51 266 0175
35
Tel: +44 1684 290 781
Fax: +44 1684 290 786 Pusan
Tel: +82 51 205 0236
Fax: +82 51 205 0235

SECTION 3.0 SERVICE LOCATIONS:

(continued)

RUSSIA New Orleans

ROLLS-ROYCE Tel: +1 504 464 4561
Vladivostok Fax: +1 504 464 4565
Tel: +7 5232 495 484
Fax: +7 5232 495 484 Pascagoula (Cast Iron)
Tel: +1 228 762 0728
Fax: +1 228 769 7048
AMERICAS
Seattle
BRAZIL Tel: +1 206 782 9190
ROLLS-ROYCE Fax: +1 206 782 0176
Rio de Janeiro
Tel: +55 21 507 4992 Walpole (Propulsion)
Fax: +55 21 509 5610 Tel: +1 508 668 9610
Fax: +1 508 660 6152
CANADA
ROLLS-ROYCE
Halifax
Tel: +1 902 468 2883
Fax: +1 902 468 2759

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

Fort Lauderdale
Tel: +1 954 581 2757
Fax: +1 954 581 2785

Houston
Tel: +1 281 497 5220
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Fax: +1 281 497 4903

37
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 Marine dep. 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.

38
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 Marine dep. 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 FRYDENBØ SERVICE ENGINEER.

39
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.

40
 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.

41
 SECTION 4
REPAIR INSTRUCTION

42
43
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.

44
FIG.2.

45
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/lubricate all new seals before assembly as shown on drawing 33637E.

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

46
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.

47
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 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 "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.

48
 PP
SECTION 4.4 THE PUMP UNIT - CHANGE OF THE PUMP

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.

49
 PPS
SECTION 4.4-1 THE PUMP UNIT - CHANGE OF THE ELASTIC RINGS
(Dwg. 16175/P82167)

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

(Dwg. 44702- Part no. 170.)

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

(Dwg 44702 - Part no. 52.)

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.

50
SECTION 5

DRAWINGS

51
SECTION 5.0 DRAWING LIST

Drawing no.: Partlist

General arrangement 16170

Rudder actuator - assembly 15004 P82094
Safety relief valve 13869 P81158
Interconnecting/Isolating valve, upper 15688 P81736
Interconnecting/Isolating valve, lower 15026 P81064
3" Automatic Lock valve 44749
IMO valve assembly 15312
Pump unit type PPSMI 3 " 16115 P82095
Control valve for pump unit 23651 P80406
Pump insert 44702
Top end of rudderstock 15001
Limit switch arrangement 24125
Hydraulic nut 24213
Hydraulic diagram 15808
Operation procedure - IMO System 24062
Grease & Oil Usage Chart 33637E

52
 SECTION 6

PARTS CATALOGUE

53
 FRYDENBÖ
SPARE PARTS FOR STEERING GEAR-
ACTUATOR AND PUMP UNIT
YARD: Brodosplit Shipyard DATE: 21 March 2024
Steering gear type: Hull no: Order no:

IRV 2700-2 460 - 461 Page 1 8662 - 8663

POS DWG. NO. ITEM QTY. PART DESCRIPTION

01 14992 14 1 SEALING RING, 33034-9

02 14992 12 4 GLAND SEALING RINGS, 45011

03 14992 13 2 O-RINGS FOR GLAND, 44822

04 15798 14 4 FILTER ELEMENT, 70105

54
 SECTION 7

ELECTRICAL PART

55