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FOR
ROLLS-ROYCE MARINE
FRYDENBÖ
STEERING GEAR
9064 9065 9066 9067 9068 9069 9070 9071 9072 9073
SPP Shipbuilding
HULL NOS:
4001 4002 4003 4004 4005 4006 4007 4008 4009 4010
4011 4012 4013 4014 4015 4016 4017 4018 4019 4020
ROLLS-ROYCE MARINE
Dep.: Steering Gears - Rolls-Royce Marine 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 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 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 5 DRAWINGS
5.0 Drawing list 51
GENERAL INFORMATION
2
SECTION 1.0 INTRODUCTION
This instruction manual, issued for Rolls-Royce Marine 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 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
(See general arrangement dwg.)
A. STEERING GEAR
The ROLLS-ROYCE MARINE FRYDENBÖ steering gear on this vessel is composed of one
hydraulic rotary vane actuator mounted directly on the rudderstock, 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 maneuvers 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 oil tank.
4
SECTION 1.2 TECHNICAL DATA
1) RUDDER ACTUATOR
Type RV 1050-3
Rudderstock diameter 430 mm
Maximum rudder angle 37,5 deg
Maximum working pressure 57,5 BAR
Relief valve setting 71,9 BAR
Working torque 730 KNm
Design torque 913 KNm
Displacement (35-0-30) = 65 144 liters
degr.
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
3) ELECTRIC MOTOR
No. 2 Port No. 1 Starbord
Type ABB M3AA 180 LB-2 ABB M3AA 180 LB-2
Speed 3500 RPM 3500 RPM
Rating output 35 kW S1 = 35 kW
Current In / Is 55 / 424 A 55 / 424 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
5
SECTION 1.3 WEIGHT LIST
DRY: W/OIL:
6
SECTION 1.4 OIL SPECIFICATION
FOR
Use only a high quality hydraulic oil with a viscosity index of 100. The oil should have anti-
foam, anti-oxidant and anti-rust additives.
OIL SPECIFICATION
Viscosity: ISO 68
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. 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 that operates the
two spring-loaded valves.
CASE 1
CASE 2
9
SECTION 1.5 THE ACTUATOR
(Continued)
SAFETY VALVE
10
SECTION 1.6 THE PUMP UNIT
12
SECTION 1.7-1 FUNCTIONING OF THE PUMP/CONTROL UNIT
The steering gear is normally operated from the steering controls initiating the pilot valve
solenoids.
For emergency operation, the pilot valves are equipped with push button controls that make it
possible to operate the steering gear manually from the steering gear compartment.
CONTROL UNIT:
1. Solenoid - Pilot valve.
2. Safety relief valve.
3. Control valve.
4. By-pass valve.
FIG. 1.
IDLING:
Fig.1 shows the pump unit when idling. The control valve, 3, and the solenoid valve, 1, are kept
in center position by spring load when no steering signal is given.
13
SECTION 1.7-2 FUNCTIONING OF THE PUMP/CONTROL UNIT
(Continued)
FIG. 2.
Steering is carried out by operating the solenoid valve (1). Fig.2 on the diagram shows the
beginning of the steering process when the right solenoid is operated. The control valve (3) will
be pushed over to the right side, by the oil pressure in the left chamber.
The control valve (3) is now at the beginning of its stroke. Some of the oil flows through the
throttling slots to the actuator, and overflow is by-passed at the by-pass valve (4) back to the
suction side of the pump. The smaller oil volume being directed gradually to the actuator will
give a soft start.
14
SECTION 1.7-3 FUNCTIONING OF THE PUMP/CONTROL UNIT
(Continued)
FIG. 3.
STEERING:
After approximately one second, the control valve (3) is moved over to it's end position, see fig.
3.
The oil-flow from the pump has now free passage from channel (1) into pipe (B) leading to the
actuator. The return oil from the actuator flows through pipe (A) and has free passage to channel
(2) and back to the suction side of the pump.
15
SECTION 1.7-4 FUNCTIONING OF THE PUMP/CONTROL UNIT
(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).
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
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 axial bearing thrust ring 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.
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.
NOTE: Fill oil through all filling plugs in order to fill all chambers of the actuator.
18
1.10 Water/Oil Cooler.
2
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.
Oil connection diameters should always be larger than water connection diameters.
Connect inlet oil to lower left connection (F1)
Connect oil outlet to upper left connection (F3)
Connect water inlet to upper right connection (F4)
Connect water outlet to lower right connection (F2)
19
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.
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 T Water – Oil = 23°C
Water flow rate approx = 25l/min
Max cooling capacity approx = 13kw
20
21
22
SECTION 2
INSTALLATION
COMMISSIONING
SEA TRIAL
23
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.
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.
24
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.
25
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).
NECESSARY EQUIPMENT:
OIL SPECIFICATION:
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.
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.
26
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).
10. Wait about 30 minutes, and then relieve the pressure from pump 1.
DISMOUNTING
3. Mount pump 1 for oil pressure to the nut, and pump 2 for oil-pressure to the
taper.
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.
27
SECTION 2.1-3 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTING
(Continued) OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK.
FIG 1.
28
SECTION 2.2 FILLING OF OIL AND VENTING PROCEDURE.
To fill actuator and pump unit with oil, see section 1.9.
Before starting to fill oil, open all vent plugs on the actuator.
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.
29
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.
- 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).
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.
30
SEATRIAL DATA
Please fill in this form during the sea trial and send it to our head office for later reference.
Name of ship:....................................
Shipyard:........................................
Hull no:.........................................
Owner:...........................................
Speed:.........knots
Comments:
.............................................................……………………………………………………………
31
SECTION 3
MAINTENANCE
INSTRUCTION
32
SERVICE LOCATIONS
33
SERVICE LOCATIONS (continued)
34
SERVICE LOCATIONS (continued)
Houston
RUSSIA Tel: +1 281 497 5220
ROLLS-ROYCE Fax: +1 281 497 4903
Vladivostok
Tel: +7 5232 495 484 New Orleans
Fax: +7 5232 495 484 Tel: +1 504 464 4561
Fax: +1 504 464 4565
St. Johns
Tel: +1 709 364 3053
Fax: +1 709 364 3054
Vancouver (Propulsion)
Tel: +1 604 942 1100
Fax: +1 604 942 1125
35
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 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.
1) Date
2) Vessel name
5) Description of problem
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.
36
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 Frydenbö 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.
37
SECTION 3.3 PERIODICAL MAINTENANCE
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 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.
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 lifetime of the rotor seals is 5 to 10 years. For change of rotor
seals, see instructions.
38
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.
39
SECTION 4
REPAIR INSTRUCTION
40
41
SECTION 4.1 REPLACEMENT OF THE ACTUATOR SEALS
(See fig. 1.)
GLAND SEALS.
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.
42
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:
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.
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
Assemble the actuator and fill up with oil. (See oil filling procedure).
43
SECTION 4.2 CONTROL AND REPLACEMENT OF THE
THRUST BEARINGS (See assembly dwg.)
44
SECTION 4.3 CONTROL AND REPLACEMENT OF THE LINERS
(See assembly dwg.)
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.
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.
45
SECTION 4.4 THE PUMP UNIT - CHANGE OF THE PUMP
(See assembly dwg.)
1. Unscrew the bolts and lift the cover off the tank.
3. Loosen the bolts and disconnect the electric motor from the pump.
46
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.
47
SECTION 5
DRAWINGS
48
SECTION 5.0 DRAWING LIST
Description:
General arrangement 16445
Rudder actuator - assembly 13140
Part list P82412
Safety relief valve 23317
2´ Automatic Lock valve 44299
Pump unit type PPSMI 2" 16102
Part List P82413
Controle valve for pump unit 23710
Part List P80536
Pump Insert 44702
Top end of rudderstock 13393
Hydraulic nut 23637
Hydraulic Block Diagram 45909
Grease & Oil Usage Chart 33637E
49
SECTION 6
PARTS CATALOGUE
50
FRYDENBÖ
SPARE PARTS FOR STEERING GEAR-
ACTUATOR AND PUMP UNIT P80910
51
SECTION 7
ELECTRICAL PART
52