INSTRUCTION MANUAL

FOR

FRYDENBÖ

STEERING GEAR RV1350-3

Chengxi Shipyard P. R. China Hull No. CX4204/05/06/07/08/09Frydenbö Order No: 7474-7479

Classification: DnVType of vessel: 53.000 DWT Bulk Carrier

ROLLS-ROYCE MARINEDep.: Steering Gears - Frydenbö

N-5217 Hagavik, NorwaySwitchboard + 47 56 57 16 00. Telefax + 47 56 30 82 41

CONTENTS PAGE:

SECTION 1 GENERAL INFORMATION1.0 Introduction 31.1 General description 4

1.2 Technical data 51.3 Weight list 61.4 Oil specification 71.5 The actuator 81.6 The pump unit 111.7 Functioning of the pump/control unit 121.8 Functioning of the actuator 161.9 Storing of the equipment and filling of oil 17

SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL2.0 Installation 192.1 Mounting/dismounting rudderstock 212.2 Filling of oil and venting procedure 242.3 Procedure for start-up and sea-trial 25

SECTION 3 MAINTENANCE INSTRUCTION3.0 Service locations 283.1 Maintenance reporting 303.2 Maintenance 313.3 Periodical maintenance 323.4 Cleaning the strainer/filter of the pump unit 33

SECTION 4 REPAIR INSTRUCTION4.0 Fault finding chart 354.1 Replacement of the actuator seals 364.2 Control and replacement of the trustbearing 384.3 Control and replacement of the liners 394.4 Pump unit 40

SECTION 5 DRAWINGS5.0 Drawing list 43

SECTION 6 PARTS CATALOGUE 6.0 Parts list - Actuator and Pump unit 45

SECTION 7 ELECTRICAL PART 46-

1

SECTION 1

GENERAL INFORMATION

2

SECTION 1.0 INTRODUCTION

This instruction manual, issued for Frydenbö rotary vane rudder actuator, is prepared for use of the operating personnel.

The operators should familiarise themselves with the working principles of the equipment and with the instructions and precautions contained herein.

The manual should be kept handy for reference at all times so that the proper and correct operating instructions can be observed and followed.

No dismantling or adjusting work should be started unless the pertinent instructions have been carefully studied so that the work sequence is clear and all of the necessary tools are available.

It is of paramount importance that extreme cleanliness is observed during all work on the equipment. Sand, dust, or other impurities are detrimental to the hydraulic equipment and will most likely impair the proper operations. Keep hands and tools clean. Use only clean linen rags, - never cotton waste.

Ulstein Frydenbö is ready to be of assistance and service at all times and will appreciate the operator's comments on any phase of the equipment's operation and it's maintenance.

3

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

A. STEERING GEAR

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

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

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

The pump is submerged in the oiltank. The tank is divided into three chambers, one for each pump unit and one for the integrated storage tank, with one low level alarm-switch in each of the pump unit chambers.

From top of the steering gear leakage oil will run through pipe to the oiltank.

4

SECTION 1.2 TECHNICAL DATA

1) RUDDER ACTUATOR

Type RV 1350-3Rudderstock diameter 428 mmMaximum working pressure 70,1 barMaximum design pressure 87,7 barMaximum rudder angle, mechanical 2 x 46,5 degr.Maximum rudder angle, electrical 2 x 36,0 degr.Design torque 1438 kNmDisplacement (35-0-30) = 65 degr. 186 litersSteering time (35-0-30) degr.with one pump running max.28 secondsSteering time (35-0-30) degr.with two pumps running max.14 seconds

2) PUMP UNIT

Type PPSM 2"Screw pump "Leistritz " type L3MF 52-104Revolution 3500 R.P.M.Capacity at 3500 R.P.M. 430 l/minRelief valve setting 70,1 barMaximum temperature system 70 degr.C.Solenoid valve Vickers 24 V DC

3) ELECTRIC MOTOR

Type ABB M3AA 200 MLB2Rating 43 kWRevolution 3500 R.P.M.Voltage 3 x 440 V ACCurrent In= 68A, Is=442 S1 100%Frequency 60 HzProtection degree IP 54Heating element 220 V AC

4) OIL CAPACITY

Rudder actuator 270 LitersPipe lines / hoses 50 LitersPump units 2x500 ltrs 1000 LitersMin. storage tank , yard supply 1000 Liters*

Total oil volume 2320 Liters

* Volume to be verified by shipyard

5

SECTION 1.3 WEIGHT LIST

STEERING GEAR TYPE RV 1350-3

EQUIPMENT: WEIGHT

DRY: W/OIL:

Rudder Actuator 6000 kg 6320 kgPump Unit 1000 kg 1500 kg EL-motors 400 kg 400 kg ------- -------

TOTAL 7400 kg 8220 kg------- -------

6

SECTION 1.4 OIL SPECIFICATION

HYDRAULIC OIL TYPE

FOR

FRYDENBØ ROTARY VANE STEERING GEAR

Use only a high quality hydraulic oil with a viscosity index of approximate 100. The oil should have anti-foam, anti-oxidant and anti-rust additives.

OIL SPECIFICATION

Viscosity: ISO 68

Oil temperatures should be limited to 70 °C.

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

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

7

SECTION 1.5 THE ACTUATOR 1

The actuator consists of these main components:

1. Housing2. Cover3. Rotor4. Stoppers5. Vanes6. Safety relief valve

8

SECTION 1.5 THE ACTUATOR (Continued)

LOCK VALVE The automatic lock valve mounted on the actuator consists of a housing, where both pipes from the pump unit are connected. Between inlet and outlet there is a pilot-piston which operates the two spring-loaded valves.

CASE 1

STEERING TAKES PLACE

Oil pressure from thepump unit opens boththe inlet and the outlet side of thevalve.

CASE 2

THE ACTUATOR CLOSED-RUDDER BLOCKED

9

When there is no oil

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

10

SECTION 1.5 THE ACTUATOR(Continued)

SAFETY VALVE

There is one safety valve-block on the actuator consisting of:1. Pilot relief valve.2. Pilot piston.3. Check valve.4. Spring loaded main valve.5. Adjusting screw for relief pressure.

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

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

11

SECTION 1.6 THE PUMP UNIT PPSM-2

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

1. Gear pump.2. Oil tank with two chambers.3. Flexible coupling between motor and pump.4. Solenoid operated control valve for connection to steering controls, with emergency

push-button steering controls.5. Electric motor.6. Pressure gauge.7. Safety relief valve.8. Filter.

12

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

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

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

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

FIG. 1.

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

13

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

FIG. 2.

BEGINNING OF STEERING (MODULATED FLOW):

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

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

14

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

FIG. 3.

STEERING:

After approximately one second, the control valve (3) is moved over to it's end position, see fig. 3.The oil-flow from the pump has now free passage from channel (1) into pipe (B) leading to the actuator. The return oil from the actuator flows through pipe (A) and has free passage to channel (2) and back to the suction side of the pump.

15

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

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

SETTING THE RELIEF VALVE. (Item 2)Opening pressure for relief valve, see technical data sheet.To increase the pressure, turn adjusting screw, 6, clockwise.Safety valve opening pressure has been set during assembly by the suppliers and possible adjustment should only be carried out by a competent person.

EMERGENCY OPERATIONDuring 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 bolted-on cover.

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

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

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

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

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

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

AUTOMATIC LOCK VALVE

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

SAFETY VALVE

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

17

SECTION 1.9 STORING OF THE EQUIPMENT AND FILLING OF OIL.

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

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

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

1. Open all bleeding plugs on top of the rudder actuator and the pump unit (See venting procedure section 2.2).

2. Use pump or gravity connected to the filling holes, tofillthe 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

INSTALLATIONCOMMISSIONING

SEA TRIAL

19

PPSECTION 2.0 INSTALLATION

RUDDER ACTUATOR

Sufficient space for inspection and service of the gland seals must be provided (see arr. dwg). There should be sufficient space between top of the rudder actuator and the deck above to permit the cover and the rotor to be lifted. If this cannot be arranged, a hatchway in deck may be provided. Tackle bracket should be arranged.

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

Make sure that rudderstock and actuator are aligned.

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

20

PPSECTION 2.0 INSTALLATION (Continued)

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

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

21

SECTION 2.1-1 PROCEDURE FOR HYDRAULIC MOUNTING/DISMOUNTINGOF 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 40°C.Note! No anti-friction additives allowed in oil.

MOUNTING.

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

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

3. Mount the hydraulic nut and tighten by hand.

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

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

6. Mount the dial gauge and adjust to zero.

22

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

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

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

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

9. Relieve the pressure from pump 2.

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

11. Check the length "L".

12. Dismount the pumps and the dial gauge.

13. Tighten the nut to contact with the actuator.

14. Secure the rudderstock nut.

DISMOUNTING

1. Dismount the lockplate.

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

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

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

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

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

23

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

FIG 1.

RRM-Frydenbö Order No. 7474-7479CALCULATION NO.: 2804RUDDERSTOCK DIA.: 428 mmPULL UP LENGTH MIN:PULL UP LENGTH MAX:

10,12 mm10,44 mm

PISTON AREA: 940 cm2

PISTON STROKE: 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 MARINEDEP.: STEERING GEARS - FRYDENBÖN-5217 HAGAVIKNORWAY

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:

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

27

SECTION 3

MAINTENANCEINSTRUCTION

28

SECTION 3.0 SERVICE LOCATIONS:

29

NOTHERN EUROPE

DENMARKROLLS-ROYCEAalborg (Service)Tel: +45 98 114 955Fax: +45 98 114 945

EsbjergTel: +45 75 14 15 22Fax: +45 75 14 41 02

FINLANDROLLS-ROYCEHelsinkiTel: +358 96866330Fax: +358 968663339

Kokkola (Water jets)Tel: +358 68324500Fax: +358 68324511

Rauma (Winches, thrusters)Tel: +358 2 83 791Fax: +358 2 8379 4804

FRANCEROLLS-ROYCERungisTel: +33 1 468 62811Fax: +33 1 468 79398

GERMANYROLLS-ROYCEHamburgTel: +49 40 381 277Fax: +49 40 389 2177

Hamburg (Service)Tel: +49 40 78091910Fax: +49 40 78091919

THE NETHERLANDSROLLS-ROYCEGroningenTel: +31 50 54 25 425Fax: +31 50 54 25 588

Purmerend (Service)Tel: +31 299 641 118Fax: +31 299 644 999

Rotterdam (Service)Tel: +31 10 42 61 227Fax: +31 10 42 64 298

NORWAYROLLS-ROYCE

Bergen (Cast Iron)Tel: +47 55 53 65 00Fax: +47 55 53 65 05

Bergen (Engines)Tel: +47 55 53 65 00Fax: +47 55 19 04 05

Bergen (Service)Tel: +47 56 57 16 00Fax: +47 56 30 82 41

Bergen (Frydenbö steering gear)Tel: +47 56 57 16 00Fax: +47 56 30 82 41

Bergen (Turbines)Tel: +47 55 53 64 50Fax: +47 55 53 60 60

Brattvaag (Deck machinery)Tel: +47 70 20 85 00Fax: +47 70 20 86 00

Hareid (Rudders)Tel: +47 70 09 55 00Fax: +47 70 09 55 55

Longva (Automation)Tel: +47 70 20 82 00Fax: +47 70 20 83 51

Tennfjord (Steering gear)Tel: +47 70 20 88 00Fax: +47 70 20 89 00

Ulsteinvik (Adm.)Tel: +47 70 01 40 05Fax: +47 70 01 40 01

Ulsteinvik (Ship design)Tel: +47 70 01 40 00Fax: +47 70 01 40 13

Ulsteinvik (Propulsion)Tel: +47 70 01 40 00Fax: +47 70 01 40 17

Volda (Propulsion)Tel: +47 70 07 39 00Fax: +47 70 07 39 50

Oslo (Repr. office)Tel: +47 23 31 04 80Fax: +47 23 31 04 99

Aalesund (Ship design)Tel: +47 70 10 37 00Fax: +47 70 10 37 01

POLANDROLLS-ROYCEGniew (Deck machinery)Tel: +48 69 135 22 71Fax: +48 69 135 22 18

RUSSIAROLLS-ROYCEMoscowTel: +7 095 230 6441Fax: +7 095 230 6441

St. PetersburgTel: +7 812 960 4627Fax: +7 812 325 5604

SWEDENROLLS-ROYCEGøteborgTel: +46 31 492 202Fax: +46 31 497 531

Kristinehamn (Propulsion)Tel: +46 550 84000Fax: +46 550 18190

UNITED KINGDOMROLLS-ROYCEAberdeenTel: +44 1224 58 1722Fax: +44 1224 58 1723

DartfordTel: +44 1322 394 300Fax: +44 1322 394 301

Dunfermline (Propulsion)Tel: +44 1383 82 31 88Fax: +44 1383 82 40 38

Edinburgh (Stabilisers)Tel: +44 131 556 2440Fax: +44 131 556 3253

Newcastle (Bearings)Tel: +44 191 273 0291Fax: +44 191 272 2787

Tewkesbury (Service)Tel: +44 1684 290 781Fax: +44 1684 290 786

SOUTHERN EUROPE

ITALYROLLS-ROYCEGenova (Marine Sales & Service)Tel: +39 010 839 1561Fax: +39 010 839 3663

30

CROATIAROLLS-ROYCERijekaTel: +38 5512 54882Fax: +38 5512 55154

MALTAROLLS-ROYCEVallettaTel: +356 805 497Fax. +356 677 747

SPAINROLLS-ROYCEMadridTel: +34 91 372 81 42Fax: +34 91 372 87 28

TarragonaTel: +34 977 296 444Fax: +34 977 296 450

ASIA PACIFIC

AUSTRALIAROLLS-ROYCEMelbourneTel: +61 3 9848 6061Fax: +61 3 9848 6078

PerthTel: +61 8 9336 7910Fax: +61 8 9336 7920

CHINAROLLS-ROYCEDalian (Purchasing Office)Tel: +86 411 281 5791Fax: +86 411 263 1573

Hong KongTel: +852 2526 6937Fax: +852 2868 5344

ShanghaiTel: +86 21 6387 8808Fax: +86 21 5382 5793

INDIAROLLS-ROYCEMumbaiTel: +91 22 820 45 41Fax: +91 22 820 45 42

NORTH EAST ASIA

JAPANROLLS-ROYCETokyoTel: +81 3 3237 6861Fax: +81 3 3237 6846

REPUBLIC OF KOREAROLLS-ROYCEInchonTel: +82 32 888 4576Fax: +82 32 888 4579

Pusan (Deck machinery)Tel: +82 51 266 0170Fax: +82 51 266 0175

PusanTel: +82 51 205 0236Fax: +82 51 205 0235

RUSSIAROLLS-ROYCEVladivostokTel: +7 5232 495 484Fax: +7 5232 495 484

AMERICAS

BRAZILROLLS-ROYCERio de JaneiroTel: +55 21 507 4992Fax: +55 21 509 5610

CANADAROLLS-ROYCEHalifaxTel: +1 902 468 2883Fax: +1 902 468 2759

St. JohnsTel: +1 709 364 3053Fax: +1 709 364 3054

Vancouver (Propulsion)Tel: +1 604 942 1100Fax: +1 604 942 1125

USAROLLS-ROYCEAnnapolis (Propulsion)Tel: +1 410 224 2130Fax: +1 410 266 6721

Fort LauderdaleTel: +1 954 581 2757Fax: +1 954 581 2785

HoustonTel: +1 281 497 5220Fax: +1 281 497 4903

New OrleansTel: +1 504 464 4561Fax: +1 504 464 4565

Pascagoula (Cast Iron)Tel: +1 228 762 0728Fax: +1 228 769 7048

SeattleTel: +1 206 782 9190Fax: +1 206 782 0176

Walpole (Propulsion)Tel: +1 508 668 9610Fax: +1 508 660 6152

31

SECTION 3.1 MAINTENANCE REPORTING

It is requested that any failures or maintenance work on the equipment, no matter how small, should be reported to Frydenbö. By reporting any failures and maintenance work, an accurate machinery history can be maintained. This history will be continuously monitored and compared to other vessels with similar equipment. With this information, we can provide better service, faster delivery of spare parts, and guidance for preventive maintenance.

When reporting, the following information should be included:

1) Date

2) Vessel name

3) Date of installation - order number

4) Operating hours (if available)

5) Description of problem

6) Did the problem impair vessel's operation

7) Corrective action taken

8) How many man-hours were required to repair it

In reporting a failure or request for service, the following additional information is requested in addition to items 1-8 above. This will insure more efficient service.

9) Working and idling pressures

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

32

SECTION 3.2 MAINTENANCE

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

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

IF PROBLEMS OCCUR, USE THE FAULTFINDING CHART.

IF THE PROBLEM CANNOT BE SOLVED BY YOUR MAINTENANCE MEN,

CALL IN A SERVICE ENGINEER.

33

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 oil2. 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.

34

PPSECTION 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.

35

SECTION 4REPAIR INSTRUCTION

36

SECTION 4.1 REPLACEMENT OF THE ACTUATOR SEALS

37

(See fig. 1.)GLAND SEALS.

Upper gland seals. (Item 5). Remove the upper gland ring. Remove the old gland seals.Grease new seals, before they are inserted, and also apply grease before replacing gland ring.

Lower gland seals, (Item 6). Same procedure as for the upper seals.To facilitate reassembling of the lower gland ring, we recommend lowering the gland ring by means of two lengthened screws.

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

FIG. 1.

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

FIG.2.

38

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 1Vertical stopper seals with springs - item 2 Vertical vane seals with springs - item 3Top vane seals - item 4

The following seals can be replaced only when the rotor has been dismounted from the rudderstock:Lower vane seals - item 4Bottom 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 seal2. Lower vane seal

After the rotor has been lowered in to the housing:3. Vertical vane seals with springs4. Vertical segment seals with springs5. Top vane seals6. Cover ring seal

B. When rotor is still attached to rudderstock:1. Cover ring seal2. Vertical vane seals with springs3. Vertical segment seals with springs4. 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. 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 actuator2. 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.

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. 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.

41

PPSECTION 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

PPSSECTION 4.4-1 THE PUMP UNIT - CHANGE OF THE ELASTIC RINGS

(See assembly dwg.)

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

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

(See dwg.no. 14702)

1. Unscrew the hexagon screw, and remove the seal cover.2. The shaft sealing-housing/bearing-housing, to be withdrawn after the fixing bolts have been

unscrewed.3. Circlips and washers, to be removed.4. The ball bearing, to be withdrawn from the shaft.5. Insert the new ball bearing on the shaft. Insert supporting washers and the circlips.6. Assemble the shaft sealing-housing/bearing-housing and the seal cover, and tighten the bolts. SECTION 4.4-3 THE PUMP CARTRIDGE-CHANGE OF THE SHAFT SEAL RING

(See dwg.no. 14702)

1. Unscrew the hexagon screw, and remove the seal cover.2. The shaft sealing-housing/bearing-housing, to be withdrawn after the fixing bolts have been

unscrewed.3. The old shaft seal rings, to be removed.4. Insert the new shaft seal rings.

Important: Do not forget to insert the supporting ring, in correct position.5. Assemble the shaft sealing-housing/bearing-housing and seal cover, and tighten the bolts.

43

SECTION 5

DRAWINGS

SECTION 5.0 DRAWING LIST

44

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 23710

Part list P80536

Top end of rudderstock 13350

Steering Loss and Recovery 32897

Hydraulic Diagram 44896

Transmitter Arr. 24122

SECTION 645

PARTS CATALOGUE

46

Rolls Royce Marine - Frydenbö

SPARE PARTS FOR STEERING GEAR- ACTUATOR AND PUMP UNIT

P80503

YARD: Chengxi Shipyard P.R. China DATE: March 2004

Steering gear type:

RV 1350-3

Hull no:

CX4204-CX4209 Page 1 of 1 ORDER NO: 7474-7479

POS Part No. QTY. PART DESCRIPTION

01 33034-7 1 SEALING RING

02 70105 2 FILTER ELEMENT

03 P80674 1 GLAND SEAL SET

03-01 45009 4 GLAND SEAL XNBR

03-02 45009 2 O-RING FOR GLAND

03-03 45009 1 MOUNTING OF GLAND SEAL

03-04 45009 1 GREASE TUBE 0,4 KG

04

05

06

07

08

09

10

11

12

13

47

SECTION 7

ELECTRICAL PART

48