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Maintenance Manual

KONGSBERG PROPRIETARY.

This document and its accompanying elements contain KONGSBERG

information which is proprietary and confidential. Any disclosure, copying, distribution or use is prohibited if not
otherwise explicitly agreed with KONGSBERG in writing. Any authorized reproduction, in whole or in part, must
include this legend. ©2022 KONGSBERG - All rights reserved.

P a g e

22 |

73

8.

System Oil Volume

Oil volume for Steering Gears

–

approximate values:

Model type

Oil volume

IRV 900-2

Approx. 270 litre

IRV 1400-2

Approx. 470 litre

IRV 2050-2

Approx. 680 litre

IRV 2700-2

Approx. 880 litre

IRV 3050-2

Approx. 800 litre

IRV 4200-2

Approx. 1050 litre

Oil volume for Power Pack

–

approximate values:

Power Pack

Oil volume

PPS 2

”

Small

Approx. 2x 300 litre

PPSI 2

”

Small

Approx. 2x 300 litre + 450 litre

PPS 2

”

Approx. 2x 500 litre

PPSI 2

”

Approx. 2x 500 litre + 1100 litre

PPS 3

”

Small

Approx. 2X 700 litre

PPSI 3

”

Small

Approx. 2x 700 litre + 1450 litre

PPS 3

”

Approx. 2x 1000 litre

PPSI 3

”

Approx. 2x 1000 litre + 1850 litre

PPS 3

”

Large

Approx. 2x 1400 litre

PPSI 3" Large

Approx. 2x 1400 litre + 2850 litre

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Содержание Frydenbo IRV-2

Страница 1: ...Maintenance Manual Frydenb IRV 2 Steering Gear 2022 08 26 14 02 CET RELEASED...

Страница 2: ...GSBERG information which is proprietary and confidential Any disclosure copying distribution or use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproducti...

Страница 3: ...prohibited if not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 3 73 Doc no...

Страница 4: ...which is proprietary and confidential Any disclosure copying distribution or use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in p...

Страница 5: ...tasks 17 7 Oil Recommendations 20 8 System Oil Volume 22 9 Grease Recommendation for Stuffing Box 23 10 Tightening Torque for Bolts 24 11 Maintenance Instructions 25 11 1 Oil Sampling 26 11 2 Venting...

Страница 6: ...Switches in Feedback Unit 52 11 18 Adjustment of Amplifier Card if KONGSBERG delivery 53 11 19 Adjustment of FU Controller if KONGSBERG delivery 54 11 20 Replacement of Alarm System Card 55 11 21 Rep...

Страница 7: ...rformed by Kongsberg Maritime service engineers Any other information may be found in the Steering Gear USER MANUAL or by contacting service dmss km kongsberg com The IRV Steering Gears are of robust...

Страница 8: ...2 KONGSBERG All rights reserved P a g e 8 73 By reporting any failures or maintenance work an accurate equipment history is maintained This history can continuously be monitored and compared to other...

Страница 9: ...TROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY LEGAL AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFE...

Страница 10: ...3 Safety Annotations All safety directions must be respected in order to avoid damage to personnel environment and equipment In this document the following annotations are used with belonging signific...

Страница 11: ...ring is lubricated by the system oil The sealing system consists of synthetic oil resistant material resting in seal grooves The sealing system prevents both internal and external leakage The IRV Stee...

Страница 12: ...s case emergency steering mode is automatically activated Detection is done by the electrical level switches located in the hydraulic Power Pack tank illustrated in the figure below For a situation wh...

Страница 13: ...l separate system 1 and system 2 3 Outcome loss of steering Defect system will be identified by Low Low Oil Level alarm 4 Press MANUAL ISOLATION Continue operation Check situation in Steering Gear roo...

Страница 14: ...verhaul x x x x x O ring return pipe and bend x x x x x Tank cover gasket x x x x x Hydraulic hose cooler x x Seal kit valves x x Overhaul kit IMO valves x x O ring and plugs for hydraulic nut x x x x...

Страница 15: ...dditional service or maintenance needed ref chapter 13 Self Assessment or Maintenance Inspection 15 years Service and maintenance recommendations Open rudder actuator for inspection and measure cleara...

Страница 16: ...ce 10 Year Service Lifting equipment for removal of cover Hydraulic torque wrench 500 3700Nm Equipment for draining oil from the actuator 2 High pressure pumps with gauges Minimum 1000 bar Dial gauge...

Страница 17: ...ing Gear system Cleaning of Steering Gear unit and surroundings Prev 1 mth CL A A Steering Gear system Hydraulic System Perform test of Steering Gear modes Emergency Steering and normal steering from...

Страница 18: ...t an oil change Column h identifies which skill level is required for the maintenance activity Column i identifies what facility is required for the maintenance activity Maintenance categories Abrevia...

Страница 19: ...lude this legend 2022 KONGSBERG All rights reserved P a g e 19 73 Steering Gear and Power Pack Illustrations Below illustrations show where the different critical parts are found on the Steering Gear...

Страница 20: ...sity of the oil The surrounding temperatures of the hydraulic components when operating at extreme temperature conditions tropic or arctic waters must be considered when selecting type of oil The oil...

Страница 21: ...inematic Viscosity cSt Pour point o C 0o C 40o C 100o C TEXACO RANDO HDZ 68 181 500 69 12 3 36 FUCHS HYDRAWAY HVXA 68 172 62 11 0 39 FUCHS RENOLIN B 68 HVI 153 68 11 0 36 For storage of hydraulic oil...

Страница 22: ...ars approximate values Model type Oil volume IRV 900 2 Approx 270 litre IRV 1400 2 Approx 470 litre IRV 2050 2 Approx 680 litre IRV 2700 2 Approx 880 litre IRV 3050 2 Approx 800 litre IRV 4200 2 Appro...

Страница 23: ...BERG All rights reserved P a g e 23 73 9 Grease Recommendation for Stuffing Box Standard Grease The following standard greases are approved and recommended for use in the Stuffing Box delivered by Kon...

Страница 24: ...ion coefficient 0 15 normally oiled threads is assumed in the calculations of the preceding tightening torques For other values of the friction coefficient the tightening torques should be adjusted ac...

Страница 25: ...instructions on packaging carefully Always follow protective measures such as using a protective mask goggles gloves etc Ensure that other personnel are not unknowingly exposed to harmful substances...

Страница 26: ...tch on the relevant motor controller to position 3 LOCAL CONTROL 7 Make sure the hose valve if mounted is completely open and let the pump run until you are completely sure that the hose is flushed th...

Страница 27: ...ore than 2 3 rotations 3 Manually move the rudder from hard over to hard over a few times by using the handles on the control valve 4 Loosen the leakage pipe coupling 2 and fill the pipe connector wit...

Страница 28: ...hin what is recommended use a 10 m mesh sized filter to filter the oil before filling it into the Steering Gear 1 Turn the selector switch on the motor controller to position 2 STOP 2 Open the breathi...

Страница 29: ...again with pump no 2 The maneuvering time must be taken while the rudder is moving The rudder must start at 35 When passing 30 the stopwatch must be started and stopped when passing 35 on the opposite...

Страница 30: ...e leak oil every other day to ensure lubrication of seals Upper gland seals 2 pcs 1 Remove the upper gland ring Remove the old gland seals Grease the new seals with Mobilith SHC 460 before installment...

Страница 31: ...prohibited if not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 31 73 Note A...

Страница 32: ...cover on the filter housing by loosening the nuts in diagonal order Note Be aware of spring loaded cover 3 Lift the disposable filter element with the filter holder out of the housing 4 Place a bucket...

Страница 33: ...in part must include this legend 2022 KONGSBERG All rights reserved P a g e 33 73 Replacement of Flexible Coupling in Pump Unit 1 Turn the selector switch on the motor controller to position 2 STOP 2...

Страница 34: ...tor based on tank height and oil density normally 0 88 for ISO 68 Place the adjusting lever accordingly 4 Perform 0 adjustment by turning the slotted screw CW or CCW maximum 1 revolution until the poi...

Страница 35: ...1100L 802 mm 0 88 PPSI 3 2X700L 1450L 792 mm 0 87 PPSI 3 2X1000L 1850L 871 mm 0 96 PPSI 3 2X1400L 2850L 1171mm 1 29 Settings for separate storage tanks oil density 0 88 Tank item no Tank Volume Inter...

Страница 36: ...indicator 3 The position where the indicator stops will be the contents tank level Note Gauging shall not be done during filling Faultfinding Fault Possible reason Action The pointer goes beyond the m...

Страница 37: ...clogging problem Check water inlet and outlet temperature Clogging results in reduced difference in water inlet and outlet temperatures and a rise in oil temperature Check for a pressure drop across...

Страница 38: ...rpendicular to the air fins as illustrated 3 Make sure the system is depressurized and disconnect the hydraulic pipes from the cooler matrix 4 Loosen the screws with washer 1 fixing the cooler matrix...

Страница 39: ...ise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 39 73 10 Prior to start up check The...

Страница 40: ...work is carried out Figure 1 Item Component Description Reference Status Sign 1 Feedback Units Make sure the locking nuts 15 is properly tightened Figure 2 2 Shaft 4 Check that the center shaft is lo...

Страница 41: ...g Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 41 73 Item Component Description Reference Status Sign 6 Feedback Unit With one of...

Страница 42: ...sion element is made of rubber only and the purpose of this element is to absorb the necessary compression created at installation In special cases it can be used for small adjustment of the length of...

Страница 43: ...ing Gear locally Clogged filter Disconnect sensor from PP High oil temp Disconnect sensor from PP Low oil pressure Close handle before starting the pump Power failure aux steering Remove fuse F41 42 4...

Страница 44: ...G All rights reserved P a g e 44 73 Clogged filter Remove the plug on the filter sensor This alarm does not include an auto start of the stand by pump High oil temp Remove the plug on the temperature...

Страница 45: ...y activating the push button Manual Disconnection the system will be disabled and monitoring of hydraulic system is switched off Indication System Disconnected shall illuminate Expected outcome the st...

Страница 46: ...xpected 4 Return system to automatic mode by deselecting Manual By pass System 2 push button 11 14 2 Local Operation from IMO Control Cabinet If the manual control from the bridge panel is out of func...

Страница 47: ...Locked Isolation mode and by pass system 1 activated 2 Ask bridge to stop pump 1 3 Apply a steering command from pump 2 using manual steering lever Expected outcome no rudder response as the system is...

Страница 48: ...e S21 oil level switch above the oil level in tank to allow the floater to activate the switch Solenoid Y21 activates and by pass system 1 indication in bridge control panel and in the control cabinet...

Страница 49: ...e limited or no rudder movement 2 Activate Y20b by hand then apply a port direction order from pump 1 valve Expected outcome limited or no rudder movement Isolation valve System 2 Prior to the test se...

Страница 50: ...arboard push buttons 3 Set the selector switch the Motor Controller to position 2 STOP 4 Remove the cover on the feedback unit 5 At the terminal block disconnect the red wire 2 to the center point of...

Страница 51: ...dicators are out of zero position a zero adjustment can be done on the rudder indicator amplifier adjuster P20 2 2 degrees 3 Operate the Steering Gear manually from the Steering Gear room until the me...

Страница 52: ...es in Feedback Unit 1 Set the Steering Gear Motor Controller switches to position 3 LOCAL CONTROL 2 Remove the cover of the feedback unit which limit switches are to be adjusted 3 Loosen the nut insta...

Страница 53: ...ntrol panel 2 Set the switch to follow up steering 1 mode 3 Move the selected controller 2 to 30 degrees port or starboard side 4 Adjust gain on amplifier card P20 4 until the position of the Steering...

Страница 54: ...roller if KONGSBERG delivery Start the pumps from the main control panel Push the corresponding IN COMMAND button 1 to engage the follow up controller Operate the controller to mid ship command and ma...

Страница 55: ...include this legend 2022 KONGSBERG All rights reserved P a g e 55 73 Replacement of Alarm System Card 1 At the bridge distribution board make sure that the power supply to the alarm system is switched...

Страница 56: ...power supply to the corresponding motor controller 2 Open the control system cabinet 3 Disconnect all connected wires from the pump control card 4 Loosen the four screws securing the pump control car...

Страница 57: ...57 73 Replacement of Amplifier Card 1 Switch off the main power supply to motor controller by turning the S1 isolating switch 2 Open the control system cabinet 3 Use the EDS wristband 4 Remove the fau...

Страница 58: ...d P a g e 58 73 Replacement of Selector Card 1 Switch off the main power supply to motor controller by turning the S1 isolating switch 2 Open the control system cabinet 3 Use the EDS wristband 4 Remov...

Страница 59: ...otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 59 73 Replacement of Start Rel...

Страница 60: ...not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2022 KONGSBERG All rights reserved P a g e 60 73 Replacement of Solen...

Страница 61: ...Feedback Units 1 Switch off the main power supply to Motor Controller by turning off the S1 isolating switch 2 Remove the cover on the feedback unit 3 Identify the defective limit switch 2 4 Loosen th...

Страница 62: ...witch 1 Set the selector switch on motor control cabinet to position 2 STOP 2 There will be slight oil spill Place a suitable container under the sensors to be replaced 3 Disconnect the wires in the c...

Страница 63: ...art must include this legend 2022 KONGSBERG All rights reserved P a g e 63 73 Note Springs in the 2 control and control lock valve delivered prior 2011 is recommended to be upgraded 2 Control valve Ty...

Страница 64: ...sition via aux relays early version or a relay module later version Operate the steering from bridge and check the following signals NO RUDDER COMMAND PORT RUDDER COMMAND STBD RUDDER COMMAND Led 17 OF...

Страница 65: ...Pad mini for the Self Assessment inspection How to access the Self Assessment mobile application Download the application called Kongsberg Mobile Forms from Apple Store or Google Play When application...

Страница 66: ...ound on a sticker on the inside of all the electrical cabinets KONGSBERG recommend keeping the below listed spare parts on board as a minimum of on board spare parts For additional tailored recommenda...

Страница 67: ...fifth year please contact our service engineers at service dmss km kongsberg com Please see below table for specified spare part kits and relevant maintenance items Seal kits for valves Overhaul kits...

Страница 68: ...e part kit for each Leistritz pump cartridge is available given in the table Please contact service dmss km kongsberg com if a pump overhaul spare part kit is needed If both pumps are to be overhauled...

Страница 69: ...Set the selector switch on motor controller to position 2 STOP 2 Disconnect the electrical cables in the outlet box 3 Disconnect SAE flanges and pipes 1 leading to the actuator 4 Loosen the bolts 2 an...

Страница 70: ...the ball bearing and shaft seal ring 1 Remove the key 9 and loosen the bolts 10 to remove the cover driving side 11 2 Remove the circlip 12 and supporting disk 13 3 Withdraw the ball bearings 14 from...

Страница 71: ...ectively 2 Mount the SAE flange 5 to the pump unit and replace the oil tank cover 3 Replace the coupling 8 on the pump shaft The coupling shall be mounted so that the distance to the bell house to the...

Страница 72: ...this legend 2022 KONGSBERG All rights reserved P a g e 72 73 15 Contact Contact information NORWAY KONGSBERG MARITIME AS Deck Machinery and Motion Control Ulvenvegen 345 N 5217 Hagavik Support and Spa...

Страница 73: ...ERG information which is proprietary and confidential Any disclosure copying distribution or use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction...

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