Doc.

Type: Issued by/Date:

Doc. No.: 02MA01_0000 Rev by/Date:

Maintenance Rev. No.: 01

Title:
Table of Contents Issued Date: 20 Aug. 08

Table of Contents:

6 Hydraulic Maintenance

Oil sampling and Recommendations

Oil sampling for contamination controls 05MA02_0003

Recommended Oil types for Hydraulic Power Unit PS 1954

(if installed)

Valve block

Maintenance and instruction manual 8MBP 05MA02_0004

Aker Pusnes AS

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Doc. Type: Issued by/Date:
Doc. No.: 05MA02_0003 Rev by/Date:
Maintenance Rev. No.: 00
Title:
Oil sampling for contamination control Issued Date: 21 Aug. 08

Oil sampling for contamination control

An accepted procedure for extracting samples from dynamic fluid lines is ISO
standard 4021.

Fig 1
Pertinent detail of procedure:

1. Before extracting or collecting the sample, a quantity of oil should be

allowed to flush from the assembly equal to at least five times the
volume between the port and the existing point.

2. Sufficient sample should be withdrawn from the line to yield enough

oil to fill approximately 70% of the sample bottle volume. This leave
enough room to effectively shake the bottle before analysing.

3. Although the rate of sampling does no affect the quality of the sample,
the sampling rate should in general not exceed 1% of the main line
flow.

4. Oil is extracted through fully open ball valves from high pressure line.
To reduce the oil velocity in the sample line, the size and length of the
hypodermic or capillary tubing can be varied.

5. Take at least two samples from each sampling place in the system

6. Mark the bottles clearly.

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 RECOMMENDED OIL TYPES
FOR PS 1954
Aker Pusnes AS Hydraulic Power Unit (HPU)
Design Approved Edition Valid from Sheet no. Total pages
ØJ KHØ 5 10. June 2002 1 1

OIL COMPANY OIL TYPE VISCOSITY VISCOSITY FLASH POINT, POUR POINT
cSt at 40OC o o
INDEX C, COC C
BARTRAN HV 32 32,0 153 190 -39
BP
BARTRAN HV 46 47,0 152 198 -36
HYSPIN AWH-M 32 32,0 150 190 -42
CASTROL
HYSPIN AWH-M 46 46,0 150 190 -39
MECHANISM LPS 32 32,0 151 200 -48
CHEVRON
MECHANISM LPS 46 46,0 151 210 -45
HYDRELF DS 32 34,0 152 226 -39
ELF
HYDRELF DS 46 49,0 152 234 -39
UNIVIS N 32 32 173 210 -42
ESSO
UNIVIS N 46 46 171 220 -40
HYDRAN TSX 32 32,6 151 196 -48
FINA
HYDRAN TSX 46 45,2 151 204 -45
DTE 13M 33,0 140 177 -46
MOBIL
DTE 15M 47,0 140 185 -40
TELLUS T 32 32,0 150 195 -42
SHELL
TELLUS T 46 46,0 150 200 -39
HYDRAWAY HVXA 32 32,0 199 200 -39
STATOIL
HYDRAWAY HVXA 46 46,0 194 198 -39
RANDO OIL HD Z 32 32,4 185 160 -42
TEXACO *
RANDO OIL HD Z 46 51,5 185 175 -39
EQUIVIS ZS 32 32,0 160 200 -39
TOTAL
EQUIVIS ZS 46 46,0 160 215 -36
RANDO OIL HD Z 32 32,4 185 160 -42
FAMM *
RANDO OIL HD Z 46 51,5 185 175 -39

Other mineral based hydraulic oils, which fulfil the minimum requirements of HLP oils
according to DIN 51524 part 2 can be used. The viscosity index should be above 140
and viscosity class according to IS0 VG 32 or 46. Maximum allowable pour point
–30oC

x Please note that Texaco and FAMM hydraulic oils are the same formulation,
FAMM brand name are the marine product line to ChevronTexaco.
Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Maintenance and instruction manual for Valve Block 8MBP

Features ................................................................................................................................................... 1
General Description ................................................................................................................................. 2
Valve Description ..................................................................................................................................... 2
Item 254 Main block. ..................................................................................................................... 2
Item J Directional control valve 4/3. .......................................................................................... 3
Item C Counterbalance valve A→T. .......................................................................................... 4
Manual operated version: ........................................................................................................................ 5
Remote controlled version: ...................................................................................................................... 5
Item R Pressure reducing valve................................................................................................. 6
Item S Adapter plate .................................................................................................................. 6
Item FC Shuttle valve for the pressure compensator. ................................................................. 7
Item F Pressure compensator element. .................................................................................... 7
Item Z Nozzle ........................................................................................................................... 7
Item 238 Nozzle ............................................................................................................................ 7
Item FA Compensator pilot valve................................................................................................. 7
Adjustment Procedure ............................................................................................................................. 8
Preparation before adjustment .................................................................................................... 10
Adjustment of counter balance valve (C) .................................................................................... 10
Adjustment of throttling (Q) for the counter balance valve .......................................................... 10
Adjustment of pressure relief valve (d) ........................................................................................ 11
Adjustment of max flow ............................................................................................................... 11
Adjustment of pressure reducing valve (R) ................................................................................. 11
Technical Data ....................................................................................................................................... 12
Pressure Drop 8MBP ............................................................................................................................. 13
Maintenance .......................................................................................................................................... 14
Storage................................................................................................................................................... 14

3D view of 8MBP with two speed selector valve and adapter for motor mounting.

Features
8MBP modular unit is a complete unit for control of hydraulically driven
winches. 8MBP is designed for constant pressure /variable pump system.
8MBP has excellent metering characteristics, and is specially designed to
withstand marine surroundings.

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

General Description
8MBP modular unit includes in basic version directional control valve (J),
pressure compensation flow control system (F, 238, FA, FC and Z), free flow
check valve (CA), load control (C and Q), pressure relief (D), pressure
reducing valve item R, adapter plate (S) and two-speed selector valve item H.
(See diagram page 8)

Valve Description
Item 254 Main block.
The marking of ports and screw in cartridge valves is very distinct on
the block, engraving is done in the CNC machining centre. The main
block NG6 flanges are prepared for more than 1 station in parallel, by
use of specially designed top plates. Top plate is fastened to the main
block by solid bolts, and not by NG6 standard type screw dimension

3D view of 8MBP with 3 stations top plate.

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Item J Directional control valve 4/3.

This is a three position directional spool valve with hand lever. When
activating the directional valve handle, the operator controls the direction and
drive speed on the drum.

Throttling groves in the main spool open progressively for flow either to
A or B ports.

The spool has adjustable end stoppers in both end covers for decrease of the
spool stroke and then increase of the pressure drop through the spool.

The spool mechanism is prepared to be locked in two positions.

1. In neutral position spool can be locked for preventing operation
unless the safety lock is manual released.
2. Spool mechanism also prepared to be locked with 30% opening
to A, when require certain oil flow to the motors in tension mode.
Only to be used when auto-mooring function is enabled. NOT
TO BE NORMALLY USED.

Option:
Directional valve is prepared to be hydraulic proportional remote
controlled. Pilot pressure 5-20 bar.

Section of main directional (J) valve of 8MBP

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Item C Counterbalance valve A→T.

The counter balance valve keeps the load under control during
lowering operations.
By the variation of opening area cause by input signal from B port/port
3 counter balance poppet open progressively for flow from A→T port,
and thus give a smooth lowering operation and low pressure rise with
full flow. The counter balance cartridge have integrated free flow check
valve from P-A (section drawing port 2→1)

Section of Counter balance valve (C) with integrated free flow check
8MBP-***

Item CA Check-valve free flow P→A

Free flow check valve in parallel with the counter balance valve, for
reduce pressure drop in Heave P→A.

Section of Free flow check valve item CA

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Item Q Adjustable throttling.

Throttling for the counter balance pilot channel. For

dampening the counter balance valve if the valve is
fluctuating.

Section of Throttling screw item Q

Item D Pressure relief valve A→B

The pilot operated pressure relief is connected between motor ports A→B to
secure the hydraulic motor and limit the maximum pressure.

Item H Directional control valve 4/2.

This is a two position directional spool valve. To be used for switching two-
speed system in the hydraulic motor.

Manual operated version:

Manually controlled directional valve, where spool position and oil flow on/off
is controlled by a hand lever. The valve can be delivered with centring spring
and/or detents. After operating the valve to one of the end positions the
centring spring will return the spool to neutral position, and hold it in this
position. If the valve is supplied with detents, the lever can be left and the
spool will remain in this position. Oil in the end cambers are drained to port T.

Remote controlled version:

Manual/remote controlled directional valve, where the spool position and oil
flow on/off is controlled by hand lever or an external pilot pressure.

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Pilot pressure at port SA or SB, controlled by an external valve, is applied

direct to the pressure chamber, and moves the main spool to one of the end
positions.

Section of NG6 directional valve item H.

Item R Pressure reducing valve

The pilot operated pressure reducing valve for reduced pressure to the two-
speed system.

Item S Adapter plate

Adapter plate for connecting 8MBP control valve to the hydraulic
motor.

Generally about the pressure compensator system.

This is a load independent system, which means that equal spool stroke on
the directional valve will give equal flow independent on load at the motor.

Main directional spool (J) in conjunction with pressure compensator flow

control system (F, FA, 238, FC and Z), regulate proportional oil flow to either
A (Heave rotation) or B (Lower rotation) by sensing pressure either in A or B
line through the shuttle valve (FC). When operating directional valve (J), spool
will open progressively to A or B. Pressure compensation element will
maintain equal Δp across the directional valve. Maximum flow over the main
directional valve is depending on the force induced on the pressure

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

compensator element (F). This force is made up of a spring force in the

compensator element item (F), and adjustable spring force in the
compensator pilot valve (FA) and the load pressure sensing in A or B via (FC).
When setting is altered on the compensator pilot valve (FA), flow will change.
When adjusting pressure relief valve FA, the Δp through the directional valve
will alter, and thus maximum flow to the hydraulic motor.

Item FC Shuttle valve for the pressure compensator.

Load sensing either in A or B line.

Item F Pressure compensator element.

Normally open modulating element which act as a pressure
compensator to maintain a constant pressure drop across the
directional valve (together with FC, FA, 238 and Z).

Section of pressure compensator element (F) of 8MBP-***

Item Z Nozzle
For dampening the pressure compensator element.

Item 238 Nozzle

Maintain flow to by pass compensator pilot valve FA.

Item FA Compensator pilot valve.

The spring on the compensator is rather weak. Therefore, pressure created by
adjustable pressure relief valve is added to the spring force.

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Adjustment Procedure

Hydraulic diagram of 8MBP* (Manual version, with two-speed selector

valve and adapter for motor mounting)

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Internal valve placement on 8MBP* (Shown version, with two-speed selector

valve and adapter for motor mounting)

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

AS Hydranor has performed a complete function and pressure test before

shipment, to ensure that every unit fulfil its given specification.

Preparation before adjustment

• Check that all connections to be properly connected and according to
existing drawings.
• Operate the directional valve (J) and run motor unloaded in both
directions until air is evacuated and system is preheated.

Adjustment of counter balance valve (C)

Factory preset to 60 bar. (320 bar without pilot assist).

• Connect pressure gauge in port TPB.

• Loosen cap nut and nut for the counter balance valve adjusting screw.
• Turn adjusting screw counter clockwise to max.
• Turn adjusting screw clockwise 1 turn clockwise to reduce setting.
Verify opening pressure is 60 bar. Switch directional valve to lower.
Do not have full deflection on the handle, but check with minimum
flow. Counter balance opens when the motor start to rotate.
• Tighten nut and cap nut.
• Disconnect pressure gauge in TPB

Adjustment of throttling (Q) for the counter balance valve

Factory preset to ½ turn from closed position.

Note: Be sure that the throttle screw is not in closed (bottom)

position; this will prevent the counter balance
valve from opening. Closed (bottom) position is when screw
is turned completely clockwise.

When lowering it can occur that the counter balance valve will knock if the
dampening (Q) is not correct adjusted. When adjusting at the throttle valve
(Q) the reaction of the counterbalance valve will change.

If having fluctuation:
• Loosen cap nut and nut for the throttle valve (Q).
• Switch directional valve to lower.
• Turn screw clockwise to increase dampening.
• Turn screw counter clockwise to decrease dampening.
Recommended adjustment is ½-¾ from closed position. Turn
adjustment screw to achieve satisfactory stability.
• Tighten nut and cap nut for item (Q).

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Adjustment of pressure relief valve (d)

Factory preset to 270 bar.

• Connect pressure gauge in port TPA.

• Block the motor.
• Loosen cap nut and nut for the relief valve adjusting screw (D).
• Switch directional valve to Heave. Do not have full deflection on the
handle, but adjust with minimum flow.
• Turn adjusting screw clockwise to increase pressure setting for the
pressure relief valve (D). Turn adjusting screw counter clockwise to
decrease pressure setting for the pressure relief valve (D).
Complete adjustment range is 5 turns.
• Tighten nut and cap nut for item (D).

Adjustment of max flow

• Loosen cap nut and nut for the adjustable spring on relief valve
(FA).
• Switch directional valve to Heave, and move the operator handle in
full deflection.
• Turn adjusting screw clockwise on the relief valve (FA) to increase
the flow, and thus increase force induced on the pressure
compensator element. Turn adjusting screw counter clockwise on
the relief valve (FA) to decrease the flow. Complete adjustment
range is 5 turns.
• Tighten nut and cap nut for item (FA).

Adjustment of pressure reducing valve (R)

Factory preset to 160 bar.

• Connect pressure gauge in port TPR.

• Loosen cap nut and nut for the reducing valve adjusting screw (R).
• Turn adjusting screw clockwise to increase pressure setting for the
pressure reducing valve (R).Turn adjusting screw counter
clockwise to decrease pressure setting for the pressure reducing
valve (R). Complete adjustment range is 5 turns.

Tighten nut and cap nut for item (R).

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Technical Data
Description Symbol Unit Value
Flow Qmax l/min 8MBP-140 8MBP-200

70-150 140-220
Max. operating pressure in port P, pnom bar 315
A and B
Test pressure P, A and B pmax bar 420
Max operating pressure in T pnom bar 20
Test pressure T pmax bar 50 (10 bar tested when at
motor)
Directional valve pilot pressure p bar 5-20
Weight basic version m kg 32
Hydraulic fluid Mineral oils for hydraulic
systems.
Viscosity range ν mm²/s 10 to 350 (cSt)
Viscosity index VI >120
Filtration Class 9
Recommended filter with according to
β20 ≥ 100 NAS 1638,
18/15
according to
ISO 4406
Fluid temperature range T °C -20 to +70
Ambient temperature range T °C -20 to +50
Body material EN-GJS-400-15 (GGG40)
Seals Buna-N
Connections
Code Dimensions 8MBP-140/200
P ¾” SAE 6000
T 1” SAE 3000
A, B ½” BSPP
SA, SB, TA, TB ⅜” BSPP
L ½” BSPP
TPR, TPP, TPT, TPA, TPB, A3, ¼” BSPP
P4 and P7

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Pressure Drop 8MBP

Aker Pusnes AS

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Doc. Type: Installation Issued by/Date: CO 26. sept 05
Doc. No.: 05MA02_0004 Rev by/Date:
Hydraulic Maintenance Rev. No.: 00
Title: Maintenance and instruction manual for Valve
Block 8MBP Rev. Date: 21 aug. 08

Maintenance
Check the 8MBP Modular Unit for proper function.
Visual check the 8MBP Modular Unit, and if required, paint unpainted
areas.

CAUTION
Do not paint the hand levers shaft seals.

Storage
If longer storage than 6 months is expected, the valve must be kept in a dry
room free from dust. Sudden large temperature variations must be avoided.
For storage longer than one year, the valve must be filled with inhibition oil.
Before use check all visible seals and flush with clean oil.

Aker Pusnes AS

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