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User’s 9107 16 Usman 9107

Manual.
PG Hydraulics AS 6092 Eggesbønes

1 27.11.2009 For Release E.Haugan

Rev Date Reason for issue Prepared Checked Approved

Hydraulic High Pressure Unit

(Drawing no.: 1004-M, 1005-P, 1006-P, 1007-S)

USER’S MANUAL

PG 20082997
PG Hydraulics 9107

This document is the property of PG Hydraulics AS and is not to be reproduced or disclosed

to any party without the written consent of PG Hydraulics AS.
HPU User Manual PG Hydraulics AS Order no. 9107

TABLE OF CONTENTS
1 ADDRESS FOR INFORMATION AND ASSISTANCE: ............................................ 3

2 TECHNICAL SPECIFICATION ................................................................................... 4

2.1 EL-HYDRAULIC POWER PACK ......................................................................................... 4
2.2 PIPE / HOSE CONNECTION ................................................................................................ 5
2.3 SURFACE TREATMENT ..................................................................................................... 5
2.4 WEIGHT ........................................................................................................................... 5
3 OPERATION .................................................................................................................... 6
3.1 HYDRAULIC PRESSURE UNIT (HPU) ............................................................................... 6
3.2 RELIABILITY.................................................................................................................... 6
4 INSTALLATION ............................................................................................................. 7
4.1 FASTENING TO FOUNDATION ........................................................................................... 7
4.2 CONNECTIONS ................................................................................................................. 7
4.3 ELECTRICAL CONNECTIONS ............................................................................................. 7
4.4 FILLING OF RESERVOIR .................................................................................................... 7
5 OPERATION .................................................................................................................... 8
5.1 SAFETY PRECAUTIONS .................................................................................................... 8
5.2 PREPARATIONS BEFORE STARTING THE HPU ................................................................... 8
5.3 START ............................................................................................................................. 8
5.4 STOP ................................................................................................................................ 8
5.5 STOP BECAUSE OF HIGH TEMPERATURE .......................................................................... 9
5.6 RESTART AFTER A HIGH TEMPERATURE STOP ................................................................. 9
5.7 STOP BECAUSE OF LOW OIL LEVEL ................................................................................... 9
5.8 RESTART AFTER A LOW OIL LEVEL STOP .......................................................................... 9
6 INSTRUCTIONS FOR MAINTENANCE .................................................................. 10
6.1 SAFETY PRECAUTIONS .................................................................................................. 10
6.2 RESERVOIR .................................................................................................................... 10
6.3 PROCEDURE FOR ADDING OIL TO THE RESERVOIR .......................................................... 10
6.4 SERVICE ........................................................................................................................ 11
6.5 REPLACING THE PRESSURE FILTER ELEMENT (28P-2)ERROR! BOOKMARK NOT DEFINED.
6.6 REPLACING THE RETURN OIL FILTER ELEMENT (FTC-2A) ............................................. 11
6.7 REPLACING THE LEAK OIL FILTER ELEMENT (FTB-2) .................................................... 12
6.8 PREVENTIVE MAINTENANCE .......................................................................................... 12
6.8.1 Everyday maintenance ......................................................................................... 12
6.8.2 Weekly Maintenance ............................................................................................ 13
6.8.3 Monthly Maintenance........................................................................................... 13
6.8.4 Periodical maintenance ....................................................................................... 13
6.8.5 Long-term storing................................................................................................. 14
6.9 OIL CHART .................................................................................................................... 14
6.10 TROUBLE SHOOTING ...................................................................................................... 15

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7 RECOMMENDED SPARE PARTS (1 TO 2 YEARS SERVICE PERIOD) ........... 16

8 DRAWINGS ................................................................................................................... 16

9 DATA FOR HYDRAULIC COMPONENTS .............................................................. 16

Tables
Tab. 1 Preventive maintenance ................................................................................................ 13
Tab. 2 Oil Chart ....................................................................................................................... 14
Tab. 3 Trouble Shooting on HPU............................................................................................. 15
Tab. 4 Recommended spare parts. ........................................................................................... 16
Tab. 5 Drawings ....................................................................................................................... 16

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1 ADDRESS FOR INFORMATION AND ASSISTANCE:

Mjølstadneset
6092 Eggesbønes
Norway

24 hours phone: +47 7008 6060

Telefax: +47 7008 6061
www.pg-hydraulics .com

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2 TECHNICAL SPECIFICATION

2.1 El-Hydraulic Power Pack

Pump Types 2 each. variable axial piston pumps 92 ccm,

Flexible coupling between el. motor and pump.

Pump Control Standard pressure compensated, Constant Pressure

Tank / oil capacity Appr. 750 litres brt., built in steel painted acc. to PG Hydraulics AS
std.

El. motors 2 x 480V, 60 Hz.

RPM : 1770
Power : 2x51kW@60Hz
Termistor : N/A
Heating : 230V 50W

Flow Capacity 2 x 120 l/min

Hydraulic Pressure 230 bar

Equipment

• 2each Relief valves.

• 1 each Return oil filter 05μ
• 1 each Leak oil filter 05μ
• 1 each Common: Low level switch for alarm/autom. stop, and high temp. switch for alarm/
autom. stop
• 1 each oil cooler.
• 1 each Oil level gauges with temp. indicator.
• 2 each Pressure gauge.
• 2 each Check valves.
• Damping ring under motor for reduction of noise/vibration.

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2.2 Pipe / Hose connection

Pressure lines HP : 2each connection for pipe ø30x3

Return line : 1 each connection for pipe ø42x3

Drain line : 1 each connection for pipe ø35x3

Oil cooler
connections : 4 pcs., 1 ¼” Water IN/OUT+ 1 ¼”Oil IN/OUT

2.3 Surface Treatment

Foundation frame/tank in St.52 / 42 / NVA, painted acc. to PG Hydraulics AS standard.

2.4 Weight
Approx. 1500 kg when empty tank.

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3 OPERATION

3.1 Hydraulic Pressure Unit (HPU)

The Hydraulic Power Pack consists of 2 pcs axial piston pumps, 1 pcs oil reservoir, 2 pcs
electrical motors, 2 pcs safety valves, 1 pcs returnfilters, 1 pcs leakoilfilters, and temperature-
and level switches and indicators.
The axial piston pump is mounted to the electric motor by use of a mounting flange.
Electric motors are mounted on damping rings to prevent vibrations. Large pumps like these are
equipped with unloading valves for smoother start.
If the pressure is exceeding the set value, oil flow will be by-passed through the safety
valve directly back to the oil reservoir.
Oil flows from the pressure filter to the hydraulic equipment. The return oil from the
hydraulic equipment is passing through the return filter before it ends up in the reservoir.
The return filter secures a clean oil flow back to the HPU tank. If the filter is clogged, the
oil will be by-passed via an internal by-pass valve in the filter. Note that in this situation the oil
is not being filtrated (change the filter element immediately). There will be an alarm on the
return filter when the delta pressure is less than bypass pressure.
A dual-stage oil level/temperature switch will activate an alarm if the oil level in the
reservoir is lower than the 1st set point. If lower than 2nd set point, automatic stop of pumps will
be activated. The switch is also equipped with two stages for temperature control, working in the
same way; if higher than 1st set point, there will be an alarm, and if higher than 2nd set point,
automatic stop of pumps will be activated.
Oil level gauges with temperature indicator mounted on the reservoir enables a visual
observation of the oil level and the temperature.

3.2 Reliability
Equipment that makes the system more reliable:
• Pressure relief valve for each pump.
• Return filter with el. and visual indicators.
• Leak-oil filter with el. and visual indicators.
• Level switch for stop when low oil level in reservoir.
• High temp switch which gives automatic stop when oil temperature is too high.
• Oil level gauges, makes it possible for visual inspection of oil level in reservoir.
• Pressure gauge for each pump, for visual inspection of oil pressure.
• El.indicators for return and leak oil filter, giving alarm if clogged filter.
• The pump-units are mounted with damping rings on the tank/foundation.
• Temperature indicator.

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4 INSTALLATION
Before the equipment is handed over to the customer, PG Hydraulics AS service engineers carry
out all necessary preparations and adjustments to the pumps and valves.
Before installation and start-up, read the safety precautions in chapter 6.1.

4.1 Fastening to foundation

The HPU is to be welded or screwed to a suitable foundation preferably mounted with machine
vibration dampers under foundation.

4.2 Connections
• Ensure that all pipes, hoses and connections are sealed until final assembly, and filling
of the reservoir.
• All connections as pressure line, return line and drain oil line must be cleaned before
assembly to the HPU. Hydraulic pipes outside HPU to be flushed to correct cleanliness
class acc to customers requirement.
• All pipes are to be clamped to a suitable foundation. Use correct clamp size.
• Avoid hot work on the pipes. If any piping has to be welded, make sure to clean the
pipes thoroughly before reassembling (slag, scale).
• All couplings are to be mounted and tightened according to instructions.
• All connections to HPU should be hoses, instead of pipes, to prevent vibrations.

4.3 Electrical connections

Electrical connections for electrical motors, pumps and temp-/level switches must be carried out
by authorised personnel, and according to wiring diagram. Check also that the voltage is in
accordance to the equipment.

4.4 Filling of reservoir

Hydraulic reservoirs are always to be filled through either the drain filter, or the return filter.
NEVER FILL THE OIL RESERVOIR THROUGH THE BREATHER. The oil reservoir to be
filled using a filtering unit with good filtering properties.
Beta ratio 200, 5 micron absolute or better.

Ref. PG Hydraulic AS’s procedure for oil filling, PGH 11-07.

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5 OPERATION

5.1 Safety Precautions

1. Before starting the HPU, inform all involved personnel that previously dead electrical
circuits will become live, and that previously depressurised circuits will become
pressurised.
2. No hydraulic couplings or components that are pressurised must be loosened or
tightened up, before the circuit is depressurised.
3. The HPU is connected to a 480 V power supply, and generates hydraulic pressure up to
appr. 230 bar. Normal caution is necessary with consideration to the pressurised circuits and
the danger of electrical shock when working on the equipment.

5.2 Preparations before starting the HPU

1. Check oil level in reservoir.

2. Check hydraulic hoses, pipes, components, and couplings for any leakage or damages.
3. Check that the suction valve to the pump is open.
4. Check that the pump is filled with oil before starting.

5.3 Start

1. Make a short start/stop and check direction of rotation.

2. Start the HPU by switching the START button for each motor.

NOTE !
Any indication of system irregularities or failures must be strictly
observed during the first start up. In any case of possible failure, stop
HPU, see cpt. 6.10; Trouble shooting, or contact PG Hydraulics AS.

5.4 Stop

1. Stop the HPU by switching the STOP button at the starter cabinet.

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5.5 Stop because of High Temperature

A temperature switch is built into the reservoir. The purpose of this switch is to stop the
Hydraulic Power Pack if the oil temperature in the reservoir exceeds the temp switch's set
point/value.

5.6 Restart after a High Temperature Stop

• Wait until the oil temperature in the reservoir is below 60°C / 140 °F
• Start the HPU according to procedure in chapter 5.2 and 5.3.

5.7 Stop because of low oil level

An oil level switch is built into the reservoir. The Purpose of the oil level switch is to stop the
Hydraulic Power Pack if the oil level in the reservoir is goes below the level switch's set point.
Too low oil level in the tank can cause breakdown of the pump if the pump starts sucking air.

5.8 Restart after a low oil level stop

• Refill oil according to procedure in chapter 4.4.
Check out what caused low oil level in the reservoir.
(Heavy heeling of a vessel may cause low level stop.)

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6 INSTRUCTIONS FOR MAINTENANCE

6.1 Safety Precautions

All personnel that shall perform maintenance or installation of the equipment must have
knowledge to the system's limitations and to the used components. Experience with maintaining
hydraulic systems are also required to maintain a clean hydraulic system.

Warning!
No pressurised hydraulic couplings must be adjusted, loosened or tightened up. Hydraulic
circuits must be depressurised before work is done on circuits or components. Check that all
connections, couplings, pipes and hoses are clamped to a foundation, and that clamps has the
correct size. Loose hoses may strike if pressure peaks appear in the system.

6.2 Reservoir
Maintain oil level at all times. The oil should be checked after the first 100 hours for verification
of cleanness. The oil test result should as a minimum be according to ISO 4406 class 18/14. The
result should normally be according to ISO 4406 class 16/13. (NAS class 1638, 5-6)
Once a year an oil sample should be analysed to find out when to change the oil in the reservoir.
It is difficult to set a time interval for changing the oil, the interval depends on the application
and on the operation environment. An oil sample can be taken from the reservoir, and be
compared with a new and fresh oil sample. If the oil smells or look different from the new oil, it
may be time to change the oil. Factors that affects the wear of the oil can be dirt, water in the oil
or if the oil has been overheated.

6.3 Procedure for adding oil to the reservoir

Use recommended hydraulic oil only.
1. Stop the HPU.
2. When refilling the reservoir, make sure to use the same type of oil that is present in the
reservoir.
3. Pour the new oil from a clean container, (oil from an oil drum is not clean enough) through
the return filter(not the breather/filler-cap). Do not remove the filter element when filling.
4. If the reservoir is filled in another way, the oil is to be filtrated thoroughly by using a filter
cart before entering the reservoir. (10 micron absolute, or better).

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6.4 Service
Change the filter elements as indicated on the visual indicators supplied with the filters.
Filters must be checked at normal operating temperature (approx. 50°C). Filters with "pop-up"
indicators may sometimes indicate clogged elements. Reset the indicator at normal operating
temperature, and check if this is correct.

• Inspect filter elements that have been removed from the system for signals of failure
which may indicate that the service interval should be shortened, and for impend
system problems.
Important!
Never return to the system any fluid that has leaked out.
• Always keep the supply of fresh fluid covered tightly.
• Use clean containers, hoses, and funnels when filling the reservoir. Use of a filter cart
when adding oil is highly recommended.
• Use common sense precautions to prevent entry of dirt into components that have been
temporarily removed from the circuit. NOTE: IT IS THE PARTICLES SMALLER
THAN THE EYE CAN SEE THAT PRIMARY MUST BE PREVENTED FROM
ACCESSING THE SYSTEM.
• Make sure that all clean-out holes, filler caps, and breather cap filters on the reservoir
are properly fastened.
• Do not run the system unless all normally provided filtration devices are in place.
• Make certain that the fluid used in the system is of type recommended by PG
Hydraulics AS.
• Before changing from one type of fluid to another, consult PG Hydraulics AS.
WORTH KNOWING
It is the particles smaller than the eye can see that primary must be prevented from accessing
the system.

6.5 Replacing the return oil filter element (FTC-2A)

When servicing the filter, use the following procedure:

• Stop the system’s power unit

• Relieve pressure in the filter line. Drain fluid from housing if desired.
• Locate the filter.
• Remove the spring-loaded cover. Carefully lift and remove the cover.
• Remove element from the cover by removing socket-bolt in bottom of element. Discard
all disposable elements as they are not cleanable.
• Inspect the bowl and cover seals and replace if necessary.

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• Place new element securely in housing.

• Install cover (spring-loaded), and tighten up.

6.6 Replacing the leak oil filter element (FTB)

The filter element is to be replaced before the telltale indicator is at the red sector.

• Stop the Hydraulic Power Pack (all pumps).

• Locate the filter.
• Remove top of filter.
• Discard the used element and clean the inside of the bowl.
• Inspect the bowl and cover seals and replace if necessary.
• Place the new element securely in the housing.
• Replace the filter top, and tighten up.

6.7 Preventive maintenance

6.7.1 Everyday maintenance

1. Check oil level in reservoir. Even if the reservoir is equipped with an oil level switch that
stops the pump at low oil level, it is a good rule to do a visual observation of the oil level
before starting the pump.
2. Check filter indicators (Tell Tale), this is to be done during max. supply volume and at
normal operation temperature. The indicator shall point at the green sector. Before the
indicator is pointing at the yellow sector it is time to check that a spare filter element is
available. When the indicator is pointing at the red sector, the oil flow is bypassing the
filter, and the oil is not being filtrated. Change the filter element before the indicator is
pointing at the red sector.
3. When renewing the filter elements, always write it down in a maintenance log. Frequent
change of filter elements may indicate that one or several components are worn out.
4. Check hydraulic hoses, pipes, components and couplings for oil leaks or damages.

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6.7.2 Weekly Maintenance

1. Inspect all pressure hoses and pipes.

2. Check for leaks.
3. Clean the HPU and the surrounding area.

6.7.3 Monthly Maintenance

1. We recommend that oil samples be taken for further analysis. Log time, when and how the
sample is taken. The sample has to be taken the very same way every time, to be comparable.

6.7.4 Periodical maintenance

1. Subsequent to 2000 working hours, change the hydraulic oil and clean the reservoir.
2. Subsequent to 5000 working hours, lubricate the bearings inside the electrical motor.

6.7.5 Table for preventive maintenance

Check points Every Weekly Monthly Every

day year
Check oil level in reservoir.
Check filter indicators.
Check hydraulic hoses, pipes, couplings
and components.
Wash the HPU and surrounding area.
Collect an oil sample (Recommended).
Clean the reservoir and change the
hydraulic oil.
Tab. 1 Preventive maintenance

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6.7.5 Long-term storing

1. Store the HPU indoor, covered with a waterproof tarpaulin or similar.

2. Plug or seal all open connections.
3. Fill the reservoir completely full with clean hydraulic oil (to prevent condensation inside the
reservoir). Do not forget to drain out some of the oil before use.
4. Check the hydraulic hoses, piping couplings and components for leaks or damages.
5. The HPU shall be stored in a dry place.
-Storing temperature -20 to +40oC (-4 to +104oF)
-Maximum air humidity < 95%

6.8 Oil Chart

Recommended hydraulic oils for PG Hydraulics AS products.
Oil Company Hydraulic Oil
Valvoline Ultramax
Castrol Hyspin AWH 32
Chevron EP Hydr.oil 32
Esso Univis N 32
Fina Hydran TXS 32
Mobil DTE 13 (32 cst)
Shell Tellus T32
Texaco Rando HDZ 32
Nynaas Hydol 32
Statoil Hydraway HVXA 32
BP Energol SHF 32
Tab. 2 Oil Chart

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6.9 Trouble shooting
This chapter is dealing with the most common faults and problems, and what the user can do to
repair them.
Please call PG Hydraulics AS 24 hours phone +47 7008 6060 for more information, if necessary.
When contacting PG Hydraulics AS please make reference to Our order number 9107.
Indication
The hydraulic pressure is
dropping unintended.
Low hydraulic pressure.
The HPU will not start.
No oil flow.
Noisy operation.
Temperature in reservoir is
increasing unintended.
Tab. 3 Trouble Shooting on HPU
PG Hydraulics AS Order no. 9107
Possible Cause
Malfunction in the control
valve.
Malfunction in the relief
valve. The valve is by-
passing the oil back to the
reservoir.
Noisy. Hot oil.
The set value for the relief
valve is lower than the set
value for the pressure
regulator.
Adjusting screw on relief
valve is loose.
Noisy.
Malfunction in the pressure
adjuster.
Low oil level in reservoir.
High oil temperature.
Flexible coupling damaged.
Low oil level in reservoir.
The pump is sucking air.
Pump or electrical motor is
damaged.
Heat exchanger clogged.
Water supply to plate heat
exchanger is shut off /
blocked.
Relief valve on HPU is open.
Malfunction in control
valves.
15
Corrective Action
Contact PG Hydraulics AS.
Inspect and confirm.
Contact PG Hydraulics AS .
Set value for relief valve =
10% or min. 15 bar, above
maximum pressure.
Adjust the relief valve, and
lock the adjusting screw.
Inspect and change.
Refill clean oil.
Restart HPU.
Run the cooling unit, or wait
until the oil has cooled
down.
Check / Change.
Inspect level switch. Refill
oil immediately.
Contact PG Hydraulics AS.
Clean.
Inspect and open water
supply.
Adjust to correct settings.
Inspect.
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HPU User Manual PG Hydraulics AS Order no. 9107

7 RECOMMENDED SPARE PARTS (1 TO 2 YEARS SERVICE PERIOD)

The service intervals may vary from system to system. The filter elements shall be changed
before the visual indicators are at the red sector. Hoses and rubber bellows only to be changed if
damaged.

1 each Filter element, type FTC-05Q art. no.: 121623

for Return filter, type FTC (art. no.: 121424)
1 each Filter element, type FTB-05Q art. no.: 121615
for Leakoil filter, type FTB (art. no.: 121416)
1 each Pressure hose PV076 art. no.: 10039
1 each Leak oil hose PV076 art. no.: 10041
1 each Pump compensator, type “MMC” art. no.: 106714
1 each Damping cross for Coupling PV076 art. no.: 100141
Tab. 4 Recommended spare parts.

When ordering spare parts from PG Hydraulics AS, please note our order no. 9107 in addition to
PG Hydraulics AS art. no as listed above.

8 DRAWINGS
Drawing no: Title:
1004-M Dimensional Sketch, High Pressure Unit
1007-S Assembly Drawing, High Pressure Unit
1005-P Piping Diagram, High Pressure Unit
1006-P Piping Diagram, Cargo system
Tab. 5 Drawings

9 DATA FOR HYDRAULIC COMPONENTS

Please see appendix.

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