5-1. Maintenance

Index
Operation
Commissioning
Maintenance
Components
Electrical Wiring
Cylinder Lubricators 103-2
Data
SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
103-2 Data
0020 Cylinder
S80MC-C
Lubricators
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubrication oil
Lock turbocharger rotors
Data
Ref. Description Value Unit
D-1 Nitrogen pressure

– inlet accumulator 25-30 bar
D-2 Nitrogen pressure

– outlet accumulator 1.5 bar
D-3 Plug screw

– tightening torque 30 Nm
0-60 bar
0-10 bar
When referring to this page, please quote Data D10302 Edition 0020 Page 1 (2)
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
Data
Spare Parts
Plate – Item No. Description Qty
Page 2 (2) When referring to this page, please quote Data D10302 Edition 0020
MAN B&W Diesel A/S
Cylinder Lubricators 903-2.1
Checking
0236
Cylinder
S42MC Lubricators
Checking
903-2.1
1.
Check of Oil Injection:
With stopped engine and normally when the

system has been disassembled:
1. Press the ESC + PRELUB.-button on the HMI

control panel, and check that all lubricators
are operating correctly by watching the
LEDs on the intermediate boxes for each lu-
bricator.
2. If the cylinder cover or the exhaust valve is

removed, check inside the liner that all lu-
bricating points are working properly.
Otherwise, remove the covers for scavenge

port inspection.
Turn the piston to BDC and check inside the

liner with a mirror and a powerful light
source that all lubrication points are work-
ing properly.
NA903-2.1 225 01
With running engine:
3. Check that all lubricators are operating cor-

rectly by watching the LEDs on the interme-
diate boxes for each lubricator.
2.
The LEDs give signal when oil is injected.
Check the pressure shocks from the injec-

tion of the lubricators on each lubricator
pipe by feeling with a hand.
If in doubt, disconnect the pipe at the cylin-

der liner to observe the oil flow.
NA903-2.1 225 02
When referring to this page, please quote Procedure M90302 Edition 0236 Page 1 (10)
0$1% :'LHVHO$6
903-2.1 Cylinder Lubricators
Checking
3. Check of Accumulators:
4. Measuring the nitrogen pre-pressure can

only be done with stopped engine and pres-
sure-free lubrication system.
Stop both oil pumps. Close the inlet valve

and open the equalizing valve on the re-
spective lubricator.
D03-11
The nitrogen pressure in the inlet accumu-
D03-10 lator (0.7 litre) can be checked without dis-
EN903-2.1 219 04
mounting the accumulator. For use of the

pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), the accumu-
5. lator or the lubricator with accumulator
must be dismounted.
See Procedure 903-2.2.
For nitrogen pressure in the accumulators,

see Data.
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor.
NA903-2.1 222 05
Mount a 0-60 bar pressure gauge on the fill-

ing valve when the inlet accumulator (0.7 li-
tre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
Page 2 (10) When referring to this page, please quote Procedure M90302 Edition 0236
0$1% :'LHVHO$6
Checking
6. C
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean. A
D03-13
E
Mount the filling valve on the relevant accu- F
mulator with the union nut. Check that
valves C and F are closed.
Loosen the plug screw in the accumulator

B
using a ½” square drive handle in socket E.
It is now possible to read the actual nitro-

gen pressure in the accumulator on the dial
NA903-2.1 222 06
gauge on the filling valve.
8. If the accumulator needs to be refilled with

nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in Da-
ta.
Open valve C until the accumulator is filled

to the correct pressure.
Close valve C and tighten the plug screw

with socket E to the torque stated in Data.
Release the pressure in the filling valve at

bleed screw F.
Unscrew the filling valve from the accumu-

lator. Retighten the plug screw to the torque
stated in Data. Remount the accumulator.
0$1% :'LHVHO$6
Dismantling
Dismantling
903-2.2
1. Dismantling of lubricators:
The engine must be stopped and blocked be-

fore dismounting a lubricator. Stop the cylinder
oil pump station.
1. Close the supply valve for the lubricator and

open the equalizing valve (turn both han-
dles to a horizontal position). Remove the
upper shield, if installed.
Disconnect the electrical plug on the side of

the lubricator.
EN903-2.2 219 01
2. Unscrew the three screws in the bottom of

the lubricator and disconnect the cover with
pertaining pipes.
3. Unscrew the four screws on the side that

2. secure the lubricator to the hydraulic block,
and remove the lubricator.
Special running
It is possible to change a lubricator while the

engine is running if a spare lubricator with O-
rings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
• Reduce the engine load to below 40% of

MCR
EN903-2.2 219 02
• Let the lubricator pump station run
• Dismount the lubricator as described in

steps 1-3
• Mount a spare lubricator as described in

Procedure 903-2.4.
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Dismantling
Dismantling of accumulators: 4.
4. The engine must be stopped and blocked

before the accumulator is dismounted.
Stop the cylinder oil pump station.

Close the supply valve for the lubricator and
open the equalizing valve.
Note!
When the oil pressure is released, a

nitrogen pre-pressure of 25-30 bar will
EN903-2.2 219 04
remain in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the
hydraulic block.
0$1% :'LHVHO$6
Overhaul
Overhaul
903-2.3
1. 1. Place the lubricator in a bench vice with

soft “jaws”.
Remove the adjusting screw with bushings.

Unscrew the oil accumulator.
Discard the O-ring from the adjusting

screw.
2. Remove the screws from the cylinder block.
3. Pull up the cylinder block.

EN903-2.3 219 01
Remove the spring and actuator piston with

plungers.
Remove and discard the O-ring from the

cylinder block.
2.
Remove the cover for the non-return valves.
Take out springs and balls. Remove and
discard the O-rings.
EN903-2.3 219 02
3.
EN903-2.3 219 03
0$1% :'LHVHO$6
Overhaul
4. Remove the cover from the terminal box, 4.

and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box.
Carefully, unscrew the feedback sensor and

remove and discard the O-ring.
EN903-2.3 221 04
Clean the housing with diesel oil or kero-
sene and dry with a non-fluffy cloth.
5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass. 5.
Check that the balls from the non-return

valves are in good condition.
Check the seats for the non-return valves.

EN903-2.3 219 05
0$1% :'LHVHO$6
Overhaul
6. Before mounting the feedback sensor,

6. check that the sensor is flush with the sen-
sor housing.
Mount the feedback sensor or a new one, if

necessary, with a new O-ring.
Check with an object with a straight edge

(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.
Mount the terminal box.
Connect the wires and mount the cover on

the terminal box.
1 1
EN903-2.3 219 06
2 Solenoid valve
7. Fit the cylinder block with new O-rings.
2
3 BN (brown)
4 BK (black) Feedback sensor Assemble the non-return valves in the cyl-
5 BU (blue) inder block.
6a. Mount the cover with the three inner

screws.
LED
Check with a small screwdriver that the
+1 –2 springs are correctly centered.
3 2
6 5 1
4
5V
+1
wn
B ro
e OV al
Blu ign
F B-s
ck
Bla
707-40C-7A
7.
EN903-2.3 219 07
0$1% :'LHVHO$6
Overhaul
8. Fit the cylinder block with a new O-ring. 8.

Pre-assemble the cylinder block with the
actuator piston and plungers to ensure the
correct guidance of the plungers, before fi-
nally assembling the cylinder block unit.
Mount the spring and press down the actu-

ator piston with plungers. Mount an M6 x 60
screw with a washer to keep the spring
compressed.
9. Mount the cylinder block assembly in the

cylinder housing.
EN903-2.3 219 08
Mount the screws and tighten the block to
the housing.
Remove the M6 x 60 screw with washer.

9.
10. Mount the adjusting screw fitted with a new
O-ring and the distance bushing.
Mount the oil accumulator.
11. If the lubricator is not to be mounted on the

engine immediately after overhauling, cover
all openings with plastic to prevent dirt from
entering the lubricator during storage.
Coat all surfaces with a thin layer of oil.

EN903-2.3 219 09
10.
EN903-2.3 219 01
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Mounting
Mounting
903-2.4
1. 1. Before mounting the accumulator, check

the nitrogen pressure, see Data.
Mount the accumulator.
2. Mount new O-rings on the hydraulic block

and on the cover with pipes.
Mount the lubricator and tighten the screws

on the hydraulic block.
Tighten the screws in the bottom of the lu-

bricator to the pipe connection.
EN903-2.4 219 01
3. Close the equalizing valve and open the

supply valve (handles to be in a vertical po-
sition).
2. Mount the electrical plug. Check the injec-

tion of cylinder oil on the feedback LED on
the terminal box for the specific lubricator.
EN903-2.4 219 02
3.
EN903-2.4 219 03
0$1% :'LHVHO$6
MAN B&W Diesel Checking

1.
1. Press the ESC + PRELUB.-button on the

HMI control panel, and check that all lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.


port inspection.
Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
ing properly.
M903020245C01
3.
M903020245C02
Checking MAN B&W Diesel

4.
Inlet
rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.

D0311
If in doubt, disconnect the pipe at the cyl-
D0310 inder liner to observe the oil flow.
M903020249C03
Check of Accumulators:
4. Measuring the nitrogen pre-pressure can

only be done with stopped engine and
5. pressure-free lubrication system.
Stop both oil pumps. Close the inlet valve

and open the equalizing valve on the re-
spective lubricator.
The nitrogen pressure in the inlet accumu-

lator (0.7 litre) can be checked without dis-
mounting the accumulator. For use of the
pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), the accumu-
M903020245C05
lator or the lubricator with accumulator

must be dismounted.
For nitrogen pressure in the accumulators,

see Data.
MAN B&W Diesel Checking

Assemble the pressure setting tool as 7.
C
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor. A E D0313
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7 F
litre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
B
is clean.
M903020247C07
Mount the filling valve on the relevant accu-



to 1-2 bar above the pressure stated in
Data.



bleed screw F.

lator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.
Dismantling MAN B&W Diesel
Dismantling of lubricators:
1.
The engine must be stopped and blocked be-
fore dismounting a lubricator. Stop the cylinder
Inlet oil pump station.
1. Close the supply valve for the lubricator

and open the equalizing valve (turn both
handles to a horizontal position). Remove
the upper shield, if installed.
Disconnect the electrical plug on the side

of the lubricator.
M903020249D01
2. Unscrew the six screws in the bottom of

the lubricator and disconnect the cover
with pertaining pipes.
3. Unscrew the four screws on the side that

2.
Inlet
secure the lubricator to the hydraulic block,
Special running
It is possible to change a lubricator while the

engine is running if a spare lubricator with O-
rings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
• Reduce the engine load to below 40%

of MCR
M903020249D02
• Let the lubricator pump station run
• Dismount the lubricator as described in

steps 1-3
• Mount a spare lubricator as described

in Procedure 903-2.4.
MAN B&W Diesel Dismantling
Dismantling of accumulators:
5.
4. The engine must be stopped and blocked
before the accumulator is dismounted.
Inlet
Stop the cylinder oil pump station.
Close the supply valve for the lubricator

and open the equalizing valve.
Note!
When the oil pressure is released, a ni-
M903020249D04
trogen pre-pressure of 25-30 bar will re-
main in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the hy-
draulic block.
Overhaul MAN B&W Diesel
1. Place the lubricator in a bench vice with

1. soft “jaws”.


screw.
2. Remove the screws from the cylinder

block.

M903020247O01
Remove the spring and actuator piston

with plungers.
Remove and discard the O-ring from the

cylinder block.
2.
Remove the cover for the non-return
valves. Take out springs and balls. Remove
and discard the O-rings.
M903020247O02
3.
M903020247O03
MAN B&W Diesel Overhaul
4. Screw out the non-return valves and re-

move and discard the O-rings. 4.
Clean the valves and check them with

compressed air.

glass.
6. Fit the non-return valve with new O-rings.
Mount the non-return valves in the cylinder

block.
M903020247O04
5.
M903020247O05
6.
M903020247O06
7. Pre-assemble the cylinder blockwith the

7. actuator piston and plungers to ensure the
Mount the spring and press down the ac-

tuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
Fit the cylinder block with a new O-ring.

M903020247O07
8. Remove the cover from the terminal box

and disconnect the wires for the feedback 8.
(pick-up) sensor.
Remove the terminal box and the plug for

the solenoid valve.
Carefully unscrew the feedback sensor and


9 Turn the lubricator upside down in the vice.
M903020247O08
Unscrew the solenoid valve.
Discard the O-rings.
10. Solenoid valve: 9.
Disassemble and clean the valve.
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be re-
placed by a new one.
Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
the housing.
Assemble the valve.

M903020247O09
See also manufacturer’s instructions.
10.
M903020244O12

sor housing.
Mount the feedback sensor or a new one,

if necessary, with a new O-ring.


M903020245O10
1 1
2 2 Solenoid valve 11. Connect the wires and mount the cover on
3 BN (brown) the terminal box.
BK (black)
4
BU (blue) Feedback sensor
5 13. Mount the solenoid valve fitted with new
O-rings. Coat the O-rings with a little
12. grease to keep the rings in place during
LED
mounting.
2
Brown+15
Blue OV
Black FBsignal
M903020242O08
13.
M903020247O13

cylinder housing. 14.
Check that the spring pin engages cor-

rectly with the cylinder block assembly.

the housing.
Remove the M6 x 60 screw with disc.
15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.
M903020247O14
16. If the lubricator is not to be mounted on

the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor- 15.
age.
Cover all surfaces with a thin layer of oil.

M903020247O01
Mounting MAN B&W Diesel
1. Before mounting the accumulator, check

1. Inlet the nitrogen pressure, see Data.
Mount the accumulator.


Tighten the screws in the bottom of the lu-

bricator to the pipe connection.
M903020249M01
3. Close the equalizing valve and open the

supply valve (handles to be in a vertical po-
sition).
Mount the electrical plug. Check the injec-

2. tion of cylinder oil on the feedback LED on
Inlet the terminal box for the specific lubricator.
M903020249M02
3.
Inlet
M903020249M03
Checking
0237
Cylinder
K98MC Lubricators
Checking
903-2.1
1.

1. Press the ESC + PRELUB.-button on the HMI

control panel, and check that all lubricators
are operating correctly by watching the
LEDs on the intermediate boxes for each lu-
bricator.


port inspection.
Turn the piston to BDC and check inside the

liner with a mirror and a powerful light
ing properly.
NA903-2.1 225 01

rectly by watching the LEDs on the interme-
diate boxes for each lubricator.
2.

If in doubt, disconnect the pipe at the cylin-

der liner to observe the oil flow.
NA903-2.1 225 02
0$1% :'LHVHO$6
Checking
4. Check of Accumulators:
4. Check of Inlet Accumulator

Checking the inlet accumulator can be done
with running engine.
D-1
Close the valve that connects the accumu-
lator to the distributor block.
Mount the special hose on the minimess

coupling and drain all oil out of the accumu-
lator.
NA903-2.1 222 03
Check the nitrogen pressure.

For use of pressure setting tool, see Step
6. For correct pressure, see Data.
5. Check of Outlet Accumulator

5. The outlet accumulators are to be dis-
mounted while the nitrogen pressure is
checked.
Dismount the outlet accumulator.

D-2 See Procedure 903-2.2.
Check the nitrogen pressure, using the

pressure setting tool.

shown in the Figure, and mount the reduc-
ing valve on the nitrogen cylinder. If neces-
NA903-2.1 222 04
sary, use a threaded adaptor.
Mount a 0-60 bar pressure gauge on the fill-

ing valve when the inlet accumulator (0.7 li-
6. tre) is checked, and a 0-10 bar pressure
gauge when the outlet accumulators (0.16
litre) are checked.
NA903-2.1 222 05
0$1% :'LHVHO$6
Checking
7. C
is clean. A E
Mount the filling valve on the relevant accu- D-3 F

B

NA903-2.1 222 06

to 1-2 bar above the pressure stated in Da-
ta.



bleed screw F.

lator. Retighten the plug screw to the torque
stated in Data. Remount the accumulator.
0$1% :'LHVHO$6
Dismantling
Dismantling
903-2.2
1. Dismantling of lubricators:
Both lubricators can be dismounted with run-

ning engine, one at a time. If the engine is run-
ning when a lubricator is dismounted, it is
important to check that the other lubricator is
doubling injection frequency.
A B
1. Close the supply valve for the lubricator
concerned, using the special tool. The out-
er valve is for lubricator marked A and the
inner valve is for lubricator marked B.
NA903-2.2 222 01
Let the lubricator inject oil until the feed-

back LED stops flashing. Disconnect the
electrical plug on the front of the lubricator.
2. Unscrew the three screws in the top of the

2. lubricator and disconnect the cover with
pertaining pipes.
3. Unscrew the four screws on the front that

4. Inlet Accumulator

NA903-2.2 222 02
coupling and drain the oil out of the accu-

mulator.
Unscrew the accumulator. If the engine is

4. running, a new or checked accumulator
should be mounted at once.
NA903-2.2 222 04
0$1% :'LHVHO$6
Dismantling
5. Outlet Accumulator 4.
Close the supply valve for the accumulator
er valve is for accumulator marked A and
the inner valve is for accumulator marked
B. A B

back LED stops flashing.
If space conditions permit, unscrew the ac-

cumulator; otherwise the lubricator must be
NA903-2.2 222 05
dismounted, see Step 1 .
0$1% :'LHVHO$6
Overhaul
Overhaul
903-2.3
1. 1. Place the lubricator in a bench vice with

soft “jaws”.


screw.

EN903-2.3 219 01

plungers.
2. Remove and discard the O-ring from the

cylinder block.
Remove the cover for the non-return valves.

Take out springs and balls. Remove and
discard the O-rings.
EN903-2.3 219 02
3.
NA903-2.3 222 03
0$1% :'LHVHO$6
Overhaul
4. Remove the cover from the terminal box, 4.

(pick-up) sensor.
Remove the terminal box.
Carefully, unscrew the feedback sensor and

NA903-2.3 222 04

glass. 5.
Check that the balls from the non-return

valves are in good condition.
Check the seats for the non-return valves.

EN903-2.3 219 05
0$1% :'LHVHO$6
Overhaul

sor housing.

necessary, with a new O-ring.

Connect the wires and mount the cover on

the terminal box.
1 1
EN903-2.3 219 06
2 2 Solenoid valve
7. Fit the cylinder block with new O-rings.
3 BN (brown)
BK (black)
4 BU Feedback sensor
(blue) Assemble the non-return valves in the cyl-
5
inder block.
6a.
Mount the cover with the three inner
LED
screws.
+1 –2 Check with a small screwdriver that the

springs are correctly centered.
3 2
6 5 1
4
5V
+1
wn
B ro
e OV al
Blu ign
F B-s
ck
Bla
707-40C-7A
7.
EN903-2.3 219 07
0$1% :'LHVHO$6
Overhaul
8. Fit the cylinder block with a new O-ring. 8.

Pre-assemble the cylinder block with the
actuator piston and plungers to ensure cor-
rect guidance of the plungers, before finally
assembling the cylinder block unit.
Mount the spring and press down the actu-

ator piston with plungers. Mount an M6 x 60
screw with a disc to keep the spring com-
pressed.

cylinder housing.
EN903-2.3 219 08
Check that the spring pin engages correctly
with the cylinder block assembly.

the housing. 9.

O-ring and the distance bushing.
11. If the lubricator is not to be mounted on the

engine immediately after overhauling, cover
all openings with plastic to prevent dirt from
entering the lubricator during storage.
NA903-2.3 222 09
10.
EN903-2.3 219 01
0$1% :'LHVHO$6
Mounting
Mounting
903-2.4
1. Mounting of Lubricators


Tighten the screws in the top of the lubrica-

tor to the pipe connection.
2. Open the supply valve and mount the elec-

trical plug. Check the injection of the cylin-
NA903-2.4 222 01
der oil on the LED on the terminal box for the

specific lubricator.
For checking injection timing, see Proce-

dure 905-8.1.
2.
Mounting of Accumulator
3. Mount the accumulator. Remove the drain

hose from the minimess coupling. Open the
valve that connects the accumulator to the
distributor block.
A B
Check the oil injection.
NA903-2.4 222 02
3.
NA903-2.4 222 03
0$1% :'LHVHO$6
MAN B&W Checking

1.
1. Press the ESC + PRELUB.button on the

HMI control panel, and check that all lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.


port inspection.
Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
ing properly.
M903020245C01

rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
3.

If in doubt, disconnect the pipe at the cyl-

inder liner to observe the oil flow.
M903020245C02
Checking MAN B&W
Check of Accumulators:
4.
D03-10 4. Check of Inlet Accumulator
Checking the inlet accumulator can be
done with running engine.


coupling and drain all oil out of the accu-
mulator.
Check the nitrogen pressure.

M90302-0256C04
For use of pressure setting tool, see Step

6. For correct pressure, see Data.
5. Check of Outlet Accumulator

The outlet accumulators are to be dis-
5. mounted while the nitrogen pressure is
checked.
Dismount the outlet accumulator.

See Procedure 9032.2.
Check the nitrogen pressure, using the

pressure setting tool.

shown in the Figure, and mount the reduc-
ing valve on the nitrogen cylinder. If neces-
M903020256C05
sary, use a threaded adaptor.

Mount a 060 bar pressure gauge on the
D0311 filling valve when the inlet accumulator (0.7
litre) is checked, and a 010 bar pressure
gauge when the outlet accumulators (0.16
6. litre) are checked.
M903020245C05
MAN B&W Checking

cumulator, check that the accumulator top 7.
C
is clean.
Mount the filling valve on the relevant ac- A E D0313

cumulator with the union nut. Check that
valves C and F are closed. F
B
M903020247C07
outlet pressure from valve C on spindle
B to 12 bar above the pressure stated in
Data.



bleed screw F.
Unscrew the filling valve from the accu-

mulator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.
Dismantling MAN B&W
Dismantling of lubricators:
1.
Both lubricators can be dismounted with run-
A B ning engine, one at a time. If the engine is
running when a lubricator is dismounted, it is
important to check that the other lubricator is
doubling injection frequency.
1. Close the supply valve for the lubrica-

tor concerned, using the special tool. The
lowermost valve is for lubricator marked A
and the uppermost valve is for lubricator
marked B.
M903020256D01

back LED stops flashing. Disconnect the
electrical plug on the topside of the lubrica-
tor.
2. 2. Unscrew the screws in the pipe flange of

the lubricator and disconnect the cover
with pertaining pipes.
3. Unscrew the four screws from the top that

M903020256D02
MAN B&W Dismantling
4.
4. Inlet Accumulator
coupling and drain the oil out of the accu-
mulator.
Unscrew the accumulator. If the engine is
running, a new or checked accumulator
should be mounted at once.
5. Outlet Accumulator
M903020256D04
Close the supply valve for the accumulator
er valve is for accumulator marked A and
the inner valve is for accumulator marked
B.
5.
back LED stops flashing.
A B
If space conditions permit, unscrew the ac-

cumulator; otherwise the lubricator must be
dismounted, see Step 1.
M903020256D05
Overhaul MAN B&W
1. Place the lubricator in a bench vice with

1. soft “jaws”.

Discard the Oring from the adjusting

screw.

M903020247O01
plungers.
Remove and discard the Oring from the

cylinder block.
2. Remove the cover for the nonreturn

valves. Take out springs and balls. Remove
and discard the Orings.
M903020247O02
3.
M903020247O03
MAN B&W Overhaul
4. Screw out the nonreturn valves and re-

move and discard the Orings. 4.
Clean the valves and check them with

compressed air.

glass.
6. Fit the nonreturn valve with new Orings.
Mount the nonreturn valves in the cylinder

block.
M903020247O04
5.
M903020247O05
6.
M903020247O06
Overhaul MAN B&W
7. Preassemble the cylinder blockwith the

7. actuator piston and plungers to ensure the
Mount the spring and press down the ac-

tuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
Fit the cylinder block with a new Oring.
8. Remove the cover from the terminal box

(pickup) sensor.
Remove the terminal box and the plug for

the solenoid valve.
Carefully unscrew the feedback sensor and

remove and discard the Oring.
M903020247O07

sene and dry with a nonfluffy cloth.
8.
M903020247O08
MAN B&W Overhaul
9 Turn the lubricator upside down in the vice.

9.
Unscrew the solenoid valve.
Discard the Orings.
10. Solenoid valve:
Disassemble and clean the valve.
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be re-
placed by a new one.
M903020247O09
Lubricate the slide with oil and check that
the slide can move lightly with a good fit in
the housing.
Assemble the valve.

10.
See also manufacturer’s instructions.

check that the sensor is flush with the sen-
sor housing.

necessary, with a new Oring.

M903020244O12
11.
M903020245O10
1 1
2 2 Solenoid valve
3 BN (brown)
BK (black)
4
BU (blue) Feedback sensor
5
Overhaul MAN B&W
12. Connect the wires and mount the cover on

12. the terminal box.
LED
13. Mount the solenoid valve fitted with new
2 Orings. Coat the Orings with a little
grease to keep the rings in place during
mounting.

Brown+15
cylinder housing.
Blue OV
Black FBsignal Check that the spring pin engages correctly

with the cylinder block assembly.
M903020242O08

the housing.
13.
M903020247O13
14.
M903020247O14
MAN B&W Overhaul

Oring and the distance bushing. 15.
16. If the lubricator is not to be mounted on

the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor-
age.
M903020247O01
Mounting MAN B&W
Mounting of Lubricators
1.
1. Mount new Orings on the hydraulic block

Tighten the screws between the lubricator

and the pipe connection.
2. Open the supply valve and mount the elec-

trical plug. Check the injection of the cyl-
inder oil on the led on the terminal box for
the specific lubricator.
For checking injection timing, see Proce-

dure 9058.1.
M903020256D02
2.
A B
M903020256M02
MAN B&W Mounting
Mounting of Accumulator
3.
3. Mount the accumulator. Remove the drain
hose from the minimess coupling. Open the
valve that connects the accumulator to the
distributor block.
Check the oil injection.

See Procedure 9032.1.
M903020256M03
Tacho Pick-Ups 105-7
MAN B&W Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X Stopped engine
X Shut off starting air supply – At starting air receiver
X Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME engines
Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
D05-40 Tacho pick-ups for governor system

– check distance 3 ±0.5 mm
D05-41 Tacho pick-ups for Alpha lubricator

– check distance 3 +0/-1 mm
Regarding distance: Always refer to manufacturer’s instructions.
D05-42 50 ±2 mm
D05-43 10 ±2 mm
105-7 Tacho Pick-Ups
Data MAN B&W
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
Tacho Pick-Ups 905-7.1
MAN B&W Checking
The engine is equipped with two sets of pick-

1.
ups:
• Governor system pick-ups
• Alpha Lubricator system pick-ups.
Governor system pick-ups:
1. The tacho pick-ups are placed next to the

turning wheel.
2. Check the distance between the tacho

pick-ups and the turning wheel, see Data.
If necessary, adjust the distance.
If the tacho pick-ups are renewed, note

down the wiring to ensure the correct re-
mounting.
M90507-0205C01
2.
D05-40
Turning wheel
M90507-0205C02
905-7.1 Tacho Pick-Ups
Checking MAN B&W
Alpha Lubricator system pick-ups

3.
(backup system for angle encoder):
3. Turn the crankthrow for Cylinder 1 to TDC.
Check the TDC of Cylinder 1 against the

mark on the turning wheel.
4. The pick-ups are placed next to the turning

wheel, see the sketch.
5. Check that the upper marker piece edge is

in the centreline of the pick-ups.
M906030218C01
Check the distance between the pick-ups

and the marker piece on the turning wheel.
Adjust the distance if necessary. See Data.
4. If the pick-ups are renewed, note down the

wiring to ensure the correct remounting.
M90507-0205C04
5.
D05-41
M90507-0205C05
50 ± 2mm
Tacho Pick-Ups 905-7.1
MAN B&W Checking
6. To ensure an applicable pulse to the tacho

6.
pick-ups, it is very important that the mark-
er piece, as a minimum, complies with the
dimensions stated in drawing 5 and 6.
M90501-0205C06
10 ± 2mm
Angle Encoder 105-8
Data
SAFETY PRECAUTIONS
MC
Special Data 0007
D10508 Edition
105-8 Angle Encoder
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
MAN B&W Diesel A/S
105-8 Angle Encoder
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
MAN B&W Diesel A/S
Angle Encoder 905-8.1
MAN B&W Checking
1. Turn the crankthrow for cylinder 1 to TDC.

1.
Check the TDC of cylinder 1 against the
2. Check that power is supplied to the inter-

mediate box.
The green indicator should now light.
For adjustment of the angle encoder, see

Procedure 905-8.3.
3. Remove the inspection cover.
M90508-0206C01
Check that the rubber damper is intact.
Assemble the cover.

2.
M90508-0206C02
3.
M90508-0206C03
905-8.2 Angle Encoder
Dismantling MAN B&W
1. Remove the inspection cover.

1.
Cut the cable tie which holds the rubber
damper around the coupling, in the end
nearest to the engine, and loosen the cou-
pling.
2. Loosen the three adjusting screws on the

front flange, and remove the angle encoder
and the coupling.
3. Screw out the flange screws and remove

the encoder housing. Take care not to
damage the guide pins.
M90508-0206D01
2.
M90508-0206D02
3.
M90508-0206D03
Angle Encoder 905-5.3
MAN B&W Adjustment
1. Turn the crankthrow for cylinder 1 to TDC.

1.
Check the TDC of cylinder 1 against the
Check the TDC position with the pin gauge

on the crankthrow, cylinder 1.
Note!
Before using the pin gauge, check the
measurement from tip to tip with the val-
ue stamped on the pin gauge, and/or the
check-marks stamped on the fore end of
M90508-0206O01
the cylinder frame.
2. Loosen the adjusting screws which fasten

the encoder to the housing. Slowly turn the
encoder until the green indicator lights on
the intermediate box. 1.
Tighten the screws to secure the encoder

in the correct position.
M90508-0206O02
2.
M90508-0206O03
905-8.4 Angle Encoder
Mounting MAN B&W
1. Assemble the encoder housing. The two

1.
guide pins indicate the correct positioning
of the housing. Tighten the screws.
2. Fit the angle encoder and the coupling.
Tighten the coupling, and mount new cable

ties around the rubber damper.
Adjust the angle encoder according to Pro-

cedure 905-8.3.
Note!
M90508-0206M01
The adjustment will be easier if mounting

is in the same crank position as disman-
tling.
3. Assemble the cover.

2.
M90508-0206M02
3.
M90508-0206M03
Alpha Lubricator System S903-0040
MAN B&W Check and Adjustment of Index Transmitter
Check and adjustment of index transmitter
The following guidelines are relevant for the adjustment or replacement of the index transmitter
on engines in service.
Adjustment of index transmitter
Adjust the index transmitter electrically until:

The minimum index from the engine side control console corresponds to 4.5 MA.
The maximum index from the engine side control console corresponds to 19.5 mA.
See instruction S903-21, Testbed Commissioning Procedure.
Calibration of index signal 120

Engine speed
120
Adjust the fuel rack on the engine side Index
control console to an index corresponding 100 bar

Oil pressure
to 50% load at testbed conditions (relevant
values can be found in the shoptest report). °C rpm
Deg. %
Min. bar
Navigate, via the HMI panel, to the Index Oil pressure low
Adjust menu. Index failure
Mark/trig failure
Choose either the generator curve or the Feedback failure
propeller curve, depending on the measure- Common alarm
S90321-0021
ments obtained on the testbed. LAMPTEST ESC ENTER
PUMP 1 PUMP 2 PRELUB.
Select 50% in the Menu, and

Password press [enter].
NOTE: When the propeller

curve and 50% are selected,
and enter is pressed, the in-
dex reading will be: 63%
Adjust the fuel rack on the

S90321-0022
engine side control console

to an index corresponding to
100% load at testbed condi-
(Password) tion (relevant values can be
found in the shoptest report).
Navigate, via the HMI panel, to the Index Adjust menu.

Choose either the generator curve or the propeller curve, depending on the measurements ob-
tained on the testbed.
Select 100% in the Menu, and press [ENTER].

The index transmitter has now been adjusted.
These settings are only 100% valid when running on diesel oil. When running on heavy fuel
there can be a minor offset, which can be compensated for by adjusting the mechanical con-
nection from the fuel rack to the index transmitter.
When referring to this page, please quote S-Instruction S903 Edition 0040 Page 1 (1)

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Index

SAFETY PRECAUTIONS Standard Tools: See Section 913

D-1 Nitrogen pressure

D-2 Nitrogen pressure

D-3 Plug screw

Plate – Item No. Description Qty

With stopped engine and normally when the

1. Press the ESC + PRELUB.-button on the HMI

2. If the cylinder cover or the exhaust valve is

Otherwise, remove the covers for scavenge

Turn the piston to BDC and check inside the

With running engine:

3. Check that all lubricators are operating cor-

Check the pressure shocks from the injec-

If in doubt, disconnect the pipe at the cylin-

4. Measuring the nitrogen pre-pressure can

Stop both oil pumps. Close the inlet valve

mounting the accumulator. For use of the

5. To measure the nitrogen pressure in the

For nitrogen pressure in the accumulators,

6. Use of Pressure Setting Tool

Mount a 0-60 bar pressure gauge on the fill-

Loosen the plug screw in the accumulator

It is now possible to read the actual nitro-

8. If the accumulator needs to be refilled with

Open valve C until the accumulator is filled

Close valve C and tighten the plug screw

Release the pressure in the filling valve at

Unscrew the filling valve from the accumu-

The engine must be stopped and blocked be-

1. Close the supply valve for the lubricator and

Disconnect the electrical plug on the side of

2. Unscrew the three screws in the bottom of

3. Unscrew the four screws on the side that

It is possible to change a lubricator while the

• Reduce the engine load to below 40% of

• Let the lubricator pump station run

• Dismount the lubricator as described in

• Mount a spare lubricator as described in

4. The engine must be stopped and blocked

Stop the cylinder oil pump station.

When the oil pressure is released, a

Carefully unscrew the accumulator to re-

1. 1. Place the lubricator in a bench vice with

Remove the adjusting screw with bushings.

Discard the O-ring from the adjusting

2. Remove the screws from the cylinder block.

3. Pull up the cylinder block.

Remove the spring and actuator piston with

Remove and discard the O-ring from the

4. Remove the cover from the terminal box, 4.

Remove the terminal box.

Carefully, unscrew the feedback sensor and

5. Inspect the plungers, actuator piston and

Check that the balls from the non-return

Check the seats for the non-return valves.

6. Before mounting the feedback sensor,

Mount the feedback sensor or a new one, if

Check with an object with a straight edge

Mount the terminal box.