MAN Diesel 3045-0110-0001.

Alpha Lubricator System

Alpha Lubricator System
Operation Manual
MC Engines

MAN B&W Diesel A/S

Teglholmsgade 41
DK-2450 Copenhagen SV, Denmark
Phone +45 33 85 11 00
Fax +45 33 85 10 30
E-mail [email protected]
3045-0110-0001.1
2008-12-12

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 MAN Diesel 3045-0110-0001.1

Table of Contents

Alpha Lubricator System

Page
List of Abbreviations: 7

1. General Information 9
1.1 Main components 9
1.2 Working principle 12
1.3 Guidance values automation 13

2. Operation of the System 13

2.1 HMI-Panel/Operating Panel 13
2.2 Control buttons and indicator lamps on pump station starter panels 14
2.3 Start-up of Alpha Lubricator System (Engine not running) 14
2.4 Checks during start-up of the engine 15
2.5 Periodic checks during normal operation of the engine 16

3. HMI-Panel and Configuration of MCU 16

3.1 Description of HMI Panel 16
3.2 HMI-Panel operation and configuration of MCU 17
3.2.1 Navigation principle 17
3.2.2 Reading of total stroke/min [rXXX] 18
3.2.3 Reading of total strokes [Str.hi] and [Str.lo] 18
3.2.4 Reading of active alarms [ALRXX] 18
3.2.5 Reading of logged alarms [LALXX] 18
3.2.6 Adjustment of cylinder oil feed rate [F.rAtE] 19
3.2.7 Monthly change of operating pumps (master pump) 20
3.2.8 Test sequence for inspection during standstill 20
3.2.9 Menu structure 20
3.2.10 HMI panel parameter reference list 24
3.3 MCU setup 35
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3.3.1 Dip switches for MCU 35

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3.3.2 Upload of MCU basic program 37

3.3.3 Upload MCU set-up file 38
3.3.4 MCU LED information 38
3.3.5 Read-out of raw parameters in HMI Panel 38

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Table of Contents
Alpha Lubricator System

Page
4. Configuration of BCU 39
4.1 Injection rate with BCU in control 39
4.2 Detection rate (BCU take over from MCU) 39
4.3 Number of cylinders for the engine 40
4.4 BCU board revision 40
4.5 Slow down output 40
4.6 Number of lubricators 41
4.7 Upload of BCU basic program 41

5. Alpha Lubricator - Alarm Handling and Trouble Shooting Guide 43

5.1 Fuses 43
5.1.1 MCU-Unit 43
5.1.2 BCU-Unit 47
5.2 External alarm signals 49
5.2.1 Common alarm 49
5.2.2 MCU power failure 49
5.2.3 BCU power failure 50
5.2.4 MCU failure 50
5.2.5 BCU failure 50
5.2.6 Slow-down 50
5.2.7 BCU in control 50
5.3 MCU - alarm handling and trouble shooting 51
5.3.1 Alarms 1-24-Feedback failure 51
5.3.2 Alarm 29 - Marker signal failure from encoder 52
5.3.3 Alarm 30 - BCU pickup 1 failure 53
5.3.4 Alarm 31 - Trigger signal failure from encoder 54
5.3.5 Alarm 33-Engine stop signal failure 54
5.3.6 Alarm 34 - LCD signal abnormal 55
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5.3.7 Alarm 35 - BCU alive signal missing 55

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5.3.8 Alarm 36 - Astern signal abnormal 55

5.3.9 Alarm 37 - Prelubrication signal abnormal 55
5.3.10 Alarm 38 - Oil temperature high 55
5.3.11 Alarm 39 - Oil pressure low 56

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Table of Contents

Alpha Lubricator System

Page
5.3.12 Alarm 40 - Speed deviation alarm 56
5.3.13 Alarm 41 - Index transmitter abnormal 56
5.3.14 Alarm 42 - Cable failure index transmitter 56
5.3.15 Alarm 43 - BCU pickup 2 failure 56
5.3.16 Alarm 44 - BCU in control 57
5.3.17 Alarm 45 and 46 - Thermal overload electric motor 57
5.3.18 Alarm 47 - MCU parameter list not loaded 57
5.3.19 Alarm 48 - Angle deviation fail 57
5.3.20 Alarm 49 - Stand-by pump is running 57
5.4 BCU alarms 58
5.4.1 Led # 1 BCU internal failure 58
5.4.2 Led # 2 Engine stop signal failure 58
5.4.3 Led # 3 MCU alive signal missing 59
5.4.4 Led # 4 Feedback signal missing on two lubricators 59
5.4.5 Led # 5 Feedback signal missing one lubricator 60
5.4.6 Led # 6 BCU marker signal 1 and 2 missing 60
5.4.7 Led # 7 and 8 BCU marker signal 1 or 2 missing 60
5.5 Emergency running without external trigger signals 61
5.6 Sequence diagram for alarm handling 63

Appendix 1
Function of the LEDs in the Intermediate Box 65
Appendix 2
Control Unit Cylinder Lubrication - Logic Diagram 66
Appendix 3
Replacement of MCU, BCU, SBU Boards 75
Appendix 4
Cylinder oil feed rate during running-in 77
Appendix 5
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ALCU signal description 84

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Appendix 6
Back-up Control Unit 88

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List of Abbreviations:

Alpha Lubricator System

This is a list of abbreviations used in this manual.

AC Alternating Current

ACC Adaptive Cylinder oil Control

ALCU Alpha Lubricator Control Unit

AMS Engine alarm System

BCU Backup Control Unit

DC Direct Current

ECR Engine Control Room

FBU Fuse Board Unit

FPGA Fast Programmable Graphic Array

HMI Human Machine Interface

IC Integrated Circuit

Lcd Load change dependent

LED Light Emitting Diode

MCU Master Control Unit

MEP Mean Effective Pressure

PCB Printed Circuit Board

RPM Revolutions Per Minute

SBU Switch Board Unit

TDC Top Dead Centre

UPS Uninterruptable Power Supply

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1. General Information

Alpha Lubricator System

1.1 Main components

The Alpha Lubricator System Layout is shown in the diagram below: Alpha Lu-
bricator System Layout

TANK
LUBRICATOR

3045-0110-0001.1

HMI
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707-X01 40C 01B

ALCU
Description

PUMP
STATION Pipe System
Electrical Connection

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Pump station and starter panels

Alpha Lubricator System

The pump station consists of two individu-

ally operating pumps, heating coil, filters
and a suction tank. The power supply to
the pump station starter panels is taken
from two separate circuit breakers, one
supplying each pump.

For further information, see Maker’s pump

station manual.

Lubricator units

The lubricator units, one for each cylin-

der, each comprise two lubricators for
98-70 bore engines and one lubricator for
medium and small bore engines. Each lu-
bricator unit is equipped with one accu-
mulator with nitrogen pre-pressure of 25-
30 baron the inlet side, and one accumu-

707X03 40C 01
lator on the outlet side of each lubricator,
with nitrogen pre-pressure of 1.5 bar.

Each lubricator features 3, 4, 5 or 6 lubri-

cating pistons, depending on engine type,
a feedback pickup and a solenoid valve.

One-lubricator unit Two-lubricator unit

XZ707.40A 02

XZ707.40A
XZ707.40A 03 03
XZ707.40A02

Alpha lubricator control unit - ALCU

3045-0110-0001.1

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The three main electronic components for controlling the lubricating oil are com-
prised in one steel cabinet -the so-called ALCU unit.
Description

The three units are: MCU (Master Control Unit)

BCU (Backup Control Unit)
SBU (Switch Board Unit)

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 MAN Diesel 3045-0110-0001.1

A terminal block interfaces all electrical connections to the engine.

Alpha Lubricator System

MCU

SBU

BCU
707-X01 40C 11

The 24 V DC power is supplied from two individual power sources, from different
breakers in the UPS unit. Please note that some installations might be connected
differently by the shipyard.

Load transmitter

The load transmitter is connected to the fuel

rack, thereby continuously transmitting the fuel
index % to the MCU, which calculates the en-
gine load from this information and the detected
engine rpm.
XZ707.40B 05

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Description

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Trigger system (Shaft encoder)

Alpha Lubricator System

The shaft encoder is connected to the fore

end of the crankshaft, and the signals are
transmitted to the computer panels via a
terminal box. For engines on which the
crankshaft fore end is not available for angle
encoder installation, a trigger ring and tacho
pickups are installed at the turning wheel.

XZ707.40A 05
Backup trigger system

XZ707.40A05
The backup trigger system comprises two
tacho pickups in a box at the turning wheel,
thereby transmitting the engine rpm to the
BCU. The backup pickups are also connect-
ed to the MCU for surveillance purposes.

Human Machine Interface (HMI) panel

On the HMI panel, individual cylinder lu-

brication adjustment is possible, various
values and alarms are displayed, control
XZ707.40B 07
buttons for the pump station are available,
and manual execution of prelubrication is
possible.

As standard the HMI-panel is mounted in the engine control room.

"#5æINæ#TRL
 æ

%NGINEæSPEED

 æ

)NDEX

,UBRICATION

ª# RPM

K.M 

!UTO -#5 "#5    

BHP BAR
/ILæPRESSæLOW

)NDEXæFAILURE

-ARKTRIGæFAIL

&EEDBACKæFAIL

#OMMONæALARM

,!-04%34 %#3 %.4%2

3045-0110-0001D13

05-0æ 05-0æ 02%,5"

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1.2 Working principle

Description

• The pump station supplies the Alpha Lubricators with 40-50 bar oil pres-
sure.
• The MCU controls the oil injection by activating a solenoid valve situated
on the relevant lubricator.

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• A feedback signal from each lubricator indicates that oil injection has

Alpha Lubricator System

taken place. This is shown by Light Emitting Diodes (LEDs) on intermedi-
ate boxes for each cylinder.

• Timing is based on two signals from the angle encoder, a TDC cyl. 1
marker and a crankshaft position trigger. The Alpha Lubricator system is
normally timed to inject cyl. oil into the piston ring pack during the com-
pression stroke.

• The cylinder lubrication is based on a constant amount of oil being sup-

plied per injection. The specific feed rate is controlled by variation of the
injection frequency.

• The injection frequency is calculated from index and speed, and is nor-
mally proportional to the engine MEP. However, a power Mode or RPM
Mode is possible.

• The basic cylinder oil feed rate at MCR (100%) is calculated as a correla-
tion between a number of injections / rpm and the stroke of the lubrica-
tors.

• On the HMI panel, adjustment of lubrication feed rate for individual cylin-
ders is possible between 60% and 200%. Default value is 100%.

• During normal operation the system is controlled by the MCU. If any fail-
ures are detected in the system, a common alarm is activated in the con-
trol room. The detailed alarm reference is displayed on the HMI panel.

• If a critical failure in the MCU is detected, the BCU automatically takes

over (Note - control switch must be in “auto” position). An indication
lamp “BCU in control” is lit on the panel that contains the HMI panel.
Note that on older installations, the indication lamps can be situated
elsewhere.

• The BCU is based on random timing and RPM Mode. The injection fre-
quency is adjustable on the BCU and is normally, as minimum, set to the
basic cylinder oil feed rate for the engine, plus 50%.

1.3 Guidance values automation

Cylinder Lub. Oil Pressure Cylinder Lub. Oil Temperature

Normal Service Value 40 - 50 bar Normal Service Value 30 - 60° C
Alarm min. 35 bar Alarm max. 70° C
Alarm max. 60 bar
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2. Operation of the System

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2.1 HMI-Panel / Operating Panel

Description

1. As standard, the HMI panel (for description, see Section 3), a three-posi-
tion mode switch, and an indicator lamp are mounted in the engine con-
trol room.

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However, an additional HMI panel, etc. can, as an option, be installed in

Alpha Lubricator System

one of the pump station starter panels. In this case a local/remote switch
has to be installed.

The three-position mode switch enables selection between

• Auto-mode - BCU takes over automatically, if lubrication cannot be

maintained by the MCU. If the BCU has taken over the control, this
mode can only be cleared by manually switching to MCU-mode, and
back to Auto-position.

• MCU-mode - Forced MCU control.

• BCU-mode - Forced BCU is in control.

2. An orange Indicator lamp - Indicates that BCU is in control.

2.2 Control buttons and indicator lamps on pump station starter panels

Each starter panel contains the following switches, buttons and lamps:

1. A three-position switch controls the pump activity as follows:

• REM.(Remote) - Automatic control of pumps (normal working posi-

tion)

• LOC.(Local) - Manual start of the pump

• OFF - Manual stop of pump.

2. A two-position main switch - Switches off 3 x 440 V AC power supply.

3. A green indicator lamp - lights if pump is running.

4. A white indicator lamp - lights if 3 x 440 V AC from fuse panels is

switched ON.

2.3 Start-up of Alpha Lubricator System (Engine not running)

1. To fill the pump station with cylinder oil, open the valves for the cylinder
oil supply line and the venting cock (if installed). Close the venting cock
when cylinder oil flows out into the venting line.

2. Switch on the main switches on the pump station starter panels.

3. Switch to “Local” and manually start pump 1 and subsequently pump 2.

Check that both pumps can run simultaneously.
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4. Check that the pressure differential indicator on the pump station filter is
green, when one pump is operating.
Description

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 MAN Diesel 3045-0110-0001.1

5. Check that the oil pressure

Alpha Lubricator System

builds up to 40-50 bar, or carry
out adjustment on the pres-
sure control valve on top of the
pump station.

Check that the pressure re-

mains at an acceptable level,
also with two pumps running.

XZ707.40A 08
6. Press [esc] and [prelub] at the
same time on the HMI panel to
activate the test sequence, and
check that all lubricators are
operating correctly by watching
the LEDs (feedback signals) on
the intermediate boxes for each
lubricator.

Stop the test sequence by

pressing [prelub] again.
NA903-2.1 225 02

At commissioning or after
overhaul of the system, check
visually from the scavenge
air receiver that all non-return
valves inject cylinder oil into the
cylinder liners.

7. Stop the pumps manually, and switch to “Remote” on the starter panels.
The Alpha Lubricator System is now ready for normal operation.

8. For engineers commissioning the Alpha Lubrication System, procedures

are made for Testbed Commissioning and Dock Trial Commissioning.
The procedures are shown in the Commissioning chapter. For flushing
the system, please read special instruction.

2.4 Checks during start-up of the engine

1. Upon start of the engine’s auxiliary blowers, the Alpha Lubricator Sys-
tem is programmed to carry out automatic prelubrication. The pump sta-
tion will automatically stop if the engine is not started shortly after.

2. Check that the pump station automatically starts up when the engine is
started, and that the cyl. oil pressure builds up to 40-50 bar.

3. Check that all the green LEDs flash on the intermediate boxes for each
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lubricator.
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4. Check that no alarm is detected in the control room and on the HMI
Description

panel.

5. Start of engines under cold conditions occasionally results in feed-back

failures.

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3045-0110-0001.1 MAN Diesel

In order to prevent this, the circulation of the cylinder oil in the main
Alpha Lubricator System

pipes under these cold conditions is improved by introducing a manu-

ally-operated by-pass valve provided in the opposite end of the lube oil
inlet.

This by-pass valve is only introduced on engines with two lubricators per
cylinder.

On engines with one lubricator per cylinder, the valve on the cylinder
block intended for emptying the accumulator at overhaul can also be
used as a by-pass valve.

The main purpose of the new by-pass valve is to heat up the pipes by
circulating the cylinder oil in the main pipes with open by-pass valve be-
fore engine start. The valve is to be closed just before engine start.

2.5 Periodic checks during normal operation of the engine

1. Check that all lubricating points supply oil by:

a) inspecting that all LEDs for feedback indication on the intermediate

boxes are flashing

b) feeling the pressure shocks from injection of the lubricators on each

lubricator pipe. If in doubt, dismantle the pipe at the cylinder liner to
observe the oil flow.

2. Inspect the local oil pressure gauge on the pump station. Normal service
value = 40-50 bar.

3. Check for oil leakages in the system.

3. HMI-Panel and Configuration of MCU

3.1 Description of HMI Panel

Bar graphs

The two upper bar graphs display relative values in percent of engine speed and
fuel index (≈ mep%), respectively. The range is from 0 to 120 percent, where 100
percent corresponds to the physical values at MCR. The third upper bar graph
displays oil pressure in the range of 0 to 100 bar.

Fault category indicators

Five LEDs for indication of fault category are placed below the numerical display,
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as follows:
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• Oil pressure low

Description

• Fuel index failure

• Marker/Trigger failure

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 MAN Diesel 3045-0110-0001.1

• Feedback failure

Alpha Lubricator System

• Common alarm -
For explanation of the alarm code, see the alarm list in Section 5.

Buttons

[ p ] Move up in the HMI panel menu structure. See item 3.2.9.

[ q ] Move down in the HMI panel menu structure. See item 3.2.9.

[esc] Move to the left in the HMI panel menu structure.

See item 3.2.9.

[enter] Move to the right in the HMI panel menu structure.

See item 3.2.9.

[lamptest] All lamps are lit in the HMI panel.

[pump1] Starts or stops booster pump 1.

[pump2] Starts or stops booster pump 2.

[prelub] Can only be activated when engine is stopped. Activates prelubrica-

tion sequence.
The lubricators will be activated continuously from Lubricator 1A, 1B,
2A,... 14B. The cycles will be repeated a pre-programmed number of
times (normally 12).

[esc] + [prelub] Starts test sequence of 1000 pre lubrications. The test se-
quence is stopped by pressing [prelub] again.

[esc] + [pump1] Selects default booster pump to be pump 1.

[esc] + [pump2] Selects default booster pump to be pump 2.

3.2 HMI-Panel operation and configuration of MCU

This section describes the menu system in the HMI-panel numerical display. Six
of the most common manoeuvres are described below and the complete struc-
ture and parameters are shown in items 3.2.9 and 3.2.10.

3.2.1 Navigation HMI panel menu system is a hierarchic menu system. The following four buttons
principle are used to navigate through the menu system.

[ p ] Move up in the HMI panel menu structure. See item 3.2.9.

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[ q ] Move down in the HMI panel menu structure. See item 3.2.9.
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[esc] Move to the left in the HMI panel menu structure. See item 3.2.9.
Description

[enter] Move to the right in the HMI panel menu structure. See item 3.2.9.

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3.2.2 Reading of Press [ p ] or [ q ] until rXXX is shown in the display (Note that this value is an
Alpha Lubricator System

total stroke/min average value over 1 min.).

[rXXX]

3.2.3 Reading of 1. Press[ p ] or [ q ] until

total strokes [Str. diSP is shown in the dis-
hi] and [Str.lo] play.
Str. hi
2. Press [enter] and [ p ] or xxxxx
Str. lo
[ q ] until Str.hi or Str.lo is
shown in the display. diSP

3. Press [enter] to read the stroke counter.

4. Press [esc] to return to main menu (one press [esc] = one step back-
wards).

5. The total number of strokes is a ten digit number and is obtained by

combining the values of Str.hi and Str.lo as follows:

The value of Str.lo represents the five rightmost figures and the value of
Str.hi the five leftmost figures.

Example:

Str. hi Str. lo
707-X10 40C 3235

Total number
of strokes = 12345 67890 =1234567890

The total stroke amount is used to calculate the amount of cylinder lube oil used
within a specified amount of time. The following formula can be used:

See example on page 31 (str.hi).

3.2.4 Reading of Press [ p ] or [ q ] until ALRXX is shown in the display.

ALRXX
707-10 40C 323

active alarms [AL- For explanation of the alarm code see the alarm list in Section 5.
RXX]

3.2.5 Reading 1. Press [ p ] or [ q ] until LALxx is shown in the display.

of logged alarms For explanation of the alarm code see the alarm list in Section 5.
[LALXX]
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2. To clear a logged alarm, press [enter] when the alarm is shown in the dis-
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play. To clear all logged alarms, press [enter] for 5 seconds while an LALxx
is shown in the display.
Description

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 MAN Diesel 3045-0110-0001.1

3.2.6 Adjustment The feed rate is entered in the

Alpha Lubricator System

of cylinder oil feed HMI panel as a percent value.
rate [F.rAtE] Cyl.xx xxxxx
- For systems with MEP
regulation, 100% feed
rate setting normally cor-
Cyl.1

707-10 40C 324

responds to the basic
setting with reference to SEt.Al
service letters and general F.rAtE
guidelines for cylinder lu-
brication.

For systems with Alpha ACC (Adaptive Cylinder oil Control) the feed rate is set
proportionally to the sulphur content in the fuel oil. The feed rate setting percent-
age can be obtained from the regulation plates.

Reference is made to all time latest service letter concerning cylinder condition.
An example is given in appendix 4.

1. Press [ p ] or [ q ] until F.rAtE is shown on the display.

2. Press [enter] and [cyl1] is shown on the display.

3. Press [ p ] or [ q ] until the cylinder to be adjusted is shown or select SEt.

Al to set all the cylinders to the same value.

4. Press [enter] and the current feed rate is shown. Please note that if SEt.
Al was selected the value shown is the last value saved in SEt.Al, and
this value is not true if any cylinder has been individually adjusted since.

5. Press [ p ] or [ q ] - The oil feed rate can be changed to the desired

value between 60 and 200%.

6. Press [enter] - The value is stored in the computer memory, and the main
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display will prompt with “Save”.

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7. Press [esc] three times to return to main menu.

Description

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3.2.7 Monthly 1. Check which pump is running (1 or 2)

Alpha Lubricator System

change of operat-
ing pumps (master 2. Press [esc] + [pump 1] or [pump 2] (pump not running).
pump)
3. New master pump is now chosen and running.

3.2.8 Test se- 1. Press [esc] + [prelub] simultaneously

quence for inspec- (the lubricators will lubricate 1000 times).
tion during stand-
still 2. Press [prelub] the test sequence will stop.

3.2.9 Menu struc- The following pages show how to navigate in the HMI-panel menu structure.
ture
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Description

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 MAN Diesel 3045-0110-0001.1

Alpha Lubricator HMI Panel menu structure - part 1

Alpha Lubricator System

Menu navigation :

up = [?
] down = [?
] right = [ENTER] left = [ESC]

n [rpm] CYL. XX XXX

(engine speed) .. press "? 
? " to change
.. press "ENTER" to SAVE

MEP [%] CYL. 1

(mean efficient SEt.Al
pressure) (set all cylinders)
pOil [bar]
(norm. 40-50 bar)
(alarm 35 bar) 5 XXXXX
Str.hi [strokes* 1*10 ]
toil [°C] (total lubricator stroke counter)
5 9
(norm 40-60 °C) (5 highest digits, 1*10 - 1*10 )
(alarm 70 °C) Str.Lo XXXXX
r XXX (total lubricator stroke counter)
(total stroke/min) (5 lowest digits, 0-99999)

Lub XX XXX [ms]

Lcd X ..
(LCD status) t.dLy [ms] ..
(0=0ff, 1=on) (delay from activation of solenoid valve Lub. 1
to feedback signal)
ALR XX
(active alarms)
(see alarm list) Lub XX XXX [°]
LAL XX ..
(logged alarms) A.inJ [°] ..
clear = [ENTER] (crank angle for oil injection) Lub. 1
F.rAtE
(feed rate adj.) in.A [mA]
(index transmitter raw value) XXX [mA]
diSP
(display menu) tELE.P [%]
(telegraph position scaled value)

tEcH SoFt
(technical parameters, advanced (MCU software revision number)
parameters)

FPgA
(FPGA software revision number)

Connt Par.Ch
(connection test (MCU program parameter check sum)
menu)

SEtuP Par
(setup menu) (read out of all setup parameters)
(MBD Service)

Sol.t Lub XX oFF / on

(solenoid valve test - manual
manuel activation
activation .. [? ] [? ] toggles
3045-0110-0001.1

of solenoid valves)
.. value
Co.ALr Lub. 1
2008-12-12

A activation
(manuel
(manual activation of MCU common
alarm output - MCU J32 terminal 1,2)
oFF / on
Description

Cr.Ang [°] [? ] [? ] toggles

(crank angle. only valid after turning value
one revolution ahead)

XXX [°]

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3045-0110-0001.1 MAN Diesel

Alpha Lubricator HMI Panel - menu structure - part 2, setup menu

Alpha Lubricator System

n [rpm] PASS ProP Menu navigation

(engine speed) password = (propeller, adjustment in case press "? 
? " to select
"[? ] [? ] [ESC] [ENTER] of propeller curve) press "ENTER" to SAVE

MEP [%] gEn 50 [%]

(mean efficient (generator, adjustment in case (to be selected at 50 % load)
pressure) of generator curve)
in.AdJ
pOil [bar] (index transmitter adjustment vALue 100 [%]
menu) (manuel
(norm. 40-50 bar) (manual correction
correction of
of values)
values) (to be pressed at 100 % load)
(alarm 35 bar)

toil [°C]
(norm 40-60 °C)
(alarm 70 °C)
in.hi [%]
r XXX (index high, theoretical index
(total stroke/min) % at 20mA)

ti.Adj inJ.oF [°] in.Lo [%]

Lcd X (injection timing adjustment (injection offset, common (index low, theoretical index
menu) angle offset for all cylinders) % at 4mA)
(LCD status)
(0=0ff, 1=on) hY.dEL [ms]
ALR XX (hydraulic delay, common
time offset for all cylinders)
(active alarms) XXX
(see alarm list) press "? 
? " to change
press "ENTER" to SAVE
LAL XX
(logged alarms) P.6
clear = [ENTER] (telegraph signal scale)
(0-200 %)
F.rAtE XXX
(feed rate adj.) P.5 press "? 
? " to change
(LCD factor) press "ENTER" to SAVE
(norm 125 %)
diSP
(display menu) P.4
(holding time) Menu navigation
(norm 30 min.)
Connt press "? 
? " to select
press "ENTER" to SAVE
(connection test LCd P.3
menu) (load change dependent (average time) tELE.P
lubrication adj. menu) (norm 10 sec.)
SEtuP (telegraph position, analog
(setup menu) P.2 signal from governor)
(MBD Service) (deviation %) E.Sig
(norm. 10 %) (external signal, LCD start
controlled externally)
P.1
inJ.AL (LCD mode) E.FL
(injection amount algorithm (norm. E.FL) (external flag, start and
menu)(norm. po) duration controlled ext.)

FE.AD int.
(feed rate regulation Menu navigation (internal, LCD controlled
parameter adjustment) internally)
press "? 
? " to select
press "ENTER" to SAVE
n.PrL on
(number of pre-lubrications) Po. underneath (permanent on)
(For Test Only)
(power proportional feed rate
calculation)
r.run oFF
(rpm run adjustment) rPnn (permanent off)
(rpm proportional feed rate
calculation)
Ang.dE
(angle deviation limit bet. nnep
MCU and BCU tacho)
(MEP, mean efficient pressure
prop. feed rate calc..)
Pu
3045-0110-0001.1

(booster pump mode

adjustment)
2008-12-12

Str.hi
(total lubricator stroke counter
Description

adjustment)

Str.Lo
(total lubricator stroke counter
adjustment, )

Par
('raw' adjustment out of all
setup parameters)

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 MAN Diesel 3045-0110-0001.1

Alpha Lubricator HMI Panel - menu structure - part 3, setup menu

Alpha Lubricator System

n [rpm] PASS rE.inj [rev./injection] XXX
(engine speed) password = (revolutions per injection at press "? 
? " to change
"[? ] [? ] [ESC] [ENTER]" 100 %, norm. 2 to 6) press "ENTER" to SAVE

MEP [%] nor.hi [%]

(mean efficient (upper limit for LCD extra
pressure) lubrication, norm 150)
in.AdJ
pOil [bar] (index transmitter adjustment nne.Li [%]
menu) (mep relative limit)
(norm. 40-50 bar)
(alarm 35 bar) (norm. 63)
ti.Adj
toil [°C] (injection timing adjustment Po.Li [%]
menu) (power relative limit)
(norm 40-60 °C)
(alarm 70 °C) (norm. 40)
LCd
r XXX (load change dependent AbS.Lo [%]
(total stroke/min) lubrication adj. menu) (absolute low limit)
norm. 40)
inJ.AL
Lcd X (injection amount algorithm F.SCuF [%]
menu)
(LCD status) (extra feed rate for scuffing)
(0=0ff, 1=on) (norm. 200)
FE.AD
ALR XX (feed rate regulation F.hi [%]
parameter adjustment)
(active alarms) (feed rate setting high limit)
(see alarm list) (norm. 200)

LAL XX F.Lo [%]

(logged alarms) (feed rate setting low limit)
clear = [ENTER] (norm. 50)

F.rAtE Ser.hi [%]

(feed rate adj.) (level for change to 'manuel
extra lubr.', norm. 199)

diSP n.PrL
(display menu) (number of pre-lubrications)
(norm. 12)

Connt r.run [rpm]

(connection test (rpm run adjustment)
menu) (norm. 5)

SEtuP Ang.dE [°] XXX

(setup menu) (angle deviation limit bet. press "? 
? " to change
(MBD Service) MCU / BCU tacho, norm. 3) press "ENTER" to SAVE

Pu Pu.SEt Menu navigation

(booster pump mode (pump mode setup) press "? ?
" to select
adjustment) (norm. bacup) press "ENTER" to SAVE

Auto
(change master with interval
of Pu.int )

bacup
(backup mode, fixed master
pump)
Pu.dEF
(default pump selection, pump
1 or 2)(norm. 1)
Str.hi
(total lubricator stroke counter Pu.int [hour] XXX
adjustment) (pump interval time) press "? 
? " to change
(norm. 12) press "ENTER" to SAVE
Str.Lo
(total lubricator stroke counter
adjustment, )

Par XXX
3045-0110-0001.1

('raw' adjustment of all setup press "? 

? " to change
parameters) press "ENTER" to SAVE
2008-12-12

Description

PASS XXX XXX

password = " to select
press "? ? press "? 
? " to change
"[ESC] [?
 ] [?
 ] [ENTER]" parameter number press "ENTER" to SAVE

Caution !
Adjusting of the values in the "Par" menu may cause damage to the
engine and should be done by authorised personnel only

Doc-ID: 3045-0110-0001.1 23 (90)

3045-0110-0001.1 MAN Diesel

3.2.10 HMI panel parameter reference list

Alpha Lubricator System

A.inJ [°] (abbr. of angle injection)

The specific crank angles for oil injection for each lubricator. Normally it is the
crank angle at the point where No. 1 piston ring passes the oil quills on the up-
ward stroke of the piston.

The number consists of an online measurement of the angle for the first flank of
the feedback signal plus the angle corresponding to the hydraulic delay time.
Only active when engine is running ahead. Normal value for cylinder one is around
270 to 310°.

AbS.Lo [%] (abbr. of absolute low)

Absolute minimum reduction percentage. The injection frequency can be re-

duced to the value of AbS.Lo in % of the basic frequency. The basic frequency is
the frequency at 100 % load, 100 % rpm, 100 % feed rate setting and is defined
as 1/rE.inj

Example:

Maximum number of revolutions between injections = 10 revolutions =>

1 1
minimum injection frequency   
max. nos. of rev between injections 10

 0.1;inj / rev=
1 1
rE.inj = 4 revolutions => basic frequency    0.25 ;inj / rev =
rE .inJ 4

minimum injection frequency 0.1

AbS.Lo =   0.40  40%
basic frequency 0.25

The normal maximum number of revolutions between injections is 15.

ALR XX (abbr. of alarm XX)

Code number for active alarms, where the number ‘XX’ represents the alarm
code. For explanation of the alarm code see the alarm list in Section 5.

Ang.dE (abbr. of angle deviation)

3045-0110-0001.1

The Maximum allowable angle difference between the marker signal (TDC signal)
2008-12-12

from the encoder (or trigger ring) and the marker signal from the BCU pickups.
Only valid when engine is running ahead. Normal value is 2 degrees.
Description

Co.ALr (abbr. of common alarm)

Manual activation of the MCU common alarm output.

ALCU/x1:1, ALCU x1:2 (MCU/J32:1, MCJ/J32:2), dry contact, normally closed.

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 MAN Diesel 3045-0110-0001.1

Connt (abbr. of connection test)

Alpha Lubricator System

Connection test menu. Blocked when the engine is running.

Cr.Ang [°] (abbr. of crank angle)

Indication of actual crank angle from the shaft encoder. Blocked when the engine
is running. Only valid when continuously turned in same direction by turning gear
and after having passed TDC cyl. 1. The indication is sensitive to rocking motion
and should therefore only be used as an indication.

diSP (abbr. of display)

Display menu. Values and parameters are displayed, but cannot be changed
from diSP menu.

F.hi [%] (abbr. of feed rate high)

Feed rate setting high limit. The maximum possible feed rate setting on the HMI
panel. The value is a percentage of the basic recommended feed rate setting.
Normal value is 200 %.

F.Lo [%] (abbr. of feed rate low)

Feed rate setting low limit. The minimum possible feed rate setting on the HMI
panel. The value is a percentage of the basic recommended feed rate setting.
Normal value is 50%.

F.rAtE (abbr. of feed rate)

Feed rate setting adjustment. The feed rate can be adjusted individually for each
cylinder or for all cylinders at one time with the SEt.Al function. Please note that
the value shown when entering the SEt.Al menu is the last value saved in the
SEt.Al menu. Thus if the cylinders have been adjusted individually since, the value
shown when entering the SEt.Al function is no longer true for all cylinders.

100 % feed rate setting normally corresponds to basic setting. (Reference is ma­
de to the guidelines for cylinder lubrication)

F.SCuF [%] (option) (abbr. of feed rate scuffing)

Feed rate increase in case of scuffing. Input for each cylinder on the MCU board
can receive signal from a cylinder liner temperature monitoring system. If begin-
ning scuffing is detected, a signal can be given and extra lubrication activated.
Please contact MAN B&W if this function is needed. Normal value is 200 %

FE.AD (abbr. of feed rate adjustment)

3045-0110-0001.1
2008-12-12

Feed rate regulation parameter adjustment menu.

Description

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3045-0110-0001.1 MAN Diesel

FPgA (abbr. of fast programmable graphic array)

Alpha Lubricator System

FPGA software revision number. The IC (Integrated Circuit) (u33) contains the
program for the FPGA. If the FPGA code is updated, a new IC will have to be
installed. The current FPGA software revision is 7.

gEn (abbr. of generator)

Load transmitter calibration menu for generator curve running. When the engine
is running 50 % load and 100 % load (with reference to testbed results), enter the
menu by pressing [enter] and choose the correct engine load (50 % or 100 %)
followed by pressing [enter]. The program will respond with donE.

hY.dEL [ms] (abbr. of hydraulic delay)

Hydraulic delay (time offset value). The value is inserted to compensate for the
time-delay from the first flank of the feedback signal, until the oil enters the cylin-
der through the cylinder liner non-return valves. The longer the hydraulic delay -
the earlier the solenoid valve is activated. The Hydraulic delay is calculated in the
design process and is confirmed by measurements on prototype engines. A good
estimate of the value is 1 ms for each meter pipe length from the lubricator to the
cylinder liner. The value cannot be adjusted individually for each cylinder, but is
common for all cylinders. Normally values are from 1 to 6 ms.

in.A [mA] (abbr. of index ampere)

Read out of the index transmitter current. The mA signal from the index trans-
mitter without scaling. Used for mechanical adjustment of the index transmitter
during commissioning. The index transmitter is adjusted to 4.5 mA at mechanical
minimum index and to 19.5 mA at mechanical maximum index. The adjustment
is made on testbed before initial start up.

in.AdJ (abbr. of index adjustment)

Index transmitter adjustment/calibration menu. The adjustment is done during

running at testbed, at 50 % load and at 100 % load. Choose between propel-
ler curve (ProP) or generator curve (gEn). Select the load percentage (50 % or
100 %) corresponding to the actual load. Press [enter] and the system replies
donE. Afterwards press [esc] 4 times until you are back in the main menu show-
ing RPM. The system has now been calibrated. Use the vALue menu if manual
correction of the parameters is necessary.

in.hi [%] (abbr. of index high)

Index transmitter raw calibration value. The index transmitter calibration values
are given as an index low (in.Lo) value and an index high (in.hi) value. These
values are the theoretical index percentages when the pickup gives respectively
3045-0110-0001.1

4 and 20mA. Estimated values are pre-programmed from MAN B&W, and the
2008-12-12

system is calibrated by means of the (ProP) or (gEn) menus on testbed. The raw
values should only be changed if the automatic calibration in the ProP and gEn
Description

menus, proves insufficient.

The values are normally around -30 to -10 for [in.Lo] and around 125 to 140 for
[in.hi].

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 MAN Diesel 3045-0110-0001.1

in.Lo [%] (abbr. of index low)

Alpha Lubricator System

See in.hi.

inJ.AL (abbr. of injection algorithm)

Injection amount algorithm menu. Injection rate calculation can be chosen in pro-
portion to mean efficient pressure (nneP), rpm (rPnn) or power (Po.). Normal mode
is power Po proportional.

inJ.oF [°] (abbr. of injection offset)

Injection offset. Angle offset inserted to compensate for small deviations between
the injection angle determined in the design process and the actual crank angle
for injection. The actual crank angle for injection is normally when the first piston
ring passes the oil quill during the upward stroke of the piston. inJ.oF can be
adjusted within +/– 5 °.

The value cannot be adjusted individually for each cylinder, but is common for
all cylinders.
Normal value is 0.

LALXX (abbr. of logged alarm XX)

Logged alarms where the number ‘XX’ represents the alarm code. When an alarm
is activated, it will appear as both ALRXX and LALXX. The LALXX will remain
after the alarm is gone. For explanation of the alarm code see the alarm list in Sec-
tion 5.

To clear a logged alarm press [enter] while the alarm code is displayed. To clear
all logged alarms press [enter] for 5 seconds while one of the alarm codes is
displayed.

Lcd X (abbr. of load change dependent X)

Load change dependent extra lubrication status. X indicates the status. When
LCD is active, i.e. when a load change situation occurs, the status changes from
0 (=off) to 1 (=on). The normal hold time is 30 min.

Lcd (abbr. of load change dependent)

Load change dependent extra lubrication parameter adjustment menu. Six pa-
rameters, P1 to P6, can be adjusted. For further explanation see P1 to P6.

MEP [%] (abbr. of mean efficient pressure)

Mean effective pressure percentage (equal to torque percentage and index per-
3045-0110-0001.1

centage). Scaled read out of the index transmitter input. The value is used for the
2008-12-12

amount regulation. When generator curve running the value is equal to the load
percentage. When ideal propeller curve running normal values are: 25 % load =
Description

40 % MEP, 50 % load = 63 % MEP, 75 % load = 82 % MEP, 100 % load = 100 %

MEP. The value changes according to the propeller margin.

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3045-0110-0001.1 MAN Diesel

n [rpm] (abbr. of speed)

Alpha Lubricator System

Engine speed.

n.PrL (abbr. of number prelubrications)

Number of prelubrications. Number of prelubrication sequences carried out when

signal is given to ALCU/X1:25, ALCU/X1:26 (MCU/J30:7, M CU/J30:8) or [PRELUB.]
button in HMI panel is pressed. Only active when the engine stopped.
Normal value is 12.

nne.Li [%] (abbr. of MEP limit)

MEP relative limit. Only used when inJ.AL is set to nnep. Minimum relative re-
duction percentage for the MEP dependent amount regulation. The parameter
is used for defining the level where the algorithm changes from MEP dependent
regulation to RPM dependent regulation. The parameter is relative i.e. the load
point of change is independent of the feed rate setting.

Example 1 (propeller curve running):

Desired: Change to RPM dependent lubrication under 25 % load.

Conditions at change point: Load % = 25 % propeller curve ∼ MEP % =

= 40 % ∼ RPM % = 63 %.
MEP% × 100 40% × 100
nne.Li = = = 63%
RPM % 63%
Example 2 (generator curve running):

Desired: Change to RPM dependent lubrication under 25 % load.

Conditions at change point: Load % = 25 % generator curve ∼ MEP % =

= 25 % ∼ RPM % = 100 %.

MEP % × 100 25% × 100

nne.Li = = = 25%
RPM % 100%

nor.hi [%] (abbr. of normal high)

Normal high limit. Upper limit for automatic extra lubrication (LCD).
Example: If the feed rate setting is set to 145 % and nor.hi is set to 150 %, the
3045-0110-0001.1

LCD function can only increase the feed rate from 145 % to 150 %.
2008-12-12

Normal value is 150 %

Description

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 MAN Diesel 3045-0110-0001.1

P.1 (abbr. of parameter 1)

Alpha Lubricator System

LCD mode. The following modes can be chosen:

oFF Off Permanent off - e.g. used for testing

on On Permanent on - e.g. used for testing
int. Internal All functions controlled internally by ALCU, based on index
deviation.
E.FL External Start and duration is controlled externally by binary input from
flag governor. Only amount is controlled by ALCU. Dry contact
from governor to ALCU/X2:1, ALCU/X2:2 (MCU/ J30:3, MCU/
J30:4)
E.Sig External Start is controlled externally by binary input from governor.
signal Duration and amount are controlled by ALCU. Dry contact
from governor to ALCU/X2:1, ALCU/X2:2 (MCU/ J30:3, MCU/
J30:4)
tELE.P Telegraph All functions controlled internally by ALCU based on analogue
position input from governor proportional to telegraph handle position.
4-20 mA signal from governor to ALCU/ X1:33, ALCU/X1:34
(MCU/J40:1, MCU/J40:3) Used in case of mechanical gover-
nor.

Normal mode is E.FL.

P.2 [%] (abbr. of parameter 2)

LCD deviation percentage. Used only when P.1 is set to int. or tELE.P. To activate
LCD, the index (or telegraph position in case of tELE.P mode) must change more
than the LCD deviation percentage (P.2) within the reset time (P.3).

Normal value is 10 % in case of internal mode (int.). Normal value in telegraph

position mode (tELE.P) is 2 % or a sufficient value to insure that the smallest step
on the telegraph handle (e.g. dead slow to slow) releases LCD.

P.3 [sec.] (abbr. of parameter 3)

Average time or more correct: reset time. Used only when P.1 is set to int. or
tELE.P. To activate LCD, the index (or telegraph position in case of tELE.P mode)
must change more than LCD deviation percentage (P.2) within the reset time
(P.3).
Normal value is 10 sec.

P.4 [min.] (abbr. of parameter 4)

Holding time. Used only when P.1 is set to int., E.Sig, or tELE.P. When the LCD
function is activated, it will remain active for a period of the holding time (P.4).
Normal value is 30 min.
3045-0110-0001.1
2008-12-12

Description

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3045-0110-0001.1 MAN Diesel

P.5 [%] (abbr. of parameter 5)

Alpha Lubricator System

LCD factor. When LCD is active the feed rate setting for each cylinder multiplied
by the LCD factor (P.5). When the LCD function is active, the injection algorithm
(inJ.AL) is set to RPM (rPnn).
Normal value is 125 %.

P.6 [%] (abbr. of parameter 6)

Telegraph signal scale (used in tELE.P mode only). Scale factor for the mA input
to terminals ALCU/X1:33, ALCU/X1:34 (MCU/J40:1, MCU/J40:3).

Examples:
1) If 4-20 mA corresponds to 0-100 % RPM, the value of P.6 should be 100 %.
2) If 4-20 mA corresponds to -100 to 100 % RPM, the value of P.6 should be
200%:
Normal value is 100 %.

Par (abbr. of parameter) (in diSP menu) (for MAN B&W service engineers)

‘Raw’ read out of all setup parameter values. The parameters are numbered 1
through 176. Please contact MAN B&W for further information.

Par (abbr. of parameter) (in SEtuP menu) (for MAN B&W service engineers)

Adjusting the values in the “Par” menu may cause damage to the engine
CAUTION and should be done by authorised personnel only.

‘Raw’ adjustment of setup parameters. The parameters are numbered 1 through

178. Please contact MAN B& W for further information.

The menu is entered in the following way:

1. Navigate through the SEtuP menu until Par is displayed on the HMI panel.

2. Press [enter] - the system will respond PASS.

3. Enter the password sequence: [esc] [p] [q] [enter]

4. Press ““p q”” to select parameter number.

Par.Ch (abbr. of parameter check)

MCU program code parameter check sum.

3045-0110-0001.1

PASS (abbr. of password)

2008-12-12

Password required. The menu you wish to enter is password protected to prevent
Description

access.

The password for the SEtuP menu is = [p] [p] [esc] [enter]

The password for the Par sub menu in the SEtuP menu is = [esc] [p] [q] [enter]

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 MAN Diesel 3045-0110-0001.1

Po.Li [%] (abbr. of power limit)

Alpha Lubricator System

Power relative limit. Only used when inJ.AL is set to Po. Minimum relative reduc-
tion percentage for the power dependent amount regulation. The parameter is
used for defining the level where the algorithm changes from power dependent
regulation to RPM dependent regulation. The parameter is relative, i.e. the load
point of change is independent of the feed rate setting.

Example 1 (propeller curve running):

Desired: Change to MEP dependent lubrication under 25 % load.

Conditions at change point:

Load % = 25 % propeller curve ^ MEP % = 40 % ^ RPM % = 63 %.

Load % r 100 25% r100

Po.Li    40%
RPM % 63%
Example 2 (generator curve running):

Desired: Change to MEP dependent lubrication under 25 % load.

Conditions at change point:

Load % = 25 % generator curve ^ MEP % = 25 % ^ RPM % = 100 %.

Load % r 100 25% r 100

Po. Li    25%
RPM % 100%

Normal value is 40 %.

pOil [bar] (abbr. of oil pressure)

Booster pump pressure.

Normal value is 40-50 bar.
Alarm level is 35 bar

ProP (abbr. of propeller)

Propeller curve index adjustment menu. Used for calibrating the index transmitter
during propeller curve running. Please note that load conditions must be similar
to testbed.

Pu (abbr. of pump)

Booster pump adjustment menu. The following parameters can be adjusted:

3045-0110-0001.1

Pu.SEt, Pu.dEF, Pu.int. For details see the respective parameters.

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Description

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3045-0110-0001.1 MAN Diesel

Pu.dEF (abbr. of pump default)

Alpha Lubricator System

Default pump selection. Used only when Pu.SEt is set to backup mode. If e.g. P1
is chosen, pump no. 2 will only start in case of low pressure alarm. The default
pump can also be chosen by “short cut” from the HMI panel by pressing [esc]
and [pump1] or [pump2] simultaneously.

Pu.int [hour] (abbr. of pump interval)

Pump interval time. Used only when Pu.SEt is set to Auto mode. After an interval
of Pu.int the master pump is automatically changed from pump 1 to 2 and vice
versa.
Normal value is 12.

Pu.SEt (abbr. of pump setup)

Pump mode setup. backup or Auto mode can be chosen. In backup mode the
master pump is selected manually by the operator by pressing [esc] and [pump X]
on the HMI panel. In Auto mode the master pump changes automatically after
an interval of Pu.int.
Normal value is backup.

r XXX (abbr. of rate xxx)

Strokes per minute. Read out of total number of lubricator strokes per minute for
the whole engine. The number is the average over one minute. The instant feed
rate can be calculated based on total strokes per minute:

Example:
3
Lubricator volume (compensated for volumetric efficiency 0.97) = 1.8 cm
(The value can be found on page 2 of the setup document enclosed with the
ALCU unit)
oil density = 0.94 kg/l
power = 70000 kw
r XXX = strokes per minute = 462

Feed rate ;g/kwh= 

; = ;
rXXX;stroke/min=r lubricator volume cm3 r oil density g/cm3 r 60 =
power ;kw =

Feed rate ;g/kwh= 

; = ; =
462;stroke/min= r 1.8 cm 3 r 0.94 g/cm 3 r 60
 0.65;g/kwh=
70000 ;kw=
3045-0110-0001.1

Please note that a much more accurate calculation can be made using
2008-12-12

the Str.hi and Str.Lo in the diSP menu.

Description

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 MAN Diesel 3045-0110-0001.1

rE.inj [revolutions] (abbr. of revolutions/injection)

Alpha Lubricator System

Revolutions per injection. The number of revolutions between oil injections on a
cylinder at 100 % load, 100 % rpm and 100 % feed rate setting. The parameter
has to be changed if the recommended basic setting of cylinder oil feed rate is
changed. Reference is made to our general guidelines for cylinder lubrication
and service letters.
Normal values are 2 to 6.

r.run [rpm] (abbr. of rpm run)

Rpm run. Engine run detection limit. When the engines rpm is above r.run, lubri-
cation will start and when rpm is below r.run lubrication will stop.

Please note that the parameter influences the alarm delays for the tacho system
and should therefore not be changed without consideration. Normal value is 8
rpm.

Ser.hi [%] (abbr. of service high)

Feed rate setting max. normal service. Only used when inJ.AL is set to nneP
or Po. If the feed rate is set above Ser.hi - the feed rate is set over the limit for
normal service lubrication. A feed rate setting over the limit for normal service
lubrication is per definition “manual extra lubrication”, i.e. used for breaking-in
new liners and rings. The feed rate calculation algorithm is therefore changed to
RPM dependent, disregarding the setting of inJ.AL. (Reference is made to the
guidelines for cylinder lubrication and service letters).
Normal value is 199 %.

SEtuP (abbr. of setup)

Setup menu. Values and parameters can be changed in the SEtuP menu. The
menu is password protected to prevent access.

The menu is entered in the following way:

1. Navigate through the outer menu level until SEtuP is shown in the display.

2. Press [enter] -the system will respond PASS.

3. Enter the password sequence: [p] [q] [esc] [enter]

4. Press ““p q”” to select the parameter you want to adjust.

SoFt (abbr. of software)

MCU software revision number.

3045-0110-0001.1

The current MCU software revision is 1.77

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Sol.t (abbr. of solenoid valve test)

Description

Solenoid valve test - Manual activation of solenoid valves. Blocked when the
engine is running.

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3045-0110-0001.1 MAN Diesel

Each solenoid valve can be activated in the following way:

Alpha Lubricator System

1. Enter the Sol.t menu

2. Choose the lubricator number by pressing the [p] and [q] key.

3. Select the lubricator by pressing [enter].

4. Press [p] to set lubricator on, press [q] to set lubricator off.

Str.hi [strokes* 105] (abbr. of stroke high) (in diSP menu)

Total lubricator stroke counter. The total number of solenoid valve activations
during the lifetime of the engine. The Str.hi menu shows the values from 105 to
109. The Str.Lo shows the values from 1 to 105.
The feed rate can be calculated based on the change of Str.Lo and Str.hi over
a period of time.

Example:
3
Lubricator volume (compensated for volumetric efficiency.) = 1.8 cm
(The value can be found on page 2 of the setup document enclosed with the
ALCU unit)
oil density = 0.94 kg/l
power = 70000 kw

Measurements at time = 00:00

Str.Lo = 11111
Str.hi = 12345

Measurements at time = 01:00

Str.Lo = 44444
Str.hi = 12345

Feed rate [g/kwh] =

(total stroke 2 - total stroke 1) r lubricator volume [cm 3 ] r oil density[g/cm3 ]

power [kw] r .(time 2 - time 1 [hour])

Feed rate [g/kwh] =

(1234544444 - 1234511111) r 1.8 [cm 3 ]r 0.94[g/cm 3 ]

70000 [kw] r .(01:00- 00:00 [hour])
 0.81 g/kwh ; =
3045-0110-0001.1

Str.hi [strokes* 105] (abbr. of stroke high) (in SEtuP menu)

2008-12-12

Total lubricator stroke counter. Adjustment of total stroke counter in case of i.e.
Description

change of MCU board, etc.

Str.Lo [strokes] (abbr. of stroke low) (in diSP menu)

See Str.hi (in diSP menu)

34 (90) Doc-ID: 3045-0110-0001.1

 MAN Diesel 3045-0110-0001.1

Str.Lo [strokes] (abbr. of stroke low) (in SEtuP menu)

Alpha Lubricator System

See Str.hi (in SEtuP menu).

t.dLy [ms] (abbr. of time delay)

Activation delay time. On line measurement of the time from activation of solenoid
valve to the first flank of the feedback signal, used for automatic compensation
of timing of the solenoid valve activation.

The delay can also be used for trouble shooting by observing if the delay time
deviates on a lubricator.

tEcH (abbr. of technical)

Technical parameters. Sub menu in diSP menu containing the menu items, which
are not used for normal operation.
For explanation of their functionality see SoFt, FPgA, Par.Ch and Par.

tELE.P [mA] (abbr. of telegraph position)

Telegraph position raw value. Used with mechanical governor. Read out of the
4-20 mA signal from governor to ALCU/X1:33, ALCU/X1:34 (MCU/J40:1, MCU/
J40:3).

ti.Adj (abbr. of timing adjustment)

Injection timing adjustment menu. Used during commissioning.

For further explanation see hY.dEL and inJ.oF.

toil [°C] (abbr. of temperature oil)

Booster pump suction tank oil temperature.

Normal value is 40 to 60 °C.
Alarm level is 70 °C.

vALue (abbr. of value)

Manual correction of index transmitter calibration values.

For further explanation see in.hi and in.Lo

XXX

Display of a number.

3.3 MCU setup

3045-0110-0001.1

3.3.1 Dip switch- Three double 4-position dip switches are available on the MCU board, SW 1, SW2
2008-12-12

es for MCU and SW 3. The dip switches represent binary values of 1, 2, 4 and 8, respectively,
when counting from the left. A switch is ON in the “up-position” and OFF in the
Description

“down-position”.

Doc-ID: 3045-0110-0001.1 35 (90)

3045-0110-0001.1 MAN Diesel

SW1 positions 1 and 2 are used to define the Baud rate at which the MCU com-
Alpha Lubricator System

municates via a serial connection with a PC.

SW1.1-2: OFF, 1)
1)
Example:
-> 38400 Baud
Example:
38400 Baud
(p) Baud
38400 6)
6)
ON
1) Example: 38400 Baud ON 6)
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
SW
ON
SW 1
1
1 2 3 4 5 6 7 8 SW 1
OFF
OFF
1 2 4 8 2 4 8 16
1 2 4 8 2 4 8 16
SW1.1: OFF, SW1.2:ON -> 19200 Baud OFF
1 2 4 8
SW1.1: ON, SW1.2:OFF -> 9600 Baud 2 4 8 16
SW1.1-2: ON,
2)
2) -> 4800 Baud
7)
7)
ON
2) SW3.1-6 are presently not used,ON
SW1.3-8, SW2.1-8 and and the positions are 7)
not relevant.
1 2 3 4 5 6 7 8 ON
1 2 3 4 5 6 7 8
SW 1
SW 1
1 2 3 4 5 6 7 8 SW
OFF 1
OFF
1 2 4 8 2 4 8 16
1 2 4 8 2 4 8 16
OFF
1 2 4 8 2 4 8 16 ON
ON
8)
8)
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
SW
ON
SW 2
2
8)
1 2 3 4 5 6 7 8 SW 2
OFF
OFF
1 2 4 8 2 4 8 16
1 2 4 8 2 4 8 16
OFF
1 2 4 8 2 4 8 16 ON
ON
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
SW
ON
SW 3
3
9)
9)
1 2 3 4 5 6 7 8 SW 3
OFF
OFF
1 2 4
1 2 4
8 2 4 8 16
8 2 4 8 16 9)
OFF
1 2 4 8 2 4 8 16

SW3.7 is to be set to OFF (Multiple trigger systems)

3)
3) (not used in SW version 1.6x and later)
ON
3) ON
SW
ON 3 10)
10)
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8 SW 3
1 2 3 4 5 6 7 8 SW 3 10)
OFF
OFF
1 2 4 8 2 4 8 16
1 2 4 8 2 4 8 16
OFF
SW3.8 is to be set to ON 1 (MCU
2 4revision
8 2 C4and8 later)
3045-0110-0001.1

16
4) OFF (MCU Null-series)
4)
2008-12-12

ON
4) ON
Description

1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
SW
ON
SW 3
3
1 2 3 4 5 6 7 8 SW 3
OFF
OFF
1 2 4 8 2 4 8 16
1 2 4 8 2 4 8 16
OFF
1 2 4 8 2 4 8 16
5)
5)
ON
36 (90) 5) 3045-0110-0001.1
Doc-ID: ON
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
SW
ON
SW 1
1
 MAN Diesel 3045-0110-0001.1

3.3.2 Upload of A VT100 terminal is part of the standard Windows software on a PC, and the

Alpha Lubricator System

MCU basic pro- ‘Hyper Terminal’ can be found in the Programs directory ‘Accessories’ and ‘Com-
gram munications’.
Connect the PC to the MCU by means of the serial cable, and start the VT100
terminal. The settings for the serial port in the PC are:
- Bits per second: 19,200 (must correspond to setting of Dip Switch SW1,
pos. 1 and 2, see item 3.3.1.)

If the MCU main led (positioned in the upper left corner) is flashing red/
NOTE green, the MCU only contains production test software. In this case the
baud rate must be set to 38,400. When the main program has been
uploaded to the MCU, set the baud rate to 19,200 before uploading the
set-up file.

- Data bits: 8
- Parity: None
- Stop bits: 1
- Flow control: None

Transfer menu: Transmit / Receive Protocol: Xmodem.

Press [Space] on the PC keyboard and the screen will display a menu as fol-
lows:

(/) Alpha Lubricator

[1] Transfer of set-up data
[2] Connection test
[3] System and alarm status
[4] Feedback failure status
[5] Mechanical delay
[6] Logged alarms
[7] Logged feedback alarms
[8] Revision menu
[9] MBD development menu

[R] Reset

The PC is connected to the MCU by means of the RS 232 serial cable, and the
VT100 terminal is started.

From the Alpha Lubricator menu, press [R] followed by [Y], [ASD and [Ctrl-U].
Send / transfer the latest version from ASD of the E-prompt file called *.epr from
3045-0110-0001.1

the PC to the MCU by means of menus in the VT100 terminal program. Make sure
2008-12-12

to use Xmodem protocol. When the file is transmitted to the MCU, press [Ctrl-P]
after confirming that calculated and read check sums are equal. Now the basic
Description

program is uploaded to the MCU board.

If a new basic program is uploaded to a MCU in service, the original set-up file
is deleted and a default set-up file is loaded in the MCU. Consequently, a new
setup file must be uploaded to the MCU in this case.

Doc-ID: 3045-0110-0001.1 37 (90)

3045-0110-0001.1 MAN Diesel

3.3.3 Upload MCU The PC is connected to the MCU by means of the RS 232 serial cable, and the
Alpha Lubricator System

set-up file Vt100 terminal is started.

From the Alpha Lubricator menu, press [1] (Transfer of setup data), followed by [1]
(Upload setup file). A capital C will start moving from left to right, indicating the
time remaining for uploading of set-up file. If the file is not uploaded successfully
the first time, just try again. This is not critical.

In the VT100 terminal, select menu item [Transfer] followed by [Send File], then
browse until you have found the correct setup file on your PC. Select the file and
press [Send].

When the file is transferred, ignore the command “Type password”, which is
displayed for a few seconds. Press [Y]. Now the new configuration parameters
are uploaded.

Interrupt the 24DC volt power supply. The green light will turn on and the MCU
is ready for operation.

If the MCU set-up file generated by the set-up program does not match the basic
MCU program, the VT100 terminal will display an error message and the MCU
will load the default set-up file.

The remedy for this is to download the default set-up file from the MCU to your
PC and manually change the displayed parameters for this specific file to match
the originally generated parameters. Save the new set-up file on your PC and
upload it to the MCU.

If the MCU is not able to receive the set-up file, turn to the VT100 menu 9 (MBD
Development menu) in order to reset RAM.
3.3.4 MCU LED On the MCU a main LED is positioned in the upper left corner. The status of the
information unit is given as follows:

Red/green flashing: The MCU basic program file is not loaded. Green flashing:
MCU set-up file is not loaded. Green light: Normal condition. Red light: Alarm
condition
3.3.5 Read-out of The HMI panel facilitates a menu that enables the use of read-out of all set-up
raw parameters in parameters. This feature might be helpful when troubleshooting the system.
HMI Panel
To read-out the raw parameter, follow the instruction below:

Navigate through the menu as follows:

3045-0110-0001.1

diSP
2008-12-12
Description

tEcH

Par

38 (90) Doc-ID: 3045-0110-0001.1

 ON

1 2 3 4 5 6 7 8 SW 3
9)
MAN Diesel OFF 3045-0110-0001.1
1 2 4 8 2 4 8 16

Press [ p ] or [ q ] to display the parameter number. When the requested param-

Alpha Lubricator System

eter number is displayed, press [enter]. The parameter value is displayed.
3)
To view a new parameter number, press [esc] until the parameter number is dis-
played again. Press [ p ] or [ q ] to select a different parameter.ON
To return to the
RPM read-out, press [esc] four times.
1 2 3 4 5 6 7 8 SW 3 10)

4. Configuration of BCU OFF

1 2 4 8 2 4 8 16
Two dip switches, SW1 and SW2, are placed in the upper left corner of the BCU
board. These dip switches are used to configure the BCU, see below in Items 4.1
4)
to 4.6. (See also Appendix 6).
ON
4.1 Injection rate with BCU in control
1 2 3 4 5 6 7 8 SW 3
Injection rate for the BCU is set on the dip switches SW1 positions 1 - 4, as a
binary value. OFF
1 2 4 8 2 4 8 16
Examples:
If SW1.1-2 is ON and SW1.3-4 is OFF, the injection rate will be 3 rev/injection.
5)
ON

3 rev / inj 1 2 3 4 5 6 7 8 SW 1
OFF
1 2 4 8 2 4 8 16

4.2 Detection rate (BCU take over from MCU)

The lowest injection rate the MCU can perform before the BCU takes over, is set
on the dip switches SW1 positions 5-8, as a binary value.

Examples:
If SW1.6 and SW1.8 are ON and SW1.5 and SW1.7 are OFF, the lowest injection
rate is 20 rev/injection for the MCU before BCU will take over control.
) Example: 38400 Baud 6)
ON ON

1 2 3 4 5 6 7 8 SW 1 20 rev / inj 1 2 3 4 5 6 7 8 SW 1
OFF OFF
1 2 4 8 2 4 8 16 1 2 4 8 2 4 8 16
3045-0110-0001.1

) 7)
2008-12-12

ON ON
Description

1 2 3 4 5 6 7 8 SW 1 1 2 3 4 5 6 7 8 SW 2
OFF OFF
1 2 4 8 2 4 8 16 1 2 4 8 2 4 8 16

ON
8)
1 2 3 4 5 6 7 8 SW 2 Doc-ID: 3045-0110-0001.1 ON 39 (90)

OFF 1 2 3 4 5 6 7 8 SW 2
1 2 4 8 2 4 8 16
1) Example: 38400 Baud 6)
1) Example: 38400 Baud
ON 6) ON
3045-0110-0001.1 ON MAN
ON Diesel
1 2 3 4 5 6 7 8 SW 1 1 2 3 4 5 6 7 8 SW 1
1 2 3 4 5 6 7 8 SW 1 1 2 3 4 5 6 7 8 SW 1
OFF for the engine
4.3 Number of cylinders OFF
Alpha Lubricator System

1 2 4 8 2 4 8 16 OFF 1 2 4 8 2 4 8 16 OFF
1 2 4 8 2 4 8 16 The number of cylinders for the specific
1 2engine
4 8 is 2set4on 8SW2
16 positions 1-4, as
a binary value.
2) 7)
2)
1) Example: 38400 Baud ON 7)
6) ON
ON
ON ON
ON
1 2 3 4 5 6 7 8 SW1 e.g. 7 cyl. 1 2 3 4 5 6 7 8 SW 2
1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 SW 1 1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 SW 2
1
OFF OFF
1 2 4 8 2 4 8 16 OFF 1 2 4 8 2 4 8 16 OFF
OFF OFF
1 2
1 2 44 8 2
8 2 44 88 16
16 1 2
1 2 4 4 88 2 2 4 4 88 16
16
4.4 BCU board revision
ON
ON 8)
The revision number of the printed circuit board is set on SW2.6.
2) 1 2 3 4 5 6 7 8 SW 2 7)
8) ON
1 2 3 4 5 6 7 8 ON SW 2 ON
OFF 1 2 3 4 5 6 7 8 SW 2
1
1 2
2 4
3 8
4 2
5 46 87 16 SW 1
8 OFF 1 2 3 4
1 2 3 4 5 6 7 85 6 7 8 SW 2
1 2 4 8 2 4 8 16 OFF
ON
OFF 1 2 4 8 2 4 8 16 OFF
1 2 4 8 2 4 8 16 ON 1 2 4 8 2 4 8 16 2.6
1 2 3 4 5 6 7 8 SW 3 2.6
1 2 3 4 5 6 7 SW 3
ON8 9)
OFF
For
8)
9) ON
1
1 2
2 4
3 8
4 25 46 8
7 16 SWinstallations
8 OFF 2 with revision B, SW2.6 must be OFF.
ON
For other installations SW2.6 must be ON.
1 2 4 8 2 4 8 16 1 2 3 4 5 6 7 8
The revision is printed on top of the board below the MAN B&W logo,SW 2
OFF 1 2 3 4 5 6 7 8
as “BCU-250-X” where X is the revision. SW 2
1 2 4 8 2 4 8 16 OFF
3) 4.5 Slow down output 1 2 4 8 2 4 8 16 OFF
3) ON 1 2 4 8 2 4 8 16 2.7
The slow down output switch (BCU terminal J8.3, 4) is 2.6
2.7 closed) if
NC(normally
1 2 3 4 5 6 7 8
ON
SW 3is ON and NO (normally
SW2.7 10) open) if SW2.7 is OFF.
1 2 3 4 5 6 7 8 SW 3 10)
9) ON
OFF ON
ON
1 2 4 8 2 4 8 16 OFF 1 2 3 4 5 6 7 8 SW 2
1 2 4 8 2 4 8 16 1 2 3 4 5
1 2 3 4 5 6 7 8 6 7 8 SW
SW 2 2
OFF
4) 1 2 4 8 2 4 8 16 OFF
OFF2.8
4)
3) ON 1
1 2 2 44 8 8 22 4 4 8 8 16
16
ON 2.8
2.7
1 2 3 4 5 6 7 8 ON SW 3
1
1
2
2
3
3
4
4
5
5
6
6
SW
7
The
7
OFF
8
83 is connected in 10)
3
SWoutput parrallel with slow-down output from MCU. The MCU
slow-down output is non-configurable, always NO. Consequently ONthe BCU slow-
1 2 4 8 2 4 8 16 OFF
down output must also be NO, i.e. SW2.7 OFF.
3045-0110-0001.1

OFF
1
1 2
2 4
4 8
8 2
2 4
4 8
8 16
16 1 2 3 4 5 6 7 8 SW 2
2008-12-12

5)
5)
Description

ON OFF
4) 1 2 4 8 2 4 8 16
ON 2.8
1 2 3 4 5 6 7 8 SW
ON 1
1 2 3 4 5 6 7 8 SW 1
1 2 3 4 5 6 7 8 SW 3
OFF
1 2 4 8 2 4 8 16 OFF
1 2 4 8 2 4 8 16 OFF
1 2 4 8 2 4 8 16
40 (90) Doc-ID: 3045-0110-0001.1
5)
ON
 OFF
ON 1 2 4 8 2 4 8 16
2.6
1 2 3 4 5 6 7 8 SW 3
9)
MAN Diesel OFF
ON 3045-0110-0001.1
1 2 4 8 2 4 8 16
1 2 3 4 5 6 7 8 SW 2
4.6 Number of lubricators

Alpha Lubricator System

OFF
) The number of lubricators for each cylinder
1 2 4is set
8 on2 SW2.8.
4 8 16
2.7ON.
For installations with one lubricator on each cylinder SW2.8 must be
ON
For installations with two lubricators on each cylinder SW2.8 must be OFF.
1 2 3 4 5 6 7 8 SW 3 10)
ON
OFF
1 2 4 8 2 4 8 16 1 2 3 4 5 6 7 8 SW 2
OFF
) 1 2 4 8 2 4 8 16
ON 2.8

1 2 4.7
3 4 Upload
5 6 of
7 BCU SW program
8 basic 3
OFF
To identify the component, see Document: ASD244-4090.
1 2 4 8 2 4 8 16
1. Connect a NULL-MODEM cable between the PC and BCU (J27)]
) 2. Connect the BCU to a suitable power supply (24V and minimum 2A)
ON
3. Set Switch (SW3) on the BCU in position “Program Mode”
1 2 3 4 5 6 7 8 SW 1
4. Press [RESET] button (SW4) on the BCU (the LED D50 located in the upper
OFF left corner of the PCB will turn off)
1 2 4 8 2 4 8 16
5. The device is now in programming mode (ISP mode)

6. Start the FlashMagic program

7. In the FlashMagic program window part 1 - key in the following data:

COM Port : COM1 (or which ever com port is used)

Baud Rate : 115200
Device : P89C51RD2XX
(processor versions can vary - the version can be read
on the processor it selves - U24 on the BCU board)
Oscillator Freq : 22Mhz

8. In the FlashMagic program window part 2 - key in the following data:

Select “Erase all Flash+Security+Clks”

9. In the FlashMagic program window part 3 - key in the following data:

3045-0110-0001.1

Enter the path/filename of the relevant INTEL hex file to be programmed

2008-12-12

into the device, or press the [BROWSE] button to choose the file.
Description

10. In the FlashMagic program window part 4 - key in the following data:

Select “Verify after programming”

Check that “6 clks/cycle” (if present) is NOT selected

Doc-ID: 3045-0110-0001.1 41 (90)

3045-0110-0001.1 MAN Diesel

11. Press the [START] button

Alpha Lubricator System

12. In the FlashMagic status line, the following information should appear:

Erasing Device
Programming Device
Verifying
Finished
The BCU has now been programmed

13. When the uploading is completed, set switch SW3 on the BCU back in po-
sition [NORMAL] and interrupt the power supply.

14. Verification

When the power supply is reconnected, the diode D50 in upper left cor-
ner will initially lit constantly green. This verifies that the unit is now pro-
grammed with application software. The diode may change to constantly
red if e.g. external signals are not present.

The actual software revision programmed can be verified by connecting to

the BCU via the Hyper Terminal program.

The hyper terminal communication settings should be:

Baud rate : 57600

Data bits : 8
Parity : None
Stop bits : 1
Flow control : Xon – Xoff

When connected press [esc] and a menu is shown

Press [RN] and the software revision number is shows as below:
Type (SC, SS , SL, UC, US, UL, HH, RN, ES) : Revision Number: 13.11

The [reset] button (SW 4) must not be pressed during normal opera-
CAUTION tion. This will cause “Internal Failure” (Alarm LED #8).

If, by mistake, the [reset] button has been activated and the LED #8 is lit, the error
message can be removed by interrupting the 24V power as follows:

- Remove plug FJ1 on the filter board of the BCU.

3045-0110-0001.1

2008-12-12
Description

42 (90) Doc-ID: 3045-0110-0001.1

 MAN Diesel 3045-0110-0001.1

5. Alpha Lubricator - Alarm Handling and Trouble Shooting Guide

Alpha Lubricator System

If you encounter difficulties while operating the engine with the Alpha Lubricator
system, this guide will help find and solve some of the problems.

The information in this section will help you with:

5.1 Fuses
5.2 External alarm signals
5.3 MCU - alarm handling and trouble shooting
5.4 BCU alarms
5.5 Emergency running without external trigger signals
5.6 Sequence diagram for alarm handling

5.1 Fuses

Schematic drawing of the ALCU power connections are shown in Appendix 2,

page 3.

5.1.1 MCU-Unit Normally, a fuse does not blow without reason. It is therefore important to locate
and correct the problem before normal operation can be restored.

There are two different fuse ratings: 12 Amp and 3 Amp. It is very important to
replace a fuse with one of the correct rating and type.

3045-0110-0001.1
2008-12-12

Description

Doc-ID: 3045-0110-0001.1 43 (90)

3045-0110-0001.1 MAN Diesel

MCU fuses
Alpha Lubricator System

The MCU unit has three fuses located on the filter board, as indicated in the
drawing below.

MCU board

FBU board
XZ707.40C 01

The designations are F1, F2 and F3.

F1 Main fuse

Fuse F1 is rated 12 Amp and is the main fuse for the MCU unit.

If this fuse is blown, a consumer connected to plugs FJ8, FJ9, FJ11, FJ12, FJ13,
FJ14 may be suspected of overloading the fuse.

Check for shorts by removing the fuse. Connect a multimeter to the right fuse
holder and measure the resistance to the negative terminal of FJ1
3045-0110-0001.1

2008-12-12
Description

44 (90) Doc-ID: 3045-0110-0001.1

 MAN Diesel 3045-0110-0001.1

Alpha Lubricator System

MCU board

FBU board
XZ707.40C 02

A measurement below 10 ohm is defined as a short. If the measurement indicates

a short, disconnect plugs FJ8 to FJ14 one by one and observe the reading on
the meter.

If the short can be located by this method, continue investigating the problem in
the circuit connected to the suspected plug.

If the reason for the short cannot be found by the procedure described above,
an internal MCU failure may be suspected.

F2 and F3

Fuse F2 is rated at 3 Amp and is the main fuse for the SBU unit when running
MCU mode.

This fuse supplies control power (pump running signal) to the pump station via
the SBU unit when running in MCU mode as well as power to the feedback sen-
sors.

If this fuse is blown, a fault in the pump station wiring or in the connections to the
cylinder intermediate boxes may be suspected.
3045-0110-0001.1
2008-12-12

Description

Doc-ID: 3045-0110-0001.1 45 (90)

3045-0110-0001.1 MAN Diesel

In order to check whether the problem is in the pump station or the intermediate
Alpha Lubricator System

boxes, follow the check procedure below:

Remove fuse F2. Connect a multimeter to the right fuse holder clip, and measure
the resistance to the negative terminal of FJ1 (right terminal). A measurement
below 10 ohm is defined as a short.

If the measurement indicates a short, disconnect plug FJ5 on the MCU filter
board (disconnecting the supply to the pump station) and observe the meter
reading. If the short is still present, disconnect the plugs L1 to L14 in the SBU
one by one until the short is located. Investigate the problem further by discon-
necting the plug J1 in the intermediate box and reconnect the suspected plug in
the SBU. If the problem disappears, the short is located in the intermediate box
or the lubricator units.

Fuse F3 is rated at 3 Amp, and is the main fuse for the shaft encoder. If this fuse
is blown, a fault in the encoder connections may be suspected.
3045-0110-0001.1

2008-12-12
Description

46 (90) Doc-ID: 3045-0110-0001.1

 MAN Diesel 3045-0110-0001.1

5.1.2 BCU-Unit There are two different fuse ratings 12 Amp and 3 Amp. It is very important to

Alpha Lubricator System

replace a fuse with one of the correct rating and type.

BCU fuses

The BCU unit has three fuses located on the filter board as indicated in the draw-
ing below.

BCU board Alarm Led

FBU board
XZ707.40C 03

The designations are F1, F2 and F3.

F1 Main fuse

Fuse F1 is rated at 12 Amp and is the main fuse for the BCU unit.

If this fuse is blown, a consumer connected to the plugs FJ8, FJ9, FJ11, FJ12,
FJ13, FJ14 may be suspected of overloading the fuse.
3045-0110-0001.1
2008-12-12

Check for shorts by removing the fuse. Connect a multimeter to the right fuse
holder, and measure the resistance to the negative terminal of FJ1.
Description

Doc-ID: 3045-0110-0001.1 47 (90)

3045-0110-0001.1 MAN Diesel

Alarm Led
Alpha Lubricator System

BCU board

FBU board
XZ707.40C 04

A measurement below 10 ohm is defined as a short. If the measurement indicates

a short, disconnect plugs FJ8 to FJ14 one by one and observe the reading on
the meter.

If the short can be located by this method, continue investigating the problem in
the circuit connected to the suspected plug.

F2 and F3

The fuse F2 is rated at 3 Amp and is the main fuse for the SBU unit when running
BCU mode. This fuse supplies power to the feedback sensors in BCU mode as
well as power to the pump station.

If this fuse is blown, a fault in the pump station wiring or in the connections to the
cylinder intermediate boxes might be suspected.

Remove fuse F2. Connect a multimeter to the right fuse holder clip, and measure
the resistance to the negative terminal of FJ1 (right terminal). A measurement
below 10 ohm is defined as a short.
3045-0110-0001.1

If the measurement indicates a short, disconnect plug FJ5 on the BCU filter board
2008-12-12

(disconnecting the supply to the pump station) and observe the meter reading.
If the short is still present, disconnect the plugs L1 to L14 in the SBU one by one
Description

until the short is located. Investigate the problem further by disconnecting the
plug J1 in the intermediate box and reconnect the suspected plug in the SBU.
If the problem disappears, the short is located in the intermediate box or the
lubricator units.

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 MAN Diesel 3045-0110-0001.1

Fuse F3 is rated at 3 Amp, and is the main fuse for the BCU pickups. If this fuse

Alpha Lubricator System

is blown, a fault in the wiring to the BCU pickups or a fault in the BCU box con-
nections might be suspected.

5.2 External alarm signals

Alarm system signals:

- Common alarm
- MCU power failure
- BCU power failure
- MCU failure
- BCU failure

Safety system signals:

- Slow-down

State indicator:
- BCU in control

Please note that some installations might have some alarm signals connected in
serial to save alarm channels in the alarm system.

5.2.1 Common The common alarm is a normally closed contact. In case the MCU system detects
alarm a fault, the alarm will be released. Information about the cause of the alarm can
be read of the number in the HMI panel.

To solve the problem, read the information related to the alarm number found in
the HMI panel.

5.2.2 MCU power The MCU power failure alarm is a normally closed contact.
failure In case the power to the MCU system is interrupted the alarm will be released.

Start by checking the breaker and fuse in the UPS cabinet. If no problem can be
found in the UPS, check that 24 V is present at terminal X1 PWR A in the ALCU
box. Continue by checking the fuse F2 on the MCU filter board (see page 41).
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3045-0110-0001.1 MAN Diesel

5.2.3 BCU power The BCU power failure alarm is a normally closed contact.
Alpha Lubricator System

failure In case the power to the BCU system is interrupted, the alarm will be released.

Start by checking the breaker and fuse in the UPS cabinet. If no problem can be
found in the UPS, check that 24 V is present at terminal X1 PWR B in the ALCU
box. Continue by checking the fuse F2 on the BCU filter board (see page 44).

5.2.4 MCU failure The MCU failure alarm is a normally closed contact.
The BCU system has detected that the MCU system program execution has
halted.

Start by checking if the power to the MCU system is OK.

See Item 5.2.2 MCU power failure.

If the Power supply is OK interrupt the power to the MCU for 5 secs. in order to
reset the MCU. If the MCU failure alarm is still active, the MCU itself might be
damaged and has to be replaced.

Note that if the power to the BCU is interrupted, the MCU failure will be activated
eventhough the MCU system is working well.

5.2.5 BCU failure The BCU failure alarm is a normally closed contact.
The BCU system has detected a fault in the BCU system.

Check the LED on the BCU board and read the instruction in item 5.4.

The BCU is not connected to the HMI panel and, consequently, no alarms from
the BCU will be displayed.

5.2.6 Slow-down The slow-down output is a normally open contact.

The slow-down command is released if the MCU and BCU systems fail to lubri-
cate one or more cylinders.

Check for other alarms in the HMI panel and follow the recommendations stat-
ed.

5.2.7 BCU in control The BCU in control is a normally closed contact.

This output indicates that the backup control unit is controlling the lubrication.

If the BCU system is able to re-establish the lubrication, the lubricators are work-
ing properly. The problem is to be found in the MCU system. Check for other
alarms and read the alarm codes on the HMI panel and follow the recommenda-
tions stated.
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 MAN Diesel 3045-0110-0001.1

5.3 MCU - alarm handling and trouble shooting

Alpha Lubricator System

5.3.1 Alarms If for any reason a feedback signal from a lubricator is measured as abnormal
1-24- Feedback by the MCU a feedback alarm will be given. A common alarm will trig the AMS
failure system (engine alarm and monitoring system) and an alarm code will be stored
in the HMI panel.

If the alarm stated in the HMI panel is a logged alarm (the alarm has disappeared
again) the alarm will be displayed as LAL XX

The alarm code in the HMI panel provides information about which lubricator is
suspected to fail. (Alr 2 in the HMI panel indicates that lubricator 2 on cylinder 1
is failing.)

Note that in case of one lubricator per cylinder (engines with a bore below 0,60 m),
the alarm will only read uneven numbers e.g. 1, 3, 5, 7 for cylinder 1, 2, 3, 4.

Generally it is recommended that a defect lubricator is replaced completely with

a spare when convenient (in case of one lubricator per cylinder, the defect unit
must be replaced immediately)

In the event of feedback failure, check MAN B&W Diesel A/S

as follows:
Lubricator 1 Lubricator 2

First check the feedback indicator light

on the intermediate box

If the feedback indicator light is:

XZ707.40C 05

• Continually on the lubricator

might be sticking in a position
where the feedback sensor gives
signal all the time.

To verify that the problem is in the lubricator, disconnect the plug for the lu-
bricator and observe the indicator light on the intermediate box. If the light
turns off after the plug is removed, the problem is located in the lubricator.
The lubricator must be replaced and overhauled (instruction 903-2).

Alternatively, if the light in the intermediate box remains lit after the plug to
the lubricator has been removed, the fault is not in the lubricator. Check the
cable and plugs from the intermediate box to the lubricator for shorts.

The intermediate PCB might also be suspected.

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3045-0110-0001.1 MAN Diesel

• Continually off start by checking

Alpha Lubricator System

if the red light in the lubricator

solenoid plug flashes.

Note that in the event of a feedback

failure, the remaining working lubrica-
tor is running double feed rate, and
the defective lubricator is only activat-
ed once every ten lubricator strokes
by the Mcai tor strokes by the MCU to
check if the lubricator is still failing.

XZ707.40C 06
If no light flashes in the solenoid plug,
remove the plug from the solenoid and
check again if the light starts flashing.
If yes, the solenoids coil may have an
internal short, which can be confirmed by measuring the coil resistance. The
normal resistance is 15 to 22 ohm for a new solenoid.

If the red light flashes in the solenoid plug, but no feedback is observed, check
the connections in the lubricator plugs, mounted on the cable from the intermedi-
ate box, for loose connections or shorts.

If connections in the plug are OK, the

lubricator must be replaced and over-
hauled (Instruction 903-2 (change of LED

sensor)).
+1 –2

Flashes according to the light in the

lubricator plug (once every ten lubrica- 3 2
6 1
tor strokes) the lubricator is working well 5 4
but the feedback signals are not detect- 15
V
ed by the MCU. Replace the intermedi- n+
ow
Br
ate box PCB (Printed Circuit Board). e OV al
Blu -sig
n
FB
l ack
If the fault is still present, check the ca- B

ble to the ALCU box.

707-40C-7A

5.3.2 Alarm 29 - The Marker signal (one pulse per revolution) is abnormal. The system will change
Marker signal fail- to random lubrication based on the remaining good signals. First check the elec-
ure from encoder trical connections in the encoder terminal box as well as the connections to the
ALCU control box.
If no problems are found in the wiring or fuse, replace the encoder.
3045-0110-0001.1

Adjustment procedure can be found in Procedure 905-8.

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In the event of failure of all Tacho signals, see item 5.5.

Description

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 MAN Diesel 3045-0110-0001.1

5.3.3 Alarm 30 - The two marker pickups mounted on the flywheel side of the engine gives one

Alpha Lubricator System

BCU pickup 1 fail- pulse every one engine revolution. These signals are used by the BCU system
ure to determine the engine speed. The signals are also used by the MCU system to
monitor the signals and release an alarm in case of signal failure.

Alarm number 30 indicates that BCU pickup # 1 is abnormal and alarm number
43 indicates that BCU pickup # 2 is abnormal.

If the Alpha lubricator system is running in BCU mode due to a MCU unit failure
the alarms for pickup failure can be found by observing the LED on the BCU pcb
(see picture below).

Alarm Led
S903-21 10B

The BCU system can be operated with only one pickup signal present.
Failure of one sensor is not critical and can be replaced when convenient.
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3045-0110-0001.1 MAN Diesel

The BCU pickups have a built-in indi-

Alpha Lubricator System

cator lamp which will flash once every

one engine revolution.

In case one of the pickup alarms is ob-

served, first check that the light flashes
in the pickup. If not, check that there is
24 volt at terminals 1, 2 and 4-5 in the

EN905-7.1 203 05
BCU terminal box. If power is present
at terminal 1 and 2 disconnect the
sensor wire connected to terminal # 3
(sensor # 1) or terminal # 6 (sensor # 2)
and observe if the light starts flashing.
If yes the wiring from the sensor to the ALCU box is shorted. If the indicator light
still does not flash, replace the pickup.

Sensor gap is to be adjusted to 3+0/–1 mm.

NOTE Regarding distance: Always refer to manufacturer’s recommendation.

In the event of failure of all Tacho signals, see item 5.5.

5.3.4 Alarm 31 - The trigger signals (1024 pulses per revolution) are abnormal. The system will
Trigger signal fail- change to random lubrication based on the remaining good signals. First check
ure from encoder for loose connection and shorts in the encoder terminal box, as well as the wiring
to the ALCU control box.

If no problems are found in the wiring or fuse, replace the encoder.

Adjustment procedure can be found in Procedure 905-8.

In the event of failure of all Tacho signals, see item 5.5.

5.3.5 Alarm 33 - Engine stop signal failure will be released if the engine stop signal is detected as
Engine stop signal abnormal by the MCU.
failure
There are two cases that will trigger the stop signal alarm.

1. The engine is running above 8 r/min and engine stop signal is present at the
MCU input for more than 20 minutes.

Check the engine stop signal circuit in the bridge control system.

2. The engine is stopped (detection is only active for 30 seconds after stop)
but there is no engine stop signal present at the MCU input.
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Check the engine stop signal circuit in the bridge control system.
Description

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 MAN Diesel 3045-0110-0001.1

5.3.6 Alarm 34 - The MCU has detected that the external LCD signal has been continuously ON

Alpha Lubricator System

LCD signal abnor- for more than 48 hours.
mal
Check the LCD signal and parameters in the governor system.

5.3.7 Alarm 35 - The MCU has detected that the BCU is abnormal.
BCU alive signal
missing Start checking if there are other alarms from the system. Power fail from the BCU
will give this alarm.

Check the wiring in MCU plug J52 terminal 4 and 5 as well as BCU plug J7 termi-
nal 3 and 4. (BCU alive signal connections) The alive signal is a pulse signal with
a frequency of approximately 1 Hz. An oscilloscope or a multimeter, capable of
measuring frequency, must be used to measure this signal.

If none of the above problems are found, try to interrupt the power to the BCU
unit for 5 sec. If the problem is still present, the BCU is probably damaged and
must be replaced. However, the engine can be operated in MCU mode until a
new BCU unit can be obtained.

5.3.8 Alarm 36 - The MCU unit has detected that the astern signal has been ON for more than 24
Astern signal ab- hours.
normal
The engine can be operated with this alarm present, however the lubrication
amount is increased.

Check the astern signal circuit in the bridge control system.

5.3.9 Alarm 37 - The MCU has detected that the prelubrication signal is ON and the index is higher
Prelubrication sig- than 80%.
nal abnormal This fault is not critical.

Check the prelubrication signal circuit.

5.3.10 Alarm 38 - The oil temperature has exceeded the alarm level normally adjusted to 70°C.
Oil temperature
high Check the oil temperature sensor (Pt-100 type) by disconnecting the plug from
the sensor and measure the sensor resistance.

At: 0°C, the reading must be 100.0 ohm

20°C, the reading must be 107.8 ohm
30°C, the reading must be 111.7 ohm
40°C, the reading must be 115.6 ohm
50°C, the reading must be 119.4 ohm
60°C, the reading must be 123.2 ohm
70°C, the reading must be 127.1 ohm.
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If the readings do not correspond the values stated above, the sensor is damaged
and must be replaced. This fault is not critical and the sensor can be replaced
Description

when convenient.

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5.3.11 Alarm 39 - The oil pressure is below the normal alarm level of 35 bar.
Alpha Lubricator System

Oil pressure low

Automatic start of stand-by pump and common alarm is activated plus alarm 49
in the HMI panel.

If oil pressure is re established after start of stand-by pump, common alarm is

not de-activated until the stand-by pump is manually stopped.

Both pumps will run continuously due to the detected fault. This fault is cleared
by manually pressing one of the PUMP-buttons on the HMI panel.

Check if the pumps are running. Check for leaks in the high-pressure supply
lines.

Check the oil pressure sensor (4-20 mA type) by measuring the sensor current
and comparing it with the pressure.

If the current and pressure differ, the sensor must be replaced/calibrated.

5.3.12 Alarm 40 - The MCU has detected that one or more of the four speed measurements are
Speed deviation abnormal.
alarm
Check the alarm list in the HMI panel to see which sensor is abnormal (BCU
pickups or the angle encoder) alarm 29, 30, 31 and 43 and read the chapter
concerning the alarm.

5.3.13 Alarm 41 - The index level does not correspond to the engine rpm.
Index transmitter
abnormal Fuel index is internally set to a fixed value of 100 percent due to the detected fault.
The fault is cleared by activation of engine stop signal.

Check the adjustment of the index transmitter, according to instruction S903-21.

The index transmitter itself might be damaged.

5.3.14 Alarm 42 - The index transmitter cable is interrupted or the index transmitter is damaged.
Cable failure index Correct the cable failure or replace the index transmitter.
transmitter
If the index transmitter is replaced, readjustment is needed. Follow the index
adjustment instruction S903-25.

5.3.15 Alarm 43 - Please see item 5.3.3.

BCU pickup 2 fail-
ure
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 MAN Diesel 3045-0110-0001.1

5.3.16 Alarm 44 - The lubricators are running BCU

Alpha Lubricator System

BCU in control mode. BCU in Ctrl. 120
Engine speed
120
Check that the mode switch is in Fuel Index

auto position. Oil pressure

100 bar

°C rpm
Find the cause for the BCU takeover. Deg. %

If the BCU mode has been started Auto MCU BCU

Min. bar
Oil pressure low
automatically and is running with- Index failure

out slow down command, the MCU Mark/trig failure

system may be abnormal.

Feedback failure
Common alarm

LAMPTEST ESC ENTER

PUMP 1 PUMP 2 PRELUB.

707 40C 09
5.3.17 Alarm 45 Electric motor # 1 or 2 is tripped by thermal overload.
and 46- Thermal
overload electric Check the thermal trip breaker in the pump station control box.
motor
Press the reset button on the thermal overload breaker to reactivate the pump
motor and check the current at the ammeter local side.

Check that the voltage on all three phases is OK. If not, check the fuses in the
feeder panel. Also verify that the motor windings are OK by measuring the resist-
ance of the individual windings.

If no electrical fault can be found check the oil pump for mechanical damage.

5.3.18 Alarm 47 - This alarm indicates that the MCU computer has lost its configuration file or that
MCU parameter it is missing.
list not loaded
Change to forced BCU operation by using the mode switch and replace the MCU
with a spare when possible.

5.3.19 Alarm 48 - The angle difference between the TDC marker from the angle encoder and the
Angle deviation TDC markers from the BCU pickups exceeds the alarm level.
fail
Check the Initial adjustment of the angle encoder and adjust as necessary. The
adjustment procedure can be found in Procedure 905-8.

Also check the flexible coupling between the engine and angle encoder for good
condition.

5.3.20 Alarm 49 - The stand-by pump has been activated either by the user or automatically due to
Stand-by pump is a low-pressure alarm. See alarm 39.
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5.4 BCU alarms

Alpha Lubricator System

BCU board Alarm Led

FBU board
XZ707.40C 10

Below is a list of BCU alarms and their description:

5.4.1 Led # 1 BCU internal failure

An internal failure in the BCU is detected. Check that the small switch SW3 on
the BCU board is in the normal position.

Reboot the BCU computer by interrupting the power supply for 5 sec. (Plug
FJ 1).

DO NOT PRESS THE RESET BUTTON on the BCU unit.

WARNING

If the alarm comes on again, the BCU board might be damaged and must be
replaced.
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5.4.2 Led # 2 Engine stop signal failure

Description

The engine stop signal has been on for more than 20 minutes with the engine
running. The engine stop signal is off and the engine is not running (only for 30
seconds). Check the stop signal wiring and the engine control system for correct
operation.

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5.4.3 Led # 3 MCU alive signal missing

Alpha Lubricator System

The BCU unit has detected that the MCU unit is abnormal. The BCU is still full
operational in this condition.

Start checking if there are other alarms from the system. Power failure from the
MCU will give this alarm as well as a common alarm.

Normally this situation will give a BCU take over.

Check the wiring in MCU plug J52 terminal 2 and 3 as well as BCU plug J7 ter-
minal 1 and 2. (MCU alive signal connections).

The alive signal is a pulse signal with a frequency of approx. 0,5 Hz. An oscil-
loscope must be used to measure this signal.

If no problems, as described above, are found try to interrupt the power to the
MCU unit for 5 sec. If the problem is still present the MCU unit is probably dam-
aged and must be replaced. However, the engine can be operated in BCU mode
until a new MCU unit can be obtained.

5.4.4 Led # 4 Feedback signal missing on two lubricators

If, for any reason, a feedback signal from a lubricator is measured as abnormal
by the BCU, an alarm will be given (BCU fail alarm).

Note that if the system is running in BCU mode due to a MCU failure, the MCU
might not be able to show any alarm codes in the HMI panel. The defect lubri-
cators are to be found by observing the feedback signal indicator lights at the
intermediate boxes at the engine.

This alarm indicates that the lubrication is stopped on a cylinder. A slow-down

command will be released.

First check if the fault is concerning more than one cylinder. If more than one
cylinder is affected, check the oil supply system. The oil pressure might be low
or the oil supply from the gravity tank has stopped. Check for leaks on the oil
supply lines.

If the problem can be isolated to only one cylinder, check the feedback wiring
from the defect cylinders intermediate box to the control box (ALCU). The inter-
mediate PCB (Printed Circuit Board) itself might be damaged.

To check if the BCU board is damaged, the plug for the defect cylinder can be
removed from the BCU and a plug from a working cylinder can temporally be
mounted instead. If this cylinder that previously worked well is now faulty, the
BCU board is probably damaged.
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Remember to remount the plugs in the correct sockets.

Description

The BCU computer can be rebooted by interrupting the main power supply for
5 sec. (Remove plug FJ1 on the BCU filter board).)

DO NOT PRESS THE RESET BUTTON!

WARNING

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5.4.5 Led # 5 Feedback signal missing one lubricator

Alpha Lubricator System

If, for any reason, a feedback signal from a lubricator is measured as abnormal
by the BCU, an alarm will be given (BCU fail alarm).

Note that if the system is running in BCU mode due to a MCU failure, the MCU
might not be able to show any alarm codes on the HMI panel. The defective lu-
bricators are to be found by observing the feedback signal indicator lights at the
intermediate boxes on the engine.

Generally it is recommended that a defect lubricator is replaced completely with

a spare when convenient (in the case of one lubricator per cylinder, the defective
unit must be replaced immediately)

For further information, see chapter covering MCU feedback fail alarms.

5.4.6 Led # 6 BCU marker signal 1 and 2 missing

The two marker pickups mounted on the turning wheel end of the engine give
one pulse every engine revolution. These signals are used by the BCU system
to determine the engine speed. The signals are also used by the MCU system to
monitor the signals and release an alarm in case of signal failure.

Note that if the system is running in BCU mode due to a MCU failure, the MCU
may not be able to show any alarm codes on the HMI panel.

This case needs prompt attention. The lubrication will stop, and a slowdown
command will be activated.

This type of fault is normally caused by mechanical damage to the pickups or

interruption of the power supply to the BCU pickups.

Check the sensors and the trigger-bracket on the flywheel for mechanical dam-
age. Sensor gap is 3.0 mm. (Regarding distance: always refer to manufacturer’s
recommendation).

Check that there is 24 volt on terminals 1 and 2 in the BCU terminal box. If there
is no power present on terminals 1 and 2, investigate further for short-circuited
wiring to the BCU pickup system.

5.4.7 Led # 7 BCU marker signal 1 or 2 missing

and 8
The BCU system can be operated with only one pickup signal present.

Failure of one pickup is not critical and it can be replaced when convenient.

The BCU pickups have a built-in indicator which flashes once for each engine
3045-0110-0001.1

revolution.
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 MAN Diesel 3045-0110-0001.1

If one of the pickup alarms are ob-

Alpha Lubricator System

served, first check that the lamp in
the pickup is flashing. If not, check
that there is 24 volt on terminals 1 and
2 in the BCU terminal box. If power is
present at terminals 1 and 2, discon-
nect the pickup wire connected to
terminal # 3 (pickup # 1) or terminal
# 6 (pickup # 2) and observe if the
light starts flashing. If yes, the wiring

EN905-7.1 203 05
from the pickup to the ALCU box is
shorted. If the indicator light still does
not flash, replace the pickup.

Pickup gap is to be adjusted to 3+0/-1 mm.

(Regarding distance: Always refer to manufacturer’s recommendation).

5.5 Emergency running without external trigger signals

We strongly recommend that all efforts are made to repair the trigger system
before switching to the emergency mode.

In the event that all trigger signals to the lubricator system fails (angle encoder
and pickups for the BCU system), it is possible to maintain a certain level of lubri-
cation by means of an internal stroke generator on the MCU or BCU card.

This stroke generator emits one pulse per second, i.e. approx. 60 rpm.

To be able to run in this “emergency mode”, the following electrical connections

must be changed:

Remove the wire from MCU-J22 terminal 1

Connect an extra wire from MCU-J52 terminal 4 to MCU-J22 terminal 1.

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Alpha Lubricator System

MCU board

XZ707.40C 13

The system now starts lubricating regardless of whether the engine is running
or stopped.

The system will also give various alarms.

However, feedback alarms will still function and indicate whether all cylinders are
being lubricated. When running in this mode, the BCU system is not active.

The MCU slow-down function remains active.

Lubrication is effected as “random” and “rpm-dependent”, however with a sup-

plement of 25% of the amount set for the individual cylinders, but with a fixed
number of revolutions of 60.
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5.6 Sequence diagram for alarm handling

Alpha Lubricator System

MCU BCU
MODE MODE

One Remaining lubri- Com. Alarm

Lubricator Yes cator running +
failure double feedrate Alr 1-24

No
Two lubricator Automatic
BCU in Control Startning two (2)
on one Cyl. Yes change over
Alr 44 Booster pumps
failure to BCU
No
Com. alarm
MCU Automatic Running
MCU Power fail
power Yes change over continuously
BCU in Control
failure to BCU Untimed
MCU fail
No

MCU Automatic One Running BCU Fail

BCU in Control Lubricator Yes continuously Alarm
alive signal Yes change over
MCU failure failure Untimed LED 5
missing to BCU
No No

Encoder Running Com. Alarm Two lubricator BCU Fail

TDC signal Yes continuously + on one Cylinder Yes Alarm Slow down
missing Untimed Alr 29 failure LED 4

No No

Encoder Running Com. Alarm BCU Running BCU Fail

trigger signal Yes continuously + Pickup #1 Yes continuously Alarm
missing Untimed Alr 31 missing Untimed LED 8

No No

Encoder Running Com. Alarm BCU Running BCU Fail

signals Yes continuously + Pickup #2 Yes continuously Alarm
missing Timed Alr 29+48 missing Untimed LED 7

No No
MCU Running Com. Alarm BCU BCU Fail
BCU Pickup #1 Yes continuously + Pickup signals Yes Alarm Slow down
missing Timed Alr 30 missing LED 2
No No
MCU Running Com. Alarm MCU BCU Fail
BCU Pickup #2 Yes continuously + alive signal Yes Alarm
missing Timed Alr 43 missing LED 3
No No
Com. Alarm
MCU Running Com. Alarm BCU
MCU fail
BCU Pickup signals Yes continuously + power Yes Slow down
BCU fail
missing Timed Alr 30+43 failure
BCU power fail
No No
MCU Automatic BCU in Control
Failure Encoder Yes change over Com. Alarm OK
BCU Failure Pickups to BCU Alr 44
No
Low Start Two lubricator
booster oil Yes stand-by fails on one unit HMI Panel Alarm list
pressure pump BCU in Control

No Yes Alr 1-24 : Feedback signal failure

Com. Alarm Alr 29 : Marker failure - encoder / trigger ring
Yes +
Alr 39+49 Alr 30 : Marker failure - BCU pickup no. 1
Com. Alarm Alr 31 : Trigger failure - encoder / trigger ring
BCU
Running MCU fail, BCU fail, Alr 33 : Engine stop signal failure
Yes continuously BCU power fail
Power failure
MCU mode +
Alr 34 : LCD signal abnormal
Alr 30+35+43 Alr 35 : BCU Alive signal missing
No
Alr 36 : Astern signal abnormal
BCU Running Com. Alarm
Alive signal Yes continuously +
Alr 37 : Pre-lubrication signal abnormal
Alr 38 : Oil temperature high
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missing MCU mode Alr 35

No
Alr 39 : Oil pressure low
Alr 40 : Speed deviation ÿ marker trigger
2008-12-12

Index Running Com. Alarm

transmitter Yes continuously + Alr 41 : Index transmitter ÿ abnormal
failure 100% MEP Alr 42 or 41 Alr 42 : Cable failure ÿ index transmitter
Description

No Alr 43 : Marker failure ÿ BCU pickup no. 2

Temperature Com. Alarm Alr 44 : BCU in control
Running
sensor Yes
continuously
+ Alr 45 : Thermal overload ÿ el. Motor 1
failure Alr 38
Alr 46 : Thermal overload ÿ el. Motor 2
No Alr 47 : MCU parameter list not loaded
Alr 48 : Angle deviation ÿ marker signals
OK
Alr 49 : Stand-by pump running

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Appendix 1

Alpha Lubricator System

Function of the LEDs in the Intermediate Box

D7 D17
Error FB-signal output

FB-signal input A
D5 FB-signal input B
D6

J2

J4

J1

The two green LEDs D5 and D6 (FB-signal input A and FB-signal input B) light
when there is an input from one of the feedback sensors.

FB-signal output is also a green LED D17, which flashes every time a feedback
signal is sent to the Switch Board Unit. There has to be a flash at FB-signal output
every time, shortly after there is an input on one of the two FB-signal input.

The Error LED D7 indicates with a red light, if there is an error on the cable from
the FB-signal output, or if the input at the Switch Board Unit has an error.

If there is an error, remove the plug from J1 and see if the LED still indicates error.
If it does then change the circuit board, if this does not remove the indicated error,
then look for any damage on the cable. If the cable is damaged, then change it or,
if possible, repair the damage. If there is not any damage on the cable, then the
source of the error could be the input channel at the Switch Board Unit.
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Appendix 2
Alpha Lubricator System

Control Unit Cylinder Lubrication — Logic Diagram

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Appendix 3

Alpha Lubricator System

Replacement of MCU, BCU, SBU Boards

If one of the PCB’s in the ALCU box is to be replaced, note as follows:

Before removing any plugs from the PCB ensure that the plugs are numbered in
order to remount them in the correct place.

The SBU unit does not need any programming or setup. This board can be re-
placed directly with a spare.

MCU and BCU units:

Normally the spare units are delivered programmed and ready to use.

Remove all plugs from the PCB.

Remove the eight screws that fasten the unit to the ALCU.
Mount the new unit and remount the plugs in the correct position.

MCU replacement

If the MCU unit has been replaced, check the following:

Note that a new MCU unit is adjusted to a feed rate of 200% (factory setting).

1. Read out the feed rate setting for the individual cylinders on the old MCU in
order to adjust the new MCU to the same setting

2. Start the prelubrication sequence and check that all cylinders are lubricat-
ed by observing that all LEDs on the intermediate boxes flash. Also check
that no feedback alarms are present in the HMI panel.

3. With the engine running, check the injection angles in the HMI panel and
compare these with the angles stated in the test sheet supplied with the
ALCU box.

4. Adjust the lubrication feed rate according to the settings the engine had
before this replacement.

5. Check and adjust the Index Transmitter as explained in S-procedure

S903‑25
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BCU replacement
Alpha Lubricator System

If the BCU unit has been replaced, check the following:

1. Check that the DIP switch settings on the new board are corresponding to
the settings of the old board.

2. With the engine running, switch to forced BCU operation and check that
all cylinders are lubricated by observing that all LEDs on the intermediate
boxes flash. Switch back to auto mode.

3. Check that no alarms from the BCU are present.

4. If the SBU unit has been replaced, check the function by carrying out the
checks stated under both MCU and BCU replacements.
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Appendix 4 FOR REFERENCE ONLY

Alpha Lubricator System

The service letter SL07-479 is enclosed for reference only.
NOTE Always refer to the latest service letter issued with recommendations
regarding actual cylinder lubrication settings.

Cylinder Lubrication

All MC/MC-C and ME/ME-C type engines

Mk 6 and higher, with Alpha ACC System

Since our last Service Letter SL05-455 concerning Cylinder Lubrication, the de-
fault feed rate sulphur proportional factor has been in the range of 0.34 to 0.26 g/
kWh x S%, with an absolute minimum at 0.70 - 0.60 g/kWh.

However, many engines have followed the lowest level in the range, and evalua-
tions of the results regarding wear, scuffing resistance and TBO show that this
dosage is superior to higher levels. Therefore, we now recommend a fixed sched-
ule for navigating from the upper level to the lower level in the range, within a
2,000-hour period.

Consequently, the recommended basic feed rate after running-in is 0.26 g/kWh x
S%, with the absolute lower limit at 0.60 g/kWh.

Specific Cylinder Oil Dosages

Alpha ACC is the default lubrication mode for modern MAN B&W two-stroke
engines, i.e. lube oil is dosed at a feed rate proportional to the engine load and
proportional to the sulphur content in the fuel oil. This ensures that the alkali ad-
ditives in the cylinder oil are applied proportionally with the amount of sulphur
entering into the combustion chamber. The build up of a safe oil film is ensured
at any time by the lower limit of 0.60 g/kWh. 3045-0110-0001.1
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Running-in
Alpha Lubricator System

During the first running-in, we recommend a relatively high fixed dosage: 1.5 g/
kWh for the first 250 hours succeeded by 1.2 g/kWh for another 250 hours. After
these 500 hours of initial running-in, where ample oil is used for flushing away
wear particles from the sliding surfaces, ACC running with the factor 0.34 g/
kWh x S% should be introduced.

The next 2,000 hours should be used for a gradual reduction towards the basic
setting, i.e. the ACC factor 0.26 g/kWh x S%, see the feed rate chart below.

Fig. 1: ACC Cylinder Lubrication, January 2007

Regulating from the upper ACC factor 0.34 g/kWh x S% to the basic setting at
0.26 g/kWh x S% should take place stepwise over a 2,000-hour period. The size
of the steps may depend on the evaluation of the actual lubricating and deposit
condition appearing from scavenge port inspections.

Average Cylinder Oil Consumption

Due to the sulphur dependency, the average Cylinder Oil Consumption depends
on the sulphur content in fuel bunkers. According to DNV, worldwide deliveries
in 2006 have been recorded as shown in Fig. 2 below.
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Alpha Lubricator System

Fig. 2: Sulphur content 2006

About 40% of all fuel bunkers have a sulphur content below 2.3%, and conse-
quently call for the minimum dosage of 0.60 g/kWh. About 60% of ail fuel bunkers
call for the sulphur dependent lube control, i.e. 0.26 g/kWh x S%. On average,
this results in a yearly absolute Cylinder Oil Dosage of 0.70 g/kWh.

Operating on low sulphur fuels

At sulphur ievels below 2.2%, the minimum dosages at 0.6 g/kWh should be
maintained. Consequently, when using a normal BN70 cylinder oil, there will be
a surplus of alkali additives. Unused alkali additives have a negative influence
on the cylinder condition due to accumulation on the piston top land and due to
lack of refreshment of the liner surface by corrosion. This negative influence is
naturally time based and becomes more and more severe the lower the sulphur
content gets. As a rule of thumb, we recommend to change to a lower BN cylinder
oil when operating on sulphur levels below 1.5% for more than 1 to 2 weeks.

Questions or comments regarding this SL should be directed to our Operation

Dept. LEO.
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Guiding Cylinder Oil Feed Rates

Alpha Lubricator System

S/L/K-MC/MC-C/ME/ME-C, Mk 6 and higher,

with Alpha ACC lubrication system and coated piston rings.

Standard BN 70 cylinder oil BN 40 cylinder oil

Basic setting 0.26 g/kWh x S% 0.45 g/kWh x S%

Minimum feed rate 0.60 g/kWh

Maximum feed rate

1.7 g/kWh
during normal service

Part-load control Proportional to indicated engine load

First 5 hours: 1.7 g/kWh

From 5 to 250 hours: 1.5 g/kWh
Feed
Running-in From 250 to 500 hours: 1.2 g/kWh
rate:
new or From 500 to 2500 h: Stepwise reduction from
reconditioned 0.34 to 0.26 g/kWh x S%
liners and
new piston
rings Engine
Stepwise increase to max. load over 5 hours
load:

Running-in new rings in

already run-in and well No load restrictions
running liners:

During starting, manoeuvring and load changes, the feed rate

Manoeuvring and load
should be increased by means of the “LCD” by 25% and kept at this
change situations.
level for ½ hour after the load has stabilised.
Frequent scavenge port inspections of piston rings and cylinder
liners are very important for maintaining a safe cylinder condition.
If irregularities are observed, adjustments of the lube oil rate should
Lubrication of cylinders
be considered.
that show abnormal
In case of scuffing, sticking piston rings or high liner temperature
conditions:
fluctuations, the feed rate should be raised to 1.2 g/kWh and the P-
max and Mep reduced. As soon as the situation is stabilised, the
lubrication and the pressures should be normalised.
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Adjusting Alpha Lub. using ACC, BN40 Cylinder Oil

ACC Factor g/kWh x S%:

HMI
0.45 0.47 0.51 0.52 0.54 0.58 0.60 g/kWh
setting
Sulphur Content %:
0 0 0 0 0 0 0 0.60 56
1.4 1.3 1.2 1.2 1.1 1.1 1.0 0.60 56
1.5 1.4 1.3 1.3 1.2 1.2 1.1 0.65 60
1.6 1.5 1.4 1.4 1.3 1.3 1.2 0.71 66
1.7 1.6 1.5 1.5 1.4 1.4 1.3 0.77 71
1.8 1.8 1.7 1.6 1.5 1.5 1.4 0.83 77
2.0 1.9 1.8 1.7 1.6 1.6 1.5 0.89 82
2.1 2.0 1.9 1.8 1.7 1.7 1.6 0.95 88
2.2 2.1 2.0 1.9 1.8 1.8 1.7 1.01 93
2.4 2.3 2.1 2.0 2.0 1.9 1.8 1.07 98
2.5 2.4 2.3 2.2 2.1 2.0 1.9 1.13 104
2.6 2.5 2.4 2.3 2.2 2.1 2.0 1.19 109
2.8 2.6 2.5 2.4 2.3 2.2 2.1 1.25 115
2.9 2.8 2.6 2.5 2.4 2.3 2.2 1.31 120
3.0 2.9 2.7 2.6 2.5 2.4 2.3 1.37 126
3.2 3.0 2.9 2.7 2.6 2.5 2.4 1.43 131
3.3 3.1 3.0 2.8 2.7 2.6 2.5 1.49 137
3.4 3.3 3.1 3.0 2.8 2.7 2.6 1.55 142
3.6 3.4 3.2 3.1 2.9 2.8 2.7 1.61 148
3.7 3.5 3.3 3.2 3.0 2.9 2.8 1.67 153
3.8 3.6 3.4 3.3 3.1 3.0 2.9 1.70 156

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Alpha Lubricator System

Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil

ACC factor g/kWh x S%

HMI
0.26 0.27 0.29 0.30 0.31 0.33 0.34 g/kWh
setting
Sulphur content %
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.60 56
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.60 56
1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.60 56
1.1 1.1 1.1 1.1 1.1 1.1 1.1 0.60 56
1.2 1.2 1.2 1.2 1.2 1.2 1.2 0.60 56
1.4 1.4 1.3 1.3 1.3 1.3 1.3 0.60 56
1.6 1.6 1.4 1.4 1.4 1.4 1.4 0.60 56
1.8 1.8 1.6 1.6 1.5 1.5 1.5 0.60 56
2.0 2.0 1.8 1.8 1.6 1.6 1.6 0.60 56
2.2 2.2 2.0 1.9 1.8 1.7 1.7 0.60 56
2.4 2.3 2.1 2.0 2.0 1.9 1.8 0.60 56
2.5 2.4 2.3 2.2 2.1 2.0 1.9 0.65 59
2.6 2.5 2.4 2.3 2.2 2.1 2.0 0.68 63
2.8 2.6 2.5 2.4 2.3 2.2 2.1 0.71 66
2.9 2.8 2.6 2.5 2.4 2.3 2.2 0.75 69
3.0 2.9 2.7 2.6 2.5 2.4 2.3 0.78 72
3.2 3.0 2.9 2.7 2.6 2.5 2.4 0.82 75
3.3 3.1 3.0 2.8 2.7 2.6 2.5 0.85 78
3.4 3.3 3.1 3.0 2.8 2.7 2.6 0.88 81
3.6 3.4 3.2 3.1 2.9 2.8 2.7 0.92 84
3.7 3.5 3.3 3.2 3.0 2.9 2.8 0.95 88
3.8 3.6 3.5 3.3 3.2 3.0 2.9 0.99 91
3.9 3.8 3.6 3.4 3.3 3.1 3.0 1.02 94
4.1 3.9 3.7 3.5 3.4 3.2 3.1 1.05 97
4.2 4.0 3.8 3.6 3.5 3.3 3.2 1.10 100
4.3 4.1 3.9 3.8 3.6 3.4 3.3 1.12 103
4.5 4.3 4.0 3.9 3.7 3.5 3.4 1.16 106
4.4 4.2 4.0 3.8 3.6 3.5 1.19 109
4.5 4.3 4.1 3.9 3.8 3.6 1.22 113
4.4 4.2 4.0 3.9 3.7 1.26 116
4.5 4.3 4.1 4.0 3.8 1.29 119
4.4 4.2 4.1 3.9 1.33 122
4.5 4.3 4.2 4.0 1.36 125
4.5 4.3 4.1 1.39 128
4.4 4.2 1.43 131
4.5 4.3 1.46 134
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ACC Running-in Schedule

1.8 0.52
0.50
1.6 Scavenge port insp. Fixed running-in dosage (g/kWh) 0.48
*
0.46
1.4 Feed rate factor reduction curve(g/kWh/S%)
0.44
Scavenge port insp.
* 0.42
1.2
0.40
1 0.38
0.36

Initial running-in dosage g/kWh

0.8 0.34

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* Scavenge port insp.
Scavenge port insp. * 0.32
0.6 Scavenge port insp. 0.30
*
Scavenge port insp.
0.28
0.4 *
0.26
0.24
0.2
Running-in Change to ACC 0.22
period with
0 fixed 0.20
lubrication ACC optimisation phase Optimum ACC setting 0.18
ACC feed rate factor (g/kWh/S%)

-0.2 0.16
0 500 1000 1500 2000 2500 3000 3500 4000
HRJ 2300, 11 October 2006 Hours

Description Alpha Lubricator System

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Appendix 5
Alpha Lubricator System

ALCU signal description

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Appendix 6
Alpha Lubricator System

Back-up Control Unit

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Index
Operation

Commissioning

Maintenance

Components

Electrical Wiring
Blank
 Commissioning

Table of Contents

See
1. N2 Charging Maintenance 903-2.1, page 2-3 and 103-2

2. Flushing S903-24

3. Testbed Commissioning Procedure S903-21

4. Angle Encoder Maintenance 905-8.1 and 105-8

5. Tacho Pickups Maintenance 905-7.1 and 105-7

6. Timing Check Procedure S903-20

7. Testbed Trial Test Scheme

8. Dock Trial Commissioning Procedure S903-0039

9. Dock Trial Test Scheme

When referring to this page, please quote Commissioning TOC

MAN B&W Diesel A/S, Copenhagen, Denmark
Blank
 Flushing of Pipe System on
S903-24
Alpha Lubricators

1. Preparation
1.1 Connect a 440 V power supply to the two pump starter cabinets, and start the two
pumps locally for a brief period to check that they run in the correct direction of
rotation.

1.2 Check, and if necessary adjust, the current limits on the two motor-start relays so
that they comply with the rating plate on the motor.

1.3 Connect and activate the heating element in the suction tank.

1.4 Dismount the inlet and outlet pipes to the lubricator blocks and mount U-pipes
with shut-off cocks instead (bypass the blocks).

Remember to seal off the free pipe connections on the lubricator block to prevent the in-
gress of dirt.

Mount an extra full-flow filter (15 to 35 m) in the return pipe from the engine to the pump
station.

Disconnect the service tank as hydraulic oil is to be used for flushing.

1.5 Mount a U-pipe with shut-off cock on the end of the oil supply main pipe.

1.6 Close all shut-off cocks on the U-pipes at the lubricator blocks and open the cock
at the end of the main pipe.

1.7 Fill the suction tank on the pump station with hydraulic oil.

1.8 Open all relevant cocks on the pumps.

1.9 Start pump No. 1 locally via the starter cabinet.

1.10 Adjust the pressure regulator on the pump station to maximum pressure.

1.11 Check that there are no leaks in the pipe system.

1.12 Check the oil level in the suction tank and, if necessary, top up until the level is
stable.

1.13 Shut-down pump No. 1.

1.14 Start pump No. 2 and check that it can maintain a pressure level similar to pump
No. 1.

1.15 Start both pumps.

1.16 Regularly check the oil level in the suction tank and top up as necessary.

1.17 Regularly check that the pressure drop across the suction filters and in the full-
flow filter in the pressure outlet do not exceed the maximum level. Replace the fil-
ters if clogged.

When referring to this page, please quote Procedure S903-24 Page 1 (3)
MAN B&W Diesel A/S, Copenhagen, Denmark
 Flushing of Pipe System on
S903-24
Alpha Lubricators

2. Flushing
The following flushing procedure is to be carried out before starting up on the testbed:

2.1 After five hours’ flushing, open one half of the shut-off cocks on the U-pipes on
the lubricator blocks, and close the cock at the end of the main pipe.

2.2 Continue flushing for at least five hours.

2.3 After five hours’ flushing, open the other half of the shut-off cocks on the U-pipes
and close the half that were open.

2.4 Continue flushing for at least five hours.

2.5 Close the inlet and outlet cocks on the pump station, and drain the oil from the
suction tank.

2.6 Switch-off the 440 V power supply to the pumps and tank heater via the main
switch on the starter cabinets.

2.7 Remove the inspection cover on the suction tank and clean the inside of the tank
so that it is completely free of any oil or dirt.

2.8 Dismount all U-pipes and re-install all the original pipe connections.

2.9 Open all relevant cocks on the pumps and open for the supply of cylinder oil from
the service tank (gravity tank).

2.10 Start a pump from the pertaining start button on the starter cabinet and adjust the
pressure regulator to 45 bar.

2.11 Check that there are no leaks in the pipe system or lubricators.

2.12 Check and, if necessary, adjust the thermostat to 45o C, after dismounting the
cover on the heater.

The oil system is now ready for service.

Page 2 (3) When referring to this page, please quote Procedurer S903-24
MAN B&W Diesel A/S, Copenhagen, Denmark
 Flushing of Pipe System on
S903-24
Alpha Lubricators

The filter must be a “bag-type” filter

U-pipe with valve

Cyl. #1 Cyl. #2

Return line
Extra
full float 15-30 m
flushing filter

Pump station

Supply line

Group #1 Group #2
#1 #2

When referring to this page, please quote Procedure S903-24 Page 3 (3)
MAN B&W Diesel A/S, Copenhagen, Denmark
Blank
 Cylinder Lubrication S903-21
Testbed Commissioning Procedure
Cylinder Lubrication
21
Testbed Commissioning Procedure
S903-21

1.
ALCU – Testbed Procedure

1. Disconnect the connections to the HMI pan-

el. (HMI panel side).

2. Check the power supply for correct polarity

before connecting the power to the ALCU
control box terminals. Check both Main A
and Main B.

3. Check the HMI panel power connection for

correct polarity, and connect the HMI panel.

S903-21 01
2.

TB x 1 V
Alcu Box

24 V DC

Main B

Main A
S903-21 02

3.

V
V
24 V DC
S903-21 03

When referring to this page, please quote Procedure S903-21 Page 1 (8)
0$1% :'LHVHO$6 2003-01-28
S903-21 Cylinder Lubrication
Testbed Commissioning Procedure

4. 4. Set the Index transmitter to approx. 4.5 mA

at 0 mm index and approx. 19.5 mA at max-
Zero
imum possible index on the Local Operating
Span Panel. The mA level can be read on the
HMI panel.

Navigating in the HMI panel menu is done

as follows:

• [ENTER] goes forward (right) in

the menu or changes a set point.

• [ESC] goes backwards (left) in the menu.

• [ ] goes up in the menu.

• [ ] goes down in the menu.

S903-21 04

S90321-4
diSP in.A XXX [mA]

5A. Aft Fore

5. Adjust the angle encoder to give TDC sig-
nal at TDC cylinder No. 1 (turn the engine
to bring the piston of cylinder 1 to TDC po-
0° sition, and turn the encoder until the LED
on the encoder junction box lights up).
TDC Cyl. 1 See Procedure 905-8 for angle encoder ad-
justment.
S903-21 05

Adjust the BCU pick-ups, as described in

Procedure 905-7.

Start one pump.

5B.
Check that the oil pressure builds up to 40-
50 bar, or carry out adjustment on the pres-
sure control valve on top of the pump sta-
tion. The pressure can also be read on the
HMI panel display.

Check that the pressure remains at an ac-

ceptable level, also with two pumps run-
ning.
XZ707 40A 08

Page 2 (8) When referring to this page, please quote Procedure S903-21
2003-01-28 0$1% :'LHVHO$6
 Cylinder Lubrication S903-21
Testbed Commissioning Procedure

6. Turn the mode switch to BCU position and 6A.

check that both booster pumps are running.
BCU in Ctrl.
Turn the switch back to AUTO position. Engine speed
120

120
Index
6B.
Lubrication

°C rpm

Deg. %
Auto MCU BCU Min. bar
Oil pressure low
Index failure

Mark/trig failure

Feedback failure

Common alarm

LAMPTEST ESC ENTER

PUMP 1 PUMP 2 PRELUB.

S903-21 06A

7.
S903-21 06B

MAN B&W Diesel A/S

7. Check the connections to the lubricators by Lubricator 1 Lubricator 2

activating the lubricators one by one via the

HMI panel connection test menu (start one
booster pump from the HMI panel).

Lub.XX oFF/on
S903-21 07

PRESS
S90321-7

Connt Sol.t Lub.1

8.

8. Check the lubricator system by activating

the pre-lubrication function. Press the ESC
button and the PRELUB button on the HMI
panel simultaneously. Check that no feed-
back alarm is activated.
PRESS
S903-21 08

When referring to this page, please quote Procedure S903-21 Page 3 (8)
0$1% :'LHVHO$6 2003-01-28
S903-21 Cylinder Lubrication
Testbed Commissioning Procedure

9. Turn the engine to approx. 10° before TDC

of cylinder No. 1.

Continue turning the engine and check that

the small LEDs on the MCU unit – desig-
nated D88 (above J20) D90, D91 (above
J22) – flash when the engine is turned and
passes TDC of cylinder No. 1.

Also check that the LED on the MCU unit –

designated D89 (above J20) – flashes ap-
prox. twice each second.

9A. 9B.
MCU Board
TDC Cyl. 1

350°
0°
S903-21 09A

S903-21 09B

Page 4 (8) When referring to this page, please quote Procedure S903-21
2003-01-28 0$1% :'LHVHO$6
 Cylinder Lubrication S903-21
Testbed Commissioning Procedure

10. Check the engine stop signals by simulating

run and stop condition from the governor
side. Check that LED D80 (above/right J30)
on the MCU and LED D38 (above J5) on
the BCU turn on and off accordingly.

10A.
S903-21 10A
MCU Board

10B. BCU Board

S903-21 10B

When referring to this page, please quote Procedure S903-21 Page 5 (8)
0$1% :'LHVHO$6 2003-01-28
S903-21 Cylinder Lubrication
Testbed Commissioning Procedure

11. 11. Check the common alarm connection by

simulation. Follow the HMI panel menu in-
Engine Alarm System
struction to activate a common alarm from
the lubricator system as shown below.

S90321-11
Connt. Co.ALr oFF/on

Common Alarm
12. Check the timing adjustment as described
in Procedure S903-20.
S903-21 11

12.

Alpha Lub. test doc.

Injection angle:
Programmed Corrected

Cyl. 1: 270

Cyl. 2:

Cyl. 3:
S903-20 04

Page 6 (8) When referring to this page, please quote Procedure S903-21
2003-01-28 0$1% :'LHVHO$6
 Cylinder Lubrication S903-21
Testbed Commissioning Procedure

13. Carry out the tests according to the testbed

test scheme and fill in the check boxes

Alpha lubricator testbed trial test scheme Activated alarm outputs

Function to be Alarm number Com- MCU BCU BCU in MCU BCU Slow- Checked
Test
tested: Test by displayed on Action mon power power control fail fail down
No.
HMI panel alarm fail fail

1 Standby pump Switching master pump (39) + 49 Stand-by pump starts X

OFF local side

2 BCU take-over, Disconnecting plugs on Various Change over to BCU

standby pump both lubricators for one control and standby
X X X X
start and slow- cylinder pump start, slow-down
down output

3 Common alarm Simulating common Common alarm turns

output alarm from HMI panel ON in alarm system
menu

4 Engine stop sig- Simulating Stop signal MCU LED D80 above
nal plug J30 lights Simulate engine stop signal from engine control system
BCU LED D49 above
plug J5 lights

(): logged alarm Alarm output terminal

number from:

X1 1+2 3+6

X1 9 + 12 13+14 15+16 17+18

X1 7+8

14. When the engine load is increased to 50%

load, calibrate the index transmitter at this 14.
load by means of the index transmitter ad- 120
justment menu in the HMI panel. Engine speed
Follow the example in drawing 14.a. 120
Index
100 bar
Oil pressure

°C rpm

Deg. %

Min. bar
Oil pressure low
Index failure

Mark/trig failure PRESS

Feedback failure

Common alarm

LAMPTEST ESC ENTER

S903-21 21

PUMP 1 PUMP 2 PRELUB.

When referring to this page, please quote Procedure S903-21 Page 7 (8)
0$1% :'LHVHO$6 2003-01-28
S903-21 Cylinder Lubrication
Testbed Commissioning Procedure

14a. Password

ESC ENTER

50%
Prop 100%
Gen
SETUP PASS in.AdJ Value
S903-21 22

(Password)

15. When the engine load is increased further

to 100% load, calibrate the index transmit-
ter at this load by means of the index trans-
mitter adjustment menu on the HMI panel.
Follow the HMI panel menu instruction.

15.
120
Engine speed
120
Index
100 bar
Oil pressure

°C rpm

Deg. %

Min. bar
Oil pressure low
Index failure

Mark/trig failure PRESS

Feedback failure

Common alarm

LAMPTEST ESC ENTER

S903-21 21

PUMP 1 PUMP 2 PRELUB.

Page 8 (8) When referring to this page, please quote Procedure S903-21
2003-01-28 0$1% :'LHVHO$6
 Cylinder Lubrication S903-20
Check of Injection Timing
Cylinder Lubrication
S50MC
20
Check of Injection Timing
S903-20

Injection timing 2.

1. Adjust the shaft encoder in accordance with

Procedure 905-8.3.

2. Remove the lubricator timing hole plug from

the exhaust side of cylinder liner No. 1. If
there is no timing hole, remove one cylinder
oil lubricating point non-return valve from
cylinder liner No. 1.

3. Turn the engine to BDC Cyl. 1. Check that

the timing hole is clean. Turn the engine

S903-20 02
ahead until the upper edge of the top piston
ring becomes visible.

3.
Note!

Compressed air is coming out of the tim-

ing hole when the piston is turned
upwards. Use eye protection.

4. Note the crank angle on the turning wheel. Piston ring

5. Compare the angle obtained with the angle

stated on the test sheet in the lubricator
S903-20 03

control unit. If the reading is not within the

tolerance stated on the test sheet, correct
all angles in the test sheet with the ob-
served difference.
4.

Alpha Lub. test doc.

Injection angle:
Programmed Corrected

Cyl. 1: 270

Cyl. 2:

Cyl. 3:
S903-20 04

When referring to this page, please quote Procedure S903-20 Page 1 (2)
0$1% :'LHVHO$6
S903-20 Cylinder Lubrication
Check of Injection Timing

6. 6. Run the engine at steady load. Read all in-

jection angles on the HMI panel.

Navigating in the HMI panel menu is done

as follows:

• [ENTER] goes forward (right) in

the menu or changes a set point.

• [ESC] goes backwards (left) in the menu.

• [ ] goes up in the menu.

• [ ] goes down in the menu.

7. Read all injection angles in the HMI panel,

starting at the [diSP] menu and follow the
sketch.

Check that the angles correspond with the

S903-20 06

angles on test sheet.

7.
S903-20 07

8. In case the angles are not within the stated

tolerance, adjust the common offset value
in the HMI panel SEtup menu.
See the sketch.

8.
S903-20 08

9. When the Injection offset [InJ.OF] is

checked or adjusted (if adjusted) press
[ENTER] (the HMI panel will display
[SAVE]). Return to the main menu by press-
ing [ESC].

Page 2 (2) When referring to this page, please quote Procedure S903-20
0$1% :'LHVHO$6
 Alpha lubricator testbed trail test scheme Alarm outputs to be activated

Alarm number Checked

Test Common MCU BCU power
Function to be tested: Test by displayed in HMI Action BCU in ctrl. MCU fail BCU fail Slow down
Nr alarm power fali fali
panel

Simulate common alarm from HMI panel Common alarm turns ON in alarm
1 Common alarm output
menu system
MCU LED D80 above plug J30 light
2 Engine stop signal Simulating Stop signal Simulate engine stop signal from engine control system
BCU LED D49 above plug J5 light

3 Standby pump Switch master pump OFF local side (39) + 49 Standby pump starts X

BCU take-over, standby pump Disconnect Plugs on both lubricatores Change over to BCU control and
4 Varius X X X X
start and slowdown output one cylinder standby pump start, slowdown

( ) : logged alarm Alarm output terminal number from:

Valid for ALCU system and MCU software Rev 1.6X X1 1 and 2 3 and 6
X1 9 and 12 13 and 14 15 and 16 17 and 18
X1 7 and 8
* Note that the control switch must be in AUTO position during the test
* All tests can be made with Engine running low load or with trigger simulator without engine running
* After every test the logged alarms must be deleted in the HMI panel
* After test 4 the control switch must be changed to MCU and back to AUTO mode

Minimum requirements at test bed is common alarm to be connected to AMS system

Basic Standards (MBD SB) & Suppl. Drawing No.: EN21C Surf. roughness Material / Blank:
EN21F-m Tolerances
Mass (kg) Final User Matrial:

Date Des. Chk. Appd. A.C. Change / Replacement

* Replaced by Ident No.: 9
8
7
6
5
4
3
2
1
20020430 DFA NSL JHV 0
Similar Drawing no.: Replacement for Ident no.:

Scale: Size: Type Page No.:

Testbed trail test scheme MAN B&W Diesel A/S
1:1 A3 01 (01)
Info No. Description Ident. No.

This drawing is the property of MAN B&W Diesel A/S and is to be treated as confidential by the party to whom it has been submitted by 3 02 023 INSTRUCTION 0788812-9
MAN B&W Diesel A/S and is not to be disclosed to any third party without the specific prior written permission of MAN B&W Diesel A/S Final User Info No. Final User Description Final User Ident. No.
Blank
 Cylinder Lubrication S903-0039
MAN B&W Dock Trial Commissioning Procedure

ALCU –
1.
Dock Trial Commissioning Procedure

1. Disconnect the connections to the HMI

panel. (HMI panel side).

2. Check the power supply for correct polarity

before connecting the power to the ALCU
control box terminals. Check both Main A
and Main B.

3. Check the HMI panel power connection

for correct polarity, and connect the HMI
panel.

S9030039,01
2.
+
TB x 1 V
Alcu Box

24V DC

L+
L Main B
S9030039,02

L+
L Main A

3.

+ 

24V DC
S9030039,03

When referring to this page, please quote S-Instruction S903 Edition 0039 Page 1 (5)
S903-0039 Cylinder Lubrication
Dock Trial Commissioning Procedure MAN B&W

4. 4. Check the adjustment of the angle encoder.

Turn the engine until the LED on the en-
coder junction box lights up, and check
that the crank angle reading is 0° on the
flywheel (TDC cylinder 1). See Procedure
905-8.

Adjust the BCU pick-ups, as described in

Procedure 905-7.

5. Check the connections to the lubricators by

activating the lubricators one by one via the
HMI panel connection test menu. Follow
the HMI panel menu instruction.
S9030039,04

6. Check the lubricator system by activating

the pre-lubrication function. Press the ESC
button and the PRELUB button on the HMI
panel simultaneously. Check that no feed-
5.
back alarm is activated.
S9030039,05

PRESS

6.

PRESS
S9030039,06

Page 2 (5) When referring to this page, please quote S-Instruction S903 Edition 0039
 Cylinder Lubrication S903-0039
MAN B&W Dock Trial Commissioning Procedure

7. Turn the engine to approx. 10° before TDC

7A.
of cylinder No. 1.
TDC Cyl. 1
Continue turning the engine and check that
the small LEDs on the MCU unit – desig-
nated D88 (above J20) D90, D91 (above
J22) – flash when the engine is turned and 350°
passes TDC of cylinder No. 1. 0°

Also check that the LED on the MCU unit

– designated D89 (above J20) – flashes ap-
prox. twice each second.

S9030039,07A

7B.

MCU Board
S9030039,07B

When referring to this page, please quote S-Instruction S903 Edition 0039 Page 3 (5)
S903-0039 Cylinder Lubrication
Dock Trial Commissioning Procedure MAN B&W

8A. LCD connections and setup for CPP plants

(Only for controllable pitch propeller plants)
PASS
PASS Password=
Password= esc enter 8. If the vessel is equipped with a controllable
pitch propeller the Load Change Depend-
ent extra lubrication (LCD) must be con-
in.Adj
nected and commissioned as follows:

An active 4 to 20 mA signal (not power

ti.Adj supplied from ALCU) “Telegraph handle
position”, i.e. a signal representing the or-
dered engine power must be connected
from the remote control system or tel-
SEtuP Lcd P.6 100
egraph system to ALCU/X1:33 and ALCU/
S9030039,08A

X1:34. The LCD signal connections from

the governor to ALCU/X2:1 and ALCU/X2:2
must be omitted.

Scaling:
8B.
4 mA zero load
PASS
PASS 20 mA max. handle position (overload)
Password=
Password= esc enter
The signal may be generated by the remote
control system as:
in.Adj Pitch set % * RPM set % if convenient.

The configuration of the ALCU is carried

ti.Adj
out as follows:
SEtuP/LCd/P.1 = tELE.P
SETuP/LCd/P.6 = 100

SEtuP Lcd P.1 TELE.P See Figs. 8A and 8B and also section
S9030039,08B

3.2.9, Menu Structure (-part 2).

Page 4 (5) When referring to this page, please quote S-Instruction S903 Edition 0039
 Cylinder Lubrication S903-0039
MAN B&W Dock Trial Commissioning Procedure

9. Carry out the external connection test ac-

cording to the dock trial test scheme and
fill in the check boxes.

A l pha l u br i cator dock tr i al tes t s ch eme A cti v ated al ar m ou tpu ts

Test Function to be Test by Alarm number Com- MCU BCU BCU in MCU BCU Slow- Checked
No. tested: displayed on Action mon power power control fail fail down
HMI panel alarm fail fail

1 External alarm Disconnecting X1 Change over to BCU X X X X

signals to AMS PWR A – L+ control

2 External alarm Disconnecting X1 30+35+43 BCU power fail alarm X X X X

signals to AMS PWR B – L+

3 Engine stop Simulating Stop signal MCU LED D80 above

signal plug J30 lights Simulate engine stop signal from engine control system
BCU LED D49 above
plug J5 lights

4 Ahead/Astern Simulating Astern MCU LED D78 above Simulate Astern signal from engine control system
signal signal plug J30 light

5 Pre-lubrication Simulating pre. Lub. Pre lubrication Simulate pre-lubrication signal from engine control system
signal signal sequence start

6 Standby pump Switching master pump (39) + 49 Standby pump starts X

OFF local side
S903-0039,09

7 BCU take-over, Disconnecting plugs on 44 Change over to BCU X X X X

stand-by pump both lubricators for one control and standby
start and slow- cylinder pump start, slow-down
down output

(): logged alarm Alarm output terminal

number from:

X1 1+2 3+6

X1 9 + 12 13+14 15+16 17+18

X1 7+8

When referring to this page, please quote S-Instruction S903 Edition 0039 Page 5 (5)
Blank
 Alpha lubricator dock trail test scheme Activated alarm outputs
Alarm number Checked
Function to be Common MCU BCU BCU in Slow
Test Nr Test by displayed in HMI Action MCU fail BCU fail
tested: alarm power fali power fali ctrl. down
panel
External alarm signals
1 Disconnect X1 - PWR A – L+ Change over to BCU control
to AMS X X X X
External alarm signals
2 Disconnect X1 - PWR B – L+ 30+35+43 BCU power fail alarm
to AMS X X X X
MCU LED D80 above plug J30 light
3 Engine stop signal Simulating Stop signal Simulate engine stop signal from engine control system
BCU LED D49 above plug J5 light

4 Ah/As signal Simulating Astern signal MCU LED D78 Above plug J30 light Simulate Astern signal from engine control system

5 Prelubrication signal Simulating pre. Lub. signal Prelubrication sequence start Simulate prelubrication signal from engine control system

Switch master pump OFF local

6 Standby pump (39) + 49 Standby pump starts
side X
BCU take-over,
Disconnect Plugs on both Change over to BCU control and standby
7 standby pump start 44
lubricatores one cylinder pump start, slowdown X X X X
and slowdown output
( ) : logged alarm Alarm output terminal number from:

Valid for ALCU system and MCU software Rev 1.6X X1 1 and 2 3 and 6

X1 9 and 12 13 and 14 15 and 16 17 and 18

X1 7 and 8
* Note that the control switch must be in AUTO position during the test
* All tests can be made with Engine running low load or with trigger simulator without engine running
* After every test the logged alarms must be deleted in the HMI panel Date
* After test 7 the control switch must be changed to MCU and back to AUTO mode
Sign.

Basic Standards (MBD SB) & Suppl. Drawing No.: EN21C Surf. roughness Material / Blank:
EN21F-m Tolerances
Mass (kg) Final User Matrial:

Date Des. Chk. Appd. A.C. Change / Replacement

* Replaced by Ident No.: 9
* 8
* 7
* 6
* 5
* 4
* 3
* 2
20021113 DFA NSL JHV Z4 Drawing updated. 1
20020430 DFA NSL JHV * 0
Similar Drawing no.: Replacement for Ident no.:

Scale: Size: Type Page No.:

Dock trail test scheme MAN B&W Diesel A/S
1:1 A3 01 (01)
Info No. Description Ident. No.

This drawing is the property of MAN B&W Diesel A/S and is to be treated as confidential by the party to whom it has been submitted by 3 02 023 INSTRUCTION 0788811-7
MAN B&W Diesel A/S and is not to be disclosed to any third party without the specific prior written permission of MAN B&W Diesel A/S Final User Info No. Final User Description Final User Ident. No.
Blank
Index
Operation

Commissioning

Maintenance

Components

Electrical Wiring
Blank
 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 Lubricators
S42MC
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
 Cylinder Lubricators 903-2.1
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.

When referring to this page, please quote Procedure M90302 Edition 0236 Page 3 (10)
0$1% :'LHVHO$6
903-2.2 Cylinder Lubricators
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.

Page 4 (10) When referring to this page, please quote Procedure M90302 Edition 0236
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.2
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.

When referring to this page, please quote Procedure M90302 Edition 0236 Page 5 (10)
0$1% :'LHVHO$6
903-2.3 Cylinder Lubricators
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

Page 6 (10) When referring to this page, please quote Procedure M90302 Edition 0236
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.3
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

When referring to this page, please quote Procedure M90302 Edition 0236 Page 7 (10)
0$1% :'LHVHO$6
903-2.3 Cylinder Lubricators
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

Page 8 (10) When referring to this page, please quote Procedure M90302 Edition 0236
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.3
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

When referring to this page, please quote Procedure M90302 Edition 0236 Page 9 (10)
0$1% :'LHVHO$6
903-2.4 Cylinder Lubricators
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

Page 10 (10) When referring to this page, please quote Procedure M90302 Edition 0236
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.1
MAN B&W Diesel Checking

Check of Oil Injection:

1.
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 lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.

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.
M903020245C01

3.
M903020245C02

When referring to this page, please quote Procedure M90302 Edition 0249 Page 1 (12)
903-2.1 Cylinder Lubricators
Checking MAN B&W Diesel

With running engine:

4.
3. Check that all lubricators are operating cor-
Inlet
rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.

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.
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.
See Procedure 903-2.2.

For nitrogen pressure in the accumulators,

see Data.

Page 2 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.1
MAN B&W Diesel Checking

6. Use of Pressure Setting Tool

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
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean.

M903020247C07
Mount the filling valve on the relevant accu-
mulator with the union nut. Check that
valves C and F are closed.

Loosen the plug screw in the accumulator

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
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
Data.

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 accu-
mulator.

When referring to this page, please quote Procedure M90302 Edition 0249 Page 3 (12)
903-2.2 Cylinder Lubricators
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,
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
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.

Page 4 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.2
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.

When referring to this page, please quote Procedure M90302 Edition 0249 Page 5 (12)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W Diesel

1. Place the lubricator in a bench vice with

1. 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.

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

Page 6 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.3
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.

5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
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

When referring to this page, please quote Procedure M90302 Edition 0249 Page 7 (12)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W Diesel

7. Pre-assemble the cylinder blockwith the

7. 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 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

Page 8 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.3
MAN B&W Diesel Overhaul

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

remove and discard the O-ring.

Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.

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

When referring to this page, please quote Procedure M90302 Edition 0249 Page 9 (12)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W Diesel

11. Before mounting the feedback sensor,

11. 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.

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

Page 10 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.3
MAN B&W Diesel Overhaul

14. Mount the cylinder block assembly in the

cylinder housing. 14.

Check that the spring pin engages cor-

rectly with the cylinder block assembly.

Mount the screws and tighten the block to

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
Mount the oil accumulator.

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

When referring to this page, please quote Procedure M90302 Edition 0249 Page 11 (12)
903-2.4 Cylinder Lubricators
Mounting MAN B&W Diesel

1. Before mounting the accumulator, check

1. Inlet 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.
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

Page 12 (12) When referring to this page, please quote Procedure M90302 Edition 0249
 Cylinder Lubricators 903-2.1
Checking
0237
Cylinder Lubricators
K98MC
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 0237 Page 1 (10)
0$1% :'LHVHO$6
903-2.1 Cylinder Lubricators
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.

6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
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

Page 2 (10) When referring to this page, please quote Procedure M90302 Edition 0237
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.1
Checking

7. C
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean. A E
Mount the filling valve on the relevant accu- D-3 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.

When referring to this page, please quote Procedure M90302 Edition 0237 Page 3 (10)
0$1% :'LHVHO$6
903-2.2 Cylinder Lubricators
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

secure the lubricator to the hydraulic block,
and remove the lubricator.

Dismantling of accumulators:

4. Inlet Accumulator
Close the valve that connects the accumu-
lator to the distributor block.

Mount the special hose on the minimess

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

Page 4 (10) When referring to this page, please quote Procedure M90302 Edition 0237
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.2
Dismantling

5. Outlet Accumulator 4.
Close the supply valve for the accumulator
concerned, using the special tool. The out-
er valve is for accumulator marked A and
the inner valve is for accumulator marked
B. A B

Let the lubricator inject oil until the feed-

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 .

When referring to this page, please quote Procedure M90302 Edition 0237 Page 5 (10)
0$1% :'LHVHO$6
903-2.3 Cylinder Lubricators
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.

EN903-2.3 219 01

3. Pull up the cylinder block.

Remove the spring and actuator piston with

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

Page 6 (10) When referring to this page, please quote Procedure M90302 Edition 0237
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.3
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.

NA903-2.3 222 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

When referring to this page, please quote Procedure M90302 Edition 0237 Page 7 (10)
0$1% :'LHVHO$6
903-2.3 Cylinder Lubricators
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 2 Solenoid valve
7. Fit the cylinder block with new O-rings.
3 BN (brown)
4 BK (black) Feedback sensor
5 BU (blue) Assemble the non-return valves in the cyl-
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 1
5 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

Page 8 (10) When referring to this page, please quote Procedure M90302 Edition 0237
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.3
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.

9. Mount the cylinder block assembly in the

cylinder housing.

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

Mount the screws and tighten the block to

the housing. 9.

Remove the M6 x 60 screw with disc.

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.
NA903-2.3 222 09

Cover all surfaces with a thin layer of oil.

10.
EN903-2.3 219 01

When referring to this page, please quote Procedure M90302 Edition 0237 Page 9 (10)
0$1% :'LHVHO$6
903-2.4 Cylinder Lubricators
Mounting
Mounting
903-2.4

1. Mounting of Lubricators

1. 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 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.
See Procedure 903-2.1.
NA903-2.4 222 02

3.
NA903-2.4 222 03

Page 10 (10) When referring to this page, please quote Procedure M90302 Edition 0237
0$1% :'LHVHO$6
 Cylinder Lubricators 903-2.1

MAN B&W Checking

Check of Oil Injection:

1.
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 lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.

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.
M903020245C01

With running engine:

3. Check that all lubricators are operating cor-

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

inder liner to observe the oil flow.
M903020245C02

When referring to this page, please quote Procedure M90302 Edition 0256 Page 1 (13)
903-2.1 Cylinder Lubricators
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.

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 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.

6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
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

Page 2 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.1

MAN B&W Checking

7. Before mounting the filling valve on the ac-

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
Loosen the plug screw in the accumulator
using a ½” square drive handle in socket E.
B
It is now possible to read the actual nitro-
gen pressure in the accumulator on the dial
gauge on the filling valve.

M903020247C07
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 12 bar above the pressure stated in
Data.

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 accu-

mulator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.

When referring to this page, please quote Procedure M90302 Edition 0256 Page 3 (13)
903-2.2 Cylinder Lubricators
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

Let the lubricator inject oil until the feed-

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

secure the lubricator to the hydraulic block,
and remove the lubricator.
M903020256D02

Page 4 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.2

MAN B&W Dismantling

Dismantling of accumulators:
4.
4. Inlet Accumulator
Close the valve that connects the accumu-
lator to the distributor block.
Mount the special hose on the minimess
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
concerned, using the special tool. The out-
er valve is for accumulator marked A and
the inner valve is for accumulator marked
B.
5.
Let the lubricator inject oil until the feed-
back LED stops flashing.
A B

If space conditions permit, unscrew the ac-

cumulator; otherwise the lubricator must be
dismounted, see Step 1.
M903020256D05

When referring to this page, please quote Procedure M90302 Edition 0256 Page 5 (13)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W

1. Place the lubricator in a bench vice with

1. soft “jaws”.

Remove the adjusting screw with bushings.

Unscrew the oil accumulator.

Discard the Oring from the adjusting

screw.

2. Remove the screws from the cylinder block.

3. Pull up the cylinder block.

Remove the spring and actuator piston with

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

Page 6 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.3

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.

5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass.

6. Fit the nonreturn valve with new Orings.

Mount the nonreturn valves in the cylinder

block.

M903020247O04
5.
M903020247O05

6.
M903020247O06

When referring to this page, please quote Procedure M90302 Edition 0256 Page 7 (13)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W

7. Preassemble the cylinder blockwith the

7. 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 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

and disconnect the wires for the feedback
(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

Clean the housing with diesel oil or kero-

sene and dry with a nonfluffy cloth.

8.
M903020247O08

Page 8 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.3

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.

11. Before mounting the feedback sensor,

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

Mount the feedback sensor or a new one, if

necessary, with a new Oring.

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
M903020244O12

the actuator piston cylinder.

Mount the terminal box.

11.
M903020245O10

1 1
2 2 Solenoid valve
3 BN (brown)
BK (black)
4
BU (blue) Feedback sensor
5

When referring to this page, please quote Procedure M90302 Edition 0256 Page 9 (13)
903-2.3 Cylinder Lubricators
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.

14. Mount the cylinder block assembly in the

Brown+15
cylinder housing.
Blue OV

Black FBsignal Check that the spring pin engages correctly

with the cylinder block assembly.
M903020242O08

Mount the screws and tighten the block to

the housing.

Remove the M6 x 60 screw with disc.

13.
M903020247O13

14.
M903020247O14

Page 10 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.3

MAN B&W Overhaul

15. Mount the adjusting screw fitted with a new

Oring and the distance bushing. 15.

Mount the oil accumulator.

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.

Cover all surfaces with a thin layer of oil.

M903020247O01

When referring to this page, please quote Procedure M90302 Edition 0256 Page 11 (13)
903-2.4 Cylinder Lubricators
Mounting MAN B&W

Mounting of Lubricators
1.
1. Mount new Orings on the hydraulic block
and on the cover with pipes.

Mount the lubricator and tighten the screws

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

Page 12 (13) When referring to this page, please quote Procedure M90302 Edition 0256
 Cylinder Lubricators 903-2.4

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

When referring to this page, please quote Procedure M90302 Edition 0256 Page 13 (13)
Blank
 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
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

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

When referring to this page, please quote Data D10507 Edition 0006 Page 1 (2)
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

Page 2 (2) When referring to this page, please quote Data D10507 Edition 0006
 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

When referring to this page, please quote Procedure M90507 Edition 0205 Page 1 (3)
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.
M90603
0218C01

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

Page 2 (3) When referring to this page, please quote Procedure M90507 Edition 0205
 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

When referring to this page, please quote Procedure M90507 Edition 0205 Page 3 (3)
Blank
 Angle Encoder 105-8
Data

SAFETY PRECAUTIONS
Special Edition
MC
D10508
105-8 Data 0007 Angle Encoder

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
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10508 Edition 0007 Page 1 (2)
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

Page 2 (2) When referring to this page, please quote Data D10508 Edition 0007
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
mark on the turning wheel.

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

When referring to this page, please quote Procedure M90508 Edition 0206 Page 1 (4)
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

Page 2 (4) When referring to this page, please quote Procedure M90508 Edition 0206
 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
mark on the turning wheel.

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

When referring to this page, please quote Procedure M90508 Edition 0206 Page 3 (4)
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

Page 4 (4) When referring to this page, please quote Procedure M90508 Edition 0206
 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
rpm
values can be found in the shoptest report). °C

Deg. %

Min. bar
Navigate, via the HMI panel, to the Index Oil pressure low
Index failure
Adjust menu.
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)
Blank
Index
Operation

Commissioning

Maintenance

Components

Electrical Wiring
Blank
 Cylinder Lubricator Assy Plate
P90307-0008
3
&\OLQGHU/XEULFDWRU$VV\


When referring to this page, please quote Plate P90307 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Lubricator Assy
P90307-0008

Item Item
Item Description Item Description
No. No.
700 Screw
018 Accumulator membrane
031 Shim
043 Distributor block
055 Studs
067 Nut
079 Coupling, minimess
114 Ball valve
126 Coupling
138 Distributor block
151 Stud
175 Spring pin
199 Lubricator
209 Screw
222 Accumulator membrane
234 Shim
258 Distributor block
271 Plug screw
295 O-ring
317 Non-return valve
329 Disc
330 Circlip
342 Plug screw
366 Terminal box, complete
378 Screw
391 Cable
401 O-ring
413 Inductive sensor, complete
437 Steel ball
449 Spring
462 Screw
474 O-ring
498 Coupling
508 Adjustment screw
521 Spacer
533 Cover
545 Cylinder block
557 Cover
569 Cylinder block
570 O-ring
582 Spring
594 O-ring
616 Screw
628 Screw
653 Plunger
665 Cylinder housing
677 Actuator piston
690 Solenoid valve, complete

Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0008
MAN B&W Diesel A/S
 Cylinder Lubricator Assy Plate
P90307-0011
3
&\OLQGHU/XEULFDWRU$VV\


C
A

A-A

When referring to this page, please quote Plate P90307 Edition 0011 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Lubricator Assy
P90307-0011

Item Item
Item Description Item Description
No. No.

018 Ball valve

031 Stud
043 Nut
055 Hydraulic block
079 Plug screw
092 Intermediate pipe
102 O-ring
126 Membrane accumulator
138 Shim
163 Coupling
187 Hydraulic block
209 Stud
210 Ball valve
234 O-ring
246 Mounting of pick-up, complete
271 Screw
295 Enclosure, complete
305 Screw
329 Membrane accumulator
330 Shim
354 Lubricator
366 Spring pin
391 Steel ball
401 Spring
413 Screw
437 O-ring
449 Union
462 Adjustment screw
474 Spacer
486 Cover
508 Screw
521 Screw
533 Cover
545 Cylinder block
557 O-ring
570 Spring
582 O-ring
604 Plunger
628 Cylinder housing
641 Actuator piston
665 Screw
677 Solonoid valve, complete

Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0011
MAN B&W Diesel A/S
 Cylinder Lubricator Unit Plate
MAN B&W P90307-0036

When referring to this page, please qoute Plate P90307 Edition 0036 Page 1 (2)
Plate Cylinder Lubricator Unit
P90307-0036 MAN B&W

Item Item Description

No.
018 Ball valve
031 Stud
043 Hydraulic block
055 Nut
067 Plug screw
080 O-ring
092 Intermediate pipe
114 Adjustable elbow coupling
126 Nut
138 Ball valve
151 Stud
175 Lubricator, complete
187 O-ring
199 Hydraulic block
209 Gasket
210 Membrane accumulator
234 Screw
258 Adjusting screw
271 O-ring
283 Spacer, tubular
295 Cover
305 O-ring
317 Non-return valve
329 O-ring
330 Cylinder block
342 O-ring
354 Spring
366 Plunger
378 Actuator piston
391 Straight stud coupling
401 Screw
413 Screw
437 Cylinder housing
449 Solenoid valve complete
450 Screw
474 Membrane accumulator
486 Gasket
498 O-ring
508 O-ring
521 Inductive sensor
533 Cable
545 Cable gland, complete
569 Housing
570 Plug
582 Plug
594 Screw

Note:
*

Page 2 (2) When referring to this page, please qoute Plate P90307 Edition 0036
 Cylinder Lubricator Unit Plate
MAN B&W P90307-0045

When referring to this page, please quote Plate P90307 Edition 0045 Page 1 (2)
Plate
Cylinder Lubricator Unit
P90307-0045 MAN B&W

Item Item Description Item Item Description

No. No.

018 Membrane accumulator

031 Gasket
043 Nut
055 Distributor block
067 Stud
079 Ball valve
080 Distributor block
102 Stud coupling
114 Adjusting screw
126 O-ring
138 Spacer
151 Cover
163 O-ring
175 Non-return valve
187 O-ring
199 Cylinder block
209 O-ring
210 Spring
222 Plunger
234 Actuator piston
258 Quick coupling, minimess
271 Stud
283 Plug screw
295 Banjo coupling
305 Screw
317 Screw
329 Plug screw
330 Retaining ring
342 Disc
354 Non-return valve
366 Distributor block
378 Membrane accumulator
391 Gasket
401 Cylinder housing
413 Elbow coupling
425 O-ring
437 Plug screw
449 Solenoid valve complete
450 Screw
462 O-ring
474 O-ring
486 Inductive sensor
498 Screw
508 Housing
521 Plug
533 Plug
545 Screw
557 Cable
569 Cable gland, complete

Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0045
 Cylinder Lubricator - Intermediate Box Plate
P90308-0010
3
&\OLQGHU/XEULFDWRU,QWHUPHGLDWH%R[


A A

A A

When referring to this page, please quote Plate P90308 Edition 0010 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Lubricator - Intermediate Box
P90308-0010

Item Item
Item Description Item Description
No. No.

013 Intermediate box, complete

037 Electric enclosure with cables
049 Printed circuitboard
062 Light emitting diode

Page 2 (2) When referring to this page, please quote Plate P90308 Edition 0010
MAN B&W Diesel A/S
 Arrangement of Angle Decoder Plate
P90503-0017
3
$UUDQJHPHQWRI$QJOH'HFRGHU


A-A

When referring to this page, please quote Plate P90503 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Angle Decoder
P90503-0017

Item Item
Item Description Item Description
No. No.

013 Measuring instrument, axial vibration

damper
037 Screw
049 Angle encoder
050 Housing
062 Screw
074 Shaft
086 Intermediate box
098 Coupling
108 Damper plate
121 Cable ties
145 Tools
157 Packing
169 Screw
170 Spring lock
182 Spring pin
204 Shaft
228 Packing
241 Washer
253 Shield
265 Packing

Page 2 (2) When referring to this page, please quote Plate P90503 Edition 0017
MAN B&W Diesel A/S
Index
Operation

Commissioning

Maintenance

Components

Electrical Wiring
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