Maintenance of Booster Unit

for

Alpha Cylinder Lubricator

for

MAN B&W Diesel A/S

Maltvej 12 9700 Brnderslev Denmark Tel. +45 70 10 09 11 Fax +45 98 80 09 08 E-mail: info@serman-tipsmark.dk www.serman-tipsmark.dk

Serman & Tipsmark A/S

Contents:
1. Identification of Block Components .............................................................. 3 2. Changing the Pressure Filter Element ............................................................ 6 3. Changing the Suction Filter Element ............................................................. 8 4. Setting the Pressure ........................................................................................ 9 5. Changing the Pressure Transducer ............................................................... 10 6. Changing the Pressure Gauge ...................................................................... 12

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1. Identification of Block Components

Fig. 1: Location of Block

Components can only be removed while both motors are not running, unless otherwise stated.

PRESSURE GAUGE

Fig. 2: Diagram of hydraulic system

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P11 Pressure out

(Numbers in boxes refer to diagram in Fig. 2).

P21 Tank P16

Fig. 3: Top view

P14 P9 P17

Fig. 4: Side view

P18 P26 P13

P15

Fig. 5: Front view Page 4 of 12

P11

PLUG

Note: Needle valve P10 is not fitted on all blocks. In that event, a plug is fitted in its place.

P10 (P11)

P10 (PLUG)
See remark

Fig. 6: Side view

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2. Changing the Pressure Filter Element

FILTER INDIKATOR

SHUT OFF VALVE PRESSURE FILTER

Fig. 7: Location of pressure filter

Fig. 7 shows lever for shut-off valve in operation mode (horisontal). The shut off valve must be closed before changing the filter element. Procedure for changing the pressure filter element: 1. Turn lever up ( vertical ) thereby closing the valve and bypassing the filter. Fig. 8.

Fig. 8: Shut-off lever in closed position (vertical)

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2. Unscrew the filterbowl by turning clockwise (CW). Key with: KW30. Fig. 9.

Fig. 9: Filterbowl being unscrewed

3. Remove element and replace. Fig. 10. 4. Check condition of O-ring. Replace, if necessary. 5. Remount filterbowl. Turn counter-clockwise (CCW).

Fig. 10: Replacement of filterbowl

6. Reset filter indicator. Fig. 11. 7. Set lever position to open ( horisontal) on shut off valve.

Fig. 11: Reset filter indicator

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3. Changing the Suction Filter Element

Fig. 12: Location of suction filters

The suction filters are duplicated. The element can be replaced only when the suction filter is not in operation. Procedure for replacement of the suction filter: 1. Make sure the suction filter you want to replace is not in operation. Unscrew filter top CCW. Key with: KW30. Fig. 13.

Fig. 13: Filter top being unscrewed

2. Remove element and replace. Fig. 14. 3. Check condition of O-ring. Replace, if necessary. 4. Remount filterbowl. Turn CW.
Fig. 14: Replacement of suction filter Page 8 of 12

4. Setting the Pressure

Fig. 15: Location of pressure relief valve

The pressure relief valve is preset to 45 bar. Procedure for setting the pressure: 1. Remove plastic cap. Fig. 16.

Fig. 16: Plastic cap being removed

2. Turn lock nut CCW, KW19, to loosen. Fig. 17. 3. With screwdriver, turn screw CW to raise pressure, CCW to lower pressure. 4. Turn lock nut CW to tighten. 5. Replace plastic cap.
Fig. 17: Loosening the nut-screw

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5. Changing the Pressure Transducer

While changing the transducer the signal is not active.

Fig. 18: Location of pressure transducer with needle valve shown

Procedure for changing the pressure transducer: 1. Close the needle valve by turning CW, thereby isolating the transmitter. Fig. 19.
2

Fig. 19: Needle valve being closed

2. Note: On newer systems, the needle valve (2) shown in Fig. 19, does not exist on all blocks.

Fig. 20:

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3. The transducer can now be replaced, KW27. Fig. 21. 4. After replacement, open the needle valve by turning CCW.

Fig. 21: Replacement of transducer

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6. Changing the Pressure Gauge

Fig. 22: Location of pressure gauge with needle valve shown

While changing the pressure gauge the signal is not active. Procedure for changing the pressure gauge: 1. Close the needle valve by turning CW, thereby isolating the pressure gauge. 4. The pressure gauge can now be replaced, KW18. Fig. 23. After replacement, open the needle valve by turning CCW.

Fig. 23: Replacement of pressure gauge

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