Man B& W G50me-B, Volume I

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MAN B&W 0205-0100-0001
Warning
It is important that all MAN Diesel engines are operated within the
given specifications and performance tolerances specified in the
engines‘ Technical Files and are maintained according to the MAN
Diesel maintenance instructions, in order to comply with given
emission regulations.
In accordance with Chapter I of the code of Federal Regulations, Part

94, Subpart C, §94.211, NOTICE is hereby given, that Chapter I of the
Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires
that the emissions related maintenance of the diesel engine, shall be
performed as specified in MAN Diesel instructions, including, but not
limited to, the instructions to that effect included in the Technical File.
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Preface
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MANB&W
B&W
Technical Documentation
G50ME-B9.2-TII
MAN B&W G50ME-B9.2-TII
Design Specification: 4207464-2
Preface
Original instructions
1 (2)
MAN B&W
G50ME-B9.2-TII
MAN Diesel & Turbo

DK-2450 Copenhagen SV
Phone +45 3385 1100
Fax +45 3385 1030
[email protected]
www.mandieselturbo.com
Preface
Copyright © MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
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MANB&W
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Preface Introduction .............................. ............................. 0220-0100-0001
Table of Content and Introduction

Preface Chapter Preface Chapter .......................... .......................... 0240-0100-0002
Table of contents
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MAN B&W 0220-0100-0001
Introduction
Introduction
1. MAN Diesel | PrimeServ
The MAN Diesel Group offers worldwide round-the-clock service, 365 days a
year. Apart from the MAN Diesel service headquarters in Augsburg, Copenha-
gen, Frederikshavn, Holeby, Stockport, St. Nazaire, Turbocharger and service
centres on all continents provide comprehensive and continuous support. The
long service life associated with MAN Diesel engines dictates a spare parts
programme that ensures components are available for engines in operation for
decades. Based on high-capacity machines, MAN Diesel service production
facilities are able to comply with special customer requests with the utmost pre-
cision and flexibility.
24-hour hotline number:
+49 1801 15 15 15
http://www.mandiesel.com/primeserv
2. The manual
The purpose of this manual is to provide general guidance regarding the op-
eration and maintenance, of a standard version of a MAN Diesel product e.g.
a main engine, auxilliary engine or propeller as well as to describe the design
features of such a product. This manual is of guidance only and if any doubt
should arise regarding any data stated in this manual then the engine builder’s
documentation should be reffered to and/or MAN Diesel contacted.
Deviations from a MAN Diesel product may be found in a specific plant.

If so such deviations should be noted when ordering spare parts.
Reliable and economical operation of the MAN Diesel product is conditional

upon its correct operation and maintenance in accordance with MAN Diesel’s
instructions and recommendations/guides. Consequently, it is essential that
the engine room personnel are fully acquainted with the content of this manual.
Furthermore, to ensure optimum efficiency, reliability and lifetime of the product

and its components, only original spare parts should be used when replacing
parts of the engine.
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3. The manual structure

Introduction
This manual is divided in to several chapters. Each chapter covering the com-
plete documentation for its relevant content.
Each chapter is made up from several document types e.g. 1065-0100-0001.

The documentation type number is the third and fourth digit.
Examples of document types are as follows.
15 - Preface
45 - Description
55 - Drawings
65 - Maintenance Workcard
70-90 - Spare part plates.
The following 5-8 digits are the Identification (ID) number of the document in the
relevant chapter of a certain document type.
The last 4 digits form the edition number.
Example:
2272-0420-0028
22 72 0420 0028
Chapter Document Type ID Number Edition
4. Data designations
Designations in a Workcard starting with a “T” or “F” refer to the information

given on the data sheets inserted in the beginning of the relevant Workcard.
5. Referring to this manual
When contacting MAN Diesel referring to this instruction manual, please include
title, edition no., and, if relevant, page no.
Example:
0220-0100-0001
Piston - 2265-0401-0028 - Page 2

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For a specific engine, also specify the name of the vessel, IMO number, engine
number and engine builder.
Preface
Example:
Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028
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MAN B&W 0220-0100-0001
6. Ordering of Spareparts
Introduction
When ordering/requesting spare parts for any product by MAN Diesel, add the
following information to ensure delivery of correct parts for the specific en-
gine: Document ID, Part Number, Quantity and Description. Notice that a part
number can also be a Sensor code identification number (e.g. PT 8501) as de-
scribed in chapter 70 – Control System.
Example: Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028-017 -

8 pcs - (Piston ring no. 1)
NB! Item no. “000” orders the complete assembly as displayed on the plate.
7. Service Letters
In order to ensure up-to-date manuals on operation and maintenance,

MAN Diesel and its licensees, regularly send out Service Letters, containing
first-hand information regarding accumulated service experience.
Service Letters can either deal with specific product types or contain general
instructions and recommendations for all products in a product range, and are
used as a reference when we prepare up-dated instruction manual editions.
Therefore, since new Service Letters could be of great importance to the opera-
tion of the plant, we recommend that the engine staff file them to supplement
the relevant chapters of this manual or add them to chapter 88 - Service Info.
8. Internet services
MAN Diesel is always working on new and better ways to provide up-to-date in-
formation and documentation for its customers. Visit our homepage for further
details about the current services offered and how to access these.
9. Additional Information
Further details may be found in:
Sub-supplier manuals
Plant Installation Drawings
Shop trial report
Sea trial report
EIAPP Technical File

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10. Copyrights
Introduction
This manual is subject to copyright protection. The manual must not, wheter in
whole or in part, be copied, reproduced, made public, or in any other way made
available to any third party, without the prior written consent of MAN Diesel.
11. Responsible publisher
MAN Diesel
Teglholmsgade 41
DK-2450 Copenhagen
Denmark
Homepage: http://www.mandiesel.com
Telephone: +45 33 85 11 00
Telefax: +45 33 85 10 30
CVR. No.: 31 61 17 92
0220-0100-0001
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Preface
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MAN B&W 0240-0100-0002
Table of Content
Table of Content & Introduction

This chapter of the instruction book is intended to provide the user with a table of
where the various instructions are located.
Introduction
In addition this chapter is intended to provide the user with a guide of how to use
the instruction book as well as a description of the logical structure of the instruc-
tion book.
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Preface
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Preface Chapter Safety ................................. ................................. 0540-0100-0002
Safety
Description Safety Precautions ........................ ........................ 0545-0100-0007
Tool Plate Safety Equipment ......................... ......................... 0570-0100-0001
Table of contents
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MAN B&W 0540-0100-0002
Safety
Safety
This chapter of the instruction book is intended to provide the user with relevant
details of all the safety precautions which must be observed during operation and
maintenance of the engine in order to obtain safe and reliable conditions.
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Preface
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1 General
Safety Precautions
Correct operation and maintenance, which is the aim of this book, are crucial
points for obtaining optimum safety in the engine room. The general measures
mentioned here should therefore be routine practice for the entire engine crew.
2 Engine Room Staff
Operation & Maintenance of MAN B&W engines is to be carried out by qualified

professional personal
Minimum safety equipment requirements:
1. Safety shoes.
2. Hearing protection.
3. Boiler suit or other protective wear.
3 Special Dangers
Keep clear of the space below a crane with load.

Opening of cocks may cause discharge of hot liquids or gases.
Observe which way liquids, gases or flames will move, and keep clear.
Dismantling of parts may cause the release of springs.
Do not stand near turbochargers in case of any abnormal running.
Do not stand near crankcase doors or relief valves - nor in corridors
near doors to the engine room casing - if an alarm for oil mist, high
lube oil temperature, no piston cooling oil flow, or scavenge box fire is
set off. See also Description 6645.
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0545-0100-0007
Description
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MAN B&W
4 Turning Gear
Safety Precautions
Before engaging the turning gear, ensure that the starting air supply is shut off, the
main starting and slow turning valves are blocked, and that the indicator cocks are
open.
When the turning gear is engaged, check that the indicator lamp “Turning gear in”
has switched on.
The turning gear remote control is a critical devise and should always be kept in
optimal working condition. Any fault in the devise or cable must be rectified before
use.
When operating the turning gear it is important to note the following:
The turning gear must be operated by the remote control and only by the person
working on the engine.
Warnings must be given before each turning. Operation of the turning gear from
the switchboard must not take place while maintenance work is in progress in the
engine.
Block the switch or place a “Do not touch” sign.
5 Entering the Crankcase or Cylinder
Always ensure that the turning gear is engaged and the brake
is active, to prevent external forces or unbalance of the
crankshaft from turning the crankshaft.
Check that the starting air supply to the engine and the starting air distributor is
shut off and that the main starting valve is locked.
In case of oil mist alarm, precautions must be taken before opening to crankcase
(see description 6645-0300). Before entering, ventilate the crankcase about 30
minutes after stopping the engine.
Working inside the crankcase requires the use of fall protection harness and
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0545-0100-0007
arrestor equipment.
Description
Working in the crankcase is minimum a two-man job, and good comunication

must be maintained at all times.
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The turning gear must always be operated by the person(s) who enters the crank-
Safety Precautions
case or cylinders.
6 Cleanliness
The engine and engine room should be kept clean and tidy.
Oily rags must never be left around the engine room spaces as they are highly
flamable and slippery.
Remove any oil spil at once.
If there is a risk of grit or sand blowing into the engine room, stop the ventilation
and close the ventilating ducts, skylights and engine room doors.
Welding or other work that causes spreading of grit and/or swarf must not be car-
ried out near the engine unless it is closed or protected and the turbocharger air
intake filters covered.
The exterior of the engine should be kept clean, and the paintwork maintained, so
that leakages can be easily detected.
7 Fire
Keep the areas around the relief valves free of oil, grease, etc.
to prevent the risk of fire caused by the emitted hot air/gas if
the relief valves open.
Do not weld or use naked lights in the engine room until it has been ascertained
that no explosive gases, vapour or liquids are present.
If the crankcase is opened before the engine has cooled down, welding and the
use of naked flames will involve the risk of explosions and fire. The same applies to
inspection of oil tanks and of the spaces below the floor.
Attention is furthermore drawn to the danger of fire when using paint and solvents
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0545-0100-0007
with a low flash point. Porous insulating material, soaked with oil from leakages, is
Description
easily inflammable and should be renewed. See also description 6645-0290,

6645-0300 and ‘Sealing Materials’ in this chapter
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8 Order/Tidiness
Safety Precautions
Hand tools should be securely fastened and placed on easily accessible tool pan-
els. Special tools should be fastened in the engine room, close to the area to be
used.
No major objects must be left unfastened, and the floor and passages should be
kept clear.
9 Spares
Large spare parts should, as far as possible, be placed near the area to be used,
well secured, and accessible by crane.
All spares should be protected against corrosion and mechanical damage. The
stock should be checked at intervals and replenished in good time.
10 Lighting
Ample working light should be permanently installed at appropriate places in the

engine room spaces, and portable working light should be obtainable everywhere.
24v safety lamps must be available for use inside the engine.
11 Harmful Materials
Always follow the manufacturer's specific instructions, i.e. the material safety data
sheet.
Use protective gloves, goggles, breathing mask and any other recommended pro-
tective gear, as stated in the material safety data sheet.
While handling harmful materials it is important to secure proper ventilation and

shielding if needed.
In the event of leaks or spillage, spread binding agents immediately. Disposal of

the binding agents, according to the material safety data sheet.
12 Lifting Precautions
Plan lifting of engine components through all steps of the lifting procedure.
Use tackles between engine room crane and component, when lifting loads below
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500 kg.
Description
Make sure lifting attachments are tightened into full contact with the component to
be lifted.
Only use designated lifting points, see Instruction Manual for guidance.
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Never exceed the lowest Safe Working Load (SWL) of the lifting equipment in the
Safety Precautions
lifting chain.
Keep lifting equipment clear of sharp edges.
Make sure to attach the load correctly on the crane hook.
Always keep clear of the space below a crane with load.
13 Working Air
Use of working air requires safety goggles and gloves.
Avoid blowing pressurised air directly at skin.
14 Sealing Materials
Use gloves made of neopren or PVC when removing O-rings and other rubber/
plastic-based sealing materials which have been subjected to abnormally high
temperatures.
First aid measures in the event of skin contact:

▪ Rinse with plenty of water
▪ Remove all contaminated clothing
▪ Consult a doctor
▪ Dispose of all material and gloves in accordance with laws and regulations.
15 Hot Surfaces
Beware of hot surfaces and use gloves.
16 Alarms
It is important that all alarms lead to prompt investigation and remedy of the error.
No alarm is insignificant. The most serious alarms are equipped with slow-down
and/or shut-down functions. It is therefore important that all engine operation per-
sonnel are familiar with and well trained in the use and importance of the alarm
system.
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0545-0100-0007
Description
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17 Safety Precautions at Maintenance

Safety Precautions
Before carrying out maintenance work stop and block the engine according to the
safety precautions given on the specific Work Card.
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0545-0100-0007
Description
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MAN B&W 0545-0100-0007
18 Data Sheet Signs
Safety Precautions
Data sheets may include warning signs for special dangers that could arrise in
connection with the maintenance procedures.
Warning signs Mandatory action signs

General warning sign General mandatory
action sign
Explosive material Wear ear protection
Drop (fall) Wear eye protection
Slippery surface Wear safety footwear
Electricity Wear protective

gloves
Overhead load Wear face shield
Hot surface Wear head protec-

tion
Crushing Wear mask
Overhead obstacle Wear respitory pro-

tection
Flammable Wear safety harness
Crushing of hands Disconnect before

carrying out mainte-
nance
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Pressurized cylinder
Description
Pressurized device
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��
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036
024
012
Plate Safety Equipment

0570-0100-0001
0570-0100-0001
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Item no Qty Designation

Safety Equipment
012 - Fall arrest block

024 - Safety hook
036 - Rescue harness
0570-0100-0001
��
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Plate
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Preface Chapter General Description............................................................... 0740-0100-0002
General Description
Description Software License................................................................... 0745-0150-0001
Designations.......................................................................... 0745-0500-0001
Cross Section........................................................................ 0745-0800-0001
Maintenance Checking and Maintenance Schedule, Introduction................ 0760-0300-0001
Checking and Maintenance Schedule, Major Overhaul........... 0760-0301-0002
0735-0100-0009
Table of Content
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General Description
General Description
This chapter of the instruction book is intended to provide the user with informa-
tion regarding the software license which applies to this instruction book. In addi-
tion various naming conventions (designations) used in the instruction book are
explained.
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MAN Diesel 0745-0150-0001.0
Standard Conditions of Software Licence
Software License
Software supplied by MAN Diesel separately or included as a part of any sys-
tem or embedded in any device is licensed by MAN Diesel A/S (“MAN Diesel”)
subject to the customer’s acceptance of the following standard conditions of
licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S ACCEP-

TANCE OF THESE CONDITIONS.
1. Right of Ownership
Software is delivered under a non-exclusive and non-transferable user’s licence

from MAN Diesel against a once-for-all fee. MAN Diesel and its software suppli-
ers retain the right of ownership to the software.
If the engine plant - for which the software is acquired - is transferred to a third
party the customer has the right to assign the licence to this third party, pro-
vided that the third party agrees to the terms of this licence agreement and pro-
vided that the customer does not retain any copies of the software.
2. Copyright
The customer must not copy the software or any part thereof. Furthermore the
customer is not allowed to make the software available to a third party or to re-
verse engineer, decompile or disassemble the software.
3. Support
If required by the customer MAN Diesel shall provide technical support for in-
stallation and training in use of the software against separate payment.
4. Updating
The non-exclusive user’s licence does not include any updating of the software.
If and to the extent MAN Diesel updates the programs or develops new ver-
sions, such updates or new versions shall be made available to the customer
against separate payment.
5. Warranty & Liability
MAN Diesel warrants that the software and data media containing the software
are free of defects in material and workmanship at the time of delivery. If the
software and data media are found to be defective and are returned to MAN
Diesel within 90 days from the date of delivery, they will be replaced free of
charge.
0745-0150-0001.0
Except as stated above, MAN Diesel disclaims liability for breach of conditions
2007-02-17
or warranties, either expressed or implied, with respect to the software and

Description
data media, including warranties of suitability and applicability for a particular

purpose.
Doc-ID: 0745-0150-0001.0 1 (2)

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0745-0150-0001.0 MAN B&W
MAN Diesel
MAN Diesel’s liability for damages to the customer for any cause whatsoever,
Software License
regardless of the form of any claim or action, shall not exceed the total licence
fee paid by the customer for the license to use this software under this license
agreement. MAN Diesel shall in no event be liable for any damages resulting
from loss of data, profits or use of equipment, or for any special, incidental con-
sequential damages arising out of or in connection with the use or performance
of the software.
The limitations in liability stipulated above in this clause 0 shall also apply to
MAN Diesel’s software suppliers.
6. Law
MAN Diesel’s tenders and contracts with customers regarding delivery of data
and programs, including the present licence agreement, shall be interpreted ac-
cording to Danish Law.
0745-0150-0001.0
2007-02-17
Description
2 (2) Doc-ID: 0745-0150-0001.0

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MAN B&W
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Description Designations
0745-0500-0001
0745-0500-0001
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MAN Diesel 0745-0800-0001.0
Cross Section
0745-0800-0001.0
Description
Doc-ID: 0745-0800-0001.0 1 (1)

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The Checking and Maintenance Schedules indicate the intervals at which it is
Checking and Maintenance Schedule • Introduction

deemed appropriate to inspect the individual components of the engine and to
carry out overhauls, if necessary, based on the engine condition or a criterion of
time.
The stated Regular checks or Service interval are intended primarily as a

guide, as differences in the actual service conditions, the quality of the fuel oil
or lubricating oil, the treatment of cooling water, etc., will decisively influence
the actual service results, and thus the intervals between necessary overhaul-
ing.
Design modifications may necessitate a revision of the instructions, in which

case the revised instructions and changed overhauling intervals, if any, will ap-
ply and supersede those originally issued (see e.g our Service Letters).
In addition to the checking and overhauling intervals stated in this schedule,

please note that the periodical survey requirements of the classification society
may require additional checks and reference is made to be carried out. For fur-
ther information reference is made to the classification society.
The procedures are divided into five categories:
Time-based condition marked with a C, under the heading Regular checks or Service interval, deal
checking procedures with the service condition of a number of engine components, and form the ba-
sis for estimating whether further overhauling is necessary. In a number of cas-
es the condition checking procedures refer to Volume I of the instruction book,
in which more detailed descriptions and working procedures can be found.
Condition-based over- are marked with an O, under the heading Regular checks or Service interval.
hauling procedures Under the heading Refer to (column P), a reference to additional information is
stated.
This procedure number normally refers to one of the above condition checking
procedures which form the basis of the overhaul. For this reason, the intervals
stated are for guidance only.
Time-based overhaul- also marked with an O, under the headings Regular checks or Service interval
ing procedures or Based on observations, are the procedures where an actual basis for esti-
mation is lacking. It is recommended, therefore, to carry out these procedures
at the overhauling intervals stated as a basis.
0760-0300-0001
The letters O or C in Based on observations (column B), indicate that special

2009-02-10 - en
service conditions may make checking or overhauling necessary beyond the

actual standard schedules indicated.
Work Card
(continuted)
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Initial checking marked with a C, under the heading Check new/overhauled parts at 500, 1000
Checking and Maintenance Schedule • Introduction
procedures and 1500 hours (column H), deal with initial checks that must be carried out on
a new engine, or when parts have been replaced.
After the three initial checks have been completed, checks need only be carried
out as per heading Regular checks or Service interval.
When using electronic maintenance planning systems, special attention should

be paid to all initial checking procedures, as handling of such procedures of-
ten can not be done automatically. Instead such procedures must be handled
manually.
Initial adjustment marked with an A, under the heading Check new/overhauled parts at 500,
procedures 1000 and 1500 hours (column H), deal with initial adjustment that must be car-
ried out on a new engine, or when parts have been replaced.
After the three initial adjustments have been completed, adjustments need only
be carried out as per headings Regular checks or Service interval.
When using electronic maintenance planning systems, special attention should

be paid to all initial adjustment procedures, as handling of such procedures
often can not be done automatically. Instead such procedures must be handled
manually.
Special attention should be paid to the chain tightener, which must be adjusted
NOTE three times (at 500, 1000 and 1500 hours of operation) on a new engine, or
when chains or chain wheels have been replaced.
0760-0300-0001
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Work Card
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2009-01-17
V : See descriptions M : See maker's instruction R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
H : Check new/overhauled parts at 500, 1000 and 1500 hours C : Check the condition P : refer to
Service Interval (x1000 hours of operation)
No. Procedure H 1 2 4 6 8 12 16 24 32 B P
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10 Structural Parts
1065-0101 Crankcase Relief Valve C O M
1065-0201 Holding Down and End Chock Bolts C C
1065-0301 Stay Bolts C C
10 65-0401 Crankcase o il o utlet C,R R
1065-0501 Top Bracings C C O
Cra n kc a s e C5
14 Driving Gear
1465-0101 Reciprocating Parts C C,O
1465-0201 Crosshead C C O2,3 C,O V4
1465-0301 Connecting Rod O
1465-0401 Chains C C R V
1465-0501 Chain Tightener C,A C,A A
Chain Wheel, spray nozzles, guide bars C C R
1465-0601 Camshaft C C C,A
1
Doc-ID: 0760-0301-0002
1465-0701 Exhaust Valve Cam C1 C O
1465-0801 Exhaust Valve Roller Guide C1 C1 C O
1465-1101 Replacement of Cams on Camshaft R
1465-1201 Camshaft Couplings C C
Comments :
1 : Only inspection through camshaft housing covers.
2 : Overhaul may be omitted if Bearing Wear Monitoring equipment is installed.
3 : Overhaul at 32,000 hours OR when the piston has been dismantled three times.
4 : See description 2545-0100 and service letter regarding bearing wear monitoring.
5 : Check for loose nuts and bearing material fragments
Maintenance Schedule Checking and Maintenance Schedule, Major Overhaul

0760-0301-0002 ME-B Engines
0760-0301-0002
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Maintenance Schedule
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Checking and Maintenance Schedule, Major Overhaul
0760-0301-0002 ME-B engines
0760-0301-0002

No. Procedure H 1 2 4 6 8 12 16 24 32 B P
18 Vibration Control
1865-0101 Axial Vibration Damper C O
1865-0201 Moment Compensator C C C,A
1865-0301 Torsional Vibration Damper C C M
22 Cylinder Unit
2265-0101 Exhaust Valve High-Pressure Pipe O
2265-0201 Exhaust Valve C1 O2 O2
2265-0301 Cylinder Cover C O
Indicator Cock O
2265-0401 Piston C,O
2265-0501 Piston Rod Stuffing Box C,O O
2265-0601 Cylinder Liner C O,R
25 Bearings
2565-0101 Camshaft Bearing C3 C,O
3
2565-0201 Crosshead Bearing C C3 O4,5 C,O V
Doc-ID: 0760-0301-0002
2565-0301 Crankpin Bearing C3 C3 O4,5 C,O V
2565-0401 Main Bearing C3 C3 C,O
2565-0501 Journal Bearing C3 C3 C,O
2565-0601 Thrust Bearing C C C,O
2565-0701 Guide Bearing C C C,O
Comments :
1 : Initial check only.
2 : 35-40 ME-B: 16,000 hours, 46-60 ME-B: 24,000 hours. See also MAN Diesel service letter SL01-397.
3 : Bearings should only be opened if bearing material fragments fall out or top clearance is outside allowable limits.
4 : Overhaul may be omitted if Bearing Wear Monitoring equipment is installed.
MAN B&W
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5 : Overhaul at 32,000 hours OR when the piston has been dismantled three times.
2009-01-17
2009-01-17

No. Procedure H 1 2 4 6 8 12 16 24 32 B P
MAN B&W
HYUNDAI
30 Lubricating Oil System

3065-0601 Cylinder Lubricator C,O A V,M
Cylinder Lubricator level sensor C C,O V,M
3065-0651 Cylinder Lubrication non-return valve C O
System Lubricating Oil Bottom Tank O1
34 Compressed Air System

3465-0201 Starting Air Valve C,O
3465-0501 Starting Air Distributor C A
42 Fuel System
4265-0101 Fuel Oil High-pressure Pipe O
4265-0201 Fuel Valve C,O
Fuel Nozzle C R
4265-0301 Fuel Valve Spindle Guide C R
4265-0401 Fuel Valve Non-return Valve O
Doc-ID: 0760-0301-0002
4265-0501 Fuel Oil Presure Booster O O
4265-0601 Fuel Oil Presure Booster Top Cover O
4265-0701 Fuel Oil Presure Booster Suction Valve C,O O
4265-1301 Fuel System Shock Absorber C O
Comments :
1 : Empty and clean tank

0760-0301-0002 ME-B Engines
0760-0301-0002
3 (6)
4 (6)
0760-0301-0002 ME-B engines
0760-0301-0002

No. Procedure H 1 2 4 6 8 12 16 24 32 B P
45 Hydraulics
4565-0101 Exhaust Valve Actuator O
Valve Actuator Safety Valve C,A
4565-0201 Hydraulic Oil Pump C R M
4565-0301 Hydraulic System C O
4565-0501 Hydraulic Cylinder Unit C,O
4565-0551 Accumulators C O A,O
4565-0601 Control valves C R M
4565-1001 Hydraulic Power Supply Unit O
Hydraulic System Leakage test C O V
Hydraulic oil C O M
47 Electronics
4765-0101 Pressure Sensors C A V,M
4765-0151 Pressure controllers C A V,M
4765-0201 Temperature sensors C A V,M
4765-0251 Temperature controllers C A V,M
Doc-ID: 0760-0301-0002
4765-0301 Level Sensors C A V,M
4765-0401 Proximity Sensors C A V,M
4765-0601 Displacement Sensors C A V,M
4765-1001 Cable Connections C C O V
Comments :
MAN B&W
HYUNDAI
2009-01-17
2009-01-17

No. Procedure H 1 2 4 6 8 12 16 24 32 B P
MAN B&W
HYUNDAI
4765-1201 Flow Sensors C O V,M

4765-1901 Multi-Purpose Controller R V1
Electronic boxes C O V
Thrust bearing alarm system C O
Turning gear switch C A M
54 Gas and air system

5465-0101 Scavenge Air Cooler C,O V
5465-0201 Water Mist Catcher C,O
5465-0301 Auxilary Blower Non-return Valve O
5465-0401 Scavenge Air Cooler Non-Return Valve O
5465-0501 Auxilary Blower O
5465-0601 Scavenge Air Receiver Safety Valve C O
5465-0701 Turbocharger C C,O V,M
5465-0801 Gas By-pass Valve C O
5465-0901 Exhaust Receiver C2 O
Doc-ID: 0760-0301-0002
66 Operation
6665-0101 Exhaust Valve Special Running O
Comments :
1 : See description 6645-0200.
2 : Check protective grid before turbocharger(s).

0760-0301-0002 ME-B Engines
0760-0301-0002
5 (6)
6 (6)
0760-0301-0002 ME-B engines
0760-0301-0002

No. Procedure H 1 2 4 6 8 12 16 24 32 B P
70 Control System
7065-1101 Angle Encoder C,A V,M
7065-1201 Tacho Sensor C,A V,M
76 Tools
7665-0101 Hydraulic Tools C O M
7665-0201 Standard Tightening Torques
7665-0301 Torque Spanner
7665-0401 Tightening Gauge
7665-0501 Screws and Nuts
7665-0601 Working Platforms
7665-0701 Hydraulic Nut
7665-0801 Hydraulic Ring
7665-0901 Lubricating Procedure
Doc-ID: 0760-0301-0002
Comments :
MAN B&W
HYUNDAI
2009-01-17
HYUNDAI
MAN B&W
Preface Chapter Structural Parts .......................... ......................... 1040-0100-0001
St r u c t u r a l P a r t s
Work Card Crankcase Reliefe Valve, Data ............... ............... 1065-0100-0001
Crankcase Reliefe Valve .................... .................... 1065-0101-0002
Holding Down Bolts, Data .................. ................. 1065-0200-0001
Holding Down Bolts ....................... ...................... 1065-0201-0002
Stay Bolts, Data .......................... ......................... 1065-0300-0013
Stay Bolts .............................. ............................. 1065-0301-0005
Crankcase Oil Outlet, Data .................. ................. 1065-0400-0001
Crankcase Oil Outlet ...................... ...................... 1065-0401-0001
Tool Plate Crankshaft Tools ......................... ........................ 1070-1030-0007

Thrust Shaft Tools ........................ ....................... 1070-1040-0010
Plate Crankcase Relief Valve ..................... ..................... 1072-0100-0003

Holding Down and End Chock Bolts .......... .......... 1072-0200-0003
Stay Bolts .............................. ............................. . 1072-0300-0001
Bed Plate ............................... .............................. 1072-0400-0010
Top Bracing ............................. ............................ 1072-0500-0001
Frame Box, Details ........................ ........................ 1072-0630-0008
Frame Box, Covers ....................... ....................... 1072-0640-0017
Cylinder Frame, Details .................... .................... 1072-0710-0013
Chain Drive Frame, Upper .................. .................. 1072-0800-0006
Crankshaft .............................. .............................. 1072-1000-0014
Turning Gear ............................ ........................... 1072-1100-0004
Turning Wheel ........................... .......................... 1072-1200-0019
Piston Cooling Arrangement ................ ............... 1072-1400-0002
Ta b l e o f c o n t en t s
1 (1)
HYUNDAI
MAN B&W 1040-0100-0001
01. Engine Seating
Structural Parts
Regarding the engine seating for the specific engine, see the supplier’s special
instructions.
03. Staybolts
The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.
04. Bedplate
The bedplate is made in one section. The bedplate consists of two welded, lon-
gitudinal girders and a number of cross girders which support the main bear-
ings.
Each main bearing has one main bearing cap which are secured by studs and
nuts, designed for tightening with hydraulic tools.
See also Description 2545-0100 and Chapter 25 “Bearings”.
The bedplate is fitted with an axial vibration damper. For the design and func-
tioning of the axial vibration damper, see also Chapter 18 “Vibration Control”.
06. Framebox
A framebox is bolted to the top of the bedplate. The framebox is made in one
piece. Together, the bedplate and the framebox constitute the crankcase of the
engine.
The framebox is fitted with steelplate doors for access to the crossheads and to
the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe is fitted to the crosshead shoe is able to travel.
From the slotted pipe the cooling oil is, through an outlet pipe, led to the oil tray
of the bedplate.
Equipment for local checking of the cooling oil temperature and flow, and for
temperature and flow alarms, is installed in conjunction with the outlet pipe. See
also Description 7045-0100.
Relief Valves On the exhaust side of the engine a number of spring loaded relief valves are
fitted, which will open in the event of excessive pressure in the crankcase/ chain
casing, for instance as a result of the ignition of oil mist.
1040-0100-0001
Preface Chapter
Keep the areas around the relief valves free of oil, grease, etc. to pre-
2008-06-16 - en
WARNING vent the risk of fire caused by hot air/gas emitted in the event that the
relief valves open.
Doc. ID: 1040-0100-0001 1 (4)

HYUNDAI
1040-0100-0001 MAN B&W
Regarding how to:

Structural Parts
• avoid evaporation of the lubricating oil in the crankcase,
• detect oil mist in the crankcase using an ‘Oil Mist Detector’.
See Description 6645-0300.
Do not stand near crankcase doors or relief valves – or in corridors

WARNING near doors to the engine room casing in the event of an alarm for:
a) oil mist b) high lube oil temperature c) no piston cooling oil flow, or d) scav-
enge box fire Alarms b, c and d should be considered as pre-warnings of
a possible increasing oil mist level.
See also our Service Letter SL97-348/ERO.
If there has been a crankcase explosion, the complete flame arrester

of the relief valves must be replaced.
07. Cylinder Frame
The cylinder frame is designed wih an integrated camshaft housing. The cylin-
der section is tightened together with the engine framebox and the bedplate by
means of stay bolts. Alternatively as a complete welded assembly integrating
the scavenge air receiver into the cylinder frame.
Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod stuffing
boxes.
On the exhaust side of the cylinder frame there are openings which connect the
scavenge air space around the cylinder liner with the longitudinal scavenge air
receiver of the engine.
There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.
Cylinder cover studs Studs for fastening the cylinder cover are mounted in the cylinder frame.
1040-0100-0001
Preface Chapter
2008-06-16 - en
2 (4) Doc. ID: 1040-0100-0001

HYUNDAI
MAN B&W 1040-0100-0001
10. Crankshaft
Structural Parts
The crankshaft is either of the semi-built type, where the parts are shrunk to-
gether.
The main bearings are lubricated via a main lubricating oil pipe that branches
off to the individual bearings, whereas oil for lubricating the crankpin bearings is
supplied from the crossheads through bores in the connecting rods.
The crankshaft is provided with a chain wheel for the camshaft drive and a turn-
ing wheel. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order moment compensators are installed, if required
according to vibration calculations. See chapter 18 “Vibration Control”.
Marine engines (except geared plants):
At the aftmost end of the engine, a thrust bearing is fitted. See chapter 25 “Bear-
ings”.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di-
rection.
11. Turning Gear
The turning gear is fastened to the engine bedplate and is driven by an electric
motor.
Via a worm gear and a following planetary gearing, the motor drives a horizontal
shaft equipped with a gear wheel, which can be axially displaced manually so
as to engage with the turning wheel of the engine.
This displacement is performed by means of a big vertical lever placed on the

protecting shield of the gear wheel. A small vertical lever, placed on the end
cover of the protecting shield of the turning gear, locks the position of the big
lever in, respectively, engaged and disengaged position between the gear
wheel and turning wheel.
Locking is performed by engagement of a tap of the small lever into two notch-
es of the big vertical lever.
When the big lever is in its most forward position, the turning gear is not en-
gaged with the turning wheel.
Engagement of the gear wheel with the turning wheel is achieved by moving
1040-0100-0001
Preface Chapter
the big lever to its most aftwards position. In this position, an interlock valve
2008-06-16 - en
inserted in the starting air system of the engine is actuated by the big lever.
This interlock prevents starting air from being supplied to the engine as long as
the turning gear is in the engaged position.
Doc. ID: 1040-0100-0001 3 (4)

HYUNDAI
1040-0100-0001 MAN B&W
Through an inspection groove at the top of the protecting shield, it must always
Structural Parts
be ensured that the gear wheel is in correct position according to the planned
operation of the turning gear.
Always ensure that any of the two positions of the big lever (engagement/disen-
gagement of the turning wheel) is locked by the small lever.
See also Description 6645-0120.
Dismantling of working parts: During any dismantling of working parts of the engine,
WARNING the turning gear must be in the engaged position in
order to prevent outside forces from turning the en-
gine, thus causing injuries to personnel or damage
to the machinery. See Workcards, Datapages.
Pressure testing of starting The turning gear must be in the disengaged position
valves: during pressure testing of starting valves, as a leaky
valve may cause the engine to rotate, and damage
the turning gear. See Description 6645-0170.
1040-0100-0001
Preface Chapter
2008-06-16 - en
4 (4) Doc. ID: 1040-0100-0001

HYUNDAI
MAN B&W
MAN B&W 1065-0100-0001
Safety O Stop the Engine

Precautions
Crankcase Relief Valve, Data

O Shut off starting air supply - At starting air receiver
for detailed sketch O Block the main starting valve
see 0545-0100
O Shut off starting air distributor/distributing system supply
O Shut off safety air supply - Not ME Engines
O Shut off control air supply
O Engage turning gear
O Stop lubricating oil supply
O Shut down hydraulic power supply
Data
Ref. Description Value Unit
- Table is empty on purpose. No Data needed. - -
2013-02-19 - en
1065-0100-0001
Work Card
1 (2)
HYUNDAI
1065-0100-0001 MAN B&W
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 two digits in the plate num-
Crankcase Relief Valve, Data
ber, e.g. 2570-0010 refers to chapter 25, Bearings.
Tools
Plate Item No. Description
- - Table is empty on purpose. No special tools needed.
2013-02-19 - en
1065-0100-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 1065-0101-0002
Leaks During Running
Relief Valve • Checking

During running of the engine, check
if there are any leaks.
If a leak occurs, replace the O-ring

inside the relief valve.
See separate instructions from the valve

manufacturer.
1065-0101-0002C01
Checking the plates If work involving risks of mechanical

damage to the flame arrester has taken
place, a visual inspection of the flame
arrester should always be performed
before starting the engine.
Check on the whole circumference

that all the plates in the flame arrester
are evenly distributed and that no local
openings exist.
If one or more plates in the flame arrest-

er are damaged, the relief valve must
be disassembled and the flame arrester
replaced.
1065-0101-0002
See separate instructions from the valve

manufacturer.
2008-11-05 - en
Work Card
The complete flame arrester has to be

NOTE replaced after a crankcase explosion.
1065-0101-0002C02
1 (1)
HYUNDAI
MAN B&W
MAN B&W 1065-0200-0001

Precautions
Holding Down and End Chock Bolts, Data

for detailed sketch
see 0545-0100
Data
T76-01 Hydraulic pressure, dismantling 1400-1650 bar
T76-02 Hydraulic pressure, mounting 1500 bar
2013-03-04 - en
1065-0200-0001
Work Card
1 (2)
HYUNDAI
1065-0200-0001 MAN B&W
MAN B&W
Holding Down and End Chock Bolts, Data
Tools
1070-0200 - Hydraulic Tools for End-Chock Bolts
7670-0100 011 Hydraulic pump, pneumatically operated
7670-0100 047 Hose with unions, 1500 mm
2013-03-04 - en
1065-0200-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 1065-0201-0002
Tightening the Holding Down and End Chock Bolts
Holding Down and End Chock Bolts • Checking

The hydraulic jack used for tightening the holding down bolts is marked with:
For: Holding down bolts

NOTE
The larger jack used for tightening the end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and end chock bolts is carried out as
detailed in 7665-0101. The normal tightening pressure is indicated on the Data
sheet and is also stamped on the tightening tool.
1065-0201-0002
2008-11-25 - en
Work Card
1 (5)
HYUNDAI
1065-0201-0002 MAN B&W
Checking the bolt The holding down bolts and end chock
tightening bolts must be checked for correct tight-

ness at the intervals indicated on the
Data sheet. T76-1
For this purpose, raise the pressure on
T76-2
the hydraulic tool slowly while constant-
ly attempting to loosen the nut with the
tommy bar. The oil pressure indicated
on the pressure gauge when the nut
comes loose (‘loosening pressure’) is
to be noted in the checking tables, see
pages 4 and 5, following which the bolts
are tightened to the normal tightening
pressure.
The condition of the bolted joints, and

thus the general condition of the foun-
1065-0201-0001C01
dation, can be effectively checked by
comparing the tables from successive
bolt checks.
If the ‘loosening pressure’ is below 80 per cent of the tightening pressure, the
relative chocks shall always be checked for possible defects. If the chocks are
in position and in order, the bolts should be taken out for inspection of threads
and contact faces.
Checking of epoxy If a number of measuring pins have been welded to the tanktop, the heights of
supporting chocks the epoxy supporting chocks are to be checked immediately after finishing the
checking of the loosening pressures of the holding down bolts and the retight-
ening of these.
The distance between the measuring pins and the bedplate is to be measured
with a blade gauge and noted down. Any possible settling of the chocks during
the intervals between measurements can thereby be followed.
1065-0201-0002
2008-11-25 - en
Work Card
2 (5)
HYUNDAI
MAN B&W 1065-0201-0002
Side chocks and After fitting the liners to an 80 per cent

side chock liners contact area on both sides of the lin-
ers, knock the liners a further 3 to 4 mm
inwards.
The liners located in way of each main

bearing on either side of the engine
must be fitted and knocked into position
simultaneously.
The first time the ship is sailing in a

fully-loaded condition after the engine
has been operating for 1,000 hours, all
side chocks should be checked to see
whether the liners can be knocked fur-
ther inward.
1065-0201-0001C03
The fit of the side chock liners should be checked with a feeler gauge each time
the loosening pressure of the holding down bolts is checked, and thus at the
same time intervals.
The feeler gauge is applied at the 7 points indicated in the table on page 5, and
the measurements found are to be entered in the relevant table. These results
are used to determine whether refitting or, possibly, replacement of the liners is
necessary.
If the measurements at 3 points or more have increased 5/100 mm or more

from the initial results, we recommend that the following procedure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in the table.
If this procedure does not improve the situation, the liner must be removed, and
it must be checked that the actual contact area is more than 80 per cent of the
possible contact surface areas on both sides of the liner.
The liners are secured in their correct position by means of hexagon socket set
screws with cup point.
1065-0201-0002
2008-11-25 - en
Work Card
3 (5)
HYUNDAI
1065-0201-0002 MAN B&W
Holding down bolts

Engine Port side Cylinder Starboard side Engine

frame Bolt Bolt frame
No. No. pressure % dev. remarks No. pressure % dev. remarks No. No.
1 1
2 2
1 3 3 1
4 4
1
1 1
2 2
2 3 3 2
4 4
1 2 1
2 2
3 3 3 3
4 4
1 3 1
2 2
4 3 3 4
4 4
1 1
2 2
5 3 3 5
4 4
1 1
2 2
6 3 3 6
4 4
1 1
2 2
7 3 3 7
4 4
1 1
2 2
8 3 3 8
4 4
1 1
2 2
9 3 3 9
4 4
1 1
2 2
10 3 3 10
4 4
1 1
2 2
11 3 3 11
4 4
1 1
2 2
12 3 3 12
4 4
1 1
2 2
13 3 3 13
4 4
1 1
2 2
14 3 3 14
1065-0201-0002
4 4
1 1
2008-11-25 - en
Work Card
1065-0201-0001C04
4 (5)
HYUNDAI
MAN B&W 1065-0201-0002
Side chocks and

end chock bolts
Port side Starboard side
Chock Point Cylinder
Point Chock
No. A B c d e f g No. A B c d e f g No.
1 1
2 1 2
3 2 3
4 3 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
A, B
FORE A, B
A
d
A
c
c
e
e
g
B
f
f
g
B
c, d, e, f, g c, d, e, f, g
Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure ation Point Point ation sure Bolt Ch
(kp/cm 2) (kp/cm 2)
No. No. bar % a b c d e a b c d e % bar
No. No.
1 1
E E
2 2
b c d d c b
a e e a
No. 2 Contact face No. 1 No. 2
AFT
B1
B2
B2
B1
1065-0201-0002
1065-0201-0001C05
2008-11-25 - en
Work Card
5 (5)
HYUNDAI
MAN B&W
MAN B&W 1065-0300-0013

Precautions
Stay Bolts, Data

see 0545-0100
Data
T10-07 Check measurement 125±3 mm
2013-03-04 - en
1065-0300-0013
Work Card
1 (2)
HYUNDAI
1065-0300-0013 MAN B&W
MAN B&W
Stay Bolts, Data
Tools
2570-0400 010 Hydraulic jack, complete
2570-0400 021 Support for hydraulic jack
2570-0400 141 Extension stud
7670-0100 118 3-way distributor block, complete
2013-03-04 - en
1065-0300-0013
Work Card
2 (2)
HYUNDAI
MAN B&W 1065-0301-0005
Inspection This check can be performed
Stay Bolts • Checking

during several periods of
stopped engine, but must be
performed on complete twin
stay bolt groups at a time,
thereby ensuring uniform ten-
sion in the affected bearings.
The first time this check is per-

formed it has to be completed
NOTE in one operation. The following
checks have to be completed
within a 500-hour period.
1065-0301-0001C01
Protective caps Before retightening the stay

bolts, remove the protective
caps.
1065-0301-0005C02
1065-0301-0005
2010-09-24 - en
Work Card
1 (5)
HYUNDAI
1065-0301-0005 MAN B&W
Loose stay bolts Check for loose staybolt nuts T76-1

Stay Bolts • Checking
with the tommy bar.
If a loose nut is found, unscrew

T10-7
the nut until a gap occurs be-
tween cylinder frame and nut.
Loosen and unscrew the nut

on the opposite stay bolt.
Check for the correct mount-ing 1065-0301-0005C03

of the stay bolt by comparing
with the check measurement on the Data Sheet.
If the check measurement is not reached, indicating that the stay bolt is not
screwed properly down in the thread of the bedplate, apply a screw and a
counternut in the thread in the top of the stay bolt, and turn the stay bolt
until the check measurement data is met.
Retighten Retighten the stay bolts in pairs

(athwartship), working from fore
to aft of the engine.
T76-2
1065-0301-0001C04
1065-0301-0005
2010-09-24 - en
Work Card
2 (5)
2010-09-24 - en
MAN B&W
HYUNDAI
Work Card Stay Bolts • Checking

1065-0301-0005
1065-0301-0005
3 (5)
4 (5)
1065-0301-0005
1065-0301-0005
MAN B&W
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2010-09-24 - en
2010-09-24 - en
MAN B&W
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1065-0301-0005
1065-0301-0005
5 (5)
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MAN B&W
MAN B&W 1065-0400-0001

Precautions
Crankcase Oil Outlet, Data

see 0545-0100
Data
T10-10 Metal bellow, up to 15 Kg
2013-04-15 - en
1065-0400-0001
Work Card
1 (2)
HYUNDAI
1065-0400-0001 MAN B&W
MAN B&W
Crankcase Oil Outlet, Data
Tools
2013-04-15 - en
1065-0400-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 1065-0401-0001
Crankcase Oil Outlets
Crankcase Oil Outlet • Checking

The crankcase oil outlets guide the lubricating oil from the crankcase to the
lubricating oil bottom tank. The sealing of the crankcase oil outlets must be
checked at regular intervals, for example during dockings. The crankcase oil
outlets may be equipped with either rubber diaphragm sealing or metal bellow
sealing.
If the water content of the main engine lube oil is rising, this may indicate that
NOTE the crankcase oil outlet sealings are fractured..
Rubber diaphragm To access the rubber diaphragm sealing

dismantling remove:
Screws A
Grating B
Screws C E F G D C B A
Cover plate D
Screws E
Steel ring F.
1065-0401-0001C01
Rubber diaphragm Lift away the rubber sealing diaphragms

replacement G and examine each diaphragm closely.
In case of any rips or tears in the dia-
phragms, they must be replaced.
1065-0401-0001C02
1065-0401-0001
2008-12-16 - en
It is strongly recommended always to replace the diaphragms during inspec-

Work Card
NOTE tion. If unavailable, new diaphragms may be made from three layers of 2 mm
thick oil and temperature resistant rubber.
1 (2)
HYUNDAI
1065-0401-0001 MAN B&W
Rubber diaphragm Mount:

Crankcase Oil Outlet • Checking
mounting Rubber sealing diaphragms G

Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
NOTE Remember to fit new locking plates at screws A.
Metal bellow Remove all screws A and grating B.

dismantling
Remount four of the screws A at dia-
metrically opposite positions.
C B
Remove: D
Screws C A
Cover plate D F
Screws E.
E
G
H
1065-0401-0001C04
Metal bellow Lift away metal bellow sealing F and examine it closely. If any cracks or punc-
replacement tures are found in the metal bellow sealing, it must be replaced.
It is recommended to always replace the metal bellow sealing during

NOTE inspection.
Metal bellow Replace gaskets G and H.

mounting
Mount metal bellow sealing F.
Mount:
Screws E
1065-0401-0001
Cover plate D
2008-12-16 - en
Screws C 1065-0401-0001C07
Work Card
Remove the four screws A

Mount grating B
Mount all screws A.
2 (2)
2011-11-11 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Crankshaft Tools
1 (2)
1070-1030-0007
1070-1030-0007
HYUNDAI
1070-1030-0007 MANB&W
MAN B&W

Crankshaft Tools
014 - Lifting tool for crankshaft

1070-1030-0007
2011-11-11 - en
Plate
2 (2)
2013-07-17 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Thrust Shaft Tools
1 (2)
1070-1040-0010
1070-1040-0010
HYUNDAI
1070-1040-0010 MANB&W
MAN B&W

Thrust Shaft Tools
019 - Lifting tool for thrust shaft

1070-1040-0010
2013-07-17 - en
Plate
2 (2)
2010-05-25 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Crankcase Relief Valve
1 (2)
1072-0100-0003
1072-0100-0003
HYUNDAI
1072-0100-0003 MAN B&W
MAN Diesel

Crankcase Relief Valve
015 - Relief valve, complete*

027 - Relief valve*
039 - Screw*
040 - O-ring*
052 - Packing*
1072-0100-0003
2010-05-25 - en
Note: * When ordering, please state manufacturer of relief valve and P.C.D xxx mm.
Plate
2 (2)
2011-02-23 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Holding Down and End Chock Bolts
1 (2)
1072-0200-0003
1072-0200-0003
HYUNDAI
1072-0200-0003 MANB&W
MAN B&W

Holding Down and End Chock Bolts
019 - Screw
020 - Washer
032 - Lock plate
044 - Liner for side chock, port side
056 - Liner for side chock, starboard
081 - Spherical washer
103 - Nut
115 - Protecting cap
127 - Liner for end chock
139 - Protecting cap
140 - Nut
152 - Distance tube
176 - Spherical nut
188 - Holding down bolt
211 - Stud
1072-0200-0003
2011-02-23 - en
Plate
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1072-0300-0001.0
Stay Bolts
012
024
036
048
1 (2)
HYUNDAI
1072-0300-0001.0 MANDiesel
MAN B&W

Stay Bolts
012 - Screw
024 - Protective cap for stay bolts
036 - Nut for hydraulic tightening
048 - Assembling of stay bolt
1072-0300-0001.0
Plate
2 (2) Doc-ID: 1072-0300-0001.0

2011-05-27 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Bed Plate
1 (2)
1072-0400-0010
1072-0400-0010
HYUNDAI
1072-0400-0010 MANB&W
MAN B&W

Bed Plate
016 - Flange
041 - Main bearing cap
053 - Stud
065 - Distance pipe
077 - Screw
089 - Spring pin
090 - Screw
100 - Locking piece
112 - Screw
124 - Grate
136 - Screw
148 - Cover plate
1072-0400-0010
2011-05-27 - en
Plate
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1072-0500-0001.0
Top Bracing
Engine Hull
165
082
094 128
021 104 141
033 189
190
045 045 189
057 057
069 069
070 070
1072-0500-0001.0
Plate
Doc-ID: 1072-0500-0001.0 1 (2)

HYUNDAI
1072-0500-0001.0 MANDiesel
MAN B&W

Top Bracing
021 - Screw
033 - Shim
045 - Tubular spacer
057 - Washer
069 - Nut
070 - Split pin
082 - Plate, short
094 - Plate, medium
104 - Plate, large
128 - Screw
141 - Disc spring
165 - Guide pin
189 - Shim
190 - Plate
1072-0500-0001.0
Plate
2 (2) Doc-ID: 1072-0500-0001.0

2011-05-31 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Frame Box, Details
1 (2)
1072-0630-0008
1072-0630-0008
HYUNDAI
1072-0630-0008 MANB&W
MAN B&W

Frame Box, Details
017 - Screw
029 - Cover
030 - Nut
042 - Drain pipe
054 - Screw
066 - Sealing ring
078 - Frame box door
091 - Cover
101 - Stud
113 - Spring
125 - Door fastener
137 - Wing nut
149 - Cover
150 - Cover
162 - Screw
1072-0630-0008
2011-05-31 - en
Plate
2 (2)
2012-11-23 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Frame Box, Covers
1 (2)
1072-0640-0017
1072-0640-0017
HYUNDAI
1072-0640-0017 MANB&W
MAN B&W

Frame Box, Covers
011 - Gasket
023 - Cover
035 - Stud
047 - Nut
059 - Screw
060 - Bracket
072 - Screw
084 - Flange screw
096 - Cover
106 - Screw
118 - Shield, upper
131 - Shield, lower
143 - Screw
155 - Cover
167 - Stud
179 - Nut
180 - Fitted bolt
192 - Gasket
202 - Dowel
1072-0640-0017
2012-11-23 - en
Plate
2 (2)
2012-03-30 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Cylinder Frame, Details
1 (2)
1072-0710-0013
1072-0710-0013
HYUNDAI
1072-0710-0013 MANB&W
MAN B&W

Cylinder Frame, Details
011 - Nut
035 - Stud
047 - O-ring
059 - Stud
060 - Nut
072 - Cleaning cover, complete
084 - Screw
096 - Cleaning cover, complete
106 - O-ring
118 - Nut
131 - Distance pipe
143 - Stud
155 - Screw
167 - Protective cap
180 - Stud
192 - Cam lock washer*
202 - O-ring
214 - Screw
238 - Screw
251 - Protective tube
263 - Screw
275 - Packing
287 - Sealing ring
299 - Sealing ring
309 - Cleaning cover complete
310 - Stud
322 - Screw
334 - Screw
417 - Screw
429 - O-ring
430 - Cover
442 - Screw
454 - Stud
1072-0710-0013
2012-03-30 - en
Note: * Cam lock washers are to be supplied by MAN Diesel only.

Plate
2 (2)
2011-06-06 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Chain Drive Frame, Upper
1 (2)
1072-0800-0006
1072-0800-0006
HYUNDAI
1072-0800-0006 MANB&W
MAN B&W

Chain Drive Frame, Upper
010 - Screw
034 - Top guard
046 - Cover
058 - Dowel pin
071 - Gasket
083 - Inspection cover
095 - Stud
117 - Nut
129 - Screw
142 - Screw
154 - Cover
166 - Cover
178 - Screw
191 - Screw
201 - Distance pipe
213 - Screw
225 - Screw
237 - Plug screw
249 - Stud
250 - Nut
1072-0800-0006
2011-06-06 - en

Plate
2 (2)
2012-09-28 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Crankshaft
1 (2)
1072-1000-0014
1072-1000-0014
HYUNDAI
1072-1000-0014 MANB&W
MAN B&W

Crankshaft
014 - Crankshaft
026 - Chain wheel
038 - Packing ring
051 - Cover
063 - Screw
1072-1000-0014
2012-09-28 - en
Plate
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1072-1100-0004
Turning Gear
1072-1100-0004
2009-06-02
Plate
1 (2)
HYUNDAI
1072-1100-0004 MANDiesel
MAN B&W

Turning Gear
018 - Guide pin

031 - Planet gear
043 - Cam lock washer, stainless*
055 - Screw
1072-1100-0004
2009-06-02

Plate
2 (2)
2013-02-20 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Turning Wheel
1 (2)
1072-1200-0019
1072-1200-0019
HYUNDAI
1072-1200-0019 MANB&W
MAN B&W

Turning Wheel
011 - Nut, self-locking

023 - Stud
047 - Distance pipe
059 - Tdc indicator
084 - Stud
096 - Distance pipe
143 - Dead centre pointer
155 - Spring pin
180 - Screw
202 - Turning wheel
214 - Fitted bolt
238 - Screw
1072-1200-0019
2013-02-20 - en
Note: * Cam lock washers are to be supplied by MAN Diesel Turbo only.
Plate
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1072-1400-0002
Piston Cooling Arrangement

1072-1400-0002
2008-08-06
Plate
1 (2)
Doc-ID: 1072-1400-0002
HYUNDAI
1072-1400-0002 MAN
MANDiesel
B&W

Piston Cooling Arrangement

020 - Screw
032 - Drain pipe
056 - Screw
081 - Drain pipe
093 - Plate
115 - Drain pipe
127 - Screw
152 - Packing
164 - Sight glass
176 - Flange
188 - Screw
1072-1400-0002
2008-08-06

Plate
2 (2)
Doc-ID: 1072-1400-0002
HYUNDAI
MAN
MANB&W
B&W
Preface Chapter Driving Gear ............................. ............................. 1440-0100-0001
Driving Gear
Work Card Reciprocating Parts, Data .................. .................. 1465-0100-0006
Reciprocating Parts ........................ ....................... 1465-0101-0005
Crosshead, Data ......................... ......................... 1465-0200-0011
Crosshead .............................. .............................. 1465-0201-0005
Connecting Rod, Data ..................... ..................... 1465-0300-0010
Connecting Rod .......................... .......................... 1465-0301-0004
Chain, Data ............................. ............................. 1465-0400-0007
Chain .................................. .................................. 1465-0401-0001
Chain Tighener, Data ...................... ...................... 1465-0500-0001
Chain Tighener ........................... ........................... 1465-0501-0016
Camshaft, Data .......................... .......................... 1465-0600-0003
Camshaft ............................... ............................... 1465-0601-0001
Exhaust Valve Cam, Data ................... ................... 1465-0700-0001
Exhaust Valve Cam ....................... ....................... 1465-0701-0002
Exhaust Valve Roller Guide, Data ............. ............. 1465-0800-0003
Exhaust Valve Roller Guide ................. ................. 1465-0801-0002
Replacement of Cams on Camshaft, Data ...... ...... 1465-1100-0002
Replacement of Cams on Camshaft ........... ........... 1465-1101-0002
Tool Plate Crosshead Tools ......................... ......................... 1470-0200-0001

Connecting Rod and Crosshead Tool Panel ..... ..... 1470-0300-0010
Chain Tightener Hydraulic Tools .............. .............. 1470-0500-0016
Crosshead Hydraulic Tools ................. ................. 1470-0510-0005
Chain Drive Tools Panel .................... .................... 1470-1400-0007
Plate Camshaft ............................... ............................... 1472-0600-0004

Connecting rod .......................... .......................... 1472-0300-0003
Connecting rod, Additional Mass ............. ............. 1472-0320-0003
Connecting rod, Compression Shim .......... .......... 1472-0310-0002
Chain Tightener .......................... .......................... 1472-0500-0009
Chain .................................. .................................. 1472-0400-0004
Chain Drive Guidebars ..................... ..................... 1472-1420-0023
Table of contents
1 (1)
HYUNDAI
MAN B&W
MAN Diesel 1440-0100-0001
03. Crosshead
Driving Gear
The crosshead is provided with two guide shoes fitted on the crosshead ends.
The centre part of the crosshead is designed as a bearing journal which is

housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston rod to
be assembled with the crosshead journal. See also Description 2545-0100 and
Chapter 25 “Bearings”.
Piston rod foot The piston rod foot is fastened to the crosshead. To match different engine lay
outs, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.
Lubrication The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and – through a bore in the con-
necting rod – for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder for
the purpose of checking the temperature and flow before the oil is passed on to
the lube oil tank.
Guide shoes The sliding faces of the guide shoes are lined with cast-on bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.
On some engines, the guide shoes are provided with counterweights.
Tightening The crosshead bearing is held together by studs and nuts. The nuts are tight-
ened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal and as-
sembled in the same way as the crosshead bearing.
04. Chain Drive
The camshaft with cams for operating the exhaust valves and indicator drive
(option) is driven from the crankshaft through a chain drive.
The chain drive consists of one or more roller chains running on chain wheels
fitted on the crankshaft and the camshaft. The chain is kept tightened by a
chain tightener placed in the chain casing between the crankshaft and the cam-
shaft.
1440-0100-0001
Preface Chapter
2008-06-16 - en
The long free lengths of the chain are guided by rubber-clad guide bars. Lu-
bricating oil is supplied through spray pipes fitted at the guide bars and chain
wheels.
Doc. ID: 1440-0100-0001 1 (2)

HYUNDAI
1440-0100-0001 MANDiesel
MAN B&W
06. Camshaft
Driving Gear
The camshaft is made in one or more sections.
If it is made in two sections, the sections are assembled by means of flange

couplings.
The camshaft has, for each cylinder one cam for operation of the exhaust valve.
The exhaust valve cams are shrunk on to the shaft by heating, whereas the indi-
cator cams are in two parts, which are assembled with fitted bolts.
The camshaft rotation constantly follows that of the crankshaft.
Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams or
chain wheel and the shaft, which enables the parts to be turned in relation to
each other. See also Chapter 14 and 70.
Pin gauges After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are deliv-
ered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.
1440-0100-0001
Preface Chapter
2008-06-16 - en
2 (2) Doc. ID: 1440-0100-0001

HYUNDAI
MAN B&W 1465-0100-0006

Precautions
R ec i p r o c a t i n g p a r t s , Da t a
see 0545-0100
O Shut off cooling water
Data
Acceptance criteria with piston in centre (F-A
- - -
direction)
T14-01 PF+PA, N max. 0.5 mm
T14-02 PF+PA, O max. 0.7 mm
T14-04 E+G, H+F, N max. 0.7 mm
T14-05 E+G, H+F, N min. 0.2 mm
T14-06 E+G, H+F, O max. 0.8 mm
T14-10 J+C, L+D, K+C, M+D, N max. 1.05 mm
T14-11 J+C, L+D, K+C, M+D, N min. 0.5 mm
T14-12 J+C, L+D, K+C, M+D, O max. 1.1 mm
T14-17 ZF/ZA O min. 4 mm
T14-22 Crankshaft position (after BDC). 45 °
T14-23 Piston inclination R1-R2, O max. 0.35 mm
N: New and cold engine with staybolts tight-
-- - -
ened (less than 100 running hours).
-- O: Engine in service. - -
2 0 1 3 -0 3 -0 5 - e n
1465-0100-0006
W o r k Ca r d
1 (2)
HYUNDAI
1465-0100-0006 MAN B&W
R ec i p r o c a t i n g p a r t s , Da t a
Tools
Plate
Plat e Item No.
No. Description
7670-0410 054 Feeler gauge set
7670-0410 078 Dial gauge and stand tool
2 0 1 3 -0 3 -0 5 - e n
1465-0100-0006
W o r k Ca r d
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Trim the Ship In order to achieve uniform measuring conditions on board, the ship’s trim must
Reciprocating Parts • Checking

be as close as possible to 0°.
Mount a plastic tube Mount a transparent plastic tube

along the length of the bedplate. T S S
Bend each end approx. 250 mm up
the framebox side. See T.
Fill the tube with water (preferably

coloured) until the water level is ap-
Bedplate
prox. 100 mm from the end of the
tube.
Trim the ship until the difference

between the water level S fore and 1465-0101-0001C01
aft is less than 1.5 mm per 1000
mm.
Measurements are to be taken with a ruler.
1465-0101-0005
2012-04-17
Work Card
1 (11)
HYUNDAI
1465-0101-0005 MAN
MANDiesel
B&W
The piston and the Turn the crankshaft in ASTERN di- Fore Aft
cylinder liner rection to T14-22 (see data) degrees

after BDC (the guide shoe must rest
against the crosshead guide).
Check the centering of the piston in

the cylinder liner by measuring the
clearance (use a long feeler gauge
from the scavenge air space) be-
tween the piston skirt and the cylin-
der liner in the Fore and Aft positions
(PFPA).
Make sure that the piston is clear of

the cylinder liner in the fore and aft
directions.
PA
PF
1465-0101-0005
2012-04-17
Work Card
T1422
146501010001C02
2 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Mount a dial gauge Mount a dial gauge on the flange

below the stuffing box to the front
of the piston rod with the tip of the Fore
dial gauge against the piston rod.
Note down the reading of the dial

gauge R1.
Af t R1
T14-23
1465-0101-0005C03
Turn the crankshaft Turn the crankshaft in ASTERN di-

TD C
rection to 35° before TDC. e fore
˚B
35
1465-0101-0005
2012-04-17
Work Card
1465-0101-0001C04
3 (11)
HYUNDAI
1465-0101-0005 MAN
MANDiesel
B&W
Piston inclination Note down the reading of the

dial gauge R2.

Fore
Calculate the piston inclination R1-
R2.
Af t R2
T14-23
1465-0101-0005C05
Turn the crankshaft Turn in astern direction until the

bottom of the guide shoe is 50 mm
50
above the top of the cut-out in the
web plate. EXH CAM
E 1-2 G 1-250
F 1-2
H 1-2
1465-0101-0001C06
1465-0101-0005
2012-04-17
Work Card
4 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Measure the Measure the fore and aft

clearance ZF/ZA clearances ZF and ZA between the
crankthrow and the connecting rod.
Fore Aft
ZA
ZF T14-17
1465-0101-0001C07
Measure the Measure the clearance C, between

clearance C the foremost stop plate and the
crosshead.
C
1465-0101-0005
2012-04-17
Fore
Work Card
1465-0101-0001C08
5 (11)
HYUNDAI
1465-0101-0005 MAN
MANDiesel
B&W
Measure the Measure the clearance D,

clearance D between the aftmost stop plate

and the crosshead.
Aft
1465-0101-0001C09
Measure the Measure the clearances E1 and E2 E1 E2

clearance E1/E2 between the top of the foremost
guide shoe and the exhaust-side
crosshead guide.
1465-0101-0005
Aft
2012-04-17
Work Card
1465-0101-0001C10
6 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Measure the Measure the clearances E3

E3 E4

clearance E3/E4 and E4 between the top of the aft-
most guide shoe and the exhaust-
side crosshead guide.
Fore
1465-0101-0001C11
Measure the Measure the clearances G1 and G2

clearance G1/G2 between the top of the foremost
guide shoe and the manoeuvring- J G2 G1
Measure the clearance J between

the top of the foremost guide strip
and the manoeuvring-side cross-
head guide.
Fore
1465-0101-0001C12
1465-0101-0005
2012-04-17
Work Card
7 (11)
HYUNDAI
1465-0101-0005 MAN
MANDiesel
B&W
Measure the Measure the clearances G3 and

G4 G3 L
clearance G3/G4 G4 between the top of the aftmost

guide shoe and the manoeuvring-
Measure the clearance L between

the top of the aftmost guide strip
and the manoeuvring-side cross-
head guide.
Aft
1465-0101-0001C13
Measure the Measure the clearances F1 and F2

clearance F1/F2 between the bottom of the fore-
Fore F1 F2
1465-0101-0005
2012-04-17
1465-0101-0001C14
Work Card
8 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Measure the Measure the clearances F3 and

clearance F3/F3 F4 between the bottom of the aft-
Aft
F3 F4
1465-0101-0001C15
Measure the Measure the clearances H1 and H2

clearance H1/H2 between the bottom of the fore-
most guide shoe and the manoeu-
vring-side crosshead guide.
Measure the clearance K between

the bottom of the foremost guide
strip and the manoeuvring-side
crosshead guide.
Fore
K H2 H1
1465-0101-0005
2012-04-17
Work Card
1465-0101-0001C16
9 (11)
HYUNDAI
1465-0101-0005 MAN
MANDiesel
B&W
Measure the Measure the clearances H3

clearance H3/H4 and H4 between the bottom of the

aftmost guide shoe and the ma-
noeuvring-side crosshead guide.
Measure the clearance M between

the bottom of the aftmost guide
strip and the manoeuvring-side
crosshead guide.
Aft
H4 H3 M
1465-0101-0001C17
The result The guide strip clearance, calculated as J+C, K+C, L+D and M+D, is adjusted
by the insertion of shims so that it is symmetrical in relation to the clearance
between the piston skirt and the cylinder liner.
Parallelism between the guide strip and guide is to be kept within a tolerance of
0.2 mm per 1000 mm.
1465-0101-0005
2012-04-17
Work Card
10 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0101-0005
Recommended It is recommended that the Unit mm Cyl. 1 2 3

measured results are noted down
Piston/Liner PF
so that possible later changes can PA
be ascertained.
Framebox E1
Compare the measured results E2
with the values stated on the data E3
sheet. E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J
K
L
M
C
D
R1
Piston Rod
R2
ZF
Crankthrow
ZA
1465-0101-0001C18
1465-0101-0005
2012-04-17
Work Card
11 (11)
HYUNDAI
MAN B&W
MAN B&W 1465-0200-0011

Precautions
Crosshead, Data
see 0545-0100
O Shut off air supply to exhaust valve - Only when stopped lubricating oil pumps
O Shut off fuel oil
Data
T14-24 Cooling oil outlet pipe, tightening torque 50 Nm
T14-30 Guide strip screws, tightening torque 150 Nm
T14-31 Guide plate, tightening torque 135 Nm
T14-33 Telescopic pipe, tightening torque 50 Nm
T14-34 Telescopic pipe, tightening angle 25 °
Stuffing box, telescopic pipe, tightening tor-
T14-37 50 Nm
que
T14-42 Crosshead complete 1400 kg
T14-43 Guide shoe 200 kg
T14-45 Cooling oil outlet pipe 10 kg
T14-46 Telescopic pipe 25 kg
T14-49 Crosshead without guide shoes 950 kg
T14-53 Connecting rod, without bearing caps 1400 kg
2013-03-05 - en
1465-0200-0011
Work Card
1 (2)
HYUNDAI
1465-0200-0011 MAN B&W
MAN B&W
Crosshead, Data
Tools
1470-0200 012 Guide shoe extractor
1470-0300 041 Wire guide
1470-0300 053 Lifting attachment for connecting rod
1470-0300 065 Lifting tools for crosshead
1470-0300 089 Retaining tool for telescope pipe
1470-0300 090 Bracket, support of crosshead
1470-0300 219 Torque wrench offset tool
1470-0300 220 Alignment tools
1470-0510 - Crosshead, hydraulic tools
7670-0200 - Torque spanners
7670-0300 - Lifting tools, etc
2013-03-05 - en
1465-0200-0011
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1465-0201-0005
Dismantling of oil Dismount the piston.
Crosshead • Dismantling
pipes See work card 2265-0401.
Dismount the main bearing lubricating

oil pipes.
1465-0201-0001D02
Dismantling of cooling Dismount the cooling oil outlet pipe

oil pipes from the guide shoe and the drain oil
slotted pipe.
Loosen and remove the screws which

secure the telescopic pipe to the guide
shoe.
In order to reach the screw in the corner

behind the telescopic pipe, use the off-
T14-46
set tool along with a socket wrench.
Lift up and suspend the telescopic pipe

by means of the tool.
Unscrew and remove the oil outlet pipe

for the piston cooling oil.
T14-45
1465-0201-0005
2012-02-21 - en
Work Card
1465-0201-0001D03
1 (11)
HYUNDAI
1465-0201-0005 MAN
MANDiesel
B&W
Mounting of hydraulic Turn the crankshaft to gain access to

tools the nuts on the crosshead bearing

studs.
Mount two eyebolts in the top of the T76-1

crankcase in the fore-and-aft direction.
Mount the spacer rings and the hydrau-

lic jacks for loosening the nuts on the
crosshead bearing studs.
For operation of the hydraulic tools, see

work card 7665-0101.
Loosen the nuts, remove the hydraulic

jacks and unscrew the nuts. 1465-0201-0001D04
Thrust piece Mount the lifting tool for the crosshead

dismantling bearing cap and hook the tackles on
to the lifting brackets in the top of the
crankcase.
Dismount the bearing cap and lift it out

of the engine.
Unscrew and remove the studs for the

crosshead bearing.
1465-0201-0001D05
1465-0201-0005
2012-02-21 - en
Work Card
2 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0201-0005
Mounting of lifting Remove the shim.
tools
Mount the special lifting tool on the
crosshead.
Mount the lifting attachments for fixing

the connecting rod on the connecting
rod head. T14-42
Fasten tackles to the lifting brackets on

the frame box wall and attach the tackle
hooks to the lifting attachments. Haul
the tackles tight.
Attach the flat-plaited wire strap to the

engine room crane.
Hook the engine room crane on to the

1465-0201-0005D06
lifting tool on the crosshead, and lift the
crosshead.
Tilting connecting rod T14-53

Using the tackles, tilt the connecting
rod towards the exhaust side, while
turning the crank throw towards the
manoeuvring side.
Transfer the tackles from one lifting at-

tachment to another as necessary.
When the crank throw is 90° after BDC,

stop turning.
By alternate use of the tackles, tilt the

connecting rod until it rests against a
couple of wooden planks in the bottom
of the bedplate.
1465-0201-0001D07
1465-0201-0005
2012-02-21 - en
Work Card
3 (11)
HYUNDAI
1465-0201-0005 MAN
MANDiesel
B&W
The guide strips and Lower the crosshead to a position just

plate above the main bearing caps.
Remove the guide strips and both guide

plates from the guide shoes.
Unscrew the stop bolt from the bottom

of the guide shoes.
It is recommended to tag the guide

NOTE strips and shims to avoid mixing them.
Mount lifting eyebolts in both guide

shoes.
1465-0201-0001D08
The guide shoe

Suspend two tackles from the eye- T14-43
bolts in the top of the crankcase, in
the fore-and-aft direction, and at-
tach the tackles to the guide shoes.
Push one of the guide shoes against

the middle of the crosshead. If nec-
essary, use the guide shoe extractor
tool.
1465-0201-0005
1465-0201-0001D09
2012-02-21 - en
Work Card
4 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0201-0005
Loosening the cross- Pull the “free end” of the cross-
head from the guide head into the neighbouring cylinder unit.
shoes
Mount the guide shoe extractor on the
opposite guide shoe.
Pull off the guide shoe, remove the ex-

tractor, and lift up the guide shoe.
1465-0201-0001D10
Remoiving the guide Pull the crosshead with guide shoe into
shoe the opposite neighbouring cylinder unit.
Mount the guide shoe extractor tool on

the remaining guide shoe.
Pull off the guide shoe, remove the ex-

tractor tool and lift up the guide shoe.
1465-0201-0001D11
1465-0201-0005
2012-02-21 - en
Work Card
5 (11)
HYUNDAI
1465-0201-0005 MAN
MANDiesel
B&W
Crosshead turning Turn the crosshead 90°.

1465-0201-0001D12
The wire guide tool Mount the wire guide tool in the frame-
box door opening.
Remove the crosshead from the engine,

using wire rope and tackles.
Protect the crosshead, for instance with

thick or corrugated paper, and land it
outside the engine.
If necessary, remove the guide shoes

from the engine.
1465-0201-0001D13
1465-0201-0005
2012-02-21 - en
Work Card
6 (11)
2012-02-21 - en
MAN
MAN B&W
HYUNDAI
Diesel
Work Card Crosshead • Mounting

1465-0201-0005
1465-0201-0005
7 (11)
HYUNDAI
1465-0201-0005 MAN
MANDiesel
B&W
Removing the ex- Lower the other guide shoe.

Crosshead • Mounting
tractor tool
Use the guide shoe extractor tool to
push the crosshead towards the second
guide shoe.
Remove the extractor tool and adjust

the position of the opposite guide shoe.
1465-0201-0001M04
Re-mounting the Mount the guide plates on the side of

guide strips and the guide shoes.
plate
Tighten the screws and lock them with
locking wire.
See Workcard 7665-0601.
Using the engine room crane, lift the

crosshead to a working position and
mount the guide strips on the side of
the guide shoes.
Tighten the screws and lock them with

locking wire.
T14-31
T14-30
1465-0201-0001M05
1465-0201-0005
2012-02-21 - en
Work Card
8 (11)
HYUNDAI
MAN Diesel
MAN B&W 1465-0201-0005
Re-positioning the Using the tackles, lift the
Crosshead • Mounting
connecting rod connecting rod to a vertical position
while turning the crankthrow to BDC. T14-53
Refit the studs for the crosshead bear-

ing for tightening. See Workcard 7665-
0301.
1465-0201-0001M06
Mounting the cross When the connecting rod is in a vertical

head position, lower the crosshead and land it
on the connecting rod.
Remove the lifting attachments from the

connecting rod head.
Remove the lifting tool from the cross-

head.
Replace the shim.
1465-0201-0005M07
1465-0201-0005
2012-02-21 - en
Work Card
9 (11)
10 (11)
1465-0201-0005
1465-0201-0005
MAN B&W
HYUNDAI
MANDiesel
2012-02-21 - en
2012-02-21 - en
MAN
MAN B&W
HYUNDAI
Diesel

1465-0201-0005
1465-0201-0005
11 (11)
HYUNDAI
MAN B&W
MAN B&W 1465-0300-0010

Precautions
Connecting Rod, Data

see 0545-0100
Data
T14-53 Connecting rod, without bearing caps 1400 kg
T14-54 Connecting rod complete 1600 kg
T14-55 Crosshead bearing stud 5 kg
2013-04-16 - en
1465-0300-0010
Work Card
1 (2)
HYUNDAI
1465-0300-0010 MAN B&W
MAN B&W
Connecting Rod, Data
Tools
1470-0300 041 Wire guide
1470-0300 077 Chain for suspending piston
1470-0310 - Connecting rod, hydraulic tools
2013-04-16 - en
1465-0300-0010
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1465-0301-0004
Piston Rod
Connecting Rod • Dismantling

Suspend the piston rod and
dismount the crosshead bearing cap.
See work card 2565-0201.
T76-1
1465-0301-0002D01
1465-0301-0004
2013-02-27 - en
Work Card
1 (10)
HYUNDAI
1465-0301-0004 MAN B&W
Tackles Suspend two tackles from the two lifting

brackets at the sides of the frame box.
Mount the wire guide in the top of the

crankcase doorway.
1465-0301-0002D02
Turn the crank to TDC Dismantle the crankpin bearing cap,

and remove it from the engine.
Mount the support brackets for guide

shoes on the web plates.
1465-0301-0002D03
1465-0301-0004
2013-02-27 - en
Work Card
2 (10)
HYUNDAI
MAN Diesel
MAN B&W 1465-0301-0004
Lifting attachments Mount the lifting attachments for fixing

the connecting rod on the head of the
connecting rod.
A B
There are different lifting attachments
NOTE for each end of the connecting rod.
Use the tackles fastened to lifting brack-

ets A and B on the frame box wall, and
attach the tackle hooks to the men-
tioned lifting attachments on the con-
necting rod.
Haul the tackles tight.
Also mount a lifting attachment in the

crankpin end of the connecting rod, on 1465-0301-0002D04
the exhaust side.
Carefully turn the crank down towards the exhaust side, until the crosshead
shoes rest on the supports.
Adjust the support brackets to the guide shoes so that the weight of the cross-
head is evenly distributed on the two supports.
Turn the crank BDC Turn the crankthrow towards BDC while T14-53
“following” with the tackles, thus contin- T14-55
uously supporting the connecting rod.
A B
1465-0301-0004
1465-0301-0002D05
2013-02-27 - en
Work Card
3 (10)
HYUNDAI
1465-0301-0004 MAN B&W
Turn the crank 90˚ Turn the crankthrow to 90° before BDC.
Remove the four studs from the connecting rod.
Shift the hook of the tackle attached to lifting bracket B from the lifting attach-
ment on the lowermost side of the connecting rod to the lifting attachment on
the uppermost side.
Tilt the connecting rod By means of the tackle from lifting

bracket A, tilt the connecting rod to-
wards the manoeuvre side until the
connecting rod is leaning out of the
doorway.
Attach a tackle to lifting bracket A on A B

the frame box wall and connect the
tackle hook to the lifting attachment at
the lower end of the connecting rod.
Turn the crank carefully upwards while

“following” with the tackles, guiding the
head of the connecting rod out of the
doorway.
1465-0301-0002D07
Attach a tackle Attach a tackle to the gallerymounted

lifting bracket E, and hook on to the lift-
ing attachment on the connecting rod. E
Shift the tackles from one lifting brack- B

A
et/attachment to the other, as required.
Remove the floor chequer plate for the

pertaining cylinder.
1465-0301-0004
2013-02-27 - en
Work Card
1465-0301-0002D08
4 (10)
HYUNDAI
MAN Diesel
MAN B&W 1465-0301-0004
Lifting the connecting Place a plated wire rope round the con-

rod out of the engine necting rod, hook on the engine room E
crane and haul tight. B
A
Continue turning upwards till about 30°
after TDC, while “following” with the T14-53
tackles and the engine room crane.
Lift the connecting rod out of the engine

using the engine room crane and the
tackles.
1465-0301-0002D09
1465-0301-0004
2013-02-27 - en
Work Card
5 (10)
HYUNDAI
1465-0301-0004 MAN B&W
Apply oil to the Equip the connecting rod with the same
Connecting Rod • Mounting
bearing shell lifting attachments as mentioned under

dismantling.
Turn the crank to a position about 30° B

past TDC on the manoeuvre side. A
Apply clean lubricating oil to the crank-

pin bearing shell and journal.
T14-53
1465-0301-0002M01
Moving the connect- Lift the connecting rod carefully into the
ing rod into the crank- crankcase by alternate use of the engine E
case room crane and the tackles attached to
lifting brackets A and B. B
A
Attach a tackle to bracket E and the up-
per end of the connecting rod.
1465-0301-0002M02
1465-0301-0004
2013-02-27 - en
Work Card
6 (10)
HYUNDAI
MAN Diesel
MAN B&W 1465-0301-0004
The connecting rod When the end of the connecting rod

rests on the crank pin rests on the crankpin journal, shift tack- E
journal le B from the lower end to the upper end
of the connecting rod. B
A
1465-0301-0002M03
Engine room crane Turn the crankthrow towards BDC, past

TDC, while ‘following’ with the tackles.
E
Lower the engine room crane and re-
move the strap around the connecting
rod. A B
When the uppermost lifting bracket on
the connecting rod is just below lifting
point B, remove the tackle from lifting
point E, fit a tackle between lifting point
A and the upper end of the connecting
rod.
1465-0301-0002M04
1465-0301-0004
2013-02-27 - en
Work Card
7 (10)
HYUNDAI
1465-0301-0004 MAN B&W
Lifting attachments Turn the crankthrow to 90° before BDC,

and use the tackles to raise the con-

necting rod to an upright position.
Shift tackle B from the lifting attachment A B

on one side to the other side of the con-
necting rod.
Remove tackle A from the lower end of

the connecting rod.
Remove the lifting attachment at the

lower end of the connecting rod.
1465-0301-0002M05
Connecting rod studs Screw the studs into the connecting

rod. Using the stud setter and a torque T14-55
wrench, tighten the studs.
Lubricate the crosshead bearing shell

and journal. A B
1465-0301-0002M06
1465-0301-0004
2013-02-27 - en
Work Card
8 (10)
HYUNDAI
MAN Diesel
MAN B&W 1465-0301-0004
Landing the cross- Turn the crankthrow towards TDC while

head on the connect- ‘following’ with the tackles, carefully
ing rod land the crosshead on the connecting
rod.
A B
Take care that the studs do not damage

NOTE the crosshead bearing journal.
1465-0301-0002M07
The crankpin bearing When the crank is in TDC,

cap mount the crankpin bearing cap.
Remove the crosshead supports.
Turn to BDC and mount the crosshead

bearing cap and the piston.
1465-0301-0004
2013-02-27 - en
1465-0301-0002M08
Work Card
9 (10)
HYUNDAI
1465-0301-0004 MAN B&W
Tackles and lifting Remove the tackles and lifting

attachments attachments.
1465-0301-0001M09
Turn the crosshead Tighten all four crosshead bearing cap

to BDC nuts simultaneously. See Data.
For use of hydraulic jacks, see work card

7665-0101.
T76-2
1465-0301-0001M10
1465-0301-0004
2013-02-27 - en
Work Card
10 (10)
HYUNDAI
MAN B&W
MAN B&W 1465-0400-0007

Precautions
Chains, Data
see 0545-0100
Data
T14-60 3.5" chain
T14-61 Teeth on chain wheel, max. wear 3.0 mm
T14-62 Original length (chain pitch x 10 links) 889 mm
10 links measurements + 1 of a tensioned
T14-63 898 mm
chain = scrapping of chain
2013-03-05 - en
1465-0400-0007
Work Card
1 (2)
HYUNDAI
1465-0400-0007 MAN B&W
MAN B&W
Chains, Data
Tools
1470-1000 050 Chain assembling tool
1470-1000 080 Chain disassembling tool
2013-03-05 - en
1465-0400-0007
Work Card
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1465-0401-0001.0
Carry out the inspection as follows:
Chains • Checking
1. Make a general inspection for loose bolts and screws.
2. Inspect lube oil pipes for damage, and check jet nozzles for possible stop-
pages or deformations.
3. Examine the rubber track of the guideways for cracks or other damage.
Replace the guideway if bits have started to be “plucked out” of the rubber
track.
4. Check the teeth of the chain

wheels. If abnormal wear is
found, take a measurement as
shown in the sketch or as de-
scribed in step 5.
Measurements are best taken

by placing a short straight-edge
over the straight part of the chain
wheel and then measuring the
distance T14-61. T14-61
1465-0401-0001C04
1465-0401-0001.0
2007-08-24
Work Card
Doc-ID: 1465-0401-0001.0 1 (7)

HYUNDAI
1465-0401-0001.0 MANDiesel
MAN B&W
5. If abnormal wear is observed at the

Chains • Checking
bottom of the teeth, make a drawing

in scale 1:1 of the teeth and wear
profile.
Draw two rulers on the drawing.

0
For assessing the wear profile, con-
tact MAN Diesel.
10 Scale 1:1
In most cases, scratches caused by
the side plates of the chain will be 0 10
found on the sides of the teeth. Such
scratches can generally be consid-
ered normal. 1465-0401-0001C05
6. On engines with more than one chain, the chains for the camshaft drive are
matched together to ensure an even load distribution.
To keep such matching chains in their pairs, the side plates of the outer link
nearest to the assembled link have been marked with year, month, day and
chain number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 2C, possible 3rd chain)
No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)
On the same links there is an arrow (–>) which indicates the mounting direc-
tion.
Check the chains for cracks on possibly defective rollers and side plates.
Check that the chain rollers can run freely and that the chain links can freely
move on the pin and bushing (that they are not “seized” between the pin
and the bushing).
It is normal, however, that the rollers get light, circumferential scratches dur-
1465-0401-0001.0
ing the running-in period. These fine scratches are of no importance and
need not be considered.
2007-08-24
It is recommended that each single link is checked.

Work Card
2 (7) Doc-ID: 1465-0401-0001.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0401-0001.0
7. Check chain wear by measuring the
Chains • Checking
length of 10 chain links. Use two
master squares and a steel measur-
ing tape as shown on the sketch.
Compare the result with the value
given in Data.
T14-62
If necessary, adjust the chain tight-
Ma
ener.
T14-63
x. T
14-
63
1465-0401-0001C07
1465-0401-0001.0
2007-08-24
Work Card
Doc-ID: 1465-0401-0001.0 3 (7)

HYUNDAI
1465-0401-0001.0 MANDiesel
MAN B&W
It may become necessary to disassemble the chain if, for instance, cracked
Chains • Dismantling
rollers or seizures between pin and bushing have been discovered during
the inspection.
Every time a chain link is disassembled, a new link must always be fitted as
the link pin press-fit is destroyed when breaking the chain.
NOTE On engines with more than one chain:
When a new link is fitted in one chain, the corresponding link in the other
chain must also be renewed.
1. Remove the tension on the chain

by loosening the chain tightener.
Turn the engine until the slack

part of the chain, with the chain
link that is to be disassembled,
is in a favourable position for the
work. If the engine is equipped
with balanceweights, continue
the turning until the balance-
weights are hanging vertically
downwards, as shown in the
sketch.
1465-0401-0001.0
2007-08-24
Work Card
1465-0401-0001D01
4 (7) Doc-ID: 1465-0401-0001.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0401-0001.0
2. Mount a wire round the link rollers a
short distance from the disassembly
point, and tighten the wire lightly
with a tackle.
Protect the link rollers over which

the wire is wrapped.
If the chain is to be completely re-

NOTE moved, contact MAN Diesel for fur-
ther information.
The riveting of the pins that are to

be pressed out is to be chiselled or
ground away.
If the riveting is ground away, take

care and cover exposed engine
parts. Avoid grinding dust in enter-
ing bearings.
1465-0401-0001D02
1465-0401-0001.0
2007-08-24
Work Card
Doc-ID: 1465-0401-0001.0 5 (7)

HYUNDAI
1465-0401-0001.0 MANDiesel
MAN B&W
3. Place the chain bursting tool over

the outer chain link, and disman-

tle the link by alternately tighten-
ing the screws on the tool.
1465-0401-0001D03
1465-0401-0001.0
2007-08-24
Work Card
6 (7) Doc-ID: 1465-0401-0001.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0401-0001.0
Before assembling the inner and outer links, clean the pins and bushings.
Chains • Mounting
1. Combine the inner chain link
with the outer chain link and
mount the compression tool.
Force the loose side plate of

the outer link into place by al-
ternately tightening the screws
on the compression tool.
2. When the link has been assem-

bled, remove the compression
tool and lock the pin ends by
riveting.
Repeat this procedure until the

chain has been assembled.
Remove the tackle and wire 1465-0401-0001M01

and adjust the chain tension.
See Data and Workcard 1465-0501.
1465-0401-0001.0
2007-08-24
Work Card
Doc-ID: 1465-0401-0001.0 7 (7)

HYUNDAI
MAN B&W
MAN B&W 1465-0500-0001

Precautions
Chain Tightener, Data

see 0545-0100
Data
2013-03-11 - en
1465-0500-0001
Work Card
1 (2)
HYUNDAI
1465-0500-0001 MAN B&W
MAN B&W
Chain Tightener, Data
Tools
1470-0500 - Hydraulic tools - chain tightener
7670-0100 023 Hydraulic pump, hand operated
2013-03-11 - en
1465-0500-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 1465-0501-0016
Turn the engine Turn the engine in the clockwise
Chain Tightener • Adjustment

direction to get the slack part of the
chain to the tightening wheel.
1465-0501-0001A01
1465-0501-0016
2014-02-17-en
Work Card
1 (4)
HYUNDAI
1465-0501-0016 MAN B&W
Chain tightener cover Remove the small segment of the

chain tightener cover, loosen the up-

permost guide bar support.
1465-0501-0016
1465-0501-0002A02
2014-02-17-en
Work Card
2 (4)
HYUNDAI
MAN B&W 1465-0501-0016
Mount the tightening Fit the beam C and the

tools tightening tool studs B in the threaded D
holes in the tightener wheel shaft
through beam C.
Mount the chain tightener hydraulic

jacks D.
Check by hand that the two jacks D

are screwed down to face contact.
C
Loosen the hydraulic nut A on the side
of the chain tightener wheel.
For operation of the hydraulic tools, see

Workcard 7665-0101. A
B
1465-0501-0001A03
Connect the jacks Connect the jacks D with the hy-

to the pump draulic hand pump.
Tighten the jacks to the value

stated in data T76-2.
A C
1465-0501-0016
2014-02-17-en
Work Card
1465-0501-0001A04
3 (4)
HYUNDAI
1465-0501-0016 MAN B&W
Guide bar Tighten the hydraulic nut A to the value stated in data T76-2. Use the pneumat-
ic/hydraulic pump for this operation.
Loosen the chain tightener tools and remove the tools from the engine.
Press the guide bar against the chain and tighten the guide bar support.
The covers Fit the covers.

1465-0501-0016
2014-02-17-en
Work Card
1465-0501-0002A05
4 (4)
HYUNDAI
MAN B&W
MAN B&W 1465-0600-0003

Precautions
Camshaft, Data
see 0545-0100
Data
T14-75 Max. permissible change in lead angle 2 °
T14-76 corresponding to 3.5 mm
2013-03-04 - en
1465-0600-0003
Work Card
1 (2)
HYUNDAI
1465-0600-0003 MAN B&W
MAN B&W
Camshaft, Data
Tools
1470-1400 168 Camshaft pin gauge
1470-1400 203 Crankshaft pin gauge
2013-03-04 - en
1465-0600-0003
Work Card
2 (2)
HYUNDAI
MAN B&W 1465-0601-0001.0
1. Turn the crankthrow for cylinder
Camshaft • Checking
1 to TDC.
Turn in the ahead direction to

ensure that the tension of the
chain on the chain drive is cor-
rect. If necessary, adjust the
chain tension.
Check the TDC of cylinder 1

against the mark on the turning
wheel.
1465-0601-0001C01
2. Use the check measurement

value stamped on the pin gaug-
es to check the pin gauges for
deformation.
On some engines the pin

gauges can be checked against
punch marks made on the front
cylinder frame.
1465-0601-0001.0
1465-0601-0001C02
2007-10-01
Work Card
Doc-ID: 1465-0601-0001.0 1 (5)

HYUNDAI
1465-0601-0001.0 MANDiesel
MAN B&W
3. Check the TDC position with

the pin gauge on the crank-

throw.
1465-0601-0001C03
1465-0601-0001.0
2007-10-01
Work Card
2 (5) Doc-ID: 1465-0601-0001.0

HYUNDAI
MAN B&W 1465-0601-0001.0
4. Position the camshaft pin
gauge in the centre punch
mark, and measure the devia-
tion, if any, in lead angle.
For max. permissible change,

see T14-75 or T14-76.
1465-0601-0001C04
5. When checking the camshaft

position, also check the running
surface of the cams.
As the inspection must include

the entire surface of the cam,
the cam should be turned one
complete revolution during the
inspection.
The running surface of the cam

must be completely smooth and
bright.
1465-0601-0001C05
1465-0601-0001.0
2007-10-01
Work Card
Doc-ID: 1465-0601-0001.0 3 (5)

HYUNDAI
1465-0601-0001.0 MANDiesel
MAN B&W
6. If light scratches are ascertained,

remove them by carefully pol-

ishing the cam in the direction
of rotation with a fine carborun-
dum stone. Such light scratches
can appear if the roller guide
and the cam are not correctly
aligned.
In the event of heavier scratch-

es or direct flaking of the mate-
rial on the running path, MAN
Diesel should be contacted for
further instructions.
1465-0601-0001C06
1465-0601-0001.0
2007-10-01
Work Card
4 (5) Doc-ID: 1465-0601-0001.0

HYUNDAI
MAN B&W 1465-0601-0001.0
1. If the chains prove to be so
Camshaft • Overhaul
heavily worn that the deviation
between the measuring points
and the pin gauge has reached
the maximum value T14-75 stated
in Data, MAN Diesel should
be contacted for further instruc-
tions.
T14-76
T14-75
1465-0601-0001A01
1465-0601-0001.0
2007-10-01
Work Card
Doc-ID: 1465-0601-0001.0 5 (5)

HYUNDAI
MAN B&W
MAN B&W 1465-0700-0001

Precautions
Exhaust Valve Cam , Data

see 0545-0100
Data
T14-80 Check lifting height 10 mm
2013-03-04 - en
1465-0700-0001
Work Card
1 (2)
HYUNDAI
1465-0700-0001 MAN B&W
Ex h a u s t V a l v e Ca m , Da t a
Tools
Plate
Plat e Item No.
No. Description
1470-1400 048 Impact wrench for fuel cam
2270-0200 066 Lifting tool for exhaust valve
7670-0100 202 Quick coupling, male
7670-0100 226 Disc, round-plain, Cu ø11x3 mm
2 0 1 3 -0 3 -0 4 - e n
1465-0700-0001
W o r k Ca r d
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1465-0701-0002.0
1. Turn the crank throw of the
Exhaust Valve Cam • Checking

cylinder concerned in AHEAD
direction until TDC. Check and
write down the angle indicated on
the turning wheel.
1465-0701-0001C01
2. Remove the high pressure pipe,

see Workcard 2265-0101.
Mount and tighten the lifting tool for

the exhaust valve roller guide to the
actuator piston (remove the screws
for tightening to the actuator hous-
ing and do not lift the roller guide).
Mount a dial gauge (measuring

range 0.00 - 20.00 mm) on the lift-
ing tool for the exhaust valve roller
guide.
Reset the scale and the pointer.
Press the dial gauge against the

face of the actuator housing until
the reading T14-80 + 1.00 mm is
obtained.
1465-0701-0002C02
3. Turn the roller guide in AHEAD direction until lifted to T14-80, and the dial
gauge gives the reading 1.00 mm and calculate the angle A, which is the
number of degrees the crank throw has turned from TDC position to the
present position.
Continue turning AHEAD until the roller guide again is lifted to T14-80, and
the dial gauge gives the reading 1.00 mm.
Calculate the angle B, which is the number of degrees the crank throw has
turned from TDC position to the present position.
1465-0701-0002.0
When calculating the angles A and B, remember to take into account that
NOTE
2009-05-28
the scale on the turning wheel shifts from 360 to 0 (zero) degrees.
Work Card
Doc-ID: 1465-0701-0002.0 1 (5)

HYUNDAI
1465-0701-0002.0 MANDiesel
MAN B&W
Exhaust Valve Cam • Checking
4. Calculate the lead Calculate the lead angle as:

180° – (A° + B°)/2 + (C1° + C2°)/2
The lead angle is normally a negative

figure.
The illustration shows the position of the

exhaust cam when the piston of the
relevant cylinder is in TDC.
The position of the cam must be correct C

1°
within a tolerance of +/-0.5°. °
C2
See the adjustment sheet from the

testbed results, supplied from the engine C1°= 74.2 °
manufacturer. C2°= 75.6 °
5. The cam lead angle can be

checked visually by reading di-
rectly the scale position of the
exhaust cam over the marking
scratch on the camshaft and
comparing this angle with the
angle stated in the Adjustment
Sheet.
At the same time, it is recom-

mended to check the position of
the camshaft with the pin gauge.
1465-0701-0001C05
1465-0701-0002.0
2009-05-28
Work Card
2 (5) Doc-ID: 1465-0701-0002.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0701-0002.0
Normally, adjustment of the exhaust cams should not be necessary. Before
Exhaust Valve Cam • Adjustment

adjustment of any cams, see Description 6345-XXXX.
1. Remove the inspection cover

from the camshaft housing.
1465-0701-0001O01
2. Dismount the exhaust valve high-pressure pipe,

3. Turn the camshaft until there

is access to the oil ducts in
the exhaust cam through the
inspection hole.
If fitted, remove the plugs

from the oil ducts (using, for
instance, a screwdriver).
Insert three copper gaskets

in each oil duct.
Mount snap-on couplings

in the oil ducts, but do not
tighten them.
1465-0701-0001O02
Fit hoses between the
1465-0701-0002.0
snap-on couplings and the distributor block and between the distributor
block and the hydraulic high pressure pump.
2009-05-28
Work Card
Doc-ID: 1465-0701-0002.0 3 (5)

HYUNDAI
1465-0701-0002.0 MANDiesel
MAN B&W
4. Mount the special spanner

on the exhaust cam disc, en-

suring that the two pins enter
the holes in the cam.
Apply a light pressure to the

hydraulic system and, after
venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure

until oil seeps out along the
camshaft under the cam disc.
Keep the cam pressurised for

at least two to five minutes 1465-0701-0001O03
before turning the cam.
Oil must sweep out with the pump running during the operation.
Keep the cam pressurised during turning.
5. Turn the cam disc, using the fitted

spanner, until the desired change
of lead is obtained. Check the
change on the cam scale
To increase the lead angle and

reduce the compression pres-
sure:
– turn the cam disc ASTERN.
To reduce lead angle and in-

crease the compression pres-
sure:
– turn the cam disc AHEAD.
1465-0701-0002.0
1465-0701-0001C05
2009-05-28
Work Card
4 (5) Doc-ID: 1465-0701-0002.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0701-0002.0
6. After completing the desired turning of the cam disc, relieve the hydraulic

system of pressure and dismount the spanner and the hydraulic equipment.
Wait at least 15 minutes – the cam must be allowed time to “settle” – before
mounting the plugs again in the oil ducts of the cam disc.
After carrying out adjustment, measure the exhaust cam lead again.
Write down and file the new results for the purpose of comparing with future
measurements and adjustment.
7. Mount the high pressure pipe for the exhaust valve.

9. After any adjustment of the cam position, pcomp must be recorded and com-
pared with pcomp at a known engine reference load.
1465-0701-0002.0
2009-05-28
Work Card
Doc-ID: 1465-0701-0002.0 5 (5)

HYUNDAI
MAN B&W
MAN B&W 1465-0800-0003

Precautions
Exhaust Valve Roller Guide, Data

see 0545-0100
Data
Ref.
Ref. Description
Description Value
Value Unit
Unit
T14-83 Bushing/shaft pin, max. clearance 0.5 mm
T14-85 Roller guide complete 35 kg
2013-03-04 - en
1465-0800-0003
Work Card
1 (2)
HYUNDAI
1465-0800-0003 MAN B&W
Ex h a u s t V a l v e R o l l er Gu i d e, Da t a
Tools
Plate
Plat e Item No.
No. Description
2013-03-04 -en
1465-0800-0003
W o r k Ca r d
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1465-0801-0002.0
1. The exhaust valve roller guide can be partially checked while mounted on
Exhaust Valve Roller Guide • Checking

the engine, using the following procedure:
Lift the roller guide. See Workcard1465-0701.
2. Remove the camshaft inspec-

tion cover.
Turn the engine to provide the

maximum space between the
roller guide and the cam disc.
Check the movability of the roller

by turning this by hand to ascer-
tain if the roller moves freely and
without unnecessary resistance
or “hard” points.
Also inspect the surface of

1465-0801-0001C02
the roller for possible damage
marks, seizures or scratches.
Make sure that no traces of bearing metal exist in the roller guide housing.
Check the clearance in the slide bearing by lifting the roller relative to the
roller guide and measuring the difference in distance between the cam disc
and the roller in the upper and lower positions of the roller.
3. A more suitable and reliable method is to check the roller guide and the
bearing clearance when the roller guide is dismounted.
4. Inspect the surfaces of the roller guide and the roller for damage marks, sei-
zures or scratches.
5. To measure the clearance in the

roller guide slide bearing, place
the roller guide vertically upside T14-83
down on a couple of planks with
the roller hanging freely.
6. Place a dial gauge against the

roller. Then lift the roller as much
as the clearance permits, which
makes it possible to read the
clearance directly on the dial,
1465-0801-0002.0
see Data.
2009-05-25
Work Card
1465-0801-0002C05
Doc-ID: 1465-0801-0002.0 1 (4)

HYUNDAI
1465-0801-0002.0 MANDiesel
MAN B&W
1. Dismantle the hydraulic actuator

Exhaust Valve Roller Guide • Dismantling
above the exhaust valve roller

guide.
1465-0801-0001D01
2. Lift the roller guide out of the roll-

er guide housing by hand. Take
care not to damage the sliding
surfaces of the roller guide when
lifting.
T14-85
1465-0801-0002.0
1465-0801-0001D02
2009-05-25
Work Card
2 (4) Doc-ID: 1465-0801-0002.0

HYUNDAI
MAN B&W
MAN Diesel 1465-0801-0002.0
1. Inspect and check the exhaust
Exhaust Valve Roller Guide • Overhaul

valve roller guide.
See the Checking Workcard.
1465-0801-0001O01
2. It is recommended that the roller guide should ONLY be overhauled/dis-

mantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data sheet,
• seizure marks on the slide surfaces,
have been observed during the checking of the roller guide.
For disassembling of the roller guide, contact an MAN Diesel authorized

NOTE repair shop.
3. If no irregularities are found, just

clean and lubricate the roller
guide before remounting it in the
roller guide bushing.
1465-0801-0002.0
2009-05-25
Work Card
1465-0801-0001O03
Doc-ID: 1465-0801-0002.0 3 (4)

HYUNDAI
1465-0801-0002.0 MANDiesel
MAN B&W
1. Clean and lubricate the sliding

Exhaust Valve Roller Guide • Mounting
surfaces of the roller and the

roller guide and lower it carefully
into the roller guide bushing by
hand.
1465-0801-0001O01
2. Mount the actuator.

1465-0801-0002.0
2009-05-25
1465-0801-0001D01
Work Card
4 (4) Doc-ID: 1465-0801-0002.0

HYUNDAI
MAN B&W
MAN B&W 1465-1100-0002

Precautions
Replacement of Cams on Camshaft, Data

see 0545-0100
O Shut off fuel oil
Data
T14-102 Exhaust cam screws, tightening torque 560 Nm
T14-107 Exhaust cam, marking scratch 55 mm
T14-108 Exhaust cam, axial movement 220 mm
2013-03-04 - en
1465-1100-0002
Work Card
1 (2)
HYUNDAI
1465-1100-0002 MAN B&W
MAN B&W
Replacement of Cams on Camshaft, Data
Tools
1470-1400 048 Impact wrench for turning cam
2270-0200 174 Lifting tool for roller guide
7670-0100 202 Quick coupling, male
7670-0100 240 Disc
2013-03-04 - en
1465-1100-0002
Work Card
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 1465-1101-0002
Exhaust Cam
Replacement of Cams on Camshaft • Dismantling

Remove the cover Remove the front cover of the camshaft
housing.
1465-1101-0001D01
Roller guide Lift the roller guide from the cam in

question. See Work Card 6665-01.
1465-1101-0002D02
1465-1101-0002
2009-05-29 - en
Work Card
1 (4)
HYUNDAI
1465-1101-0002 MANDiesel
MAN B&W
Marking scratch Extend the marking scratch on the exhaust

cam onto the camshaft by T14-107.
See Data.
T14-107
1465-1101-0001D03
Remove the plug Remove the plug from the cam. Mount
gaskets and snap-on connectors in-
stead.
Gasket
1465-1101-0002
2009-05-29 - en
Work Card
1465-1101-0001D04
2 (4)
HYUNDAI
MAN B&W
MAN Diesel 1465-1101-0002
Snap-on connections Connect the snap-on connectors to the

hydraulic high-pressure pump.
Apply oil pressure to the cam, using the

high-pressure pump.
When oil seeps out along the cam,

press the cam min. 120 mm to the side,
in the most convenient direction away
from obstructions, depending on the
placement of the cam.
1465-1101-0001D05
Be sure the cam is The cam should be moved as stated in

free T14-108 to be sure that it gets free of the
liner for the roller guide.
When the cam is moved, turn the engine

one revolution and check that the cam
goes clear of the housing.
In case the cam In the event that the cam cannot be

cannot be moved moved as described in item 14, MAN
Diesel should be contacted for further
instructions.
T14-108
1465-1101-0002
2009-05-29 - en
Work Card
T14-108 1465-1101-0001D06
3 (4)
HYUNDAI
1465-1101-0002 MANDiesel
MAN B&W
Exhaust Cam
Replacement of Cams on Camshaft • Mounting
Before mounting Before mounting the two-part spare

cam, the bore and the area on the shaft
must be degreased.
Place the two-part spare cam on the

shaft, mount the four screws, and tight-
en slightly, so that the gap between the
two parts is equal at both sides.
1465-1101-0001M01
Marking scratches Make sure that the marking scratches

on the cam and the camshaft coincide,
and that the running surface of the cam
is opposite the roller.
Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the exhaust cam lead

(see Work Card 1465-07 and adjust if
necessary.
Tighten the screws to T14-102 and

check that the gap is still equal at both
sides.
Lock the screws with Loctite, type 242 T14-102

(EN243S).
1465-1101-0002
2009-05-29 - en
Work Card
1465-1101-0001M02
Mount the cover

Mount the cover on the front of the camshaft housing.
4 (4)
HYUNDAI
MAN B&W
MAN Diesel 1470-0200-0001.0
Crosshead Tools
012
1470-0200-0001.0
Plate
Doc-ID: 1470-0200-0001.0 1 (2)

HYUNDAI
1470-0200-0001.0 MANDiesel
MAN B&W

Crosshead Tools
012 - Guide shoe extractor

1470-0200-0001.0
Plate
2 (2) Doc-ID: 1470-0200-0001.0

MAN B&W
HYUNDAI
Plate Connecting Rod and Crosshead Tool Panel
1 (2)
1470-0300-0010
1470- 0300- 0010

HYUNDAI
1470-0300-0010 MAN B&W

Connecting Rod and Crosshead Tool Panel
016 - Panel for tools

028 - Name plate
041 - Wire guide
053 - Lifting attachment for connecting rod
065 - Lifting tools for crosshead
077 - Chain for suspending piston
089 - Retaining tool for telescope pipe
090 - Bracket for support of crosshead
112 - Rubber cover for croshead
124 - Rubber cover for croshead
219 - Torque wrench offset tool
220 - Alignment tools
268 - Eye bolt
281 - Protective screw
293 Wire sling
1470- 0300- 0010
Plate
2 (2)
2013-03-05 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Chain Tightener Hydraulic Tools
1 (2)
1470-0500-0016
1470-0500-0016
HYUNDAI
1470-0500-0016 MANB&W
MAN B&W

Chain Tightener Hydraulic Tools
013 - Hydraulic jack, complete

037 - Tommy bar
049 - Support for hydraulic jack
050 - Sealing ring with back-up ring
098 - Stud setter
108 - Crossbar
110 - Stud
121 - Stud
133 - Hex key
145 - Ball handle
157 - Nut
1470-0500-0016
2013-03-05 - en
Plate
2 (2)
2010-09-03 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Crosshead Hydraulic Tools
1 (2)
1470-0510-0005
1470-0510-0005
HYUNDAI
1470-0510-0005 MAN B&W
MAN Diesel

Crosshead Hydraulic Tools
018 - Hydraulic jack

043 - Tommy bar
055 - Sealing ring with back-up
080 - Hex key
102 - Stud setter
1470-0510-0005
2010-09-03 - en
Plate
2 (2)
2009-04-07
MAN
MAN B&W
HYUNDAI
Diesel
Plate Chain Drive Tools Panel
1 (2)
1470-1400-0007
1470-1400-0007
HYUNDAI
1470-1400-0007 MAN
MANDiesel
B&W

Chain Drive Tools Panel

024 - Name plate
048 - Impact spanner for turning cam
050 - Chain assembling tool
061 - Chain disassembling tool
168 - Pin gauge for camshaft
203 - Pin gauge for crankshaft
1470-1400-0007
2009-04-07
Plate
2 (2)
2011-02-15 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Camshaft
1 (2)
1472-0600-0004
1472-0600-0004
HYUNDAI
1472-0600-0004 MANB&W
MAN B&W

Camshaft
010 - Camshaft
022 - Screw
034 - Cam - half
046 - Cam - half
058 - Repair cam - exhaust, complete
071 - Gear wheel
083 - Flange screw
105 - Locking wire
1472-0600-0004
2011-02-15 - en
Plate
2 (2)
2009-01-29
MAN
MAN B&W
HYUNDAI
Diesel
Plate Connecting Rod
1 (2)
1472-0300-0003
1472-0300-0003
HYUNDAI
1472-0300-0003 MAN
MANDiesel
B&W

Connecting Rod
021 - Screw
033 - Outlet pipe
045 - Guide shoe, fore
069 - Plate
070 - Screw
082 - Locking wire
094 - Screw
128 - Connecting rod stud
141 - Crosshead bearing cap
153 - Crosshead
177 - Connecting rod
190 - Crankpin bearing cap
212 - Stuffingbox,telescopic pipe
236 - Housing, stuffing box
248 - Bushing
261 - Flange, stuffing box
273 - Telescopic pipe
285 - Guide shoe, aft
297 - Shim for guide strip*
307 - Shim for guide strip*
320 - Guide strip
332 - Flange screw
344 - Dowel
356 - Screw
393 - Connecting rod stud
415 - Dowel
427 - Screw with dog point
440 - Screw
1472-0300-0003
2009-01-29
Note: * When ordering, please state thickness of shim.

Plate
2 (2)
2011-06-07 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Connecting rod, Additional Mass

1472-0320-0003
1 (2)
1472-0320-0003
HYUNDAI
1472-0320-0003 MANB&W
MAN B&W

Connecting rod, Additional Mass
019 - Screw
020 - Counterweight
032 - Counterweight
1472-0320-0003
2011-06-07 - en
Plate
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1472-0310-0002.0
Connecting Rod, Compression Shim

1472-0310-0002.0
Plate
Doc-ID: 1472-0310-0002.0 1 (2)

HYUNDAI
1472-0310-0002.0 MAN
MANDiesel
B&W

Connecting Rod, Compression Shim
014 - Guide ring for piston rod

026 - Screw
038 - Shim under piston rod
1472-0310-0002.0
Plate
2 (2) Doc-ID: 1472-0310-0002.0

HYUNDAI
1472-0500-0009 MANB&W
MAN B&W

Chain Tightener
017 - Side plate

029 - Screw
042 - Spherical nut
066 - Stud
078 - Shaft
091 - Distance piece
101 - Flange bearing
113 - Chain tightener wheel
125 - Bracket
137 - Disc
149 - Shaft
150 - Screw
162 - Locking wire
174 - Side plate
186 - Washer
198 - Screw
1472-0500-0009
2011-06-08 - en

Plate
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1472-0400-0004
Chain
1472-0400-0004
2009-04-29
Plate
1 (2)
HYUNDAI
1472-0400-0004 MAN
MANDiesel
B&W

Chain
013 - Chain, complete

037 - Outer link, 3.5"
049 - Inner link, 3.5"
1472-0400-0004
2009-04-29
Plate
2 (2)
2013-02-22 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Chain Drive Guidebars

1472-1420-0023
1 (2)
1472-1420-0023
HYUNDAI
1472-1420-0023 MANB&W
MAN B&W

Chain Drive Guidebars
015 - washer
027 - Nut
040 - Shim
052 - Bracket
076 - Screw
088 - washer
111 - Screw
123 - Locking wire
147 - Screw
159 - Screw
172 - Beam for guidebar
196 - Shim
218 - Screw
231 - Guidebar
243 - Guidebar
255 - Shim
267 - Screw
302 - Plate
326 - Screw
351 - Spring pin
375 - Screw
1472-1420-0023
2013-02-22 - en
Plate
2 (2)
HYUNDAI
MAN
MANB&W
B&W
Preface Chapter Vibration Control ......................... ......................... 1840-0100-0001
Vibration Control
Work Card Axial Vibration Damper, Data ................ ................ 1865-0100-0015
Axial Vibration Damper ..................... ..................... 1865-0101-0010
Tool Plate Axial Vibration Damper Hydraulic Tools ........ ........ 1870-0600-0002
Plate Axial Vibration Damper ..................... ..................... 1872-0100-0007

Axial Vibration Monitor ..................... ..................... 1872-0150-0005
Arrangement of Fore End ................... ................... 1872-0600-0015
Table of contents
1 (1)
HYUNDAI
MAN B&W
MAN B&W 1840-0100-0001
General
Vibration Control
Axial Vibration
Damper Section: 18XX-01YY
To counteract heavy axial vibrations, and any resultant adverse forces and vibra-
tions, the crankshaft is provided with an axial vibration damper.
The damper consists of a ‘piston’ and a slit-type housing. The ‘piston’ is made as
an integrated collar on one of the main bearing journals, and the housing is moun-
ted on the pertaining main bearing support.
The axial movement is damped as a result of the ‘restrictions’ incorporated in the

bores which interconnect the oil-filled chambers on the two sides of the ‘piston’.
Lubricating oil is supplied to both sides of the ‘piston’ from the main system.
Moment
Compensators Section: 18XX-02YY
On the basis of calculations, the engine may be provided with fly weights to coun-
teract engine forces and moments.
If the chain drives for the compensators have been dismantled,

the flyweights must be positioned correctly in relation to the
crankshaft. See Workcard 1865-0200.
Incorrectly fitted moment compensators may excite heavy vibrations.
1st order moment

Applicable on 4-cylinder engines. The moment compensator is arranged as adjust-
able flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in the main
chain drive.
This moment compensator consists of a (new) chaintightener wheel with an incor-

porated flyweight and a flyweight rotating with the crank shaft.
2012-09-25 - en
1840-0100-0001
Preface
1 (1)
HYUNDAI
MAN B&W
MAN B&W 1865-0100-0015

Precautions
Axial Vibration Damper, Data

see 0545-0100
Data
T18-03 Nuts on inner studs, tightening torque 500 Nm
T18-04 Nuts on inner studs, tightening torque+angle 100+115 Nm+°
T18-07 Horizontal screws, tightening torque 460 Nm
T18-08 Horizontal screws, tightening torque/angle 100+35 Nm+°
T18-09 Damper housing, upper part 650 kg
T18-33 Inner studs, check distance 39±2 mm
T18-34 Outer studs, check distance 88±2 mm
2013-03-05 - en
1865-0100-0015
Work Card
1 (2)
HYUNDAI
1865-0100-0015 MAN B&W
MAN B&W
Axial Vibration Damper, Data
Tools
1870-0600 - Axial vibration damper hydraulic tools
2013-03-05 - en
1865-0100-0015
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 1865-0101-0010
Checking the Effectiveness of the Axial Vibration Damper
Axial Vibration Damper • Checking

For checking the effectiveness of the axial vibration damper, it is necessary to
measure the longitudinal movements of the fore end of the crankshaft during
running.
The measurement (or reading) should be taken at the same r/min as during the
sea trials. (Preferably 90% and 100% of MCR.)
As different equipment can have been mounted on the specific engines, the
checking procedure describes two different systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, with angle encoder fore.
A: Electronic, with axial vibration monitor
A proximeter probe is built on to the lower part of the damper housing. The
probe is connected to a control unit which displays peaktopeak movements
and sends signals to the engine control system.
Concerning overhaul and

setting of the electronic
device, refer to makers in
structions and Description
7045-0100.
The peaktopeak values

displayed in mm
are to be compared with
the original values obtained
during sea trial and the
limits given in Description
7045-0100.
If the peaktopeak value

exceeds the Normal Service
Value, it is
necessary to overhaul the
axial vibration damper, see
dismantling.
1865-0101-0010
2013-02-25
Work Card
1865-0101-0001C01
1 (7)
HYUNDAI
1865-0101-0010 MAN
MANDiesel
B&W
B: Mechanical, with angle encoder fore

Stop the engine Stop the engine.
Remove the shield.
1865-0101-0010C02
Crankshaft Mount the measuring arm in the

middle hole on the flange.
Make sure that the short end of the

arm is in contact with the round
bearing above.
Attach a pencil to the arm.
1865-0101-0001C03
NOTE To obtain a correct measurement, the tip of the pencil should protrude 10 mm
from the end of the arm.
1865-0101-0010
2013-02-25
Work Card
2 (7)
HYUNDAI
MAN Diesel
MAN B&W 1865-0101-0010
Start the engine Start the engine, and let the

speed rise to the number of revo
lutions at which the measurement
is to be taken. (Preferably 90%
and 100% of MCR.)
When measuring, press the meas

uring arm against the shaft piece
with the one hand. With the other
hand, move a sheet/block of pa
per, clipped on to a solid backing
plate, lightly downwards against
the tip of the pencil.
To ensure a certain inertia, the

backing plate should have a mass
of approx. 12 kg. S2
The axial movements (S2) record 1865-0101-0010C04
ed on the paper must be meas
ured with a slide calliper as shown in the sketch.
Standard measuring Before comparing the measured S1

tool value (S2) with the Normal Service
Value (S1), stated in Description
7045-0100, it is necessary to com
pensate for the ratio in the tool.
For a standard measuring tool (L1

= 45 mm and L2 = 270 mm), the L2
ratio is 6.0 Therefore, S1 can be
calculated as follows: L1

S2
S1 = S2
6.0
If a nonstandard tool is used, S1 1865-0101-0010C05

can be calculated as follows:
L
S1 = S2 x 1
L2
1865-0101-0010
2013-02-25
If the peaktopeak value exceeds the Normal Service Value, it is necessary to

Work Card
overhaul the axial vibration damper, see Dismantling.
3 (7)
HYUNDAI
1865-0101-0010 MAN
MANDiesel
B&W
Dismantling of the axial vibration damper is carried out from the crankcase of
NOTE
Axial Vibration Damper • Dismantling
cyl. No. 1.
Turn the engine to 90º Turn the engine to 90º after TDC.
after TDC
Unfasten the lubricating oil pipes for
the main bearing and axial vibration
damper.
T76-1
Loosen and remove the nuts from
the inner studs and the hydraulic
nuts from the outer studs. For opera-
tion of the hydraulic tools, see Work
Card 7665-0101.
Loosen and remove the horizontal

screws.
Only the upper part of the hous

ing needs to be removed, while the
lower half remains mounted on the
bedplate.
1865-0101-0001D01
Eyebolt Mount an eyebolt in the centre lifting

hole on the upper part.
Engines with chain box fore:
Mount a tackle in the bracket above

the axial vibration damper inside the
chain box.
Engines without chainbox fore:
Mount a tackle below the fore end

platform, and remove the cover on
the lifting hole above the axial vibra
tion damper.
1865-0101-0010
2013-01-25
Work Card
1865-0101-0001D02
4 (7)
HYUNDAI
MAN Diesel
MAN B&W 1865-0101-0010
Raising the upper By means of the tackle and wire
Axial Vibration Damper • Dismantling

part of the damper rope, separate and raise the upper part
of the damper housing to a position at
which it is possible to change the oil
seals and springs.
Before starting the work under the sus T18-9

WARNING pended upper part, secure the upper
part with, e.g. a wire rope or another
tackle.
1865-0101-0001D03
1865-0101-0010
2013-02-25
Work Card
5 (7)
HYUNDAI
1865-0101-0010 MAN
MANDiesel
B&W
Oil sealing rings Dismantle and remove the

Axial Vibration Damper • Overhaul
springs from the oil sealing rings.
Remove the oil sealing rings.
It is recommended to discard both

NOTE the springs and the oil
sealing rings.
1865-0101-0001O01
When mounting the new oil sealing rings, first insert the lower half of the rings
in the lower housing.
Then press the tension springs into the groove between the oil sealing ring half
and the housing.
Hook the new Mount all the upper halves of the oil sealing rings in such a way that the clear
tension springs ance at both joints on each oil sealing ring is the same.
Now hook the new tension springs

into place, ensuring that they are
centered in the grooves of the oil
sealing rings.
The lower half of the oil sealing

NOTE rings will protrude above the cen
treline.
1865-0101-0010
2013-02-25
M90505-0229O02
Work Card
1865-0101-0001O02
6 (7)
HYUNDAI
MAN Diesel
MAN B&W 1865-0101-0010
Damper housing Release and carefully lower the
Axial Vibration Damper • Mounting

upper part of the damper housing.
When reaching the oil sealing

rings, take care that the rings enter T18-9
the sealing ring grooves correctly.
Before landing the upper part on

the lower part, be sure that the
guide pins have entered the guide
pin holes.
M90505-0229M01 1865-0101-0001M01
Vertical nuts Mount and tighten the vertical

nuts. See Data.
T18-33
Check the inner and the outer stud T18-3
distance according to T18-33 and
T18-34. T18-34
Mount and tighten the hydraulic
nuts. For operation of the hydrau
T76-2
lic tools, see Work card 7665-
0101.
Mount and tighten the horizontal

M90505-0229M01
screws. See Data. T18-7

T18-8
1865-0101-0006M02
Search the crankcase to ensure
NOTE that there are no tools, shackles
or rags left behind.
Engines without Mount the lubricating oil pipes.

chainbox fore
1865-0101-0010
Engines without chainbox fore.

2013-01-16
Mount the cover for the lifting hole above the axial vibration damper.
Work Card
NOTE After overhaul of the axial vibration damper, it is recommended to check the
axial vibration. See Checking.
7 (7)
2010-09-06 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Axial Vibration Damper Hydraulic Tools

1870-0600-0002
1 (2)
1870-0600-0002
HYUNDAI
1870-0600-0002 MAN B&W
MAN Diesel

Axial Vibration Damper Hydraulic Tools

038 - Tommy bar
063 - Disc
075 - Venting screw
087 - Hex key
099 - Stud setter
1870-0600-0002
2010-09-06 - en
Plate
2 (2)
2010-09-13 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Axial Vibration Damper

1872-0100-0007
1 (2)
1872-0100-0007
HYUNDAI
1872-0100-0007 MAN B&W
MAN Diesel

Axial Vibration Damper
021 - Screw
033 - Restriction for damper
069 - Axial vibration damper, upper part
070 - Screw
082 - Oil seal, axial vibration damper
094 - Spring, extention
104 - Oil seal, axial vibration damper
128 - Guide pin
141 - Dowel
153 - Axial vibration damper, lower part
165 - Nut
177 - Stud
190 - Stud
1872-0100-0007
2010-09-13 - en
Plate
2 (2)
2013-05-02 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Axial Vibration Monitor

1872-0150-0005
1 (2)
1872-0150-0005
HYUNDAI
1872-0150-0005 MANB&W
MAN B&W

Axial Vibration Monitor
012 - Cable gland, complete

024 - Terminal box
036 - Axial vibration monitor, complete
1872-0150-0005
2013-05-02 - en
Plate
2 (2)
2011-12-15 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Arrangement of Fore End

1872-0600-0015
1 (2)
1872-0600-0015
HYUNDAI
1872-0600-0015 MANB&W
MAN B&W

Arrangement of Fore End
018 - Tuning wheel

031 - Nut
040 - Locking wire
043 - Screw
055 - Fitted stud
1872-0600-0015
2011-12-15 - en
Plate
2 (2)
HYUNDAI
MAN B&W
Preface Chapter Cylinder Unit ............................ ............................... 2240-0100-0001
Cylinder Unit
Description Cylinder Condition ........................ .......................... 2245-0100-H005
Inspection of Nimonic Exhaust Valve Spindles ........ 2245-0200-0004
Drawing .
Inspection through Scavenge Ports ............ ............. 2255-0100-0002
.
Factors Influencing Cylinder Wear ............ ............. 2255-0105-0003
Abrasive Particles ............ ....................................... 2255-0110-0003
Cylinder Oil Feed Rate During Running-in ....... ....... 2255-0125-H004
Cylinder Condition Report .................. .................... 2255-0130-0003
.
Calculation of Condensate Amount .............. .......... 2255-0140-0003
.
Overview Of Piston Rings ................... ..................... 2255-0145-0001
.
Liner Condition ........................... .............................. 2255-0150-0001
Work Card Exhaust Valve High-Pressure Pipe, Data ....... ....... 2265-0100-0006
Exhaust Valve High-Pressure Pipe ............ ............ 2265-0101-0004
.
Exhaust Valve, Data ....................... ......................... 2265-0200-0012
Exhaust Valve ........................... ............................. 2265-0201-0013
Cylinder Cover, Data ...................... ........................ 2265-0300-0018
Cylinder Cover ........................... .............................. 2265-0301-0013
Piston, Data ............................. ................................ 2265-0400-0013
Piston ................................. .................................... 2265-0401-0008
.
Piston Rod Stuffingbox, Data ................ .................. 2265-0500-0008
Piston Rod Stuffingbox .................... ...................... 2265-0501-0010
Cylinder Liner, Data ....................... ......................... 2265-0600-0019
Cylinder Liner ............................ .............................. 2265-0601-0013
Tool Plate Exhaust Valve Panel Tools .................. ................... 2270-0200-0019
Exhaust Valve Extra Tools .................. ................... 2270-0220-E002

.
Exhaust Valve Hydraulic Tools ............... ................ 2270-0240-0001.0
Cylinder Cover Panel Tools ................. .................. 2270-0300-0006
Cylinder Cover Hydraulic Tools Spares ......... ......... 2270-0315-0003
Cylinder Cover Lifting Tools ................. .................. 2270-0350-0002
Piston Panel Tools ........................ .......................... 2270-0400-0028
Piston Guide Tool ........................ .......................... 2270-0430-0001.0
.
Piston Support Tools ...................... ......................... 2270-0470-0005
.
Piston Lifting Tools ........................ .......................... 2270-0480-0001.0
.
Cylinder Liner Tools ........................ ......................... 2270-0610-0001.0
Cylinder Liner Lifting Tools ........... .......................... 2270-0640-0002
Table of contents
Plate Exhaust Valve, Upper Part .................. ................... 2272-0200-0012

Exhaust Valve, Lower Part .................. ................... 2272-0210-0009
Exhaust Valve, Detail ...................... ....................... 2272-0220-0003
Exhaust Valve, Upper Part Detail ............. ............ 2272-0230-0009
Exhaust Valve Pipe ........................ ......................... 2272-0240-0003
Cylinder Cover ........................... ............................. 2272-0300-0017
Cylinder Cover Protective Shield ............. .............. 2272-0320-0003
1 (2)
HYUNDAI
MAN B&W
Piston ................................. ................................. 2272-0400-0001.0

Cy l i n d er Un i t
Piston Rings ............................. ............................. 2272-0420-0002

Piston Rod Stuffing Box .................... .................... 2272-0500-0010E
Cylinder Liner ............................ ............................ 2272-0600-0010
Indicator valve ........................... ........................... 2272-1000-0001.0E
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 2240-0100-0001
02. Exhaust Valve
2240-0100-0001
Each cylinder is equipped with an exhaust valve, which is mounted in a central
bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gastight seal against a seat in the cylinder cover.
Valve housing The valve housing has an exchangeable bottom piece.
The bore for the valve spindle is provided with an exchangeable spindle guide
liner.
Cooling The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from the
upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.
Valve spindle The part of the spindle stem which travels within the sealing arrangement of the
air cylinder is coated with a wear resistant mixture of metal carbide and super
alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is fitted which
causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:
To enable checking the functioning of the exhaust valve while the engine is run-
ning, a ‘lifting/rotation check rod’ is mounted on top of the hydraulic cylinder on
the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom posi-
tions of the check rod.
This check rod is only for checking purposes, and must not be per-
NOTE manently activated.
Pistons:
At the top of the spindle, two pistons are fitted:

2240-0100-0001
Preface Chapter
1. Air piston. The piston serves to close the exhaust valve. The piston is
2008-06-17 - en
locked to the spindle by a two-piece conical ring.
2. Hydraulic piston. The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrangement, designed
to dampen the closing of the valve.
Doc. ID: 2240-0100-0001 1 (5)

HYUNDAI
2240-0100-0001 MANDiesel
MAN B&W
The damper arrangement is of self-adjusting type.

2240-0100-0001
Air cylinder The air cylinder is mounted on top of the valve housing. Air for closing the ex-
haust valve is supplied through a non-return valve to the space below the pis-
ton.
A safety valve is mounted in the bottom of the air cylinder. The safety valve is
connected to the drain pipe which leads to the camshaft housing.
Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder on top
of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by the pis-
ton in the hydraulic cylinder.
A throttle valve designed for deaerating the oil system is fitted at the top of the
cylinder.
The Control Oil Level (COL) system incoporated into the design of the hydraulic
cylinder housing ensures that air chamber under the air piston is air tight.
04. Piston
The piston consists of two main parts:
• Piston Crown
• Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the piston
skirt is tightened to the piston crown.
The piston crown is provided with three small grooves for the fitting of lifting
tools.
The piston crown is provided with chromium plated grooves for four piston
rings.
Piston ring No. 1 is a Controlled Pressure Relief ring (CPR).
Piston ring No. 2, 3 and 4 have oblique cuts:
• piston ring No. 3 has a right-hand cut,

2240-0100-0001
Preface Chapter
and
2008-06-17 - en
• piston rings Nos. 2 and 4 have left-hand cuts.
On the ME-B series the piston rings are provided with Alu-coating to improve
the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
2 (5) Doc. ID: 2240-0100-0001

HYUNDAI
MAN B&W
MAN Diesel 2240-0100-0001
2240-0100-0001
Piston Rod The piston rod has a through-going bore for the cooling oil pipe, which is se
cured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe

or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.
The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the flow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.
05. Stuffing Box
The bore for the piston rod between the scavenge air space and the crankcase
is fitted with a piston rod stuffing box, which is designed to prevent the lubri-
cating oil in the crankcase from being drawn up into the scavenge air space.
The stuffing box also prevents scavenge air (in the scavenge air space) from
leaking into the crankcase.
The stuffing box housing consists of two parts, which are bolted together.
Scraper/sealing ringers
The housing is provided with a number of machined ring grooves:
The uppermost groove holds a scraper ring with oblique edges, which serves
to prevent sludge from the scavenge box from being drawn down to the other
rings.
Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC
type engines).
• The ring grooves in the middle are fitted with sealing rings.
2240-0100-0001
Preface Chapter
2008-06-17 - en
• The lowermost ring grooves are fitted with scraper rings which scrape the
lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase through
bores in the stuffing box housing.
Doc. ID: 2240-0100-0001 3 (5)

HYUNDAI
2240-0100-0001 MANDiesel
MAN B&W
Through bores in the housing and a pipe, the stuffing box communicates with
2240-0100-0001
a control funnel on the outside of the engine, which enables the sealing/scrap-
ing performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.
06. Cylinder Liner and Cooling Jacket
The cylinder liner is fitted with a cooling jacket. The cooling water is supplied
at the lower part of the cooling jacket.
On slimtype liners, the water continues directly to the upper part of the cooling
jacket, whereas on the borecooled type liner, the water first passes through the
cooling bores. From the top of the cooling jackets, the water flows through wa-
ter connections to the cooling jacket on the lower part of the cylinder cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by the ten-
sioning force from the cylinder cover studs being transmitted via the cylinder
cover.
Scavenge air ports The part of the cylinder liner which is located in the scavenge air space of
the cylinder frame is provided with a number of scavenge air ports, which are
uncovered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to give
the scavenge air a rotary movement in the cylinder.
Cylinder lubrication In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with non-return valves for the supply of lu-
bricating oil to the cylinder.
See also Chapter 30 “Lubricating System”.
PC-ring A piston cleaning (PC) ring is mounted at the top of the cylinder liner. The pur-
pose of the PC-ring is to prevent the building up of deposits on the piston top-
land and, in turn, prevent the wiping away of the cylinder lubricating oil. Conse-
quently, the PC-ring contributes to reducing the wear of liners and rings.
Cylinder Cover The cylinder cover is made of steel.
Valve bores The cover has a central bore for the exhaust valve, which is attached by means
2240-0100-0001
Preface Chapter
of four studs and nuts.

2008-06-17 - en
The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet and indicator cock.
4 (5) Doc. ID: 2240-0100-0001

HYUNDAI
MAN B&W
MAN Diesel 2240-0100-0001
2240-0100-0001
Cooling A cooling jacket is mounted on the lower part of the cylinder cover, whereby
a cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylin-
der cover and, further on, through the cooling bores, to the space around the
exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe.
See also Chapter 50 “Cooling Water System”.
Tightening The cylinder cover is tightened against the top of the cylinder liner with nuts
and long studs fitted in the cylinder frame. The nuts are tightened with hydrau-
lic tools.
Sealing between the cylinder cover and cylinder liner is obtained by means of a
sealing ring of mild steel.
10. Indicator Valve
Each cylinder is fitted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.
Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.
For indicator valves of the double-seated design with a spring-loaded

NOTE closing face:
In order to prevent overstressing, close the valve lightly before starting

the engine, and retighten the valve when the engine has reached its
normal service temperature.
2240-0100-0001
Preface Chapter
2008-06-17 - en
Doc. ID: 2240-0100-0001 5 (5)

HYUNDAI
/#0$9
MAN B&W
2245-0100-H005
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GPIKPGU
6JGPWODGT
QHITQQXGUVJGFKUVTKDWVKQPQP
VJGEKTEWOHGTGPEGCPFVJG
FGRVJUFGRGPFQPVJGE[NKPFGT
DQTG

%24212
(QTUOCNNDQTGGPIKPGU

VJGFGRVJUQHVJGITQQXGU
YQWNFPQVDGFGGRGPQWIJVQ
CEEGRVCTGCUQPCDNGYGCT
RQVGPVKCN+PUVGCFTKPIUYKVJ
ITQQXGURNCEGFQPVJGNQYGT
HCEGCTGWUGF6JGFGUKIPCVKQP
HQTVJKUTKPIV[RGKU212
RQTV
QPRNCPG

&GUETKRVKQP

3(24)
HYUNDAI

2245-0100-H005 /#0$9
MAN B&W
5ECXGPIG2QTV+PURGEVKQP
%[NKPFGT%QPFKVKQP
)GPGTCN
6JGUECXGPIGRQTVKPURGEVKQPRTQXKFGUWUGHWNKPHQTOCVKQPCDQWVVJGEQPFKVKQPQH
E[NKPFGTURKUVQPUUMKTVURKUVQPTQFUCPFTKPIU
6JGKPURGEVKQPEQPUKUVUQHCXKUWCNGZCOKPCVKQPQHVJGRKUVQPRKUVQPUMKTVUTQFU
RKUVQPTKPIUCPFVJGNQYGTRCTVQHVJGE[NKPFGTNKPGTFKTGEVN[VJTQWIJVJGUECXGPIG
CKTRQTVUCPFOGCUWTGOGPVUQHVJGTKPIENGCTCPEGVJG%.ITQQXGUVJG212ITQXG
QRGPKPICPFVJGVJKEMPGUUQHRQUUKDNGRKUVQPTKPIEQCVKPI
6QTGFWEGVJGTKUMQHCUECXGPIGDQZHKTGGXGPVJQWIJVJKURJGPQOGPQPKUXGT[
TCTGQPOQFGTPGPIKPGUTGOQXGCP[QKNUNWFIGCPFECTDQPFGRQUKVUKPVJGUECX
GPIGCKTDQZCPFTGEGKXGTKPEQPPGEVKQPYKVJVJGKPURGEVKQP9KVJVJGTGNGXCPV
RWORUTWPPKPICPGXCNWCVKQPECPDGOCFGQHVJGHWGNXCNXGUUGCNKPIVKIJVPGUUVJG
RKUVQPVKIJVPGUUHQTNWDGQKNCPFVJGE[NKPFGTEQXGT UUGCNKPIVKIJVPGUUHQTEQQNKPI
YCVGT
6JGRQTVKPURGEVKQPUJQWNFDGECTTKGFQWVCVVJGHKTUVUVQRCHVGTCNQPIXQ[CIGGI
D[CPEJQTKPIKHRQUUKDNGVQQDVCKPVJGOQUVTGNKCDNGTGUWNVYKVJTGICTFVQVJGGHHGE
VKXGPGUUCPFUWHHKEKGPE[QHVJGE[NKPFGTNWDTKECVKQPCPFVJGEQODWUVKQPE[ENG
EQO
RNGVGQTKPEQORNGVG#OKUNGCFKPITGUWNVOC[DGQDVCKPGFKHVJGRQTVKPURGEVKQPKU
ECTTKGFQWVCHVGTCTTKXCNCVJCTDQWTUKPEGOCPQGWXTKPIVQVJGSWC[CPFNQYNQCF
TWPPKPIGITKXGTQTECPCNRCUUCIGTGSWKTGUKPETGCUGFE[NKPFGTQKNFQUCIGKGVJG
E[NKPFGTUCTGGZEGUUKXGN[NWDTKECVGF(WTVJGTFWTKPINQYNQCFVJGEQODWUVKQPE[ENG
OKIJVPQVDGCUGHHGEVKXGCPFEQORNGVGCUGZRGEVGFFWGVQVJGCEVWCNHWGNQKNSWCN
KVKGUCPFUGTXKEG
TWPPKPIEQPFKVKQPQHVJGHWGNKPLGEVKQPGSWKROGPV+VKUJKIJN[TGE
QOOGPFGFVQVCMGVJKUKPHQTOCVKQPKPVQEQPUKFGTCVKQPYJGPGXCNWCVKPIVJGE[NKPFGT
EQPFKVKQP
6JGKPURGEVKQPOWUVVCMGRNCEGCVNGCUVVYKEGCOQPVJ+HKPRQTVCP[YC[
2TQEGFWTG
(QTVJG+PURGEVKQPRTQEGFWTGUGGYQTMECTF
5ECXGPIGRQTVKPURGEVKQPUCTGDGUVECTTKGFQWVD[VYQRGTUQPU6JGOQTGGZRGTK
GPEGFRGTUQPKPURGEVUVJGUWTHCEGUCPFUVCVGUJKUQDUGTXCVKQPUVQCPCUUKUVCPV
YJQTGEQTFUVJGOCPFNCVGTGPVGTUVJGOKP/#0&KGUGN6WTDQUVCPFCTFHQTOU
-GGREQQNKPIYCVGTHWGNQKNCPFEQQNKPIQKNEKTEWNCVKPIUQVJCVRQUUKDNGNGCMCIGU
ECPDGFGVGEVGF

&GUETKRVKQP

4(24)
HYUNDAI
/#0$9
MAN B&W
2245-0100-H005
#.9#;5DTKPIVJGVWTPKPIIGCTUYKVEJKPVQVJGUECXGPIGCKT
%[NKPFGT%QPFKVKQP
TGEGKXGTFWTKPIKPURGEVKQP
$NQEMVJGUVCTVKPICKTUWRRN[VQVJGOCKPUVCTVKPIXCNXG1RGPVJG
KPFKECVQTXCNXGU
$NQEMVJGJCVEJEQXGTVQVJGTGEGKXGTVQRTGXGPVKVHTQOENQUKPID[
CEEKFGPV
$TKPIKPDQVVNGUYKVJFTKPMKPIYCVGTHQTEQPUWORVKQPKPVJGUECXGPIG
CKTTGEGKXGT6CMGECTGYJGPOQXKPICTQWPFKPVJGTGEGKXGTCPFDTKPI
RTQRGTNKIJVKPI2QEMGVUHQTVJGTOQOGVGTUCTGRNCEGFKPJGCFNGXGN
*CTFJCVKUCNUQTGEQOOGPFGF4GOGODGTVQVCMGDTGCMUVQTGRNGPKUJ
HNWKFNQUVHTQOUYGCVKPIGURGEKCNN[KPJQVENKOCVGU
'PICIGVJGVWTPKPIIGCT4GOQXGVJGKPURGEVKQPEQXGTUQPVJGHWGNRWORUKFGQH
VJGE[NKPFGTHTCOGCPFENGCPVJGQRGPKPIU1RGPVJGFQQTUQTVJGEQXGT
UQPVJG
UECXGPIGCKTTGEGKXGT&QPQVGPVGTVJGUECXGPIGCKTTGEGKXGTDGHQTGKVJCUDGGP
VJQTQWIJN[XGPVKNCVGF$GIKPVJGKPURGEVKQPQPVJGE[NKPFGTYKVJVJGRKUVQPPGCTGUV
$&%+PURGEVVJGRKUVQPUMKTVUTQFUTKPIUCPFE[NKPFGTYCNN9KRGVJGTWPPKPI
UWTHCEGUENGCPYKVJCTCIVQGPUWTGEQTTGEVCUUGUUOGPVQHVJGRKUVQPTKPIEQPFK
VKQP
7UGCRQYGTHWNNCORVQQDVCKPCVTWGKORTGUUKQPQHVJGFGVCKNU$TKPIKPCUOCNN
ECOGTCVQOCMGFQEWOGPVCVKQPQHVJGEQPFKVKQPQHVJGUECXGPIGRQTVKPURGEVKQP
GVE+PUVGCFQHHNCUJWUGVJGNCORCUVJGNKIJVUQWTEG
4GEQTFVJGTGUWNVUQPFTCYKPICPFWUGVJGU[ODQNUCUUJQYPVQ
GPUWTGGCU[KPVGTRTGVCVKQPQHVJGQDUGTXCVKQPU
-GGRVJGTGEQTFUVQHQTOCNQIDQQMQHVJGE[NKPFGTEQPFKVKQP/GCUWTGVJGVQVCN
ENGCTCPEGDGVYGGPVJGRKUVQPTKPIUCPFVJGTKPIITQQXGU/GCUWTGVJG%.ITQQXG
FGRVJUCPFVJGVJKEMPGUUQHVJGTKPIEQCVKPIKHCRRNKECDNG%QPVKPWGVJGKPURGEVKQP
QPVJGPGZVE[NKPFGTYKVJKVURKUVQPPGCTGUV$&%CPFUQQPCEEQTFKPIVQVJGHKTKPI
QTFGT0QVGFQYPVJGQTFGTQHKPURGEVKQPHQTWUGCVNCVGTKPURGEVKQPU%JGEMVJG
PQPTGVWTPXCNXGU
HNCRXCNXGUDWVVGTHN[XCNXGUKPVJGCWZKNKCT[DNQYGTU[UVGOHQT
GCU[OQXGOGPVCPFRQUUKDNGFCOCIGCPFKPURGEVVJGEQPFKVKQPQHVJGYCVGTOKUV
ECVEJGT4GOQXGCP[QKNUNWFIGCPFECTDQPFGRQUKVUKPVJGUECXGPIGCKTDQZGU
CPFTGEGKXGT+HHWGNQKNQTGZEGUUKXGU[UVGOQKNKUHQWPFVJGHWGNXCNXGQTRWNNGFRKU
VQPUUJQWNFDGRTGUUWTGVGUVGF4GEQTFVJGQDUGTXCVKQPUQPFTCYKPI
&GUETKRVKQP

5(24)
HYUNDAI

2245-0100-H005 /#0$9
MAN B&W
1DUGTXCVKQPU
%[NKPFGT%QPFKVKQP
5ECXGPIG4GEGKXGT%QPFKVKQP
%JGEMCPFPQVGVJGEQPFKVKQPQHVJGUECXGPIGTGEGKXGT
5ECXGPIG4GEGKXGT01
5.7&)'
0QVG9CVGTYCUJKPIHTQO
FGHGEVYCVGTOKUVECVEJGTEQWNF
ECWUGCXGT[ENGCPUECXGPIGCKT
TGEGKXGT
5ECXGPIG4GEGKXGT5.7&)'s
5
0QTOCNRKEVWTG+PFKECVGUIQQF
E[NKPFGTEQPFKVKQP
5ECXGPIG4GEGKXGT/7%*
5.7&)'s/5
4GOQXGCP[QKNUNWFIGCPFECT
DQPFGRQUKVUKPUECXGPIG
TGEGKXGT

&GUETKRVKQP

6(24)
HYUNDAI
/#0$9
MAN B&W
2245-0100-H005
.GCMCIG
%[NKPFGT%QPFKVKQP
%JGEMVJGRKUVQPETQYPVQRHQTCP[NGCMCIGU
TGOGODGTVQMGGREQQNKPIYCVGT
HWGNQKNCPFNWDTKECVKPIQKNEKTEWNCVKPIFWTKPIVJGKPURGEVKQP
.GCMKPIQKN.1
+HQKNKUHQWPFQPVJGRKUVQPFGVGTOKPGKH
KVKUHWGNQKNQTNWDGQKN(WGNQKNYKNNDG
DNCEMCPFUVKEM[KPFKECVKPICHWGNXCNXG
KUNGCMKPI.WDGQKNYKNNDGDTQYPCPF
PQPUVKEM[KPFKECVKPIKVEQWNFDGHTQO
CPGZJCWUVXCNXG
.GCMKPIYCVGT.9
9CVGTQPCRKUVQPKPFKECVGUCEQQNKPI
U[UVGONGCM+HYCVGTKUHQWPFKVKU
KORQTVCPVVQFGVGTOKPGYJCVVJGECWUG
KU7UGGKVJGTCOKTTQTQTRJQVQVQ
GUVCDNKUJKHVJGNGCMKUHTQOVJGE[NKPFGT
EQXGTGZJCWUVXCNXGQTCETCEMGFNKPGT

2KUVQPTKPIUKPIQQFEQPFKVKQP
9JGPIQQFCPFUVGCF[
UGTXKEGEQPFKVKQPUJCXG
DGGPCEJKGXGFVJG
TWPPKPIUWTHCEGUQHVJG
RKUVQPTKPIUCPFE[NKP
FGTNKPGTYKNNDGYQTP
DTKIJV
VJKUCNUQCRRNKGU
VQVJGTKPIWPFGTUKFGU
CPFVJGpHNQQTqQHVJG
TKPIITQQXGUYJKEJ
JQYGXGTECPPQVDG
UGGPWPVKNCRKUVQPKU
RWNNGF
+PCFFKVKQPVJGTKPIU
YKNNOQXGHTGGN[KPVJG
ITQQXGUCPFCNUQDG
YGNNQKNGFKPVCEVCPF
PQVWPFWN[YQTP6JG
TKPIGFIGUYKNNDG
UJCTRYJGPVJGQTKIKPCN
TQWPFKPIUJCXGDGGP

YQTPCYC[DWVUJQWNF
&GUETKRVKQP
DGYKVJQWVDWTTU

7(24)
HYUNDAI

2245-0100-H005 /#0$9
MAN B&W
2KUVQPTKPIUOKETQUGK\WTG
%[NKPFGT%QPFKVKQP
6GORGTCTKN[KPETGCUGVJGE[NKPFGTQKNFQU
CIG+HUGK\WTGUCTGQDUGTXGF
+HOKETQUGK\WTGUCUQDUGTXGFQPVJGRKUVQP
TKPIUCTGPQVRTQRGTN[CVVGPFGFD[TGFWEKPI
VJGROCZCPFGPIKPGNQCFQPVJGTGURGEVKXG
WPKVCPFD[KPETGCUKPIVJGNWDTKECVKQPHGGF
TCVGCEEQTFKPIVQKPUVTWEVKQPU
IM9J
UEWHHKPIQHVJGE[NKPFGTNKPGTECPQEEWT
ECWUKPIOQOGPVCTKN[JKIJYGCTQHCNNEQO
DWUVKQPEJCODGTRCTVU
+HQXGTCRGTKQFQHVKOGVJGQKNHKNOKURCTVK
CNN[KPVGTTWRVGFQTFKUCRRGCTKPIUQVJCVFT[
CTGCUCTGHQTOGFQPVJGE[NKPFGTYCNNVJGUG
CTGCUCPFVJGRKUVQPTKPIUWTHCEGUYKNND[
HTKEVKQPCNKPVGTCEVKQPDGEQOGHKPGN[UEWHHGF
CPFJCTFGPGFKGVJGIQQFpOKTTQTUWTHCEGq
YKNNJCXGFGVGTKQTCVGF
+PECUGQHGZVTGOGOKETQUGK\WTGU
HQTUEWHH
KPIUGGKVGOUJCTRDWTTUOC[HQTO
QPVJGGFIGUQHVJGRKUVQPTKPIU
#UGK\GFUWTHCEGYJKEJJCUCEJCTCEVGTKUVKE
XGTVKECNN[UVTKRGFCRRGCTCPEGYKNNDGTGNC
VKXGN[JCTFCPFOC[ECWUGGZEGUUKXGE[NKP
FGTYGCT&WGVQVJKUJCTFPGUUVJGFCO
CIGFCTGCUYKNNQPN[UNQYN[FKUCRRGCT
TWPKP
CICKPKHCPFYJGPVJGQKNHKNOKUTGUVQTGF
#UNQPICUVJGUGK\WTGKUCNNQYGFVQEQP
VKPWGVJGNQECNYGCTYKNNVGPFVQDGGZEGU
UKXG5GK\WTGOC[KPKVKCNN[DGNKOKVGFVQRCTV
QHVJGTKPIEKTEWOHGTGPEGDWVUKPEGVJG
TKPIUCTGHTGGVQpVWTPqKPVJGKTITQQXGUKV
OC[GXGPVWCNN[URTGCFQXGTVJGGPVKTGTWP
PKPIHCEGQHVJGTKPI
6JGHCEVVJCVVJGTKPIUOQXGKPVJGKTITQQXGU
YKNNCNUQVGPFVQVTCPUOKVVJGNQECNUGK\WTGCNN
VJGYC[CTQWPFVJGNKPGTUWTHCEG
+HGZVTGOGUGK\WTGU
HQTUEWHHKPIUGGKVGO
JCXGDGGPQDUGTXGFKVKUTGEQOOGP
FGFVJCVVJGE[NQKNHGGFTCVGKUVGORQTCTKN[
KPETGCUGFVQIM9J

+HNQCFTGFWEVKQPQHOQTGVJCPQPGWPKVKU
&GUETKRVKQP
TGSWKTGFRNGCUGEQPVCEV/#0&KGUGN
6WTDQHQTCFXKEG

8(24)
HYUNDAI
/#0$9
MAN B&W
2245-0100-H005
2KUVQPTKPIUUETCVEKPI
%[NKPFGT%QPFKVKQP
5ETCVEJKPIKUECWUGFD[JCTFCDTCUKXGRCTVKENGUQTKIKPCVKPIHTQOVJGTKPIKVUGNHQT
OQTGNKMGN[HTQOVJGHWGNQKNQTCKTKPVCMG9KVJTGICTFUVQNKPGTCPFTKPIYGCTVJG
CEVWCNUETCVEJKPIKUPQVPGEGUUCTKN[CUGTKQWURTQDNGODWVVJGRCTVKENGUECPJCXG
UGTKQWUEQPUGSWGPEGUGNUGYJGTG
UGG+VGO
2KUVQPTKPIUUVKEMKPI
+HFWGVQVJKEMCPFJCTFFGRQUKVUQH
ECTDQPVJGRKUVQPTKPIUECPPQVOQXG
HTGGN[KPVJGKTITQQXGUFCTMCTGCUYKNN
QHVGPCRRGCTQPVJGWRRGTRCTVQHVJG
E[NKPFGTYCNN
VJKUOC[PQVDGXKUKDNGCV
VJGRQTVKPURGEVKQP6JKUKPFKECVGUC
NCEMQHUGCNKPIKGEQODWUVKQPICU
DNQYD[DGVYGGPRKUVQPTKPIUCPFE[NKP
FGTNKPGT
6JGDNQYD[YKNNRTQXQMGQKNHKNODTGCMFQYPYJKEJKPVWTPYKNNKPETGCUGE[NKPFGT
NKPGTYGCT5VKEMKPIRKUVQPTKPIUYKNNQHVGPNGCFVQDTQMGPRKUVQPTKPIU6JGHTGG
OQXGOGPVQHVJGTKPIUKPVJGITQQXGUKUGUUGPVKCNCPFECPDGEJGEMGFGKVJGTD[
RTGUUKPIVJGOYKVJCYQQFGPUVKEM
VJTQWIJVJGUECXGPIGRQTVUQTD[VWTPKPIVJG
GPIKPGCNVGTPCVGN[ENQEMYKUGCPFEQWPVGTENQEMYKUGVQEJGEMVJGHTGGXGTVKECN
OQXGOGPV
2KUVQPTKPIUDTGCMKPIEQNNCRUG
$TQMGPRKUVQPTKPIUOCPKHGUVVJGOUGNXGUFWTKPIVJGUECXGPIGRQTVKPURGEVKQPD[
VJGKT
ϰ NCEMQHGNCUVKEVGPUKQPYJGPVJGTKPIUCTGRTGUUGFKPVQVJGITQQXGYKVJCUVKEM
ϰ DNCEMKUJCRRGCTCPEG
ϰ HTCEVWTGFTKPIU
ϰ OKUUKPITKPIUQTOKUUKPITKPIRCTVU
2KUVQPTKPIDTGCMCIGKUECWUGFD[CRJGPQOGPQPMPQYPCUpTKPIEQNNCRUGq*QY
GXGTDTGCMCIGOC[CNUQQEEWTFWGVQEQPVKPWCNUVTKMKPICICKPUVYGCTTKFIGUQPVJG
E[NKPFGTNKPGT6&%CTGCQTQVJGTKTTGIWNCTKVKGUQPVJGE[NKPFGTYCNN%QNNCRUGQEEWTU
KHVJGICURTGUUWTGDGJKPFVJGTKPIKUDWKNVWRVQQUNQYN[CPFVJGTGD[GZGTVUCP
KPCFGSWCVGQWVYCTFRTGUUWTG+PUWEJECUGUVJGEQODWUVKQPICUECPRGPGVTCVG
DGVYGGPVJGNKPGTCPFTKPICPFXKQNGPVN[HQTEGVJGTKPIKPYCTFUKPVJGITQQXG6JKU
V[RGQHUWFFGPpUJQEMqNQCFKPIYKNNGXGPVWCNN[NGCFVQHTCEVWTGsGURGEKCNN[KHVJG
TKPIGPFUpUNCOqCICKPUVGCEJQVJGT6JKURJGPQOGPQPKUJQYGXGTUGNFQON[
QDUGTXGFQPOQFGTPGPIKPGU
6JGOGPVKQPGFUNQYRTGUUWTGDWKNFWRDGJKPFVJGTKPIUECPDGFWGVQ
ϰ ECTDQPFGRQUKVUKPVJGTKPIITQQXG
ϰ VQQUOCNNXGTVKECNTKPIENGCTCPEG

ϰ RCTVKCNUVKEMKPI
&GUETKRVKQP
ϰ RQQTUGCNKPIDGVYGGPVJGTKPICPFVJGITQQXGHNQQT
ϰ pENQXGTNGCHKPIq
UGGDGNQY

9(24)
HYUNDAI

2245-0100-H005 /#0$9
MAN B&W
p%NQXGTNGCHKPIqKUCVGTOWUGFVQ
%[NKPFGT%QPFKVKQP
FGUETKDGNQPIKVWFKPCNEQTTQUKXGNKPGT
YGCTCVUGXGTCNUGRCTCVGRQKPVUCTQWPF
VJGNKPGTEKTEWOHGTGPEGsKGKPUQOG
ECUGUVJGNKPGTDQTGOC[CUUWOGCpENQ
XGTNGCHqUJCRG
2KUVQP4KPIU$NQYD[
.GCMCIGQHEQODWUVKQPICURCUVVJGRKUVQPTKPIU
DNQYD[KUCEQPUGSWGPEGQH
UVKEMKPIEQNNCRUGFQTDTQMGPQHTKPIU
#VVJGNCVGTUVCIGUYJGPCEQORNGVGDNQYD[QEEWTUKVKUWUWCNN[FWGVQUVKEMKPI
TKPIUQTTKPIDTGCMCIGECWUGFD[EQNNCRUG
$NQYD[KUKPFKECVGFD[DNCEMFT[CTGCUQPVJGTKPIUCPFCNUQD[NCTIGTDNCEMFT[
\QPGUQPVJGWRRGTRCTVQHVJGNKPGTYCNN6JKUECPQPN[DGUGGPYJGPQXGTJCWNKPI
VJGRKUVQPQTYJGPGZEJCPIKPIVJGGZJCWUVXCNXG
&GRQUKVUQPRKUVQPU
7UWCNN[UQOGFGRQUKVUHTQOVJGE[NKPFGTQKNYKNNCEEWOWNCVGQPVJGUKFGQHVJGRKU
VQPETQYP
VQRNCPF%CTDQPFGRQUKVUQPVJGTKPINCPFU
VJGCTGCQPVJGRKUVQPU
DGVYGGPVJGRKUVQPTKPIUKPFKECVGNCEMQHICUUGCNKPICVVJGTGURGEVKXGTKPIUUGG
FTCYKPI6JGRKUVQPENGCPKPITKPIDGVYGGPVJGE[NKPFGTEQXGTCPFNKPGT
PQTOCNN[TGOQXGUWRGTHNWQWUCPFJCTOHWNFGRQUKVUQPVJGRKUVQPU
+HVJGFGRQUKVUCTGCDPQTOCNN[VJKEMVJGKTUWTHCEGUOC[DGUOQQVJCPFUJKP[HTQO
TWDDKPICICKPUVVJGE[NKPFGTYCNN5WEJEQPVCEVOC[NQECNN[YKRGCYC[QTCDUQTD
VJGE[NKPFGTQKNHKNOTGUWNVKPIKPDQTGRQNKUJOKETQUGK\WTGCPFKPETGCUGFYGCTQH
NKPGTCPFTKPIU+PUQOGKPUVCPEGUOGEJCPKECNENQXGTNGCHKPIECPQEEWTKGXGTVKECN
ITQQXGUQHUNKIJVN[JKIJGTYGCTKPDGVYGGPVJGNWDTKECVKPISWKNNU
5WEJEQPFKVKQPUOC[CNUQDGVJGTGUWNVQHCEQODWUVKQPEQPFKVKQPYJKEJQXGTJGCVU
VJGE[NKPFGTQKNHKNO6JKUEQWNFDGFWGVQHCWNV[QTFGHGEVKXGHWGNXCNXGUQTKPUWHHK
EKGPVVWTDQEJCTIGTGHHKEKGPE[

.WDTKECVKPI%QPFKVKQP
&GUETKRVKQP
0QVGKHVJGpQKNHKNOqQPVJGE[NKPFGTYCNNCPFRKUVQPTKPIUCRRGCTUVQDGCFGSWCVG
UGG+VGO$NCEMQTDTQYPKUJEQNQWTGFCTGCUOC[UQOGVKOGUDGUGGPQPVJG

NKPGTUWTHCEG6JKUKPFKECVGUEQTTQUKXGYGCTWUWCNN[HTQOUWNRJWTKECEKF
UGG+VGO
CPFUJQWNFPQVDGEQPHWUGFYKVJITG[DNCEMCTGCUYJKEJKPFKECVGUDNQYD[
6JGUGFGRQUKVUCTGQHVGPQPN[QHEQUOGVKEPCVWTGCPFYKNNPQVNGCFVQYGCTKUUWGU

10(24)
HYUNDAI
/#0$9
MAN B&W
2245-0100-H005
6JGRJGPQOGPQPKUQHVGPEQPPGEVGFVQJWOKFKV[KPVJGUECXGPIGCKTCPFOC[FKU
CRRGCTYJGPVJGXGUUGNGPVGTUEQNFCPFNGUUJWOKFCTGCU
%[NKPFGT%QPFKVKQP
5GG+VGOCPFEJCRVGT
4GRNCEGOGPVQHRKUVQPTKPIU
+VKUTGEQOOGPFGFVQTGRNCEGVJGEQORNGVGUGVQHRKUVQPTKPIUCVGCEJRKUVQPQXGT
JCWNVQGPUWTGVJCVVJGTKPIUCNYC[UYQTMWPFGTQRVKOCNUGTXKEGEQPFKVKQPUVJGTGD[
IKXKPIVJGDGUVTKPIRGTHQTOCPEG5VTGVEJKPIVJGTKPIUNGCFVQUVTGUUCPFECTGOWUV
DGVCMGPPQVVQQRGPVJGTKPIUOQTGVJCPPGEGUUCT[YJGPKPUVCNNKPIVJGOQPVJG
RKUVQP

&GUETKRVKQP

11(24)
HYUNDAI

2245-0100-H005 /#0$9
MAN B&W
%[NKPFGT1XGTJCWN
%[NKPFGT%QPFKVKQP
6QGPUWTGEQTTGEVTGEQTFKPIQHCNNTGNGXCPVKPHQTOCVKQPKVKUTGEQOOGPFGFVJCVVJG
p%[NKPFGT%QPFKVKQP4GRQTVq
FTCYKPIKUWUGF
+PVGTXCNUDGVYGGPRKUVQPQXGTJCWN
+VKUTGEQOOGPFVQFGEKFGVJGKPVGTXCNDGVYGGPRKUVQPQXGTJCWNDCUGFQPVJGEQP
FKVKQPQHVJGWPKVUQDUGTXGFCVUECXGPIGRQTVKPURGEVKQPUCPFPQVQPHKZGFKPVGT
XCNU+PQVJGTYQTFU+VKUPQVCIQQFKFGCVQRWNNRKUVQP0QDCUGFQPTWPPKPI
JQWTUKHKVKURKUVQP0QVJCVPGGFUQXGTJCWN
#NUQDCUGVJGCEVWCNKPVGTXCNUDGVYGGPRKUVQPQXGTJCWNUQPVJGRTGXKQWUYGCT
OGCUWTGOGPVUCPFQDUGTXCVKQPUHTQOUECXGPIGRQTVKPURGEVKQPU1HVGPVJGIWKF
KPIKPVGTXCNUDGVYGGPRKUVQPQXGTJCWNUECPDGRTQNQPIGFEQPUKFGTCDN[YKVJQWVCP[
JCTOVQVJGE[NKPFGTEQPFKVKQPRTQXKFGFHTGSWGPVUECXGPIGRQTVKPURGEVKQPUCTG
ECTTKGFQWV
4GICTFKPIRTQEGFWTGUHQTVJGFKUOCPVNKPICPFOQWPVKPIQHRKUVQPUUGGYQTMECTF
4GOQXGVJGRKUVQPENGCPKPI
2%TKPIDGVYGGPVJGNKPGTCPFVJGE[NKP
FGTEQXGTCPFOCTMVJGRQUKVKQPQHVJGTKPIVQCNNQYHKVVKPIQHVJG2%TKPIKPVJG
UCOGRQUKVKQPCUKVKUYQTPVQIGVJGTYKVJVJGNKPGT%CTGHWNN[TGOQXGCP[EQMG
FGRQUKVUCPFYGCTTKFIGUHTQOVJGWRRGTRCTVQHVJGNKPGTDGHQTGHKVVKPIVJGRKUVQP
4GICTFKPIRTQEGFWTGHQTEJGEMKPIVJG2%TKPIUGGYQTMECTF6JG
2%TKPIKURCTVQHVJGNKPGTCPFYKNNPQVPGGFVQDGGZEJCPIGFWPNGUUKVKUDTQMGP
+PKVKCNKPURGEVKQPCPFTGOQXCNQHVJGRKUVQPTKPIUYJGPVJGRKUVQPJCUDGGPRWNNGF
1PN[WUGVJGUVCPFCTF/#0&KGUGN
6WTDQTKPIQRGPGTHQTHKVVKPICPF
TGOQXCNQHRKUVQPTKPIU1PN[GZRCPF
VJGTKPIUUWHHKEKGPVN[VQHKVQXGTVJGRKU
VQP6JKUQRGPGTRTGXGPVUNQECNQXGT
UVTGUUKPIQHVJGTKPIOCVGTKCNYJKEJKP
VWTPYQWNFQHVGPTGUWNVKPRGTOCPGPV
FGHQTOCVKQPECWUKPIDNQYD[CPFDTQ
MGPTKPIU5VTCRUVQGZRCPFVJGTKPI
ICRQTVQQNUYQTMKPIQPVJGUCOGRTKP
EKRNGUJQWNFPGXGTDGWUGF

&GUETKRVKQP
%NGCPKPI
%NGCPVJGRKUVQPTKPIU%NGCPCNNTKPIITQQXGUECTGHWNN[+HECTDQPFGRQUKVUTGOCKP

VJG[OC[RTGXGPVVJGTKPIHTQOHQTOKPICRGTHGEVUGCNCICKPUVVJGHNQQTQHVJG
ITQQXG4GOQXGFGRQUKVUQPVJGRKUVQPETQYPCPFTKPINCPFU4GOQXGCP[
TGOCKPKPIEQMGFGRQUKVUHTQOVJGWRRGTUGEVKQPQHVJGNKPGT

12(24)
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/#0$9
MAN B&W
2245-0100-H005
/GCUWTGOGPVQHTKPIYGCT
%[NKPFGT%QPFKVKQP
2NGCUGTGHGTVQYQTMECTF
+PURGEVKQPQHE[NKPFGTNKPGT
6JGCKOKUVQQDVCKPEQPVTQNNGFEQTTQUKXGYGCT
OOJQHVJGNKPGT
UWTHCEGD[CRRN[KPIFKHHGTGPVE[NKPFGTQKNHGGFTCVGUFGRGPFKPIQPVJGHWGNQKNUWN
RJWTEQPVGPV
#NRJC#%%NWDTKECVKQPCNIQTKVJOVQCXQKFNKPGTRQNKUJKPICPFUWDUG
SWGPVUGK\WTGU
%[NKPFGTYGCTOGCUWTGOGPVU
5GGYQTMECTF
$GHQTGOGCUWTKPIVJGE[NKPFGTYGCTYKVJCRKPICWIG
ϰ GPUWTGVJCVVJGVQQNCPFE[NKPFGTNKPGTVGORGTCVWTGXCNWGUCTGENQUG
ϰ TGEQTFVJGVQQNCPFE[NKPFGTNKPGTVGORGTCVWTGUQPFTCYKPIVQGPC
DNGEQTTGEVKQP
ϰ ©HRQUUKDNGVCMGCp\GTQqOGCUWTGOGPV
/GCUWTGVJGYGCTYKVJVJGRKPICWIGCVVJGXGTVKECNRQUKVKQPUOCTMGFQPVJGIWKFG

TCKN/GCUWTGKPDQVJVTCPUXGTUGCPFNQPIKVWFKPCNFKTGEVKQPU6JGIWKFGTCKNGPUWTGU
&GUETKRVKQP
VJCVVJGYGCTKUCNYC[UOGCUWTGFCVVJGUCOGRQUKVKQPU4GEQTFVJGOGCUWTG
OGPVUQPFTCYKPI
6QQNUYKVJGNGEVTQPKEOGCUWTGOGPVGSWKROGPVECPDGWUGFVJTQWIJVJGUECXGPIG
RQTVUKHFKUOCPVNKPIQHVJGE[NKPFGTEQXGTKUPQVRQUUKDNG

13(24)
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MAN B&W
%QTTGEVKQPQHYGCTOGCUWTGOGPVU
%[NKPFGT%QPFKVKQP
%QTTGEVVJGCEVWCNYGCTOGCUWTGOGPVUD[OWNVKRN[KPIYKVJVJGHQNNQYKPIHCEVQTUKH
VJGVGORGTCVWTGQHVJGE[NKPFGTNKPGTKUJKIJGTVJCPVJGVGORGTCVWTGQHVJGVQQN6JKU
GPCDNGUCEQORCTKUQPVQDGOCFGYKVJGCTNKGTYGCTOGCUWTGOGPVU
ǄV
6NKPGT6VQQN %(CEVQT

'ZCORNG
DQTG
ŜVOGCUWTGF%
%QTTGEVGFXCNWG³
KGCTGFWEVKQPQH
OO
*QYGXGTC\GTQOGCUWTGOGPVECPDGOCFGKPVJGVQRQHVJGE[NKPFGTNKPGTCDQXG
TKPI0Q
6&%YJGTGVJGTGKUPQYGCT6JGYGCTECPVJGPDGECNEWNCVGF
/CZKOWOYGCT
6JGOCZKOWOCNNQYCDNGYGCTQHE[NKPFGTNKPGTUKUKPVJGKPVGTXCNQHVQQH
VJGPQOKPCNFKCOGVGTFGRGPFKPIQPVJGCEVWCNE[NKPFGTCPFRKUVQPTKPIRGTHQTO
CPEG9JGPVJGKPVGTXCNDGVYGGPPGEGUUCT[RKUVQPQXGTJCWNUDGEQOGUVQQUJQTV
HQTKPUVCPEGFWGVQQXCNKV[KVKUVKOGVQTGPGYVJGNKPGTCPFVJG2%TKPI
%JGEMKPINKPGTUWTHCEG
+PURGEVVJGNKPGTYCNNHQTUETCVEJGUOKETQUGK\WTGUYGCTTKFIGUEQTTQUKXGYGCT
CPFUWTHCEGUVTWEVWTGKHRQUUKDNG
+HEQTTQUKXGYGCTKUUWURGEVGFQTKHCTKPIKUHQWPFDTQMGPVCMGGZVTCYGCTOGCU
WTGOGPVUCTQWPFVJGEKTEWOHGTGPEGCVVJGWRRGTRCTVQHVJGNKPGT2TGUUCPGYRKU
VQPTKPIKPVQVJGE[NKPFGT7UGCHGGNGTICWIGVQEJGEMHQTNQECNENGCTCPEGUDGVYGGP
VJGTKPICPFNKPGT6JKUECPTGXGCNCP[pWPGXGPqEQTTQUKXGYGCTUGG+VGO
$GCYCTGVJCVKHVJGNKPGTKUPQVQXCNN[YQTPCPFVJGJKIJGUVYGCTFQGUPQVGZEGGF
QHVJGNKPGTFKCOGVGTKVKURQUUKDNGVQKPETGCUGVJGGZRGEVGFUGTXKEGNKHGQHVJG
NKPGTD[TGGUVCDNKUJKPIVJGYCXGEWVUJCRGQPVJGTWPPKPIUWTHCEGD[OCEJKPKPI
GKVJGTKPUKVWQTCVQPGQHVJG/#0&KGUGN6WTDQUGTXKEGEGPVTGU*QYGXGTRNGCUG
PQVGYCXGEWVOCEJKPKPI
D[ITKPFKPIFQGUPQVEQORGPUCVGHQTNKPGTQXCNKV[6Q
EQORGPUCVGHQTNKPGTQXCNKV[ECWUKPIRTGOCVWTGTKPIDTGCMCIGNKPGTJQPKPIKUTGE
QOOGPFGF

&GUETKRVKQP

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2245-0100-H005
$NCEMUJKP[CTGCUCTGQHVGPHQWPFQP
%[NKPFGT%QPFKVKQP
VJGNKPGTUWTHCEGLWUVCDQXGVJGUECX
GPIGCKTRQTVU6JGUGCTGCUQHDNCEM
FGRQUKVUECNNGFNCESWGTHQTOCVKQPUCTG
JCTONGUUCPFCTGHQTOGFD[CEQODKPC
VKQPQHYCVGTKPVJGUECXGPIGCKTCPF
E[NKPFGTQKN6JGNC[GTECPDGTCVJGTFKHHK
EWNVVQTGOQXGCPFECPDGNGHVCUKVKU
2KUVQPUMKTVETQYPCPFEQQNKPIURCEG
6JGRKUVQPUMKTVKUOCFGQHECUVKTQPCPFKUGSWKRRGFYKVJVYQDTQP\GTKPIUVQ
TGFWEGVJGTKUMQHUEWHHKPI5QOGGPIKPGUJCXGCURGEKCNOQN[DFGPWOEQCVKPIQP
VJGUMKTVUKPUVGCFQHVJGVYQDTQP\GTKPIU
5EWHHKPIQHVJGUMKTVKUTCTGCPFOQUVN[
QHEQUOGVKEPCVWTGCPFKUPQVCNYC[UC
UWHHKEKGPVTGCUQPHQTGZEJCPIG
+HVJGDWTPKPIEQTTQUKQPEQPFKVKQPQHVJGRKUVQPETQYPGZEGGFUVJGOCZKOWORGT
OKUUKDNGUGPFVJGRKUVQPETQYPHQTTGEQPFKVKQPKPI6JGOCZKOWORGTOKUUKDNG
DWTPKPIUGGYQTMECTF
+PURGEVVJGETQYPHQTETCEMUD[F[GEJGEMKPIQTUKOKNCT
2TGUUWTGVGUVVJGRKUVQPCUUGODN[VQEJGEMHQTRQUUKDNGEQQNKPIQKNNGCMCIGU
+HVJGRKUVQPKUVCMGPCRCTVHQTKPUVCPEGFWGVQQKNNGCMCIGEJGEMVJGEQPFKVKQPQH
VJGLQKPVUDGVYGGPVJGETQYPVJGRKUVQPTQFCPFVJGUMKTV+PURGEVVJGEQQNKPI
URCEGCPFENGCPQHHCP[ECTDQPEQMGFGRQUKVU

&GUETKRVKQP
4GRNCEGVJG1TKPIU%JGEMVJCVVJGUWTHCEGUQHVJG1TKPIITQQXGUCTGUOQQVJ
6JKUKUVQRTGXGPVVYKUVKPICPFDTGCMCIGQHVJG1TKPIU2QNKUJVJGITQQXGUYKVJ
GOOGT[RCRGTKHNGCMCIGUCTGHQWPFCPFPGY1TKPIUOWUVDGKPUVCNNGF2TGUUWTG
VGUVVJGRKUVQPCHVGTCUUGODNKPI

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(QTUCHGV[TGCUQPUVJGOGCUWTGOGPVUQHVJGDWTPKPIQHVJGETQYPUOWUVPQVVCMG
RNCEGYKVJVJGRKUVQPCPFE[NKPFGTEQXGTKPUKVWD[RNCEKPIVJGVGORNCVGQPVJG
%[NKPFGT%QPFKVKQP
ETQYPXKCVJGUECXGPIGRQTVU6JGE[NKPFGTEQXGTOWUVDGFKUOCPVNGFQTVJGRKUVQP
RWNNGF
2KUVQPTKPIITQQXGU
%JGEMVJGRKUVQPTKPIITQQXGUCUFGUETKDGFKPYQTMECTF
+HVJGTKPIITQQXGYGCTGZEGGFUVJGXCNWGUUVCVGFKPFCVCUJGGVUGPF
VJGRKUVQPETQYPCUJQTGHQTTGEQPFKVKQPKPI
PGYEJTQOGRNCVKPI
+HVJGTKPIITQQXGYGCTKUGZEGGFKPIVJGNKOKVUVJGTKPIITQQXGUOC[PGGFTGYGNFKPI
CPFOCEJKPKPIDGHQTGTGEJTQOKPI
%JTQOGRNCVKPIOCETQETCEMU
6JGJCTFEJTQOGRNCVKPIQHVJGTKPIITQXGUKUFGHKPGFVQDGOKETQETCEMGF6JKU
GPUWTGUVJCVVJGUVTQPIVGPUKNGTGUKFWCNUVTGUUGUKPVJGRNCVGFEJTQOGNC[GTCTG
RCTVN[TGNGCUGF
&WTKPIQRGTCVKQP
VJGTOCNKPHNWGPEGVJGEJTQOGRNCVKPIKPVJGRKUVQPTKPIITQQXGU
OC[ETCEMKPVQCOCETQRCVVGTP6JKUKUPQTOCNCPFCEEGRVCDNGCPFPQVGZRGEVGF
VQECWUGHWTVJGTFGVGTKQTCVKQP/QTGOCETQETCEMUOC[FGXGNQRFWTKPIQRGTCVKQP
4GEQPFKVKQPKPIQHVJGTWPPKPIUWTHCEGUQHNKPGTCPFUMKTV
+HVJGTGCTGOKETQUGK\GFCTGCUQPVJGNKPGTQTUMKTV
ϰ 5ETCVEJQXGTOCPWCNN[YKVJCEQCTUGECTDQTWPFWOUVQPG
ITKPFUVQPGOQXKPI
VJGITKPFUVQPGETQUUYKUGCVCPCPINGQHVQFGITGGUKPJQTK\QPVCNFKTGE
VKQP6JKUKUFQPGVQDTGCMWRVJGJCTFUWTHCEGINC\G
ϰ .GCXGVJGpUETCVEJOCTMUqCUTQWIJCURQUUKDNG+VKUPQVPGEGUUCT[VQEQO
RNGVGN[TGOQXGCNNUKIPUQHpXGTVKECNUVTKRGUq
OKETQUGK\WTG
+HJQTK\QPVCNYGCTTKFIGUCTGHQWPFKPVJGE[NKPFGTNKPGTD[VJGVQRTKPI6&%RQUKVKQP
KVKUTGEQOOGPFGFVQETGCVGCEKTEWOHGTGPVKCNITQQXGD[OKNNKPIQTITKPFKPI6JG
ITQQXGUGTXGUVQRTGXGPVVJGDWKNFWRQHCPGYYGCTTKFIGCPFRTQVGEVVJGPGYVQR
TKPIHTQODTGCMCIG
6YQOGVJQFU
ITKPFKPICPFOKNNKPIQHTGOQXKPIYGCTTKFIGUCTGFGUETKDGFKPYQTF
ECTF
2KUVQPTKPIICR
PGYTKPIU
%JGEMVJGICRCUFGUETKDGFKPYQTMECTF
(KVVKPIQHRKUVQPTKPIU
(KVVJGRKUVQPTKPIU5GGCNUQKVGO2WUJVJGTKPIDCEMCPFHQTVJKPVJGITQQXG
VQOCMGUWTGVJCVKVOQXGUHTGGN[

1PN[WUGVJG/#0&KGUGN6WTDQUVCPFCTFRKUVQPTKPIQRGPGTCPFFQPQVQRGP
&GUETKRVKQP
VJGICRGZEGUUKXGN[UGGCNUQKVGO

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2KUVQPTKPIENGCTCPEG
%[NKPFGT%QPFKVKQP
9JGPVJGTKPIUCTGKPRNCEGEJGEMCPFTGEQTFVJGXGTVKECNENGCTCPEGDGVYGGPVJG
TKPICPFTKPIITQQXG
(WTVJGTOQTGKPUGTVCHGGNGTICWIGQHVJGVJKEMPGUUURGEKHKGFKPYQTMECTF
CPFOQXGKVCNNVJGYC[TQWPFVJGITQQXGDQVJCDQXGCPFDGNQYGCEJ
RKUVQPTKPI+VUHTGGOQXGOGPVYKNNEQPHKTOVJGRTQRGTENGCTCPEGUCUYGNNCUENGCPNK
PGUU
%[NKPFGTNWDTKECVKQP
#NRJCCPF/'.WDTKECVQTCPFOQWPVKPIQHRKUVQP
%JGEMVJGE[NKPFGTNWDTKECVKQPFWTKPIRKUVQPQXGTJCWN
9KVJVJGRKUVQPFKUOCPVNGFRTGUU2TGNWDTKECVKQPQPVJG*/+RCPGNCPFEJGEMVJCV
RKRGUCPFLQKPVUCTGNGCMRTQQHCPFVJCVQKNURTC[UQWVHTQOGCEJNWDTKECVKPIQTKHKEG
QPVJGNKPGT
+HCP[QHVJGCDQXGOGPVKQPGFKPURGEVKQPRQKPVUJCXGKPFKECVGFVJCVVJGE[NKPFGTQKN
COQWPVUJQWNFDGKPETGCUGFQTFGETGCUGFCFLWUVVJGHGGFTCVGCUFGUETKDGFKP
EJCRVGT
/QWPVVJGRKUVQPUGGYQTMECTF
$GHQTGOQWPVKPIVJGQXGTJCWNGFRKUVQPTGOQXGCP[TGOCKPKPIFGRQUKVUHTQOVJG
WRRGTRCTVQHVJGNKPGT
ϰ 9KVJVJGRKUVQPFKUOCPVNGFRTGUU2TGNWDTKECVKQPQPVJG*/+RCPGNCPFEJGEM
VJCVRKRGUCPFLQKPVUCTGNGCMRTQQHCPFVJCVQKNURTC[UQWVHTQOGCEJNWDTKECV
KPIQTKHKEGQPVJGNKPGT
ϰ +HCP[QHVJGCDQXGOGPVKQPGFKPURGEVKQPRQKPVUJCXGKPFKECVGFVJCVVJGE[NKP
FGTQKNCOQWPVUJQWNFDGKPETGCUGFQTFGETGCUGFCFLWUVVJGHGGFTCVGCEEQTF
KPIN[CUFGUETKDGFKP%JCRVGT
ϰ %QCVVJGRKUVQPCPFNKPGTYKVJENGCPE[NKPFGTQKN
ϰ $GHQTGOQWPVKPIVJGQXGTJCWNGFRKUVQPTGOQXGCP[TGOCKPKPIFGRQUKVUHTQO
VJGWRRGTRCTVQHVJGNKPGT
5GGVJGUGRCTCVGKPUVTWEVKQPDQQMHQT#NRJC.WDTKECVQT
4WPPKPIKP
+HPGYQTTGEQPFKVKQPGFE[NKPFGTNKPGTUCPFQTRKUVQPTKPIUCTGKPUVCNNGFCNNQYCPEG
OWUVDGOCFGHQTCTWPPKPIKPRGTKQF
4WPPKPIKPQHE[NKPFGTNKPGTUCPFTKPIU
6JGHQNNQYKPIVGZVTGHGTVQFTCYKPICPFVJGOGPVKQPGFHGGFTCVGUCTG
The following text refer to attached service letter "SL2014-587/JAP and plate
XCNKFHQTCE[NKPFGTQKNQH$0UVCPFCTF6JGCEVWCNQDVCKPGFHGGFTCVGUJQWNF
2255-0125.
CNYC[UDGEQTTGEVGFCEEQTFKPIVQVJGCEVWCN$0+PVJGHQNNQYKPIVJGVGTOUp*KIJ
The individual feed rate ACC factor must be evaluated for each engine using
VQRNCPFqCPFp5GOKJKIJVQRNCPFqCTGWUGFHQTVJGRKUVQPU6JGVQRNCPFKUVJGFGU
drip oil analysis and frequent scavenge port inspections according to

KIPCVKQPHQTVJGVQRQHVJGRKUVQPETQYPHTQOVJGWRRGTOQUVRKUVQPTKPIITQQXGVQ
"SL2014-587/JAP".
VJGVQRQHVJGRKUVQP
&GUETKRVKQP
(QTVJGUGOKJKIJVQRNCPFVJGYJQNGCTGCHTQOVJGWRRGTOQUVRKUVQPTKPIITQQXGVQ
VJGVQRQHVJGRKUVQPECPDGQDUGTXGFCVVJGUCOGVKOGVJTQWIJVJGUECXGPIG
RQTVU(QTVJGJKIJVQRNCPFRKUVQPUQPN[RCTVQHVJGVQRNCPFECPDGQDUGTXGF6JG

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4.13.2 Running-in of a single cylinder

%[NKPFGT%QPFKVKQP
.
If only one cylinder has been overhauled, the fuel pump index for the cylinder in
question can be decreased in proportion to the required load reduction, under the
condition that the torsional vibration in the propeller shaft will allow it.
.
As the vibration condition due to the reduction of the fuel pump index of one cylin-
der is very similar to running the engine with one cylinder in misfire, a barred
engine speed range may apply. Consult the class-approved report on the torsional
vibration of the actual propeller shaft system and avoid any barred speed range
during running-in.
.
Before starting the engine, fix the fuel rack for the pertaining cylinder at 16% of
MCR index.
.
Increase the index stepwise in accordance with the breaking-in schedule.
.
Regarding the pressure rise pcomp - pmax, see comp. max., see chapter 6645-0140.
If the engine is fitted with the Turbo Compound System (TCS), the TCS must be
out of operation if running-in with reduced index is chosen so as to safeguard the
TCS gear equipment.
.
Manoeuvring and low load
See drawing 2255-0140.
In practice, the engine must be able to operate freely in the whole manoeuvring
range. The situation where a low load has to be maintained for an extended
period, the breaking-in programme should be suspended until higher loads are
continued. At this point the running in programme should also be continued.

&GUETKRVKQP

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2245-0100-H005
%[NKPFGT%QPFKVKQP
4.13.3 Feed rates
.
Feed rate recommendations for different engine types may be found in our latest
service letters.
.
Current latest service letter:
Cylinderoilfeedrate
Enginetype Serviceletter
AllME/MEͲC/MEͲB/MC/MCͲCand
SL014Ͳ587
MEͲGIengineswithelectronically
"GuidingACCvaluesforallengines".
controlledlubricators.
AllME/MEͲC/MEͲB/MC/MCͲCand
SL013Ͳ571
MEͲGIengineswithelectronically
"GuidingACCvaluesforallengines".
controlledlubricators.
60Ͳ80boretypesMC/MCͲCandME/ SL09Ͳ507
MEͲCwithhightopͲlandandAlpha "GuidingACCFeedRatesforAlpha
LubricatororMELube. LubricatorandMELube"
26Ͳ50boretypesMC/MCͲCandME/
SL07Ͳ479
MEͲB/MEͲCand60Ͳ98boretypesMC/
"NewACCGuidelines,allMC/MCͲC
MCͲCandME/MEͲCwithouthightopͲ
andME/MEͲCtypeenginesMK6and
land,andwithAlphaLubricatororME
higher,withAlphaACCsystem"
Lube.AllMK6andhigher
26Ͳ98boretypesMC/MCͲCwith SL00Ͳ385
mechanicallubricator.26Ͳ50MC/MCͲC "CylinderOilDosage,MarineMCͲ
engineswithlowtopland. Engines"
SL12Ͳ553
26Ͳ50MC/MCͲCengineswithhightopͲ
"CylinderLubricationGuidelines,Small
landandmechanicallubricator.
boreMC/MCͲCengines"
127($OZD\VFKHFNIRUWKHODWHVVHYLFHOHWWHUVIRUP0$1% :

&GUETKRVKQP

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(CEVQTU+PHNWGPEKPI%[NKPFGT9GCT
%[NKPFGT%QPFKVKQP
)GPGTCN
&TCYKPIIKXGUCUWOOCT[QHVJGOQUVEQOOQPECWUGUQHE[NKPFGT
YGCT6JGHQNNQYKPIIKXGUCDTKGHGZRNCPCVKQPQHVJGOQUVKORQTVCPVCURGEVUCPFQH
VJGRTGECWVKQPUVQDGVCMGPVQEQWPVGTCEVVJGO
/CVGTKCNU
%JGEMVJCVVJGEQODKPCVKQPQHRKUVQPTKPIV[RGCPFE[NKPFGTNKPGTOCVGTKCNEQORNKGU
YKVJVJGGPIKPGDWKNFGT UTGEQOOGPFCVKQPU(QTGPIKPGUKPIWCTCPVGGCNYC[UHQN
NQYVJGGPIKPGDWKNFGT UTGEQOOGPFCVKQPU
%[NKPFGTQKN
%JGEMVJCVVJGSWCNKV[CPFHGGFTCVGCTGKPCEEQTFCPEGYKVJVJGTGEQOOGPFCVKQPU
KPEJCRVGT
%QTTQUKXGYGCT
6JGKPHNWGPEGQHUWNRJWTKPVJGHWGN
%QTTQUKXGYGCTKUECWUGFD[HQTOCVKQPCPFEQPFGPUCVKQPQHYCVGTCPFUWNRJWTKE
CEKFQPVJGE[NKPFGTYCNN
+PQTFGTVQOKPKOKUGEQPFGPUCVKQPVJGGPIKPGFGUKIPKPEQTRQTCVGUQRVKOKUGFVGO
RGTCVWTGNGXGNQHVJGNKPGTYCNNDCUGFQPVJGCEVWCNGPIKPGNC[QWV
6QTGFWEGVJGTKUMQHEQTTQUKXGCVVCEM
ϰ -GGRVJGEQQNKPIYCVGTQWVNGVVGORGTCVWTGUYKVJKPVJGURGEKHKGFKPVGTXCNUGG
%JCRVGT
ϰ 7UGQPN[CRRTQXGFCNMCNKPGE[NKPFGTNWDTKECVKPIQKNUUGGEJCRVGT
ϰ 2TGJGCVVJGGPIKPGDGHQTGUVCTVKPICUFGUETKDGFKPEJCRVGT
ϰ %JGEMVJCVVJGFTCKPHTQOVJGYCVGTOKUVECVEJGT
UHWPEVKQPURTQRGTN[CPF
YCVGTFTQRNGVUCTGRTGXGPVGFHTQOGPVGTKPIVJGE[NKPFGTUUGGKVGO
ϰ %JGEMVJGEQPFKVKQPQHVJGYCVGTOKUVECVEJGT
UHQTETCEMUKPVJGHTCOGCPF
EQTTGEVOQWPVKPICVGXGT[KPURGEVKQPVJTQWIJUECXGPIGRQTVU%JGEMHQTEQT
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21(24)
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24(24)
Service Letter SL2014-587/JAP
Action code: WHEN CONVENIENT
Cylinder Lubrication Update

Adjusting the ACC factor in service
Replaces SL2013-571
SL2014-587/JAP
March 2014
Dear Sirs Concerns

All ME/ME-C/ME-B/MC/MC-C and ME-
Recent service experience has called for an update of our guidelines GI engines with electronically controlled
on cylinder lubrication of MAN B&W low speed engines. We have seen lubricators.
a greater challenge for lubrication in certain applications of our newer
engine types. Summary
New cylinder oil lubrication recommen-
From delivery from the yard, the basic cylinder lube oil recommenda- dation. Guiding ACC values for all en-
tion for Mk 8-8.1 engines and newer is therefore to use BN 100 cylinder gines: ACC100 (BN 100). Range 0.20-
oils and maintain a feed rate ACC100 factor of 0.4 g/kWh x S% until the 0.40 g/kWh x S% minimum 0.60 g/kWh.
actual feed rate ACC factor can be evaluated by conducting a feed rate
sweep. Guidelines for mechanical lubrication
are found in SL2000-385 and SL2012-
Engines in service may also beneǣt from the use of BN 100 oils be- 553.
cause the feed rate ACC factor can be reduced thanks to the high alka-
linity of BN 100 oils.
For engines where the feed rate ACC factor has already been estab-
lished and conǣrmed, new cylinder oils with a different BN level can
be used to change the feed rate ACC factor by multiplying the present
feed rate ACC factor by the fraction of the BN in the present and the
new cylinder oil. Afterwards, the new setting has to be conǣrmed, either
by a feed rate sweep and/or a conventional drip oil analysis.
The individual feed rate ACC factor must be evaluated for each engine
using drip oil analysis and frequent scavenge port inspections. There
are many options for this evaluation, but common to them all is the fact
that they cannot stand alone. Feed rate sweeps have to be followed by
monthly drip oil sampling and/or scavenge port inspections, in order to
assure that the engine is performing as expected.
Yours faithfully
Mikael C Jensen Stig B Jakobsen

Vice President Engineering Senior Manager Operation
HeCd oHǣce
RoUtCN CddTeUU 2TiOe5eTX 2TodWction (oTYCTdinI 4eceiXinI /AN &ieUeN TWTDo
/AN &ieUeN TWTDo Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Branch of MAN Diesel & Turbo SE,
Teglholmsgade 41 2450 Copenhagen SV 2450 Copenhagen SV 2450 Copenhagen SV Germany
2450 Copenhagen SV Denmark Denmark Denmark CVR No.: 31611792
Denmark Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 *ead ofǣce: Teglholmsgade 41
Phone: +45 33 85 11 00 Fax: +45 33 85 10 49 Fax: +45 33 85 10 17 Fax: +45 33 85 10 16 2450 Copenhagen SV, Denmark
Fax: +45 33 85 10 30 [email protected] [email protected] [email protected] German Reg.No.: HRB 22056
[email protected] Amtsgericht Augsburg
Contents This is illustrated by our feed rate guide, which sets the
Introduction .......................................................................... 2 minimum feed rate to the level needed to keep the parts
Cylinder lubrication .............................................................. 2 moving within a safe margin. However, so as to ensure the
Mid-range cylinder oil .......................................................... 2 necessary lubrication effect, an increased formation of
Optimising the ACC factor.................................................... 2 acid would call for a higher BN level than speciǣed at the
Drain oil analysis .................................................................. 3 minimum feed rate. This is compensated for by calculating
Cylinder oils with different BN levels ..................................... 4 a feed rate on the basis of an ACC factor within the guide
Low-sulphur HFO and distillates........................................... 4 shown in Fig. 1.
Slow steaming...................................................................... 4
Guiding values ..................................................................... 4 MAN Diesel & Turbo recommends using cylinder lube oils
Running-in operation ........................................................... 5 characterised primarily by its BN number and SAE viscosity
Breaking-in (0-500 rh) ......................................................... 5 and to use a feed rate according to the BN in the cylinder
Familiarization of the ACC factor .......................................... 5 oil and sulphur content of the fuel. MAN Diesel & Turbo is
Guidelines ............................................................................ 6 aware that some engines may be operated satisfactorily
at even lower feed rates. Hence, feed rates are, just as
before, based on practical experience rather than pre-
Introduction calculated ǣgures.
Lately, MAN Diesel & Turbo has concentrated on further
enhancing the fuel efǣciency while at the same time fulǣll- The above mirrors the importance of the fact that the crew
ing Tier I and Tier II. In order to improve the speciǣc fuel oil should challenge the cylinder oil feed rate ACC factor, so
consumption, the pressure in the combustion chamber has as to ǣnd the correct ACC value that suits the actual engine
been increased on the newest engine designs. This pres- conǣguration and engine load.
sure increase, together with the increased operating time at
part load, has led to increased water and acid condensa- Mid-range cylinder oil
tion on the cylinder walls, which leads to cold corrosion in In order to simplify the lubrication process onboard the
the combustion chamber. ships, as well the logistics of supply, the oil companies
started the process of developing a cylinder lube oil that
Also the most recently developed part-load and low-load can lubricate the cylinders regardless of the sulphur con-
tuning options utilise increased combustion chamber pres- tent in the fuel.
sure as the main tool to ensure a low SFOC (Speciǣc Fuel
Oil Consumption) at part load, and the same result may be Such
oils have BN levels that are lower than the tradi-
experienced. tional BN 70 cylinder lube oils.
Such oils can very well be used on earlier-type MAN

Appropriate cylinder oil feed rates and ACC (Adaptable Cyl- B&W engines that are not affected by cold corrosion,
inder oil Control) feed rate factor values must be obtained but are not applicable on newer engine designs with
on the basis of service inspections, measurements and higher levels of cold corrosion.
wear data from combustion chamber parts (piston rings, T hese oils can however be used as low BN oils for
liner, and crown), and supplemented with scavenge drain heavy fuel on all engine types.
oil analyses.
Optimising the ACC factor
Cylinder lubrication The best way to establish the optimum ACC factor is to
Cylinder oil is essential for the two-stroke engine. Today’s measure the engine wear. If the wear rate of the liner and
cylinder oils are made with a complex chemistry, and the piston rings is too high the ACC factor must be increased
individual feed rate must therefore be assessed for each oil to reduce the wear.
brand, viscosity class and BN level.
We recommend to start out with an ACC factor in the
A cylinder oil is blended to achieve the necessary level of upper end of the range, and then slowly adjust it when
detergency and dispersancy to keep the piston rings and the engine wear response has been conǣrmed by mea-
crown clean, and the necessary base number (BN) to neu- surements.
tralise the acids formed during combustion.
For more information on condition-based monitoring, we
The cylinder oil not only serves to lubricate the moving refer to our service letter SL2007-483.
parts, but is also designed to control the degree of corro-
sion on the liner surface.
Cylinder Lubrication Update. Page 2 of 11 pages

However, the ACC factor can only be assessed when the Drain oil analysis
fuel sulphur level has been high enough to ensure that the Used oil taken from the engine through the scavenge bot-
lubrication has been in the ACC active area (the blue area tom drain can be used for cylinder condition evaluation.
marked in Fig. 1), at lower fuel sulphur levels the engine is
excessively protected against corrosion because of the ac- Drain oil analysis is also a strong tool for judging the engine
tive minimum feed rate. wear condition. Drain oil samples taken in active ACC op-
eration will show if the oil feed rate can be optimised while
g/kWh keeping the BN above 10-25 mg KOH/g and the iron (Fe)
1.4 content below 200 mg/kg in the drain oil (Table 1 & Fig. 2).
1.2
It is important to note that elevated iron values may be ex-
1.0 rea perienced as the piston ring running-in coating gradually
a
ve
a cti wears off.
0.8
A CC
0.6 Onboard sets exist, but it is important to get a valid test
Minimum feed rate
result that shows the total content of iron (Fe). Laboratory
0.4
testing according to ASTM D5185-09 is the only certain
0.40
0.2 measuring method. The BN must be tested in accordance
0.20
with ISO 3771:2011(E).
0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Fuel sulphur % A cylinder oil can be degraded to a certain level where the
Fig. 1a: BN 100 ACC range Mk 8-8.1 and newer corrosion level begins to increase. The level of depletion is
different among oil brands and engines, and an individual
g/kWh
1.4 evaluation of each engine is therefore recommended.
1.2 Scavenge Drain Oil – Guiding Values

BN greater than 10-25 mg KOH/g
1.0
re a Iron [Fe] less than 200 mg/kg
ea
0.8 c tiv
Ca
AC
0.6 Table 1: Drain oil values
Minimum feed rate
0.4 Iron (Fe) total [mg/kg]
500
0.34
0.2
0.20
0 Cat ǣne
400 Danger – Do not operate in this area s
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Fuel sulphur %
Fig. 1b: BN 70 ACC range Mk 7 and older
300
Alert area – Adjustment of feed rate may be needed
The acceptable wear rates must be in line with our recom-
mendations on overhaul intervals and expected lifetime of 200
the components, see SL2009-509. Liner wear rates are Safe area
normally below 0.1 mm/1,000 running hours (rh). 100

Liner p
olish
High ovality in the liner wear could be a sign of corrosive
0
wear. As the liner surface temperature is not necessarily 0 10 20 30 40 50 60 70
uniform, more corrosion will occur in the colder areas. BN [mgKOH/g]
Fig. 2: Drain oil BN vs. iron (Fe)
The piston ring wear must also be kept under observation,
and it must be assured that the controlled leakage (CL) One possibility is to perform a stress test called “feed rate
groove on the piston rings is not worn below the accept- sweep”. This will shorten the ACC familiarization period
able minimum and that the POP-ring groove does not ex- considerably. The sweep test is based on a 4 to 6-day test
ceed its maximum allowable wear, see Encl. 3. For more at steady load and, preferably, running on fuel in the high-
information on CPR-POP rings, see SL2012-562. sulphur range of 2.8-3.5% sulphur content. The feed rate is
adjusted to set values, i.e. 1.4, 1.2, 1.0, 0.8 and 0.6 g/kWh.

Each feed rate must be applied for 24 hours before taking We therefore recommend switching to a low-BN cylinder oil
a sample and switching to the next feed rate (Fig. 3). A de- at the same time as switching to a low-sulphur heavy fuel.
tailed feed rate sweep protocol is enclosed (Encl. 6). Continuous running on high-BN cylinder oils can only be
recommended in special cases, and not for more than 1
Fe [mg/kg] BN [mg KOH/g] to 2 weeks, see Table 2.
700 50
45
600
g]
40 Application BN
O H/
500 gK 35 Distillate and LNG < = 40
[m
BN
400
30 Low-sulphur residual fuel ( Ǐ1.5% sulphur) 40-60
25 High-sulphur residual fuel ( ǐ1.5% sulphur) 70-100
300
20
200
Optimal ACC 15 Table 2: Cylinder oil guide
10
100
Fe [mg/kg] 5 Also when switching to distillate fuels (MGO/MDO), we rec-
0 0
ommend switching to a low-BN cylinder oil at the same time
0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55
as the switching of the fuel. We do not recommend the use
ACC Factor [g/kWh x S%]
of a high-BN cylinder oil when running on distillate fuels.
Fig. 3: Feed rate sweep
Slow steaming
During the sweep test period the engine operation must be When the vessel is slow steaming, the engine is oper-
kept as consistent as possible to avoid interference from ated at low load, and the liner surface will become cooler
load up and fuel change. and, therefore, increase the risk of corrosion. Waste heat
recovery and various part-load optimisation possibilities,
Cylinder oils with different BN levels e.g. TC cut-out, variable turbine area (VTA) turbocharger,
The various oil suppliers offer cylinder oils with a broad and exhaust gas bypass (EGB), ECO cam, may call for a
range of BN levels. Our MAN B&W engine design is based re-assessment of the ACC factor to accomodate the new
on the 70 BN oil traditionally used, however, as new oil corrosion level.
products have been introduced, BN levels have changed,
and today’s design standard is the new 100 BN oils. It is important to note that low-load operation (slow steam-
ing) is not the only reason for increased cold corrosion po-
When switching to a different BN level, we recommend to tential. Optimisation methods on new engines or retroǣtting
start out with scaling the ACC factor from 70 to the new on older engines increase the cold corrosion potential also
BN level by multiplying the ACC factor with the fraction of at normal load.
70 BN oil.
Guiding values
Example: Guiding values Mk 8-8.1 and newer
Using a BN 85 and ACC (BN 70) = 0.26 Base number (BN) 100
ACC (BN 85) = 0.26 × 70/85 = 0.21 SAE 50
(see Table 10 in Encl. 5) Guiding minimum feed rate 0.60 g/kWh
ACC BN100 range 0.40-0.20 g/kWh x S%
When changing to a new oil brand or type, the ACC factor
may need to be reassessed as described above, starting
with an ACC factor in the upper range. After this, a gradual Guiding values Mk 7 and older
reduction can be carried out based on actual observed Base number (BN) 70-100
conditions or the sweep test. SAE 50
Guiding minimum feed rate 0.60 g/kWh
Low-sulphur HFO and distillates ACC BN70 range 0.34-0.20 g/kWh x S%
When running on low-sulphur residual fuel (HFO), the feed
rate will be set at the minimum feed rate. High-BN cylinder Table 3: Guiding values
oils will lead to over-additivation in the aspect of controlling
the corrosion as well as lead to increased build-up of
piston crown deposits.

Running-in operation Familiarization of the ACC factor

MAN B&W two-stroke engines require extra attention and After the breaking-in period, the engine ACC factor should
lubrication during their ǣrst running hours. be assessed over a period of steps of 600 hours (see Fig.
6, Encl. 2).
The ǣrst 500 running hours are the most demanding. This
is the period where the liners are run in, which is also re- To be able to asses the engine wear, the steps must be
ferred to as the breaking-in period. completed with a fuel sulphur content that is high enough
to assure that the cylinder oil feed rate is in the ACC active
The purpose of the breaking-in period is to Ǥush away wear range. This means that the feed rate must be above the
particles and facilitate running-in of the liner surface and rings. minimum 0.60 g/kWh.
The breaking-in period is followed by a familiarization pe- Before moving to the next step, the cylinder condition and
riod, where the crew must asses the engine wear and cyl- wear must be assessed through a scavenge port inspection.
inder condition to select the right ACC factor for the engine The feed rate ACC factor should not be reduced unless the
application. cylinder condition permits it.
Breaking-in (0-500 rh) In some cases, this familiarization period extends substan-
Cylinder liner and piston ring breaking-in takes 500 running tially. However, the period can be substantially shortened
hours maximum (see Fig. 5, Encl. 2). by means of scavenge drain analyses, where the laboratory
results will show the remaining BN and Fe (iron) content. If
During this breaking-in period, the running-in coating on the samples taken during the ACC active feed rates repeat-
the piston rings will gradually wear off, and the wave cut edly show high BN and acceptable Fe levels, the ACC fac-
shape on the cylinder liner surface will smoothen. During tor can be lowered.
this process, extra lubrication oil is required to Ǥush away
wear particles and assure a satisfactory oil ǣlm between After the feed rate ACC factor has been adjusted according
the relatively rough sliding surfaces. to the sweep, the drain oil must to be monitored to verify
the ACC setting or make possible adjustments.
During breaking-in, we recommend checking piston rings
and cylinder liners through scavenge air port inspections Once the ACC factor has been conǣrmed and the wear is
for every 100 hours. Do not proceed to the next lubrication under control, the best choice of cylinder oil can be made.
step if the scavenge air port inspection reveals seizures or In special cases where the ACC factor is reasonably low,
other irregularities. and/or the fuel sulphur level usually experienced is low, the
best choice of cylinder oil could be a grade with a lower
The feed rate during breaking-in must not be set lower than BN, depending on feed rate and price.
the fuel sulphur content depending feed rate (fuel sulphur
x feed rate ACC factor). The highest feed rate of the two Please direct any inquiries and questions regarding tables
must be used. or condition-based overhaul to our Operation Department
Hours g/kWh at [email protected] or to our Service Department
0-5 hours 1.70 g/kWh at [email protected].
5-100 hours 1.50 g/kWh
100-200 hours 1.30 g/kWh
200-300 hours 1.10 g/kWh*
300-400 hours 0.90 g/kWh*
400-500 hours 0.70 g/kWh*
* Only if the ACC dependent (fuel sulphur x ACC factor) feed rate is
lower than the step, if not then the ACC dependent feed rates are to
be used.
Table 4: Breaking-in

Encl. 1 of 6
Guiding cylinder oil feed rates
All ME/ME-C/ME-B/ME/MC/MC-C and ME-GI engines
With electronically controlled lubrication system
Mk 8-8.1 and newer Mk 7 and older

Standard BN 100 Standard BN 70-100
Viscosity range SAE 50 SAE 50
ACC setting 0.40-0.20 0.34-0.20

g/kWh x S% g/kWh x S%
Guiding minimum feed rate 0.60 g/kWh 0.60 g/kWh
Maximum feed rate during running-in 1.7 g/kWh 1.7 g/kWh
Part-load control Proportional with load.

At lower loads control is automatically changed to proportional with rpm.
Breakpoint from power to rpm-dependent lubrication to be set to 25% load.
Running-in new or reconditioned liners Feed rate:

and new piston rings First 5 hours: 1.7 g/kWh
From 5 to 500 hours: Stepwise reduction from 1.5 - 0.6 g/kWh or ACC factor x fuel
sulphur (using the highest feed rate)
Engine load:
Test bed: Stepwise increase to max. load over 5 hours
In service: 50% to max. load in 16 hours
Familiarizing Starting at 0.40 g/kWh x S% Starting at 0.34 g/kWh x S%

ACC Factor (Fig. 6a) (Fig. 6b)
Reducing in steps of 0.04 g/kWh x S% after min. 600 hours where the feed rate has been sul-
phur dependent (above min. feed rate) or using feed rate sweep or continuous drain oil analysis.
If the engine is retroǣtted with means to improve part or low-load fuel consumption, the ACC
factor must be reassessed.
Running-in new rings in already run-in and From 50% to max. load in 5 hours
well running liners Feed rate 0.9 g/kWh for 24 hours.
If the fuel sulphur and applied ACC factor combination results in a speciǣc feed rate higher than
0.9 g/kWh (use the calculation feed rate), no extra lubrication is needed.
Manoeuvring and load change During starting, manoeuvring and load changes, increase feed rate by means of the “LCD” by
situations 25% of the actual ǣgure and kept at this level for hour after the load has stabilised.
Lubrication of cylinders that show Frequent scavenge port inspections of piston rings and cylinder liners are very important for
abnormal conditions maintaining a safe cylinder condition.
If irregularities are observed, adjustments of the lube oil feed rate should be considered.
In case of scufǣng, sticking piston rings or high liner temperature Ǥuctuations, raise the feed
rate to 1.20 g/kWh and lower the pmax and mep. As soon as the situation has been stabilised,
set the lubrication feed rate and pressures back to normal.
In case of high corrosive wear, the ACC factor is to be increased to the highest ACC factor
(0.40 g/kWh x S% for BN 100)) and be reduced in steps of only 0.02 g/kWh x S% when the
wear has been conǣrmed as normal.
Table 5: Guiding cylinder oil feed rates

Service Letter SL2014-5xx/JAP
Encl. 2 of 6
Breaking-in New Liners
Initial running-in dosage g/kWh

1.8 * Fixed running-in dosage (g/kWh)
1.6
*
Fixed running-in dosage (g/kWh), or
1.4
* ACC feed rate (g/kWh)
The highest of the two to be used
1.2 *
*
1 * Scavenge port inspection
0.8
*
Change to ACC
0.6
Breaking-in period with ǣxed lubrication
0 100 200 300 400 500 600 700 800 900 1,000
hours
Fig. 5: Breaking-in schedule

Encl. 2 of 6
New ACC Running-in Schedule (liner and rings)
ACC feed rate factor (g/kWh/S%)

0.40
ACC control (g/kWh/S%)
0.38 Feed rate sweep
* ACC factor based upon the
0.36 feed rate sweep
0.34 *
0.32
0.30 *
0.28
0.26 * Reduction based upon observation *

0.24
0.22
0.20
0.18 ACC familiarisation schedule

0.16
0 1,000 2,000 3,000 4,000
hours
Fig. 6a: ACC familiarisation schedule for Mk 8-8.1 and newer

0.40
0.36 ACC factor based upon the feed rate sweep
* * Reduction based upon observation
0.34
0.32 *
0.30
0.28 *
0.26
0.24 *
0.22
0.20

0.16
0 1,000 2,000 3,000 4,000
hours
Fig. 6b: ACC familiarisation schedule for Mk 7 and older

Encl. 3 of 6
Guiding Wear Rate Values
Bore size Max. radial Max. width of leakage groove Engine bore CL-groove new depth Minimum depth
[cm] ring wear [mm] (use feeler gauge) [mm]
26 cm 2.0 mm 0.6 mm
26 cm 1.8 6.6
30 cm - -
30 cm 2.0 7.0
35 cm 2.5 mm 0.8 mm
35 cm 2.2 7.4
40 cm 2.5 mm 0.8 mm
40 cm 2.2 7.4
42 cm 2.5 mm 0.9 mm
42 cm 2.2 7.4
45 cm - -
45 cm 2.2 7.4
46 cm 2.5 mm 1.0 mm
46 cm 2.2 7.4
50 cm 3.0 mm 1.1 mm
50 cm 3 9
60 cm 3.5 mm 1.3 mm
Table 6: CPR-POP top ring wear 65 cm 3.5 mm 1.4 mm
70 cm 3.5 mm 1.6 mm
80 cm 4.0 mm 1.8 mm
90 cm (Cermet 4.0 mm) 5.0 mm 2.0 mm
Table 7: CPR-CL top ring wear

Encl. 4 of 6
ACC settings for lubricating oils for MC/MC-C engines
Alpha Lube ACC

High BN Cylinder Oil
ACC factor g/kWh × S%
0.20 0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40 g/kWh HMI setting
Sulphur content %
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.59 54
3.1 2.6 2.4 2.2 2.1 1.9 1.8 1.7 1.6 1.5 0.62 56
3.2 2.7 2.5 2.3 2.1 2.0 1.9 1.8 1.7 1.6 0.64 58
3.3 2.8 2.5 2.4 2.2 2.1 1.9 1.8 1.7 1.7 0.66 60
3.4 2.8 2.6 2.4 2.3 2.1 2.0 1.9 1.8 1.7 0.68 62
2.9 2.7 2.5 2.3 2.2 2.1 2.0 1.9 1.8 0.70 64
3.0 2.8 2.6 2.4 2.3 2.1 2.0 1.9 1.8 0.73 66
3.1 2.9 2.7 2.5 2.3 2.2 2.1 2.0 1.9 0.75 68
3.2 3.0 2.8 2.6 2.4 2.3 2.1 2.0 1.9 0.77 70
3.3 3.0 2.8 2.6 2.5 2.3 2.2 2.1 2.0 0.79 72
3.4 3.1 2.9 2.7 2.5 2.4 2.3 2.1 2.0 0.81 74
3.5 3.2 3.0 2.8 2.6 2.5 2.3 2.2 2.1 0.84 76
3.3 3.1 2.9 2.7 2.5 2.4 2.3 2.1 0.86 78
3.4 3.1 2.9 2.8 2.6 2.4 2.3 2.2 0.88 80
3.5 3.2 3.0 2.8 2.7 2.5 2.4 2.3 0.90 82
3.3 3.1 2.9 2.7 2.6 2.4 2.3 0.92 84
3.4 3.2 3.0 2.8 2.6 2.5 2.4 0.95 86
3.5 3.2 3.0 2.8 2.7 2.5 2.4 0.97 88
3.3 3.1 2.9 2.8 2.6 2.5 0.99 90
3.4 3.2 3.0 2.8 2.7 2.5 1.01 92
3.4 3.2 3.0 2.9 2.7 2.6 1.03 94
3.3 3.1 2.9 2.8 2.6 1.06 96
3.4 3.2 3.0 2.8 2.7 1.08 98
3.4 3.2 3.1 2.9 2.8 1.10 100
3.3 3.1 3.0 2.8 1.12 102
3.4 3.2 3.0 2.9 1.14 104
3.4 3.2 3.1 2.9 1.17 106
3.5 3.3 3.1 3.0 1.19 108
3.4 3.2 3.0 1.21 110
3.4 3.2 3.1 1.23 112
3.5 3.3 3.1 1.25 114
3.4 3.2 1.28 116
3.4 3.2 1.30 118
3.5 3.3 1.32 120
3.3 1.33 121
3.4 1.34 122
3.4 1.35 123
3.4 1.36 124
3.4 1.38 125
3.5 1.39 126
3.5 1.40 127
Table 8: Feed rate ACC factor

Encl. 5 of 6
Speciǣc feed rate in relation to fuel sulphur % and feed rate factor
Basic Feed Rate

Feed rate ACC factor
0.20 0.22 0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40
0.5 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
0.7 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
0.9 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
1.1 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
1.3 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
1.5 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Fuel Sulphur %
1.7 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.61 0.65 0.68
1.9 0.6 0.6 0.6 0.6 0.6 0.6 0.61 0.65 0.68 0.72 0.76
2.1 0.6 0.6 0.6 0.6 0.6 0.63 0.67 0.71 0.76 0.80 0.84
2.3 0.6 0.6 0.6 0.6 0.64 0.69 0.74 0.78 0.83 0.87 0.92
2.5 0.6 0.6 0.6 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00
2.7 0.6 0.6 0.65 0.70 0.76 0.81 0.86 0.92 0.97 1.03 1.08
2.9 0.6 0.64 0.70 0.75 0.81 0.87 0.93 0.99 1.04 1.10 1.16
3.1 0.62 0.68 0.74 0.81 0.87 0.93 0.99 1.05 1.12 1.18 1.24
3.3 0.66 0.73 0.79 0.86 0.92 0.99 1.06 1.12 1.19 1.25 1.32
3.5 0.70 0.77 0.84 0.91 0.98 1.05 1.12 1.19 1.26 1.33 1.40
Table 9: Feed rate ACC factor
Correlation between feed rate ACC factors and cylinder oil BN
Cylinder oil BN
70 80 90 100
0.20 0.18 0.16 0.14
0.22 0.19 0.17 0.15
0.24 0.21 0.19 0.17
0.26 0.23 0.20 0.18
0.28 0.25 0.22 0.20
Feed rate ACC factor
0.30 0.26 0.23 0.21

0.32 0.28 0.25 0.22
0.34 0.30 0.26 0.24
0.36 0.32 0.28 0.25
0.38 0.33 0.30 0.27
0.40 0.35 0.31 0.28
0.42 0.37 0.33 0.29
0.44 0.39 0.34 0.31
0.46 0.40 0.36 0.32
0.48 0.42 0.37 0.34
0.50 0.44 0.39 0.35
0.52 0.46 0.40 0.36
0.54 0.47 0.42 0.38
0.56 0.49 0.44 0.39
0.58 0.51 0.45 0.41
Table 10: Feed rate ACC factor and cylinder oil BN

MAN Diesel & Turbo
To whom it may concern
LDF1/ JUSV/ case no: 8002-2014 25 February 2014
Sweep Test Procedure for MAN B&W Two-Stroke Diesel Engines

Finding the Optimal Cylinder Lube Oil Feed Rate Factor
Continuous monitoring of drain oil samples is a good way to optimise the cylinder oil feed rate and
consumption and to safeguard the engine against excessive wear. The fastest way to evaluate the
corrosive behaviour of an engine and optimise the feed rate is to do a stress test, a so-called sweep
test. It can also be used in the ACC familiarization period to find the suitable lube oil feed rate for your
particular engine, operating pattern and lube oil used.
During the sweep test, the vessel should be running on fuel with a sulphur content above 2.7%. The
sweep test takes 6 days and should be performed during a longer voyage where the engine load
remains constant. The feed rate of the cylinder oil is set to fixed steps and drain oil samples are taken
after 24 hours, before lowering to the next step (figure 1).
Lubeoilsample SweepTest
1,6
Drainoil sample
1,4
Feed Rate (g/kWh)
1,2
0,8
0,6
0,4
0 24 48 72 96 120
time (hours)
Figure 1. Overview of the sweep test procedure
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Samples and analysis methods

Before the test starts, a port inspection should be completed, and samples of the fuel, system oil in use
and fresh (unused) cylinder oil should be taken. When the test has been completed, all samples should
be sent ashore to a certified laboratory. The iron (Fe) content and the BN value should be analysed.
The Fe content should be analysed using the ASTM D5185-09 and the BN should be analysed using
the ISO 3771:2011(E) method. The Fe concentration will be the measurement of corrosion and wear.
The BN in the drain oil is an evaluation of the performance of the oil and the need for neutralization in
the engine. When the results are received, the suitable ACC factor/feed rate can be established for the
particular engine, fuel, and lube oil and operation pattern.
The BN and Fe content of the drain oil can also be measured by various onboard analysis equipments
(please refer to CL 118681-2013/LEO and CL 140942-2013/LEO). When measuring Fe with onboard
analysis equipment, it is important to choose an instrument which measure total Fe content.
Information about onboard analysis equipment will be updated regularly. Onboard equipment gives fast
results, however, we recommend sending the samples to a laboratory in order to secure accurate
results.
Test Procedure
Read all the instructions carefully before starting the Sweep test. The sweep test is to be made above
the lubrication breakpoint. In most cases this breakpoint is at an engine load of 25%. When the
lubricator is below the breakpoint, the cylinder feed rate for each cylinder changes from a number to
“low load” on the MOP-screen. A sweep test should not be made when the MOP screen states “low
load”.
Before starting the sweep test: Normal running condition

Figure 2 shows a MOP-screen under normal running conditions, after the initial running in of the
engine, i.e. the first 500 hours. The “Running In” mode should be “Off” (0.00) and the “Feed Rate
Adjust Factor” should be “1.00” (= 100%).
In this mode, the fuel oil sulphur content “S%” and the “Feed Rate Factor” gives the “Basic Feed Rate”
which is also shown for each cylinder as the “Actual Feed Rate. In this example, the S% was 2.82 and
the “Feed Rate Factor” was 0.50 g/kWhS%, which resulted in the “Basic Feed Rate” of 1.41 g/kWh
(Figure 2).
Figure 2. MOP-screen showing settings at normal running conditions. Running-in mode is turned OFF
Day 1: Start of sweep test (at least 24 hours after departure)

When starting the sweep test, the easiest way to set the desired cylinder oil feed rate is to use the
“Running In” mode. This mode overrules the normal running mode, as shown in Figure 2. However, the
minimum feed rate will never be lower than the “Min. Feed Rate” (here 0.60 g/kWh), even if the
“Running In” mode is set to a lower value than “Min. Feed Rate”. For the first 24 hours of the sweep
test, the “Running In” setting should be “1.40” g/kWh, as shown in Figure 3.
Figure 3. Day 1 of sweep test. The Running In mode is used and set to 1.4 g/kWh
Be sure that the correct cylinder oil is used, and take reference samples of fresh cylinder oil and fuel.
Adjust the feed rate of the cylinder oil to 1.4 g/kWh as shown in figure 3. Write down the following
information in the sweep test protocol:
a. Name of ship and type of engine

b. Date and time of starting the test.
c. Name and brand of the cylinder oil, BN and SAE viscosity number
d. Engine load
Day 2 Take drain oil samples from all cylinders after running 24 h on a cylinder oil feed rate of 1.4
g/kWh.
Important: Make sure to flush the drain valve into a bucket before taking the sample. Only
use clean bottles, and make sure not to mix drain oil form one unit with another. Mark the
bottles with the following information:
a. Cylinder no.
b. Date and time
c. The name and BN number of the cylinder oil
d. Feed rate of cylinder oil
e. Engine load
Also, write down the information in the test protocol. After this, the cylinder oil feed rate
should be adjusted to 1.2 g/kWh as shown in Figure 4.
Figure 4. Day 2 of sweep test. The Running In mode is used and set to 1.2 g/kWh
Day 3 Take drain oil samples from all cylinders after running for 24 h on a cylinder oil feed rate of
1.2 g/kWh. Sample-procedure same as Day 2. After this, the cylinder oil feed rate should
be adjusted to 1.0 g/kWh
1.0 g/kWh. Sample-procedure same as Day 2.
After this, the cylinder oil feed rate should be adjusted to 0.8 g/kWh
0.8 g/kWh. Sample procedure same as Day 2. After this, the cylinder oil feed rate should
be adjusted to 0.6 g/kWh
0.6 g/kWh. Sample-procedure same as Day 2.
When the last drip oil samples have been taken, the “Running In” setting is set to “Off” (0.00) to run in
normal cylinder oil feed rate mode, as shown in Figure 2. When results have come back and been
analysed, the suitable Feed Rate Factor can be calculated and used.
Sweep Test Protocol

Fill in the required information. Samples should be sent to a certified laboratory for analysis. Before the
test starts, a port inspection should be carried out, and samples of the fuel and system oil in use and
fresh (unused) cylinder oil should be taken. Use clean bottles and mark them with the information
stated on page 2.
Name of Ship:.................................................... IMO no:..............................................
Engine type:............................... Load:.............. Total running hours:..............................
Name of cylinder oil:....................... BN: ........ SAE Viscosity:................................
Sulphur content of fuel:...............%
Start date and time:....................... End date and time:...............................
Please fill in the Running Hours for the following

Cylinder 1 2 3 4 5 6 7 8 9 10 11 12
Cylinder
liners
Piston
crowns
Piston
rings
Fuel
valves
Cylinder oil Day 1 Day 2 Day 3 Day 4 Day 5 Day 6

Feed rate 1.4 1.2 1.0 0.8 0.6 Back to
(g/kWh) normal
Please fill in this table when taking the samples

Cylinder 1 2 3 4 5 6 7 8 9 10 11 12
Day 2 Feed
Date rate
Engine Deck temp Humidity
load °C %
Day 3 Feed
Date rate
load °C %
Day 4 Feed
Date rate
load °C %
Day 5 Feed
Date rate
load °C %
Day 6 Feed
Date rate
load °C %
How to Evaluate a Sweep Test

The aim of the test is to show the correlation between the engine’s corrosive impact and the lube oil’s
ability to counteract this. When the results from the sweep test are returned from the laboratory, the
data needs to be evaluated.
Calculating the actual ACC factor for a sweep test made on a load above the
lubricator part-load breakpoint
During the sweep test, the feed rate was set to fixed steps. The ACC factor for each step can be
calculated by dividing the feed rate step with the sulphur % of the fuel (Eq. 1).
೒
௚ ி௘௘ௗ௥௔௧௘ቂ ቃ
ೖೈ೓
‫ܥܥܣ‬஼௔௟௖௨௟௔௧௘ௗ ቂ ቃ ൌ ி௨௘௟ௌ௨௟௣௛௨௥ሾௌΨሿ (Eq.1)
௞ௐ௛ൈௌΨ
Example 1
Sulphur content of the fuel is 2.8 %.
ͳǤͶ ݃
ൌ ͲǤͷ
ʹǤͺ ܹ݄݇ ൈ ܵΨ
Feed rate step Fuel Sulphur ACC (Calculated)

[g/kWh] [S%] [g/kWh xS%]
1.4 2.8 0.50
1.2 2.8 0.43
1.0 2.8 0.36
0.8 2.8 0.28
0.6 2.8 0.21
END of Example 1
The ACC calculated values are used to correlate the Fe and BN values in the samples. In Tables 1 and 2,
you can fill in the ACC calculated and the Fe and BN values. Two graphs can then be made where the
ACC calculated is the horizontal axis (x-axis) and the Fe values are the vertical axis (y-axis) in graph 1 and
BN in graph 2. You can also plot Fe and BN in the same graph. Fe should be the left vertical axis and
BN the right (view Figure 2 as an example).
Table 1. Write the ACC calculated in the left column and the corresponding Fe value for each cylinder.
These values are then used to make a graph in Excel.
Cylinder 1 2 3 4 5 6 7 8 9 10 11 12
ACC calculatedĻ Fe values
Table 2. Write the ACC calculated in the left column and the corresponding BN value for each cylinder.
These values are then used to make a graph in excel
Cylinder 1 2 3 4 5 6 7 8 9 10 11 12
ACC calculatedĻ BN values
Figure 5 illustrates how to evaluate a sweep test. In the normal case, the Fe concentration slowly rises
until a point where it will rapidly increase. The acceptable ACC factor is found just before the rapid
increase in Fe, in other words, before the Fe concentration reach the red area (Figure 5). The choice of
an ACC factor that corresponds to acceptable Fe levels means that the corrosion is controlled. After
the ACC factor has been found in accordance with the Fe, the corresponding BN value can be found. It
shows the possible level of BN depletion of the oil, which will not jeopardize the performance of the oil.
Scavengedrainoil
Fe[mg/kg]
Iron[Fe]&BN[mgKOH/g] BN[mgKOH/g]
700 50
45
600
40
500 35
30
400
25
300
20
200 15
10
100
5
0 0
0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55
ACC Factor [g/kWhxS%]
Figure 5. The ACC factor (g/kWhxS%) is shown on the x-axis. The Fe concentration (mg/kg) is depicted with red
lines and the result is read on the left y-axis. The axis is divided into three parts. The green bar is showing safe
operation condition, 0-200 Fe (mg/kg). When the Fe concentration exceeds 200 mg/kg (the red bar), the wear or
corrosion starts to increase a lot, and the lube oil feed rate should also be increased.
The rest BN concentration (mg KOH/g) is depicted with blue lines, and the result is read on the right y-
axis. The axis is divided in two parts. The red bar (0-10 BN) means that the neutralisation ability of lube
oil has started to deplete, and the risk of corrosion is increased. The green bar (10-50 BN) shows safe
operation.
The thick blue line and the thick red line are the BN and Fe values from a sweep test. In order to find
the correct ACC factor, the procedure is as follows:
Follow the thick red line and find the Fe concentration for safe operation. In this example it would be
200, because after this the slope of the thick red line increases rapidly. The corresponding ACC factor
is found on the x-axis and, in this case, is 0.30 g/kWhxS%.
The rest-BN value, which corresponds to this safe operation, is found by using the BN curve (in this
graph, the blue thick line) and read the result of the right x-axis. In this case, the ACC factor 0.3
corresponds to 22 BN. The dashed lines are examples of what other sweep tests with other lube oils
may look like.
Please direct any inquiries and questions regarding tables or condition-based overhaul to our
Operation Department at [email protected] or to our Service Department at PrimeServ-
[email protected].
HYUNDAI
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MANB&W
B&W 2245-0200-0004
Introduction
Inspection of Nimonic Exhaust Valve Spindles

These instructions are a supplement to workcard 2265-0201, and should be used
in combination with that Procedure during inspection and overhaul of all Nimonic
spindles on MAN Diesel & Turbo engines.
All general data, including specified wear limits for the spindle used on your engine
type, are given in "data 2265-0200". Note down the actual engine data in the
“data”-box in the relevant chapters of these instructions.
The procedure is divided into the following eight sections:
1 Spindle identification
2 Inspection intervals
3 Inspecting the contact condition of the seat
4 Checking the seat for gas leakage
5 Cleaning and evaluation
6 Inspecting the valve stem wear layer
7 Grinding the spindle seat
8 Exhaust Valve Condition Report
Sections 3 to 7 are each divided into four steps:
• What to do
• Acceptance criteria
• Remarks
• Further action
1 Spindle Identification
Markings:
The tops of Nimonic spindles are marked:
“Nim”, “Nim80A”, “N80A”,”N80”, or “NCF80A”.
If in doubt, please contact MAN Diesel & Turbo, Copenhagen.

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Description
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2 Inspection Intervals
Inspection Inspections:
Initial Second Subsequent
Normal hours After 6,000 hours After 24,000 hours Every 24,000 hours
of service: (35-40 ME-B, only (35-40 ME-B, only
16,000 hours) 16,000 hours)
Recommen- After 6,000 hours Based on condition Based on condition
ded: (50-60 ME/MC at initial inspection at initial and second
3-6,000 hours) inspections *)
*) If the spindle condition is very good, the condition of other exhaust valve parts
may prove to be the decisive factor in determining the future overhaul/inspection
intervals.
Also see 'Checking and Maintenance Schedule', chapter 0760-0301.
3 Inspecting the Contact Condition of the Seat
What to do:
Do not clean the spindle disc before inspection !

Visually check that there is inner contact.
Fig. 1 shows inner contact between the seats of the spindle and bottom piece,
corresponding to slow/low-load/manoeuvring condition.
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2245-0200-0004
Description
Figure 1: Inner contact, and zone designation
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Acceptance criteria:

There must be contact around the entire inner circumference of the seat.
Remarks:
When the valve heats up in service, the angular difference between the spindle and
bottom piece seatings will decrease. At steady, full load, the seatings will be paral-
lel, as shown in Fig. 2. Thus, inner contact must be maintained in order to be sure
of parallel contact during running.
Figure 2: Contact condition during running
If there is no inner contact, outer contact (Fig. 3) will occur during running, and this
will increase the risk of blow-by.
Figure 3: Outer contact, increased risk of blow-by

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2245-0200-0004
Description
Further action:
Fill in section 8 ‘Exhaust Valve Condition Report’.
If the seat contact is incorrect, grind the spindle seating, as described in section 7.
However, before grinding, proceed to section 4, 5 and 6.
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4 Checking the Seat for Gas Leakage

What to do
Do not clean the spindle disc before inspection !

Visually check the inner part of the seating for blow-by
(Fig. 4 and Photo 1).
Figure 4: Blow-by
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Description
Photo 1. Blow-by
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B&W 2245-0200-0004

There must be no blow-by “tracks” across the inner part of the seat
(Figs. 1 + 4, and Photo 1).
Remarks:
Blow-by indications may be associated with large/deep dent marks, and will often
form a “gas-jet-fan” in the deposits on the disc cone (Photo 1).
The surface of a serious blow-by track/groove will usually show signs of hot corro-
sion, i.e. it will have an “elephant skin” texture.
Minor leakages. Small, faint, fan-shaped leakage indications on the spindle cone,
just inside the seat area (Photo 2), are harmless.
Photo 2: Minor leakages, and "fans"
Further action:
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2245-0200-0004
Fill in section 8: ‘Exhaust Valve Condition Report’.

Description
If blow-by has been found, then grind the seat, as described in section 7. How-
ever, before grinding, proceed to sections 5 and 6.
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5 Cleaning and Evaluation

What to do:
• Clean the seat with coarse emery cloth. Observe and note down the size and
number of dent marks. Also note any possible crack indications.
• Check the outer part of the seat for high temperature corrosion (Fig. 1 and
Photo 3).
Photo 3: Example of high-temperature corrosion at outer part after 33,000 hours

• Clean the contact faces on which the measuring template is to be applied,
and measure:
– the burn-off on the disc underside,
– the total amount the seat has been ground.
(See work card 2265-0201)
Dent marks, of varying number and size (up to 8-10 mm), will be seen on the seat-
ing after a few thousand service hours. The first marks may appear as early as
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2245-0200-0004
after testbed running. In general, dent marks are acceptable and should not
necessitate grinding of the seat. If, however, the marks have caused blow-by, then
Description
the seat must be ground/reconditioned.
Cracks. Any indications of cracks in the seat area should be checked carefully. If
cracking is confirmed, contact MAN Diesel & Turbo.
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High-temperature corrosion on the outer part of the seat may result in a measura-

ble difference in level between the inner and outer seat zones. In that case the
spindle must be ground. However, this will not normally happen before 20 –
30,000 hours after the previous grinding.
Wear Allowances:
• Burn-off on disc underside, (F1)

• Total grinding of seat, (G1).
Remarks:
Burn-off rate (disc underside). The number of service hours before shore-side
reconditioning usually depends upon the burn-off rate of the disc underside
Engine type: *) Max. permissible burn-off (mm)
26MC 5
35MC 6
35ME-B
40ME-B 6
42MC 7
46MC-C 8
50MC/MC-C 8
50ME/ME-C
60MC/MC-C 9
60ME/ME-C
65ME-C 9
70MC/MC-C 10
70ME/ME-C
80MC/MC-C 14
80ME/ME-C
90MC/MC-C 17
90ME/ME-C
98MC/MC-C 20
98ME/ME-C
*) Also valid for stationary engines (power plants)
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2245-0200-0004
Further action:
Description
If the burn-off or grinding limits have been reached, contact MAN Diesel & Turbo
for advice on reconditioning.
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If the seat and the disc underside are acceptable with respect to section 3, 4, and
5, then the spindle can be reinstalled without grinding after section 6 has been car-
ried out. Otherwise, proceed to section 6 and 7.
6 Inspecting the Valve Stem Wear Layer
What to do:
• Clean the valve spindle stem.
• Measure the diameter of the spindle stem in the area shown in word card
2265-0201.
• Check the surface condition of the chrome-plated/HVOF-coated area.
Min. diameter: Must not be less than that stated in work
card 2265-0201,Cracking (“meshwork cracking”) of
chrome/HVOF: Slight cracking of the lowermost part of the
chrome plating/HVOF-coating (Photo 4) has no significance,
and is therefore acceptable.
Peeling-off: The chrome plating/HVOF-coating must not

show peeling-off.
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2245-0200-0004
Description
Photo 4: Slight cracking ("meshwork cracking") of wear layer
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Further action:

If the spindle stem is acceptable, proceed to section 7. Otherwise, contact MAN

Diesel & Turbo for advice on reconditioning.
7 Grinding the Spindle Seat
What to do:
• Mount the spindle in the grinding machine and, using the dial-gauge posi-
tioned just inside the area of inner contact, (see Fig. 5), true-up to within a
maximum of 0.05 mm. This is done in order to minimize the amount of mate-
rial removed during grinding.
Figure 5: Truing-up the spindle
Grind the seat according to the special instructions from the

grinding machine supplier.
See also MAN Diesel & Turbo Service Letter SL95-332/UM,

“Grinding of Nimonic Exhaust Valve Spindles”.
Keep the grinding to a minimum!

After full contact between grindstone and seat is reached at the beginning of the
grinding process:
Normally Limit the grinding to 0.2 mm.
Rare cases Remove 0.3 mm or more.
Blow-by Continue the grinding until the blow-by marks are removed.
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Dent marks It is not necessary to continue grinding until all dent marks
2245-0200-0004
have been removed.

Description
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Photo 5 shows an overhauled Nimonic valve spindle which is ready for further
service.
Photo 5: Acceptable seat condition after grinding
The ground surface. The grindstone must have removed
material from the whole width and the whole circumference
of the seat. There must be no signs of blow-by.
Max. grinding depth: must not exceed the limit (G1) stated in
work card: 2265-0201.
If the seat surface is still not acceptable when the max. grinding depth has been
reached, contact MAN Diesel & Turbo for advice on reconditioning.
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Description
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B&W
HYUNDAI
8 Exhaust Valve Condition Report
Description Inspection of Nimonic Exhaust Valve Spindles

2245-0200-0004
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Service Letter SL2013-573/JAG
Action code: WHEN CONVENIENT
Exhaust Valve Condition

In Relation to Low Load Operation
SL2013-573/JAG
August 2013
Concerns
Owners and operators of MAN B&W
two-stroke marine diesel engines.
Dear Sirs Type: MC/MC-C and ME/ME-C/ME-B
Since we issued the three Service Letters, SL2008-501, SL2009-511 Summary

and SL2011-544, describing low-load operation down to 40% and Long-term low load operation down
10% load, we have gained valuable experience on the exhaust valve to 10% engine load is generally pos-
condition during low-load operation. sible with appropriate precautions and
without major modifications. However,
In our 2008 Service Letter (SL08-501), we informed that an increase in some cases, the thermal load profile
of the exhaust valve temperature may lead to higher exhaust valve causes the need for extra inspections
spindle wear and shorter exhaust valve overhaul intervals, i.e. shorter and overhauls.
time between disc rewelding.
With reference to the previous market situation, MAN B&W two-

stroke engines were designed for continuous operation in a high
engine load range and, accordingly, the designs and materials of
exhaust valves were optimised for this range. Also, overhaul intervals
and expected lifetimes were stipulated for engines operating in a high
load range. However, long-term low-load operation down to 10% en-
gine load is generally possible when taking appropriate precautions,
such as more frequent inspections and overhauls of exhaust valves.
In order to counteract this increased cost on exhaust valves for op-

eration at low load, we have reviewed the possibilities for rewelding
of exhaust valves and have confirmed that up to three times instead
of the present standard with maximum rewelding two times is pos-
sible. Furthermore, we have for large bore engines increased the
burn-away limits.

Yours faithfully
Mikael C Jensen Stig B Jakobsen

Vice President, Engineering Senior Manager, Operation
Head office (& postal address) PrimeServ Production Forwarding & Receiving MAN Diesel & Turbo
MAN Diesel & Turbo Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Branch of MAN Diesel & Turbo SE,
Denmark Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 Head office: Teglholmsgade 41
Contents case, temperatures increase (green and black curves)

Low-load benefits and additional costs page 2 when loads increase when operating with T/C cut-out. This
Operation condition and thermal load page 2 situation will differ depending on the engine type, size, lay-
Recommendations page 4 out point and tuning method applied. Therefore, the only
way forward in case of prolonged low-load operation is to
inspect more frequently in order to learn the specific burn-
away rate for the engine in question with the specific low-
load operation pattern.
Low-load benefits and additional costs

Operation down to 10% load is feasible for all ME/ME-C/
ME-B and MC/MC-C engines without requiring engine
Temperature
modifications.
The optimisation of engine operation at low load has put

focus on improving the fuel oil consumption at these low
loads. Retrofit of turbocharger cut-out systems has be-
come popular. And for new projects, optimisation with
exhaust gas bypass, and low-load and part-load tuning 0 10 20 30 40 50 60 70 80 90 100 110
methods (especially for the ME engines) will change the Load %
BOTTOM, normal operation SEAT, normal operation BOTTOM , T/C cut-out SEAT, T/C cut-out
thermal load on the exhaust valves.
Fig. 1: Exhaust valve temperatures, 8K90MC-C
Due to thermal load changes, especially when it comes to
exhaust valve components, continuous operation at low
load will require more attention to the engine condition and Fig. 2 illustrates exhaust valve disc bottom and spindle seat
overhaul intervals. temperatures on a 10S90ME-C9.2 engine as a function of
load. As can be seen, the temperature decreases on both
However, this cost increase is, as described in previous the exhaust valve disc bottom and disc seat when reduc-
low load Service Letters, easily outbalanced by the savings ing from 25% load to 10% load. The influence of the auxil-
gained in fuel and cylinder oil consumption per nautical liary blower on/off at 25% load can also be seen. We can
mile. only repeat our recommendation to inspect exhaust valves
when operating in the low-load range in order to schedule
reconditioning in due time.
Operation condition and thermal load
Continuous operation at low engine load requires more at-
tention from the owner or operator. Frequent inspections
are paramount to follow the condition of the engine com-
Temperature
ponents. Furthermore, planning of maintenance is crucial.
A higher thermal load on the exhaust valve components

must be expected when operating the engine in the load
area just above the cut-in point of the auxiliary blowers.
During long time low-load operation, the average tempera-
ture of the spindle disc underside will be higher and, as a 0 10 20 30 40 50 60 70 80 90 100 110
consequence, high-temperature corrosion and the calcu- Load %
BOTTOM, Aux Blower on SEAT, Aux Blower on BOTTOM , Aux Blower off SEAT, Aux Blower off
lated burn-away rate will also be higher.
Fig. 2: Exhaust valve temperatures, 10S90ME-C9.2
Fig. 1 illustrates exhaust valve disc bottom and spindle
seat temperatures on an 8K90MC-C engine as a func-
tion of the load. As can be seen, when operating at lower
loads without T/C cut-out, the temperature increases when
the load decreases (red and blue curves). However, in this
Exhaust Valve Condition. Page 2 of 4 pages

Engine type Burn away Running (hrs.) Burn away rate Spindle lifetime
K98ME 9 mm 14,000 0.64 61,000 hrs.
S60MC-C 11 mm 26,000 0.43 64,000 hrs.
K98MC-C 7.5 mm 15,000 0.50 78,000 hrs.
S90MC-C8 14 mm 15,000 0.93 39,000 hrs.
Burn away rate = mm / 1,000 hrs.

Normal lifetime = 100,000 hrs. including reconditioning of spindle
Table 1: Previous spindle lifetimes (examples)
Table 1 illustrates some examples of burn-away rates ob- Table 4 shows the calculated burn-away rate with a spindle
served during low-load operation in relation to the previous lifetime of 100,000 hours.
standard for overhaul.
Values can change if other contributing factors have an in-
We have changed our max. burn-aways as follows: fluence on engine performance.
Engine type Previous New Burn-away rate per 1,000 hrs.
60 9 mm Unchanged Engine size Previous New
70 10 mm Unchanged 60 0.27 mm 0.36 mm
80 11 mm 14 mm 65 0.30 mm 0.40 mm
90 12 mm 17 mm 70 0.30 mm 0.40 mm
98 13 mm 20 mm 80 0.33 mm 0.56 mm
90 0.36 mm 0.68 mm
Table 2: Maximum burn-aways 98 0.39 mm 0.80 mm
With these new limits, three times reconditioning and new Table 4: Allowable burn-away rates
limit for burn-away, the spindle lifetimes illustrated in Table
1 will be as follows:
Fig. 3 shows an exhaust valve on an S60MC-C8.1 engine
Spindle
Engines Burn away Running hours inspected after 26,000 hours after long-time low-load op-
lifetime
eration. The burn-away rate is more than 11 mm and, ac-
K98ME 9 mm 14,000 124,000 hrs.
cording to the instruction manual, the maximum burn-away
S60MC-C 11 mm 26,000 85,000 hrs.
for rewelding on this engine type is 9 mm. Again, in view of
K98MC-C 7.5 mm 15,000 160,000 hrs. low load, this calls for a more frequent inspection interval
S90MC-C8 14 mm 15,000 73,000 hrs. and planning of maintenance.
Table 3: Updated spindle lifetimes (examples)
As can be seen, three times reconditioning combined with

new burn-away limits will, to a large extent, mitigate the
shortening influence of low-load operation on the exhaust
valve spindle lifetime.
Fig. 3: Exhaust valve, S60MC-C8.1

Recommendations
In case of prolonged low-load operation, more frequent in-
spections are called for to judge the burn-away rate on the
exhaust valve bottom. In general, it is not possible to give
overall guidelines for overhaul intervals at low load, as the
points listed below are factors contributing in a mixture to
give different burn-away rates for a given vessel:
 full or derated engine layout

t ype of fuel valves (we recommend to use slide-type fuel

valves running at low load).
 t ype of turbocharging system layout
 auxiliary blower’s switch-off point
 f uel oil quality
 turbocharger cut-out.
D epending on the use of fuel optimisation methods at low

load, different loads can be more or less critical
If running at a load very close to and just above the auxil-
iary blower cut-in point, we recommend to change the load
slightly to keep the blower running. Alternatively, the auxil-
iary blower could be switched to “manual on”.
For any questions regarding the content of this Service

Letter, please contact our Operation department, LEO, at
[email protected].

HYUNDAI
MAN B&W 2255-0100-0002
Inspection through Scavenge Ports

1. Dismount the small covers on the scavenge
air boxes, and clean the openings.
2. When the piston has been turned below the

level of the scavenge air ports, inspect the
cylinder liner walls and the piston crown.
3. A tiltable mirror fixed to a telescopic rod can

be used as illustrated. Use a powerful light
source for inspection.
4. In order to inspect a larger area of the cylin-

der liner and piston, it is expedient to enter
the scavenge air receiver and make obser-
vations from the “exhaust side”. This should
be done every time the sludge is cleaned out
from the scavenge air receiver and box.
5. While the piston is passing the scavenge air

port, examine the piston crown, the rings,
and the skirt.
In order to be able to correctly observe the

running surfaces of the piston rings, clean
them with a rag.
Check the free movement and the tension

of the piston rings, by pressing them with a
wooden stick.
6. Measure the total clearance between the pis-

ton rings and the ring grooves.
7. When the piston has been turned upwards

past the scavenge air ports, inspect the pis-
ton rod.
8. Note down the results on this Drawing.

4255-0100-0002
2008-08-18
Drawing
Doc-ID: 2255-0100-0002 1 (5)

HYUNDAI
2255-0100-0002 MAN B&W
Record

V essel : L l . no. : B ui l der/no. :
Number of cylinders: Eng. type: Eng. hrs.: Checked by: Date:
Weeks pr. port calls: Normal service load (% of MCR): MEP lubricator type (Y/N):
Cyl. oil consump. (l/24 hrs): at load % Cyl. oil type: Position: Exhaust Manoeuvre
Cylinder No.
Condition and Symbol Engine Part 1 2 3 4 5 6 7 8 9 10 11 12
Intact - *
Burning - BU
Piston crown
Leaking oil - LO
Leaking water - LW
Topland
No deposit - *
Deposits
Light deposit - LC
Ringland 1
Medium deposit - MC
Excessive deposit - EC
Ringland 2
Polished deposit - PC
Ringland 3
Intact - * Ring 1
Ring breakage
Collapsed - C
Broken opposite ring gap - BO Ring 2
Broken near gap - BN
Several pieces - SP Ring 3
Entirely missing - M
Ring 4
Ring movement
Ring 1
Loose - * Ring 2
Sluggish - SL
Sticking - ST Ring 3
Ring 4
Clean, smooth - * Ring 1

Running surface, Black,overall - B
Running surface, Black, partly - (B) Ring 2
Black ring ends > 100 mm - BR
Surface condition
Scratches (vertical) - S Ring 3

Micro-seizures (local) - mz
Micro-seizures (all over) - MZ Ring 4
Micro-seizures, still active - MAZ
Old MZ - OZ Piston skirt
Machining marks still visible - **
Wear-ridges near scav. ports - WR Piston rod
Scuffing - SC Cylinder liner abv.
Clover-leaf wear - CL scav. ports
Rings sharp-edged Top/Bot. - T/B Cylinder liner near
scav. ports
Ring 1
Lubrication condition
Ring 2
Optimal - * Ring 3
Too much oil - O
Slightly dry - D Ring 4
Very dry - DO
Black oil - BO Piston skirt
4255-0100-0002
Piston rod
2008-08-18
Cylinder liner
Deposit
No Sludge - *
Scavenge box
Drawing
Sludge - S
s
Much sludge - MS
Scav. receiver
Flaps and nonreturn
Intact - *
valves
Running hours since last overhaul
2 (5) Doc-ID: 2255-0100-0002

HYUNDAI
MAN B&W 2255-0100-0002
Symbols

q
g
Sym- Condition of inspection part
Piston Bowl
bol
Burning Carbon
• Satisfactory
Deposits, etc.
C Carbon Deposit
BU Burning Piston Liquid
LO Leakage Oil Topland
LW Leakage Water Piston
Ringlands
• Satisfactory (no deposits) 1, 2 and 3
LC Light carbon deposit
Deposits
EC Excessive carbon deposit Piston

PC Thick carbon deposit worn Rings
bright by rubbing against Piston
cyl. liner Skirt
• Intact Piston Rod

BO Broken, opposite ring gap
Broken
BN Broken, near ring gap

SP Broken in several pieces
M Entirely missing
COL Collapsed
• Loose
SL Sluggish in groove
Sticking
ST Sticking Cyl. Liner

above Ports
B Black running surface, over-
(B) all
Black running surface, parly
• Clean, smooth
S Vertical scratches
(abrasive particles)
mz Micro Seizures in spots Area near
MZ (local) Scavenge Air
Surface condition
MAZ Micro Seizures, all over Ports

OZ Micro Seizures still active Cyl. Liner
WR Old (nearly recovered) MZ below Ports
CO Wear ridges near bottom
CL Corrosion
Wear
T/B Clover-leaf wear
Edge
Rings sharp-edged Top/Bot.
Lubr. condition
• Oil film normal

O Too much oil
D Too dry
DD Very dry
BO Black oil
4255-0100-0002
2008-08-18
A dot (•) always means that the inspected condition is satisfactory, e.g. small deposits, no leakage,
Drawing
no breakages, no sticking, clean smooth surfaces, normal oil film, etc. However, this shall be recorded
in order to show that the condition has been noted.
Doc-ID: 2255-0100-0002 3 (5)

HYUNDAI
2255-0100-0002 MAN B&W
Pictures
Running Surface of Piston Rings

NB: In file tests, use a new very finely cut file
“Polished Mirror Surface”

Photo 1 (about X3)
A normal, good running surface is smooth,

clean, and without scratches. The horizontal
line is a scratch mark resulting from a file
test, which indicates that the surface is not
hardened.
“Vertically Scratched”
Photo 2 (about X3)
Here the running surface has been

scratched by sharp, hard abrasive particles,
e.g. grains of sand.
The file test shows that the surface is not

hardened.
“Micro-Seizures”
Photo 3 (about X3)
A micro-seized running surface can appear

as shown here.
The file test gives almost no horizontal

scratch, which indicates that the surface is
4255-0100-0002
covered by a hard glaze, i.e. has been hard-

2008-08-18
ened due to micro-seizure.

Drawing
4 (5) Doc-ID: 2255-0100-0002

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MAN B&W 2255-0100-0002
Evaluation

Surface Condition Profile Running Surface
Normal good
“mirror surface”
“•” Barrel-shaped Clean, smooth, soft
Scratched by hard
abrasive particles
“S”
Uniform scratches, dull, soft
Sharp burrs
New
Micro seizures
(still active)
“MAZ”
Flat
Irregular marks, hardened
Old
Micro seizures
(restoration has
begun)
“OZ”
Curved edges, im- Smooth and soft Still hard in
plies that restora- along the edges centre area
tion has begun
Lubrication
Clover-leaf formation: orifice
heavy wear at several areas
around the cylinder liner,
in the case illustrated
concentrated between the
lubrication orifices
4255-0100-0002
2008-08-18
“CL”
Horizontal Section of Cyl. Liner
Drawing
Doc-ID: 2255-0100-0002 5 (5)

2013-02-20 - en
MAN
MANB&W
B&W
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Drawing Factors influencing cylinder wear

2255-0105-0003
2255-0105-0003
1 (1)
HYUNDAI
MAN B&W 2255-0110-0003
Grum Schwensen Drawings
Abrasive Particles
Typical observations when particles penetrate from
the combustion chamber into the piston ring zone
Exaggerated illustration of “worn and eroded” piston rings

No. 1 to 4, in “worn” grooves. It is typical for particle wear
that it excessively affects the upper ring (both the running
face and the horizontal surfaces) as well as the groove.
Some degree of micro-seizure sometimes occurs on the
lower rings, decreasing upwards. This is contrary to the
scratching intensity (or roughness) which decreases, from
ring to ring, downwards.
When particle-wear prevails, the cylinder liner wear rate
usually rises to between 0.30 and 0.50 mm/1000 hours.
Running face ring No. 1

The “trumpet-shaped” scratches
indicate that the hard particles
have penetrated from above.
Upper side of the uppermost rings

The horizontal faces, especially the
upper side, often become pock-marked
due to hard grains being crushed when
the rings are pressed upwards by the
gas trapped between the rings.
However, such an appearance can also
be the result of mechanical impact
due to ring collapse.
Upper side of the lower rings

The part sheltered in the groove
still shows intact machining marks.
The exposed part, protruding from
the groove, becomes sand-blasted
by the hard particles blown down
through the ring gap above.
Designations
“S” – Scratched running face
“PO” – “pock-marked”
“E” – Erosion. Outer edge sand-blasted

“MI” – Machining marks intact.
4255-0110-0003
2008-08-18
Numbers 1 to 5 give degree of damage

(5 being most).
Drawing
Doc-ID: 2255-0110-0003 1 (3)

Drawing
2 (3)
Abrasive Particles
4255-0110-0003
Photo 1 (X30) Photo 2 (X30)

Rough scratching Typical “older” much
(degree 5) of a top finer scratching.
piston ring running That recovery or res-
2255-0110-0003
Pictures
face. The photo toration is at work,
shows the upper can be ween from
edge, where the hard the fact that the
particles enter be- graphite flakes are
tween ring and liner distinct.
wall. This scratching Designation S2OLD.
is quite fresh, i.e. re-
covery or restoration
has not yet com-
menced.
Designation S5NEW.

Typical “pock- This photo illus-
marking” of a ring trates how small
Doc-ID: 2255-0110-0003
upper side, caused pieces of cast iron
by hard particles are “torn out” of the
penetrating into the top surface, by the
clearance above the masticating effect
ring and being of the hard parti-
crushed. This is cles. The pieces
most often seen on probably loosen
the two uppermost due to shear stress-
rings, which, during es, which cause
the last part of the fractures in the ma-
expansion stroke, terial between the
are pressed up- graphite flakes.
wards, against the Also ring collapse
ceiling of the groove, can cause “torn out”
by the gas trapped material.
between the rings
MAN B&W
HYUNDAI
2008-08-18
2008-08-18

Typical erosion or Hard particles (sand)
sand-blasting on separated from a
the part of the ring sample of piston
topside which pro- crown deposit. Oil Pictures
trudes out of the and carbon have
MAN B&W
HYUNDAI
groove. This is due been removed by in-

to hard grains being cineration, other mat-
blown down through ter by acid, magnetic
the gap in the ring separation and filtra-
above (NB: The tion. Theoretically
rings “turn” in the these particles could
grooves). Such ero- have come into the
sion is only seen on combustion chamber
rings Nos. 2, 3 and 4. either with the air or
with the fuel.

Sand (or sand-like Fuel pump suction
grains) separated valve flap after only
from centrifuge a few service hours
Doc-ID: 2255-0110-0003
sludge. In this case (the lapping marks
the centrifuge treat- are still visible. The
ed the fuel oil after depressions in the
the oil had passed a surface are in many
full flow (fabric) filter. cases made by one
The particles size is and the same parti-
10M to 15M. cle (repeated and
identical in shape
and size). Usually
the edge around the
holes is raised, and
often the original lap-
ping marks are still
visible in the bottom
of the depression
Drawing Abrasive Particles

4255-0110-0003
2255-0110-0003
3 (3)
HYUNDAI
/#0$9
MAN B&W
2255-0125-H004
Encl. 1 of 6
Guiding cylinder oil feed rates
%[NKPFGTQKN(GGF4CVGFWTKPI4WPPKPIKP
All ME/ME-C/ME-B/ME/MC/MC-C and ME-GI engines
With electronically controlled lubrication system
Mk 8-8.1 and newer Mk 7 and older

Standard BN 100 Standard BN 70-100
Viscosity range SAE 50 SAE 50
ACC setting 0.40-0.20 0.34-0.20

g/kWh x S% g/kWh x S%
Guiding minimum feed rate 0.60 g/kWh 0.60 g/kWh
Maximum feed rate during running-in 1.7 g/kWh 1.7 g/kWh
Part-load control Proportional with load.

At lower loads control is automatically changed to proportional with rpm.
Breakpoint from power to rpm-dependent lubrication to be set to 25% load.
Running-in new or reconditioned liners Feed rate:

and new piston rings First 5 hours: 1.7 g/kWh
From 5 to 500 hours: Stepwise reduction from 1.5 - 0.6 g/kWh or ACC factor x fuel
sulphur (using the highest feed rate)
Engine load:
Test bed: Stepwise increase to max. load over 5 hours
In service: 50% to max. load in 16 hours
Familiarizing Starting at 0.40 g/kWh x S% Starting at 0.34 g/kWh x S%

ACC Factor (Fig. 6a) (Fig. 6b)
Reducing in steps of 0.04 g/kWh x S% after min. 600 hours where the feed rate has been sul-
phur dependent (above min. feed rate) or using feed rate sweep or continuous drain oil analysis.
If the engine is retroǣtted with means to improve part or low-load fuel consumption the ACC
factor must be reassessed.
Running-in new rings in already run-in and From 50% to max. load in 5 hours
well running liners Feed rate 0.9 g/kWh for 24 hours.
If the fuel sulphur and applied ACC factor combination results in a speciǣc feed rate higher than
0.9 g/kWh (use the calculation feed rate), no extra lubrication is needed.
Manoeuvring and load change During starting, manoeuvring and load changes, increase feed rate by means of the “LCD” by
situations 25% of the actual ǣgure and kept at this level for hour after the load has stabilised.
Lubrication of cylinders that show Frequent scavenge port inspections of piston rings and cylinder liners are very important for
abnormal conditions maintaining a safe cylinder condition.
If irregularities are observed, adjustments of the lube oil feed rate should be considered.
In case of scufǣng, sticking piston rings or high liner temperature Ǥuctuations, raise the feed
rate to 1.20 g/kWh and lower the pmax and mep. As soon as the situation has been stabilised,
GP

set the lubrication feed rate and pressures back to normal.
In case of high corrosive wear, the ACC factor is to be increased to the highest ACC factor
&TCYKPI
(0.40 g/kWh x S% for BN 100)) and be reduced in steps of only 0.02 g/kWh x S% when the
wear has been conǣrmed as normal.

Table 5: Guiding cylinder oil feed rates

1(4)
HYUNDAI

2255-0125-H004 MAN B&W
MAN BW
Encl. 2 of 6
Breaking-in New Liners
Initial running-in dosage g/kWh

1.8 * Fixed running-in dosage (g/kWh)
1.6
*
Fixed running-in dosage (g/kWh), or
1.4
* ACC feed rate (g/kWh)
The highest of the two to be used
1.2 *
*
1 * Scavenge port inspection
0.8
*
Change to ACC
0.6
Breaking-in period with ǣxed lubrication
0 100 200 300 400 500 600 700 800 900 1,000
hours
2013-0-29 - en

&TCYKPI
2 (2)
2(4)
HYUNDAI
MAN BW
MAN B&W
2255-0125-H004
Encl. 2 of 6
New ACC Running-in Schedule (liner and rings)
0.40
* ACC factor based upon the
0.36 feed rate sweep
0.34 *
0.32
0.30 *
0.28
0.26 * Reduction based upon observation *

0.24
0.22
0.20

0.16
0 1,000 2,000 3,000 4,000
hours
Fig. 6a: ACC familiarisation schedule for Mk 8-8.1 and newer

0.40
0.36 ACC factor based upon the feed rate sweep
* * Reduction based upon observation
0.34
0.32 *
0.30
0.28 *
0.26
0.24 *
0.22

0.20
&TCYKPI

0.16
0 1,000 2,000 3,000 4,000
hours
Fig. 6b: ACC familiarisation schedule for Mk 7 and older
1 (2)
3(4)

HYUNDAI

2255-0125-H004 MAN BW
MAN B&W
Encl. 3 of 6
Guiding Wear Rate Values
Bore size Max. radial Max. width of leakage groove Engine bore CL-groove new depth Minimum depth
[cm] ring wear [mm] (use feeler gauge) [mm]
26 cm 2.0 mm 0.6 mm
26 cm 1.8 6.6
30 cm - -
30 cm 2.0 7.0
35 cm 2.5 mm 0.8 mm
35 cm 2.2 7.4
40 cm 2.5 mm 0.8 mm
40 cm 2.2 7.4
42 cm 2.5 mm 0.9 mm
42 cm 2.2 7.4
45 cm - -
45 cm 2.2 7.4
46 cm 2.5 mm 1.0 mm
46 cm 2.2 7.4
50 cm 3.0 mm 1.1 mm
50 cm 3 9
60 cm 3.5 mm 1.3 mm
Table 6: CPR-POP top ring wear 65 cm 3.5 mm 1.4 mm
70 cm 3.5 mm 1.6 mm
80 cm 4.0 mm 1.8 mm
Table 7: CPR-CL top ring wear
2013-08-29 - en

&TCYKPI
2 (2)
4(4)
2012-10-03 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Cylinder Condition Report

2255-0130-0003
2255-0130-0003
1 (1)
2012-10-03 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Calculation of Condensate Amount

2255-0135-0002
2255-0135-0002
1 (2)
Drawing Calculation of Condensate Amount
2 (2)
2255-0135-0002 2255-0135-0002
MAN
MAN B&W
HYUNDAI
B&W
2012-10-03 - en
2013-02-22 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Running-in load

2255-0140-0003
2255-0140-0003
1 (1)
2013-02-22 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Overview of piston rings

2255-0145-0001
2255-0145-0001
1 (1)
HYUNDAI
MAN B&W
MAN B&W 2255-0150-0001
Normal Condition Cold Corrosion
Liner Condition
Normal liner condition. Light corrosive sur- Cold Corrosion. Normal cold corrosion on
face. Wave cut machining marks still visible the lower liner part, the corrosion facilitate
on the lower part of the liner. good lubrication oil film, and the liner wear
rates are acceptable.
Top cold Corrosion Liner Black Deposits
Excessive Corrosive top part of the liner. Black Deposits (black lacquer). The result of
Heavily corrosive surface, may lead to high high humidity in the scavenging air, impact-
liner wear and high ovality. ing the cylinder oil, producing alkaline mate-
rial, forming a patch of deposits. Harmless
to the engine and will be worn away when
the air becomes dryer.
2013-02-22 - en
2255-0150-0001
Drawing
1 (2)
HYUNDAI
2255-0150-0001 MAN B&W
MAN B&W
Bore Polish Port Rib Marks

Liner Condition
Liner Polish. Excessive piston top land Port Rib Marks. Often seen in connection
deposits will eventually lead to liner polish with exessive top land deposits due to too
and oil film break down. Possibly related to high cylinder oil feed rates, in combination
missing or malfunctioning PC-ring in combi- with a cooler liner port area by cold climate
nation with too high oil feed rates. and low load operation. (Not harmful).
Seizure stripe Scuffing (Macro seizures)
Micro Seizures. Deriving from local oil film Scuffing (Macro seizures). The result of
break down, must be treated with increased complete oil film break down is high friction
oil feed rate to make the rings run in again. and seizures leading to heavy liner wear.
May otherwise evolve into scuffing. The liner must be exchanged or machined.
2013-02-22 - en
2255-0150-0001
Drawing
2 (2)
HYUNDAI
MAN B&W
MAN B&W 2265-0100-0006

Precautions
Exhaust Valve High-Pressure Pipe, Data

see 0545-0100
Data
T22-01 High-pressure pipe, tightening torque 36 Nm
T22-03 High-pressure pipe 32 kg
2012-12-03 - en
2265-0100-0006
Work Card
1 (2)
HYUNDAI
2265-0100-0006 MAN B&W
MAN B&W
Exhaust Valve High-Pressure Pipe, Data
Tools
2012-12-03 - en
2265-0100-0006
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 2265-0101-0004
High-pressure pipe When replacing the hydraulic
Exhaust Valve High-Pressure Pipe • Dismantling

high-pressure pipe, exhaust
valve or hydraulic actuator,
check the high-pressure pipe sealing
surfaces.
T22-3
226501010001D01
Stop hydraulic supply Before dismounting the high-pressure pipe, stop the supply for the hydraulic
»pushrod«.
Loosen the screws for the high-

Removing the high- pressure pipe and lift the pipe
pressure pipes slightly away from the actuator to
let the oil in the pipe drain through
the drain holes in the actuator.
Remove the screws in both ends

of the high-pressure pipe. Lift the
high-pressure pipe away from the
engine.
2265-0101-0004
226501010001D02
2011-12-06 - en
Work Card
1 (4)
HYUNDAI
2265-0101-0004 MAN
MANDiesel
B&W
The thrust piece The two ends of the pipe are identical
Exhaust Valve High-Pressure Pipe • Overhaul
and should both be overhauled as fol-

lows:
Remove the thrust piece from the actua-

tor/exhaust valve.
Remove and discard the O-rings from

the thrust piece and the thrust flange.
Clean and inspect the conical seats of

the high-pressure pipe and the thrust
piece.
NOTE The seats cannot be reconditioned. If a

seat is damaged, the thrust piece/high-
pressure pipe must be replaced.
226501010001D01
The sleeve To change the internal O-ring, proceed

as follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-

part sleeve.
2265-0101-0004
226501010001O02
2011-12-06 - en
Work Card
2 (4)
HYUNDAI
MAN Diesel
MAN B&W 2265-0101-0004
The O-ring Remove the thrust flange from
Exhaust Valve High-Pressure Pipe • Overhaul

the pipe end.
Remove and discard the internal O-rings.
Mount new internal O-rings lubricated

with a little camshaft lubricating oil.
226501010001O03
Assemble Assemble the high-pressure pipe in the reverse order to disassembling.
2265-0101-0004
2011-12-06 - en
Work Card
3 (4)
HYUNDAI
2265-0101-0004 MAN
MANDiesel
B&W
Mounting the high- Mount new O-rings, lubricated

Exhaust Valve High-Pressure Pipe • Mounting
pressure pipe with a little engine lubricating oil, on

the thrust pieces and thrust flanges.
Mount the thrust pieces on the ac-

tuator/exhaust valve.
Mount the high-pressure pipe on the

engine.
When mounting the high-pressure

NOTE pipe, take care not to damage the
conical seats of the pipe/thrust
pieces.
226501010001M01
Tighten After fitting the pipe to the exhaust

valve and actuator, tighten up the T22-1
screws of the pressure flanges di-
agonally, see Data.
226501010001M02
Check Check the system for oil leakages.

2265-0101-0004
2011-12-06 - en
Work Card
4 (4)
HYUNDAI
MAN B&W
MAN B&W 2265-0200-0012

Precautions
Exhaust valve, Data

see 0545-0100
O Shut off fuel oil
Data
T22-06 Safety valve, opening pressure 23 bar
T22-08 Oil cylinder, tightening torque 100 Nm
T22-09 Safety valve, tightening torque 50-80 Nm
T22-11 Throttle valve, tightening torque 50 Nm
T22-13 Bottom piece seat, grinding angle 29.9 - 30.0 °
T22-14 Valve spindle seat, grinding angle 30.5 - 30.6 °
T22-15 Check measurement G2 0 - 2.3 mm
T22-16 Gap of bottom piece seat 1.0 mm
T22-17 Spindle, max. burn-off 8.0 mm
T22-18 Spindle, max. grinding 2.0 mm
T22-19 Spindle stem, measuring area, min. 235 mm
T22-20 Spindle stem, measuring area, max. 345 mm
T22-21 Spindle stem, min. diameter 59.8 mm
T22-22 Bushing max. diameter, top 60.6 mm
T22-23 Bushing max. diameter, bottom 62 mm
T22-24 Oil cylinder max. inside diameter 71.2 mm
T22-25 Piston rings, min. thickness 2.6 mm
T22-28 Exhaust valve, complete 500 kg
T22-29 Exhaust valve housing 300 kg
2013-05-21 - en
2265-0200-0012
T22-30 Oil cylinder 75 kg

Work Card
T22-33 Bottom piece 55 kg

T22-34 Air piston 5 kg
1 (2)
HYUNDAI
2265-0200-0012 MAN B&W
MAN B&W
Exhaust valve, Data
Tools
2270-0200 078 Cone ring for pneumatic piston
2270-0200 080 Test equipment for exhaust valve
2270-0200 091 Gauge for exhust valve spindle
2270-0200 150 Gauge exhaust valve bottom piece
2270-0200 186 Grinding ring for exhaust valve bottom piece
2270-0210 - Exhaust valve, grinding tools
2270-0240 - Exhaust valve, hydraulic tools
7670-0410 066 Slide caliper
2013-05-21 - en
2265-0200-0012
Work Card
2 (2)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Checks during running
Exhaust Valve • Checking

Check of valve spin- The engine must run when the valv
dle rotation function and spindle rotation are
checked. Lift the valve spindle rotation
indicator, turn it 90° and let it rest on the
air piston.
The indicator will now follow the move-

ments of the valve spindle and the air
piston. During rotation of the valve spin-
dle, the top position of the indicator will
change about 6 mm, because of the
groove in the piston.
During engine operation, the spindle

must rotate. The rotation can vary with
unit and engine load. In the event of no
rotation, attention should be paid to
avoid seat problems. When check of the
On Surface InGroove
valve rotation is fi nished, lift the rotation
2265-0201-0013C01
indicator and lock it in the top position.
The indicator must not be in constant

operation.
Exhaust valve performance condition

See Description in chapter 6345 Per-
formance.
Check of bottom With the exhaust valve mounted in the

piece sealings cylinder cover, check the cooling water
inlet and outlet to the cylinder cover and
exhaust valve is open.
Check the tightness of the sealing rings

between the bottom piece and the
exhaust valve housing. IF water fl ows
from the small bore on the manoeuvring
side of the exhaust valve, the lowermost
sealing ring is leaking.
If water fl ows from the any of the rings,

2265-0201-0013
the exhaust valve must be dismounted

2013-03-19 - en
and the sealing rings replaced.

2265-0201-0003C02
Work Card
1 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Check with stopped engine

In connection with port stays, at an in-

terval of e.g. one month, an easy check
of all exhaust valves is recommended.
Check of spindle Engage all rotation indicators on the ex-

drop-down time: haust valves.
Shut off and release the spring air on Airsupply

the valve, next to the engineside ma- Exhaust Valve
noeuvring stand.
Check the drop down time for all spin-

dles:
• Spindles dropping down within 30

minutes: Check and overhaul, See
next step “Check of Air Spring tight-
ness”.
• Spindles dropping down between 30

minutes and 1 hour: Keep under ob-
servation.
• Spindles dropping down after 1 hour:

OK.
When check of drop down time is fi

nished, lift the rotation indicators and
lock them in the top position.
Control Air
Supply
2265-0201-0013C03
2265-0201-0013
2013-03-19 - en
Work Card
2 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Check of Air spring Connect compressed air to the non

tightness return(A) valve on the air cylinder.
Disconnect and remove the drain oil

pipe from the oil cylinder (C).
B
Check if air is coming out from: A
• The bore (B): Leakage from spindle

stem sealing, change and overhaul.
• Hole for drain oil (C): If yes, the leak-

age comes from the safety valve
or the air piston. Check the safety
valve (D). If air still is coming out, the
leakage comes from the air piston: A
D
change and overhaul.
• Remove the air supply to the nonreturn

valve on the air cylinder and check
the nonreturn valve for tightness.
The checks is for guidance only, minor

leaks is difficult to detect.
C
D
2265-0201-0013C04 2265-0201-0013
2013-03-19 - en
Work Card
3 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Close of cooling water Close the cooling water inlet and outlet
Exhaust Valve • Dismantling
connections, and drain the exhaust

valve.
Close the air supply to the exhaust

valve.
Remove the water connection
2265-0201-0013D01
Dismount the oil pipe Dismount the high-pressure pipe for the
connection hydraulic valve actuation. See work card
2265-0101.
Dismount the return oil pipe from the

exhaust valve.
2265-0201-0013D02
2265-0201-0013
2013-03-19 - en
Work Card
4 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Disconnect pipe con- Disconnect the cooling water connec-

nections tions from the exhaust valve and the air
pipe for the air spring.
Remove the plate jacket and insulation

from the intermediate pipe.
Loosen the screws which attach the inter-

mediate pipe to the exhaust valve hous-
ing.
2265-0201-0013D03
Support the intermediate pipe by e.g. a
chain block and remove the screws.
Dismantling of hy- Remove the protective caps from the

draulic units exhaust valve studs. T76-1
Connect the highpressure pump to the
jacks by means of the distributor block
and highpressure hoses.
Bleed the hydraulic system and raise the

pressure as stated in Data.
Loosen and remove the hydraulic nuts,

see Data. See work card 7665-0101.
2265-0201-0013D04
Retaining bottom Connect 7 bar working air to the valve

piece air spring, thereby keeping the valve
closed when it is removed from the en-
gine.
The 7 bar working air must be connect-

ed during the entire lift of the exhaust
valve.
2265-0201-0013
Compressed
2013-03-19 - en
air
Work Card
2265-0201-0012D06
5 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Lift of exhaust valve Check all connections to the valve are

removed.
T22-28
Attach the crane to the eye bolt fitted
on top of the valve and start lifting the
exhaust valve. During the lift check the
valve goes clear of all other engine com-
ponents.
Land the exhaust valve on a wooden

plate on the platform.
Disconnect the 7 bar working air hose.
Carefully clean the exhaust valve bore

in the cylinder cover and recondition
the seating and sealing surfaces of the
bore, if required.
For overhaul of the exhaust valve, see

overhaul.
2265-0201-0013D05
2265-0201-0013
2013-03-19 - en
Work Card
6 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Oil cylinder Place the exhaust valve on a wooden
Exhaust Valve • Overhaul

support on the platform.
Remove the nuts and the safety strap T22-30

from the oil cylinder.
Lift away and place the oil cylinder on a

wooden support.
2265-0201-0013O01
Conical locking ring Relieve the air pressure through the

nonreturn valve from below the piston.
Use a small screwdriver to press the
ball into the nonreturn valve. Cover the
nonreturn valve with a rag to catch the
oil drops.
Unscrew the non-return valve from the

air cylinder.
Remove the four screws from the flange

on top of the air piston and dismount
the flange.
2265-0201-0013O02
2265-0201-0013
2013-03-19 - en
Work Card
7 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Air piston Loosen the air piston from the conical

locking ring by means of a tin hammer,

and remove the conical locking ring. T22-34
Mount two eyebolts in the top of the air
piston. Remove the air piston from the
air cylinder.
2265-0201-0013O04
Spindle Use the oil cylinder as a lifting tool for

the exhaust valve housing. Lift the oil T22-28
cylinder with the crane, and guide it
down over the studs for the oil cylinder.
Mount four nuts so that the load from
the valve housing is evenly distributed.
Lift the valve housing clear of the valve

spindle. Take care – when the internal
Oring in the air piston and the internal
rings for the sealing arrangement at
the bottom of the air cylinder pass the
groove for the conical ring at the top of
the spindle.
2265-0201-0013O03
Bottom piece Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm. T22-33
If the bottom piece has become stuck,

use a tin hammer to release it.
Lift the valve housing away and land it

on a couple of wooden planks.
Remove the oil cylinder.

2265-0201-0013
2013-03-19 - en
Work Card
2265-0201-0013O29
8 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Guide bushing Clean the exhaust valve housing. T22-22

Inspect the bushing in the spindle guide
for wear and measure the top and bot-
tom diameters. See Data.
T22-23
2265-0201-0003O06
Bushing renewal If it proves necessary to replace the

bushing, remove the screws, place the
valve housing on one side.
Knock out the bushing with a hammer

and a suitable mandrel.
Return the housing to an upright posi-

tion. 2265-0201-0013O07
When a new bushing is mounted, mount a new Oring for sealing between bush-
ing and exhaust valve housing. Mount and tighten the screws for the bushing.
Bottom piece inspec- Before cleaning the bottom piece, See

tion Description 2245-0200.
Inspect and evaluate the seating ac-

cording to Description
2265-0201-0013
2013-03-19 - en
Work Card
2265-0201-0003O08
9 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Bottom piece Meas- In connection with evaluation of the

uring bottom piece according to description

2245-0200, wear or the total amount the
seat has been ground, is measured as
described below.
G3
Use the bottom piece template and a
feeler gauge, take measurements G2
and G3. All measurements should be T22-16
taken at four diametrically opposite
points on the circumference of the bot-
tom piece seating.
For maximum wear or grinding, see T22-13

Data.
If the seat or the recess G3 is ground,

see Data for correct grinding angle.
IF the template rests on the lower sur-

face in the groove, i.e. G2 = 0, THEN G2
Further grinding or reconditioning is not
recommended.
T22-15
2265-0201-0003O09
Bottom piece sealing If necessary grind the outside seating.

face
Use carborundum 200 and the special
grinding tool. Turn the special grinding
tool by hand, turning alternately clock-
wise and anticlockwise. Grind until a
smooth surface is achieved.
Clean the bottom piece.

2265-0201-0013
2013-03-19 - en
2265-0201-0003O10
Work Card
10 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Bottom piece seal- Mount new sealing rings on the bottom

ing rings piece.
Mount one Oring in the upper groove.
Make sure that the groove for the Useal

is clean.
Heat the Useal in 100°C hot water for

minimum five minutes and then mount it
in the groove immediately.
2265-0201-0003O11
Bottom piece Use the oil cylinder as a lifting tool for

mounting the exhaust valve housing.
Check the face on the valve housing is

clean.
If fitted, check that the guide pin in the

bottom piece enters the hole in the bot-
tom of the exhaust valve housing.
Land the exhaust valve housing on the

bottom piece. Mount and tighten the re-
taining screws for the bottom piece.
2265-0201-0013O12
2265-0201-0013
2013-03-19 - en
Work Card
11 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Spindle inspection Before cleaning the spindle, See De-

scription 2245-0200.
Inspect and evaluate the spindle ac-

cording to Description 2245-0200.
2265-0201-0003O13
Spindle burn-off and In connection with evaluation of the

grinding check spindle according to description 2245- G1
0200, burnoff and wear or the total
amount the seat has been ground, are
measured as described below.
The burnoff should be measured per-

pendicaular to the curved spindle sur- T22-18
face.
F-1 T22-14
For the maximum allowable burnoff, see
Data.
The maximum seat grinding, gap G1 A D E

is measured between the spindle tem- T22-17
2265-0201-0001O14
plate, and the seating of the spindle with
a feeler gauge.
For maximum seat grinding, see data.
If necessary to grind the seat, see Data for correct grinding angle.
2265-0201-0013
2013-03-19 - en
Work Card
12 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Spindle stem check In connection with evaluation of the

spindle according to description 2245-
T22-19
0200, the spindle stem wear is meas-
ured as described below.
T22-20 T22-21
Check the spindle stem for wear in the
area noted in data measured from the
top of the spindle.
For minimum stem diameter, see Data.
If the exhaust valve spindle needs re-

conditioning, contact MAN Diesel &
Turbo for advice.
2265-0201-0003O15
Spindle transport When lifting or handling the exhaust

valve spindle, use the special valve
spindle lifting tools.
When turning the exhaust valve upside

down, mount the small lifting tool in the
top of the spindle. Lift the spindle with
the engine room crane and land it on T22-32
one side on a wooden support (e.g. a
piece of plywood).
Mount the large lifting tool designed for

the bottom of the spindle. Lift up the 2265-0201-0005O17
valve spindle as shown in the sketch.
Spindle bushing Check the top of the spindle bushing

sealing-rings and the face on the housing is clean.
Mount new oring on the spindle bushing

as shown in the sketch.
2265-0201-0013
2013-03-19 - en
Work Card
2265-0201-0013O17
13 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Spindle mounting Lubricate the inside of the bushing in

the spindle guide with plenty of lubricat-

ing oil.
Use the oil cylinder as a lifting tool for

the exhaust valve housing.
Carefully land the exhaust valve housing

with the bottom piece on the exhaust
valve spindle.
Remove the oil cylinder.
2265-0201-0013O18
Air cylinder Clean the air cylinder.
Dismount the safety valve from the air

cylinder, use the machined faces to un-
screw the valve.
Unscrew the plug for the bore to the

spindle stem bushing. Blow through all
bores in the air cylinder. Clean the bot-
tom of the air cylinder for possible coke
Compressed Air
deposits. Remount the plug. Mount a
new Oring in the groove on the outside
of the air cylinder.
2265-0201-0013
2013-03-19 - en
2265-0201-0003O19
Work Card
14 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Safety valve Place the safety valve in the pressure

testing device. Connect the testing de-
vice with the high pressure pump by
means of a hose.
Check the opening pressure, see Data.

T22-6
If the opening pressure is not correct,

loosen the lock nut and, using a screw-
driver, adjust the safety valve until the
correct pressure is indicated. Tighten
the lock nut and test the opening pres-
sure once more.
Mount a new gasket and a new Oring

on the safety valve. Mount the safety
valve in the bore near the bottom of the
air cylinder. When mounting the safety
valve in the air cylinder, use only the ma-
chined faces on the valve housing and T22-9
2265-0201-0003O20
tighten, see Data.
Finally, mount the protective cap.
NOTE Take care not to damage the Orings on the outside of the spindle bushing.
Air piston seals Check the teflon guide ring and tefl on
sealing ring for wear, if it is necessary to
replace the sealing rings on the air pis-
ton, cut them and remove them.
Be careful not to damage the edges of

the ring grooves in the piston.
Before mounting, heat the new teflon

NOTE rings in 100°C hot water for at least
2265-0201-0006O28
five minutes. When mounting the teflon
rings, be careful not to damage the run-
ning surfaces.
2265-0201-0013
2013-03-19 - en
Mount new Orings in the inside grooves of the air piston.

Work Card
15 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Air piston mounting Oil level

Clean oil
Fill the bottom of the air cylinder up to

NOTE the drain hole with clean lubricating oil.
Lower the air piston down over the valve

spindle.
Mount the non return valve for com-

pressed air
2265-0201-0013O23
Locking ring Mount the two part conical locking ring

and apply compressed air below the air
piston to lift the piston.
Mount the flange on top of the air piston

and, by means of the four screws, tight-
en the air piston and the flange together.
On valve models where the bolts are

designed for securing, secure the bolts.
Compressed Air
2265-0201-0013O24
2265-0201-0013
2013-03-19 - en
Work Card
16 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Oil cylinder Loosen the screws and remove the lift-

ing bracket from the oil cylinder to gain
access to the orifice plug.
Remove and discard the gasket. Un-

screw and clean the orifice plug. Re-
move and discard the sealing disc.
Check and clean the bore for the orifice
plug in the top of the oil cylinder.
Place the oil cylinder in a horizontal po-

sition. Remove the flange and take out
the piston. Inspect the inside of the liner
in the oil cylinder for scoring. Measure T22-24
the cylinder diameter. If the diameter of
the oil cylinder exceeds Data T22-24,
either renew the liner or send the com-
plete oil cylinder to an authorised MAN
Diesel & Turbo workshop for overhaul,
depending on the valve model.
2265-0201-0003O25
Oil piston Remove the piston rings from the oil

piston and check them for wear. If the Top
thickness of the rings has worn down
to the minimum, see Data, discard the
rings and mount new ones. Check that
the TOP mark on the piston rings faces
upwards, when mounting
Check the mesh once more.

T22-25
2265-0201-0003O26
2265-0201-0013
2013-03-19 - en
Work Card
17 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Oil cylinder assembly Mount the piston and the flange in the
oil cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright po-

sition. Mount a new sealing disc in the
bore for the orifice plug. Screw the ori-
fice plug into the bore. Place a new gas-
ket on top of the oil cylinder. Mount the
lifting bracket on the oil cylinder. Mount
the screws and tighten to the torque
stated in Data. T22-7
2265-0201-0003O27
Oil cylinder mounting Mount the overhauled oil cylinder on

top of the air cylinder. Mount the safety
strap and tighten the nuts. See Data.
T22-8
2265-0201-0013O28
2265-0201-0013
2013-03-19 - en
Work Card
18 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Checks before Before mounting an overhauled exhaust
Exhaust Valve • Mounting

mounting valve in the engine, it is recommended
that the valve is checked and prepared
as follows:
Check the oil level in the bottom of the

air cylinder. Unscrew and remove the
non-return valve and the safety valve.
Fill oil into the non-return valve hole until T22-28

oil fl ws out from the safety valve hole.
Refit the two valves again. G3
Connect compressed air to the air cyl-

inder to close the valve. Lift up the valve
with the engine room crane.
2265-0201-0013M01
Check that a 1.0 mm feeler gauge can
be inserted about 15 mm into gap G3,
to ensure that there is a clearance be-
tween the outer parts of the seating
faces of valve housing and spindle.
The valve must be able to stay closed for a minimum of 15 minutes or according
to the dropdown test in work card 2265-0201.
If the air cylinder is mounted with new sealing rings, the time the valve is closed
NOTE may be considerably shorter than 15 minutes. The dropdown test should not
be carried out until after a »running-in« period of 500 hours on valves with new
sealing rings.
Before mounting, heat the new teflon rings in 100˚C hot water for at least five
minutes.
Exhaust valve landing Close the valve with compressed air.
Lubricate the sealing rings with vaseline

and the threads of the studs with an-
tiseizure paste. Compressed Air
Position the valve in the cylinder cover

bore, guiding it in accordance with the
exhaust flanges and the guide pin on
the exhaust side of the exhaust valve.
2265-0201-0013
2013-03-19 - en
Copper Grease
Vaseline
Work Card
2265-0201-0013M02
19 (21)
HYUNDAI
2265-0201-0013 MANB&W
MAN B&W
Mounting of hydraulic Mount and tighten the hy-

nuts draulic nuts, see Data. T76-2

Mount the protective caps on the ex-

haust valve studs.
2265-0201-0013M03
Mount the pipe con- Connect the intermediate pipe to the

nections exhaust valve.
Mount and tighten the screws to the ex-

haust valve housing.
Mount the insulation and plate jacket for

the intermediate pipe.
Mount the cooling water connections for

the exhaust valve and the air pipe for the
air spring.
2265-0201-0013M04
Mount the oil connec- Mount the high-pressure pipe

tions for the hydraulic valve actuation.
Mount the return oil pipe to the exhaust-

valve.
Check that all pipe connections are

properly tightened.
2265-0201-0013
2013-03-19 - en
Work Card
2265-0201-0013M05
20 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0201-0013
Open cooling water Check that all water connections are

supply mounted and tightened.
Open the cooling water inlet supply, and

vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust

valve.
Check the tightness of the sealing ring

between the bottom piece and the ex-
haust valve housing. See checking.
2265-0201-0013M06
Air spring check The air supply to the exhaust valve must
always be connected and pressurized
before turning on the oil supply to the
exhaust valve actuator.
If the lubricating oil pumps have been

started before the exhaust valve pneu-
matic springs are pressurize:
Engage the indicators on top of the ex-

haust valves and wait until the exhaust
valves are closed. Closed Valve Open Valve
Closing of the exhaust valves are eased 2265-0201-0003M07
if the lubrication oil pumps are stopped

and the actuators are drained at the
drain screws.
2265-0201-0013
2013-03-19 - en
Work Card
21 (21)
HYUNDAI
MAN B&W
MAN B&W 2265-0300-0018

Precautions
Cylinder Cover, Data

see 0545-0100
O Shut off fuel oil
Data
T22-40 Starting valve stud, screwing-in torque 145 Nm
T22-41 Fuel valve stud, screwing-in torque 145 Nm
T22-44 Cylinder cover stud, check distance 142±2 mm
T22-45 Exhaust valve stud, check distance 624.5 ± 1.5 mm
T22-46 Cylinder cover, complete 1700 kg
T22-47 Cylinder cover without valves 1000 kg
T22-48 Cooling jacket 70 kg
T22-49 Exhaust valve stud 10 kg
T22-50 Cylinder cover stud 40 kg
2013-03-01 - en
2265-0300-0018
Work Card
1 (2)
HYUNDAI
2265-0300-0018 MAN B&W
MAN B&W
Cylinder Cover, Data
Tools
2270-0300 046 Grinding tool for exhaust valve seat
2270-0300 058 Milling and grinding wheel for fuel valve
2270-0300 060 Milling and grinding wheel for starting valve
2270-0300 201 Handle for sundry types
2270-0315 - Cylinder cover hydraulic tools
2270-0350 - Cylinder cover lifting tools
2013-03-01 - en
2265-0300-0018
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Shut off Oil and Water Supply
Cylinder Cover • Dismantling

Check engine block- Check that the engine is stopped and blocked according to the safety precau-
ing tions given on the data sheet.
Shut off the oil supply Close the fuel oil supply for the unit
concerned.
Mount a pressure gauge in »min-

imess« point No. 455. Check the
pressure.
Close valve 420 and open valve 421

on the hydraulic block.
Check that the hydraulic cylinder unit

is pressure free.
4265-0501-0011D01
Shut off the water Shut off the water outlet on the main
supply pipe above the exhaust valve.
Shut off the water supply placed on

the exhaust side of the engine.
Open the drain next to the inlet valve.
Open the venting cock next to the

outlet valve.
2265-0301-0013D03
2265-0301-0013
2013-03-06 - en
Work Card
1 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Dismantling of Pipe
Connections
Disconnect the oil Remove the hydraulic high pressure

pipes pipe for the exhaust valve.
Unscrew the drain pipe for the ex-

haust valve.
Remove the fuel oil high pressure

pipes.
Disconnect the pipes for return fuel

oil from the fuel valves.
2265-0301-0013D04
Disconnect the water Unscrew and remove the water out-

pipes let pipes.
2265-0301-0013D05
2265-0301-0013
2013-03-06 - en
Work Card
2 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Disconnect the gas Remove the protective jacket en-

compensator closing the insulation for the in-
termediate pipe or compensator.
Remove the insulation.
Remove the screws from the flang-

es between the intermediate pipe
and the exhaust receiver.
2265-0301-0013D06
Disconnect the Unscrew and remove the control air

starting air pipe pipe for the starting air valve.
Unscrew and remove the air pipe for

the starting valve.
Disconnect the air supply for the ex-
haust valve.
2265-0301-0013D07
2265-0301-0013
2013-03-06 - en
Work Card
3 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Cylinder cover loosen- Remove the protective caps from the

ing cylinder cover nuts.
Loosen and remove the cylinder cover T76-1

nuts, see Data.
For use of hydraulic tools, see

2265-0301-0013D08
2265-0301-0013
2013-03-06 - en
Work Card
4 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Cylinder cover lift-

ing and landing
Cylinder cover lifting Hook on the engine room crane to

the lifting attachment on top of the
exhaust valve.
Check that all cylinder cover con- T22-46

nections have been loosened and
removed.
Lift away the cylinder cover com-

plete.
2265-0301-0013D09
Cylinder cover landing If the cylinder is equipped with a

protective shield the shield must be
removed before landing the cylinder
cover.
T22-46
To remove the shield:
• loosen the four screws

• lift up the shield approx.
100 mm
• turn the shield approx. 30
degrees relative to the cylin
der cover.
• lower the shield away from
the cylinder cover.
2265-0301-0013
2265-0301-0013D10
• land the cylinder cover on a
2013-03-06 - en
couple of wooden planks

Work Card
5 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Cleaning / Inspec-
tion of combustion
chamber
Tilting tool mounting Lift the cylinder cover with the engine
room crane.
Mount the tilting tool in the two holes

for the cylinder cover studs close to
the ‘neighbouring’ cylinder cover,
opposite to the starting valve.
2265-0301-0013D11
Lifting tools Mount the lifting tools in the two

cylinder cover stud holes on the
opposite side of the exhaust valve
housing, as shown.
2265-0301-0013
2013-03-06 - en
2265-0301-0013D12
Work Card
6 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
“Fore” end
For correct placement The tilting tool and the lifting tools

must be placed as shown on the Lifting tools
sketch.
Manouvering Exhaust
side side
Tilting tool
“Aft” end
2265-0301-0006D13
Cylinder cover landing Land the cylinder cover on a couple

of wooden planks on the upper plat-
form.
2265-0301-0013D14
2265-0301-0013
2013-03-06 - en
Work Card
7 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Cylinder cover lifting Hook on to the lifting tool with a

strap or a set of lifting chains, and T2246

lift the cylinder cover with the engine
room crane to an angle of approx. 45
degrees.
2265-0301-0006D15
Cylinder cover tilting For correct placement, the tilting tool

and the lifting tools must be placed
as shown on the sketch.
2265-0301-0006D16
Returning to vertical When turning the cylinder cover to

position vertical position, hook on the lifting T2246
tool with a strap or a set of lifting
chains and lift the cylinder cover with
the engine room crane to an angle of
approx. 45 degrees.
2265-0301-0013
2013-03-06 - en
Work Card
226503010006D17
8 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Landing in vertical Apply pressure (by hand) to the cyl-

position inder cover while lowering the engine
room crane and follow the movement
of the cylinder cover with the crane
until the cylinder cover is in a vertical
position.
2265-0301-0013D18
Remove sealing ring Remove and discard the sealing ring

between the cylinder cover and the
cylinder liner.
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0014D13
9 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Overhaul Prepara-
Cylinder Cover • Overhaul
tions
Dismantle valves Dismantle all valves and pipes from T22-49

and pipes the cylinder cover.
See work cards 3465-0201, 2265-

0201 and 4265-0201.
Remove all studs on top of the cylin-

der cover.
2265-0301-0001O01
Cooling Water
Jacket
Remove the cool- Mount four eyebolts and the lifting

ing water jacket chains as shown in the sketch. T22-47
Remove the screws which secure
the cooling jacket to the cylinder
cover.
Lift the cylinder cover free of the

cooling jacket and land it on a cou-
ple of planks.
Remove and discard the Orings

from the cover, and carefully clean
the cooling jacket and the cylinder
cover.
T22-48
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0004O02
10 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Mount the cooling Provide the cylinder cover with new

water jacket Orings, well lubricated with vase-
line.
Lift the cylinder cover and guide the

jacket/cover into position, so the
marking scratches on the cover and
the cooling jacket are in line (ma-
noeuvre side).
Mount and tighten the screws for

the cooling jacket.
Reconditioning of
Bores 2265-0301-0004O03
Seat reconditioning The tools for reconditioning of the

tools valve seats are found on plate 2270-
0300.
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0004O04
11 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Fuel valve bore The tool consists of a common spin-

dle with a handle, a guide, a carbon

cutter, a seating face cutter and a
grinding mandrel.
Clean the fuel valve bores using the

carbon cutter. If required, recondi-
tion the fuel valve seating with the
appropriate cutter.
Grind the seating with the grinding

mandrel and a grinding compound
(e.g. Carborundum No. 200).
After the milling/grinding, clean

the bore and seating carefully, and
check that the seating is not dam-
aged.
1 2 3
2265-0301-0004O05
Exhaust valve bore The tool consists of a spindle with a

handle and a grinding disc.
After cleaning the valve bore and

seating, grind the seating with the
grinding disc and a grinding com-
2265-0301-0013
pound (e.g. Carborundum No. 200).

2013-03-06 - en
After the grinding, clean the bore

Work Card
and seating carefully, and check that

the seating is not damaged.
2265-0301-0001O06
12 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Starting valve bore The tool consists of a guide, a cutter,

and a grinding disc.
Recondition the starting valve bore and

seating in the same way as described
for the fuel valve bore.
When replacing the valves on a cylinder

cover while it is mounted on the engine,
recondition the valve bores/seating as
described here, however, without re-
moving the studs.
1 2
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0001O07
13 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Indicator  safety Clean the bores for safety valve/indi-

valve bore cator cock.
2265-0301-0001O08
Preparations before
Mounting
Mounting of studs Lubricate the threads with ‘Never

Seize’ or molybdenum disulphide
(MoS2) and fit the valve studs. T22-49
Fill up the grooves between the

valve studs and the bores for the
valve studs with permatex to prevent T22-45
water or oil from entering the bores
during operation of the engine.
2265-0301-0008O09
Mounting of valves Mount the valves on the cylinder cover, see work cards 3465-0201, 2265-0201
and 4265-0201.
2265-0301-0013
2013-03-06 - en
Work Card
14 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Landing Preparation
Cylinder Cover • Mounting

Sealing ring Check that the liner sealing surface
is clean.
Place a new sealing ring on top of

the cylinder liner.
If necessary mount a new ‘klinger’

sealing ring in the groove of the
flange of the intermediate pipe.
2265-0301-0014M06
Protective Shield If the cylinder liner is equipped with

a protective shield, this must be
mounted on the cylinder cover be-
fore the cylinder cover is mounted
on the cylinder liner.
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0013M02
NOTE Do not lubricate the sealing ring for the cylinder liner with any kind of lubricant.
15 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Cylinder Cover
Mounting
Cylinder cover landing Carefully wipe the cylinder cover

contact surface facing the cylinder
liner.
Check the spacer O-ring condition, if T22-46

necessary mount a new O-ring.
Lift the cylinder cover by means of

the crane and lower it carefully into
position. During the landing, care-
fully check that the cooling water
connecting pipes engage correctly
with the holes in the cooling jacket.
2265-0301-0013M03
Cylinder cover stud - If the cylinder cover studs have been

check distance removed and reinstalled, check the
distance the stud is protruding from
the cylinder cover.
T22-44
If necessary, adjust to the distance
T22-44 by turning the stud.
2265-0301-0013
2013-03-06 - en
Work Card
2265-0301-0001M04
16 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Cylinder cover tight- Mount and tighten the cylinder cover

ening nuts.
For operation of hydraulic jacks, see T76-2

Mount the protective caps on the cyl-

inder cover studs.
2265-0301-0013M05
Fitting Pipe Connec-

tions
Mount the exhaust Mount the screws in the flanges be-

gas compensator tween the intermediate pipe and the
exhaust receiver and tighten the
screws.
Lubricate the screws with

NOTE »Never Seize« or molybdenum di-
sulphide (MoS2) before mounting.
2265-0301-0013M06
Mount the insulating jacket around the intermediate pipe.

2265-0301-0013
2013-03-06 - en
Work Card
17 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Connect the starting Connect and tighten the air pipe for
air pipe the starting valve.
Connect and tighten the control air

pipe for the starting air valve.
Connect the air supply for the ex-

haust valve.
2265-0301-0013M07
Connect the water Mount and tighten the water outlet

pipes pipes.
2265-0301-0013M08
2265-0301-0013
2013-03-06 - en
Work Card
18 (20)
HYUNDAI
MAN Diesel
MAN B&W 2265-0301-0013
Connect the oil pipes Mount the hydraulic high pressure

pipe for the exhaust valve.
Connect the drain pipe for the ex-

haust valve.
Connect the fuel oil high pressure

pipes.
Connect the pipes for return fuel oil

from the fuel valves.
Check that all the pipe connections

are fitted and tightened. 2265-0301-0013M09
Open Oil and Water

Supply
Close the drain and Close the venting cock next to the
open the water supply outlet valve.
Close the drain next to the inlet

valve.
Slowly open the water supply valve,

placed on the exhaust side of the
engine.
Vent the unit by releasing air 2265-0301-0013M10

through the venting cock next to
the outlet valve.
When the venting is finished, close

the venting cock. Open the water
2265-0301-0013
outlet valve on the main pipe.

2013-03-06 - en
Work Card
19 (20)
HYUNDAI
2265-0301-0013 MAN
MANDiesel
B&W
Open the oil supply Open the fuel oil supply for the unit
concerned.
4265-0501-0011M06
2265-0301-0013
2013-03-06 - en
Work Card
20 (20)
HYUNDAI
MAN B&W
MAN B&W 2265-0400-0013

Precautions
Piston, Data
see 0545-0100
O Shut off fuel oil
Data
T22-44 Cylinder cover stud, check distance 142±2 mm
T22-53 Test pressure 7 bar
T22-54 Piston rod/crosshead, tightening torque 600 Nm
T22-55 Piston rod/crown, tightening torque 500 Nm
T22-57 Piston skirt, tightening torque 80 Nm
T22-58 Cooling oil pipe, tightening torque 70 Nm
T22-59 Lifting tool, tightening torque 110 Nm
Piston rod/crosshead, tightening torque +
T22-61 100+35 Nm+°
angle
T22-62 Piston ring new, radial width 17.2 mm
T22-63 Piston ring worn, min. radial width 14.2 mm
T22-64 Groove No.1, max. vertical height 13.2 mm
T22-65 Groove Nos. 2, 3 and 4, max. vertical height 10.2 mm
T22-66 Piston top, max. permissible burn-away 15 mm
T22-67 Piston ring new, height of ring No. 1 12.4 mm
Piston rings new, height of ring Nos. 2, 3 and
T22-68 9.4 mm
4
CPR ring CL groove, min. depth / POP ring,
T22-69 1.1 / 9.0 mm
max. width of leakage groove
T22-70 Minimum free ring gap ( before dismantling ) 25 mm
2013-03-01 - en
2265-0400-0013
Minimum ring gap, ring No. 1 ( new ring in

T22-71 3.4 mm
new liner )
Work Card
Minimum ring gap, ring Nos. 2, 3 and 4 ( new

T22-72 2.4 mm
ring in new liner )
T22-73 Vertical clearance, new parts 0.38 mm
T22-74 Vertical clearance, worn parts, max. 0.87 mm
1 (3)
HYUNDAI
2265-0400-0013 MAN B&W
MAN B&W

Piston, Data
T22-78 Piston complete 1000 kg

T22-79 Piston crown 270 kg
T22-80 Piston rod 650 kg
T22-81 Piston skirt 55 kg
T22-82 Piston cooling pipe 20 kg
2013-03-01 - en
2265-0400-0013
Work Card
2 (3)
HYUNDAI
MAN B&W
MAN B&W 2265-0400-0013
Piston, Data
Tools
1470-0300 124 Rubber cover for croshead
2270-0400 040 Lifting for piston rod foot
2270-0400 075 Template for piston top
2270-0400 099 Cover for stuffing box hole
2270-0400 110 Pressure test tool for piston
2270-0400 134 Piston ring expander
2270-0400 158 Guide screw for piston crown
2270-0430 - Piston guide tool
2270-0470 - Piston support tool
2270-0480 - Piston lifting tool
2013-03-01 - en
2265-0400-0013
Work Card
3 (3)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Scavenge Port Inspection
Piston • Checking
To detect possible leakages from the piston or cylinder cover, keep the cooling
water and cooling oil circulating during the scavenge port inspection.
Inspection - how to The scavenge port inspection is car-

ried out from the scavenge air receiver.
Before entering the receiver, open the
access cover and secure it in open po-
sition. An additional view of the rings is
possible through the cleaning cover on
the manoeuvring side.
Turn the engine at least ½ a revolution,

and begin with a unit arriving down-
wards, just above the scavenge air
ports. Inspect the piston rod and the
lower part of the cylinder wall.
While the piston is passing downwards,

inspect the piston skirt, all the piston
rings, the ring lands and the piston top.
2265-0401-0004C01
2265-0401-0008
2012-04-19 - en
Work Card
1 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Ring inspection Inspect the rings, one at a time, and note

Piston • Checking
down the results.

See Description 2245-0100.
2265-0401-0001C02
Ring tension Check the tension of the piston rings, by

pressing against them with a wooden
stick.
2265-0401-0001C03
Ring grooves Measure the total clearance between the

piston ring and the ring groove. The total
clearance must not exceed the value
stated in Data.
Measure the clearance at the bottom (E) T22-73

and top (F) of the piston ring groove.
Max. 2mm
Total clearance = E + F.
2265-0401-0008
F
2012-04-19 - en
T22-74
Work Card
2265-0401-0008C04
2 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
For engines with CPR- To measure the wear of the ring, the
Piston • Checking
POP ring (Port-On- width of the leakage passage can be
Plan) installed: measured using a feeler-gauge-type
measuring tool.
The opening is 3 mm from the beginning,

and the milled passage is designed in
such a way that for every 1 mm the ring
is worn radially, the gab opens 2 mm. For
maximum allowable widt of the leakage
gab see data T22-69.
T22-69
2265-0401-0008C045
T22-69
For engines with CPR- If possible, measure the depth of the
CL ring installed: pressure relief grooves with a slide calli-
per. The piston rings must be replaced if
the radial depth of the grooves has worn
down to less than stated in Data T22-69.
2265-0401-0008C05
Checking, in connection with piston overhaul
Piston support Remove the piston from the cylinder and

place it on the piston support. See de-
It is recommended to replace all the pis-

NOTE ton rings whenever a piston is removed
from the engine.
2265-0401-0008
2012-04-19 - en
Work Card
2265-0401-0004C06
3 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Free ring gap Before dismantling the piston rings,

Piston • Checking
measure the free ring gap of all the pis-

ton rings. T22-70
2265-0401-0001C07
Radial ring width Measure the radial width of the rings.

Note down the results. See description
2245-0100.
T22-62
New
T22-63 Worn
2265-0401-0001C08
2265-0401-0008
2012-04-19 - en
Work Card
4 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Ring grooves Clean the ring grooves and check them T22-64
Piston • Checking
for burn marks or other deformation. T22-65
Measure the ring grooves with a calliper
gauge, see Data T22-64 and T22-65.
Clearance in piston ring grooves:
The maximum vertical height in a worn

ring groove must not exceed the value
stated in Data. The groove is also worn Max 2mm
out if there is no chromium layer.
If the ring grooves are worn out, the

piston crown must be reconditioned,
contact MAN Diesel for advice.
2265-0401-0001C09
Piston crown top Clean the piston crown and check the T22-66
burnaway by means of the template.
For maximum permissible burn-away

value, see Data.
Check the burnaway on the whole cir-

cumference of the piston crown top.
If the burnaway exceeds the values

given in Data, contact MAN Diesel for
advice.
2265-0401-0004C10
Note down the results for later refer-
ence.
2265-0401-0008
2012-04-19 - en
Work Card
5 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Preparations in the crankcase

Piston • Dismantling
Access Open the crankcase door to the cylinder

concerned.
Turn the crosshead down far enough to

give access to the piston rod stuffing box
and the piston rod/crosshead connec-
tion.
2265-0401-0003D01
Stuffing box Release the stuffing box by removing the

innermost screws from the stuffing box
flange.
On engine models where the drain pipe is

connected directly to the stuffing box:
Disconnect the stuffing box drain pipe.
2265-0401-0001D02
2265-0401-0008
2012-04-19 - en
Work Card
NOTE Do NOT remove the outermost screws from the flange.
6 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Loosen the piston Remove the screws from the piston
rodcrosshead con- rod.
nection
2265-0401-0001D03
Stuffing box distance Mount the two distance pieces on the

pieces piston rod foot to protect the lower
scraper ring and to guide the stuffing
box.
2265-0401-0001D04
2265-0401-0008
2012-04-19 - en
Work Card
7 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Preparations on the cylinder top

Cylinder cover Remove the cylinder cover. See Workcard

2265-0301.
Make a scratch mark in liner and pis-

ton cleaning ring to ensure correct
remounting. Remove the piston cleaning
ring.
Carefully remove any wear ridges at the

top of the cylinder liner.
2265-0401-0007D05
Piston lifting tool Turn the piston to TDC. The top of the T22-59
piston is now free of the cylinder liner.
Clean the lifting groove of the piston

crown and mount the lifting tool.
Make sure to mount the lifting tool cor-

NOTE rectly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.
2265-0401-0001D06
If the engine not is equipped with long

distance pieces, remove one or two cylinder cover studs, using a stud setter.
2265-0401-0008
2012-04-19 - en
Work Card
8 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Piston lift Lift the piston out of the cylinder liner and guide the piston rod foot through the
stuffing box flange.
If the engine is equipped with long dis-

tance pieces for the stuffing box, the
piston rod foot can pass between two
cylinder cover studs.
Place the two halves of the support

around one of the openings in the plat-
form. Lower the piston rod foot and
stuffing box through the opening in the
platform. Secure the two support halves
with screws and lower the piston on the
support. Check the piston is resting on
the piston rod flange.
Limited Lifting height:
If the piston rod foot can not be lifted T22-78

clear of the liner top with the standard
lifting tool, contact MAN Diesel for in-
structions for tilted lift.
2265-0401-0001D07
2265-0401-0008
2012-04-19 - en
Work Card
9 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Protect the crosshead Place a cover over the opening for the
bearing piston rod stuffing box in the bottom of

the cylinder unit.
Turn the crosshead down far enough to

permit mounting of the protective rubber
cover on the crosshead bearing cap. The
protective rubber cover is found on tool
panel 904.
The covers must remain in place to pro-

tect the crosshead bearing journal from
impurities until the piston is remounted.
Clean, measure and recondition the cyl-

inder liner.
2265-0401-0001D08
2265-0401-0008
2012-04-19 - en
Work Card
10 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Piston support Place the piston in the support and re- T22-78
Piston • Overhaul
move the piston lifting tool.
Clean the piston top and the piston rings.
Check the free ring gap and the burnoff

on the piston top.
Remove the stuffing box. See Workcard

2265-0501.
2265-0401-0001O01
Piston ring Take off the piston rings by means of the

dismantling ring expanders. If the engine is equipped
with two ring expanders, the short ring
expander is for the uppermost ring.
First remove the uppermost ring, then

ring no. two, three and four.
Clean and inspect the rings and the ring

grooves. See Checking.
2265-0401-0001O02
Piston crown Remove the locking wire and the inner-

dismantling most screws between the rod and the T22-79
piston crown. T22-81
Lift the piston crown and skirt clear of the
piston rod.
2265-0401-0008
2012-04-19 - en
Work Card
2265-0401-0001O03
11 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Piston rod and cooling Remove the screws from the cooling oil
Piston • Overhaul
pipe pipe flange.
Mount the eye bolts and lift out the cool-

ing oil pipe.
Clean and inspect the cooling oil pipe T22-58 T22-82

and the piston rod, then remount the T22-80
cooling oil pipe, see Data.
Check that the surfaces of the Oring

groove is clean and smooth.
Mount a new Oring on the piston rod

flange.
2265-0401-0001O04
Piston crown turning Unhook the crane from the piston lifting
tool, and connect the lifting tool and the
crane hook by means of a wire rope. Lift
up the piston crown.
Fit two eyebolts in the piston skirt and a

wire rope between the bolts as shown in
the sketch.
Install a tackle in a suitable place with

sufficient space below for the piston
crown. Attach the tackle to the wire rope
on the piston crown and carefully turn
the piston crown upside down. Use both
cranes if the engine room is equipped
with two cranes.
2265-0401-0001O05
2265-0401-0008
Land the piston lifting tool and the piston

2012-04-19 - en
crown on a sufficient support of wood

pieces. Loosen the piston lifting tool and lift the piston crown clear of the tool.
Work Card
12 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Piston crown Place the piston crown with skirt on a T22-81
Piston • Overhaul
dismantling and wooden support as shown.
cleaning
Remove the locking wire and the screws
in the skirt. If necessary use two disman-
tling screws to pull the skirt out of the
piston crown. Mount two eye bolts in the
skirt. Lift the skirt and land it on a couple
of planks.
Discard the sealing ring on the piston

skirt.
2265-0401-0001O06
Thoroughly clean and inspect all parts of the crown and skirt. If coke deposits
are found in the cooling spaces of the piston crown, they should be washed
clean with Carbon Remover or a similar cleaning fluid. When all coke deposits
have been dissolved, clean and inspect the piston crown again.
NOTE Coke deposits reduce heat transfer from the piston crown to the cooling oil.
The deposits must be removed as a routine procedure when a piston is over-
hauled.
Piston crown Mount a new Oring on the piston skirt.

T22-57
assembly Check that the surfaces of the Oring
groove are clean and smooth. Coat the
ring with lubricating oil before mounting.
Mount the piston skirt on the piston

crown.
Tighten the screws to specified torque,

see data T22-57. Lock the screws with
locking wire, see Workcard 7665-0501.
2265-0401-0008
2012-04-19 - en
2265-0401-0001O07
Work Card
13 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Piston crown and skirt Mount the guide screw to ensure the cor-
Piston • Overhaul
mounting rect positioning of the piston rod in rela-

tion to the piston crown.
Lubricate the Oring on the piston rod

flange with lubricating oil.
Land the overhauled piston crown and

skirt on the piston rod.
Remove the guide screw.
Mount and tighten the screws between

the piston rod and the piston crown,
see Data.
T22-55
2265-0401-0001O08
2265-0401-0008
2012-04-19 - en
Work Card
14 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Sealing ring and pressure test
Piston • Overhaul
According to current class rules, the piston must be pressure tested hydrauli-
cally. It is possible to carry out a test of the sealing rings with compressed air
before filling the piston with oil. The sealing ring test can also be carried out
when the piston is resting in the support tool.
Sealing ring test Mount the pressuretesting tool on the

piston rod foot. Connect compressed
air to the testing tool and fill the piston
to 45 bar. Close the valve on the testing
tool and remove the air connection. The
piston must now hold the pressure for
minimum 30 minutes.
Spray a little soap water on to the sur-

face joints between piston rod/crown/
skirt and around the bolt heads to detect
leaks.
Dry off all soap water.
2265-0401-0001O09
T22-53
Pressure test For this test, the piston must be turned
upside down (see next step to turn a com-
plete piston).
Fill the piston and piston rod with lubri-

cating oil. Mount the pressuretesting
tool on the piston rod foot. Pressuretest
the piston at the pressure stated on the
Data Sheet. Check the contact surfaces oil
of the piston and the sealing rings for
tightness. Check that there are no cracks
in the piston crown.
Turn the piston upside up and drain out

2265-0401-0008
the piston oil.

2012-04-19 - en
Work Card
2265-0401-0001O10
15 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Piston turning Lift the piston with the normal lifting

Piston • Overhaul
tool. Lower the piston rod foot until it is

close to the platform. Land the foot on a
wooden block.
Lower the piston crown to the platform

and land it on a wooden block in such a
way that it is possible to remove the lift-
ing tool.
Attach the lifting bracket to the bottom

of the piston rod foot. Hook the crane
on to the lifting bracket. Lift the piston
rod foot clear of the wooden block. Keep
lifting until the piston rod is in a vertical
position.
During the lift, follow with the crane to

NOTE keep the crane positioned vertically
above the lifting point. The stuffing box
must be removed.
2265-0401-0001O11
Piston completion Fit the new piston rings (alternately

righthand and lefthand cuts, with the A
ring gaps staggered 180° and with the
TOP mark upwards), using the ring ex- B
pander.
A C
When mounting the piston rings, use the
ring expanders to prevent unintended D
deformation of the rings.
B
Do not expand the rings more than nec-
essary. The uppermost ring (CPRring)
must be mounted with the short ring
expander, if the engine is equipped with
C
two ring expanders
Mount the piston rod stuffing box. D

2265-0401-0008
2012-04-19 - en

Work Card
2265-0401-0001O12
16 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Preparation of piston Check the piston rings and piston crown
Piston • Mounting
in accordance with the Checking Proce-
dure, if not already done.
Mount the lifting tool on the piston

crown. See Data T22-59.
2265-0401-0001M01
Stuffing box position Ensure that the stuffing box is correctly

positioned over the distance pieces
mounted on the piston rod foot. Both the
holes for the flange and the drain hole for
the drain pipe must be positioned cor-
rectly. 2265-0401-0008
2012-04-19 - en
Work Card
2265-0401-0001M02
17 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Preparation of cylinder liner

Piston • Mounting
Mount the guide ring Mount the guide ring in the top of the
cylinder liner. The cut outs for the lifting
tool must be turned to fit the piston lift-
ing tool.
2265-0401-0001M03
Stuffing box cover Remove the cover from the piston rod
stuffing box opening in the bottom of the
cylinder unit.
Clean the stuffing box flange.
2265-0401-0001M04
Crosshead position Turn the crosshead to a position 45°

from TDC (crank web pointing towards
exhaust side).
2265-0401-0008
2012-04-19 - en
45°
Work Card
2265-0401-0001M05
18 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Mounting of piston
Piston • Mounting
Coat the Orings of the stuffing box and
the piston rod with oil. Coat the piston
T22-78
rings and cylinder liner with cylinder lu-
bricating oil.
Lower the piston into the cylinder liner –

while guiding the piston rod foot through
the cutout in the stuffing box flange –
until the piston rings are inside the liner.
2265-0401-0001M06
Protective cover Remove the protective rubber cover from

the crosshead.
2265-0401-0001M07
Crosshead alignment Turn the crosshead almost to TDC, while

checking that the guide ring of the cross-
head enters the centre hole in the piston
rod.
After turning the crosshead fully to TDC,

and ensuring that the piston rod has full
contact with the crosshead, unscrew the
lifting tool and remove the lifting tool and
the guide ring for piston rings.
2265-0401-0008
2012-04-19 - en
Work Card
2265-0401-0001M08
19 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Stuffing box Turn down and land the stuffing box on

Piston • Mounting
the stuffing box flange. Check that the

holes in the stuffing box and stuffing box
flange are correctly centered.
Tighten the piston rod stuffing box by

means of the screws through the inner
holes in the stuffing box flange. For Data,
On engine models where the drain pipe

is connected directly to the stuffing box:
• Mount the stuffing box drain 2265-0401-0001M09

pipe.
Remove the distance pieces from the piston rod foot.
Tightening of the Mount and tighten the piston rod screws.

piston rod-crosshead Tighten the screws to the specified
connection torque and lock with locking wire.
See Data. Use either Data T22-54 or Data

T22-61.
2565-0201-0001M09
2265-0401-0008
2012-04-19 - en
Work Card
20 (22)
HYUNDAI
MAN Diesel
MAN B&W 2265-0401-0008
Piston cleaning ring Mount the piston cleaning ring in ac-
Piston • Mounting
cordance with the scratch mark. If the
PCring is damaged (broken or cracked),
it must be replaced by another ring.
2265-0401-0007M11
Cylinder cover studs If the cylinder cover studs have been

removed, remount them. Carefully clean
the surfaces around the base of the
studs and check the Orings on the
studs.
Mount the cylinder cover studs with the

stud setter. Screw the stud down to con-
tact and half a revolution back.
2265-0401-0001M12
2265-0401-0008
2012-04-19 - en
Work Card
21 (22)
HYUNDAI
2265-0401-0008 MAN
MANDiesel
B&W
Cylinder cover Land the cylinder cover on the T22-44

Piston • Mounting
liner and check the distance that

the stud is protruding from the
cylinder cover. If necessary, adjust
the distance T22-44 by turning the
stud.
Tighten the cylinder cover nuts

and mount the necessary pipes.
See Procedure 2265-03.
2265-0401-0001M13
Running-in Smear the piston rod with molybdenum disulphide, and turn the crankshaft a
couple of revolutions.
At the first opportunity, start the engine and keep it running for about 15 min-
utes at a speed corresponding to “Dead Slow” Ahead.
Then stop the engine and inspect the piston rod and stuffing box.
2265-0401-0008
2012-04-19 - en
Work Card
22 (22)
HYUNDAI
MAN B&W
MAN B&W 2265-0500-0008

Precautions
Piston Rod Stuffing Box, Data

see 0545-0100
O Shut off fuel oil
O Lock the turbocharger rotors
Data
Stuffing box flange, outer screws tightening
T22-86 80 Nm
torque
Stuffing box flange, inner screws tightening
T22-87 80 Nm
torque
T22-88 Stuffing box halves, tightening torque 80 Nm
Stuffing box halves fitted bolts, tightening tor-
T22-89 25 Nm
que
T22-91 Lowermost rings, ring-end clearance 3x3 mm
T22-92 Sealing ring springs new, free length 560 mm
T22-93 Scraper ring springs new, free length 480 mm
T22-102 Stuffing box complete 70 kg
T22-103 Stuffing box half 25 kg
2013-02-04 - en
2265-0500-0008
Work Card
1 (2)
HYUNDAI
2265-0500-0008 MAN B&W
MAN B&W
Piston Rod Stuffing Box, Data
Tools
1470-0300 112 Rubber cover for crosshead
2270-0400 109 Mounting tool for stuffing box spring
2270-0400 122 Worktable for stuffing box
2013-02-04 - en
2265-0500-0008
Work Card
2 (2)
HYUNDAI
MAN B&W 2265-0501-0010
Uppermost scraper Dismantle the piston rod stuffing box.
Piston Rod Stuffing Box • Checking

ring and sealing rings See Dismantling. 1
2
Check the end clearances of the
scraper rings. 3
4
5
Scraper ring no. 4 is standard type,
NOTE while scraper rings no. 1, 5, 6 and 7
6 T22-91
is Lap Joint type. The end clearances 7
for standard type and Lap Joint type
are the same.
The ring end clearance stated in Data

apply to new rings.
As a general guide, it is recommend-

ed depending on the overhauling T22-91
intervals and one’s own experience
– to replace sealing rings and scraper
rings when the specified clearance
value T22-91 have been halved. 2265-0501-0005C01
Check the springs Generally, it is recommended to T22-92

renew the springs when the seal-
ing rings and scraper rings are re-
newed.
The springs can be checked as fol-

lows:
Place the springs on the table,

T22-93
measure Lo (free length), and com-
pare with Data. If a spring is extend-
ed more than 8% from the value
given in data, it must be discarded.
226505010001C02
2265-0501-0010
2014-28-01
Work Card
1 (11)
HYUNDAI
2265-0501-0010 MAN B&W
Turn engine If, in the period between piston overhauls, it becomes necessary to inspect the
Piston Rod Stuffing Box • Dismantling
piston rod stuffing box, proceed as follows:
Turn the engine to about 90° from TDC.
Mount the rubber cover around the pis-

ton rod to protect the crosshead bearing
from impurities.
2265-0501-0007D01
Drain oil pipe Remove the drain oil pipe and all inner-
most screws and all outer screws except
for two screws placed diametrically op-
posite in the stuffing box flange, longitu-
dinally to the engine.
2265-0501-0009D02
Mount the worktable Mount the worktable around the piston

around the piston rod so that the two remaining screws in
the stuffing box flange can be loosened
through the holes.
2265-0501-0010
2014-28-01
Work Card
2265-0501-0009D03
2 (11)
HYUNDAI
MAN B&W 2265-0501-0010
Distance pipes Mount the two distance pieces for the
Piston Rod Stuffing Box • Dismantling

stuffing box.
Remove the two long dismantling screws

from the worktable.
Mount them in the stuffing box through

the holes in the worktable.
Remove the remaining two screws from

the stuffing box flange.
2265-0501-0009D04
Turn the piston to Turn the piston to BDC, thereby with-

BDC drawing the stuffing box from the cylinder
frame bottom.
T22-102
Remove the distance Remove the two long dismantling screws
secrews from the stuffing box and mount them in
the worktable.
By means of the four short screws in the

worktable, press the stuffing box out of
the flange and 30mm up.
2265-0501-0009D05
Steel bars Place two steel bars (40 x 40 mm ) be-

tween the stuffing box and the stuffing
box flange, one on each side of the piston
rod, see the sketch. Use the steel bars as
supports when the stuffing box is disas-
sembled. For overhauling the stuffing box,
see Overhaul.
2265-0501-0010
Work Card
2014-28-01
2265-0501-0009D07
3 (11)
HYUNDAI
2265-0501-0010 MAN B&W
Normally, overhaul of the piston rod stuffing box is carried out by routine meth-
Piston Rod Stuffing Box • Overhaul
ods in connection with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a support placed over one of the
cutouts in the top platform.
Work on the stuffing box is then carried out from the platform below.
If the stuffing box is overhouled inside the engine, it is also done as described
here, but the stuffing box halves are supported by the steelbars described in
Dismantling.
Remove the sheild Remove the screws holding the piston

rod shield in place and remove the two
halves.
2265-0501-0009O01
Mount work table Mount two eyebolts in the stuffing box

flange, and hook on two tackles.
Lift the stuffing box a little up the piston

rod, and mount the worktable round the
piston rod at a suitable working height.
Land the stuffing box on the worktable, T22102

and remove the tackles and eyebolts.
2265-0501-0010
2014-28-01
Work Card
2265-0501-0007O01
4 (11)
HYUNDAI
MAN B&W 2265-0501-0010
O-rings Remove the Oring of the stuffing box.

If the Oring is intact and is to be used
again, move it up the piston rod and se-
cure it in this position, for example with
tape.
Remove the nuts from the stuffing box

assembling bolts.
2265-0501-0007O02
Remove stuffing box Take out the six bolts, and pull away one
stuffing box half.
Mount two eyebolts on the stuffing box

half and remove it from the worktable.
Remove the remaining stuffing box half

and press all sealing rings and scraper
rings down against the worktable.
2265-0501-0007O03
It is important for the proper operational performance of the stuffing box that it
is not covered in sludge. A dirty stuffing box indicates that the scavenge air box
NOTE is not cleaned regularly and sufficiently.
This could damage the stuffing box and the piston rod, and pollute the system
oil.
Check the rings Measure the clearance between the segments of the scraper rings to determine
whether replacement is necessary. See Checking.
Dismantle and stack the rings in the same order as when fitted in the stuffing
box.
Check the springs Carefully clean all the ring segments.

T22-92
Inspect and assess the surface quality of
the sealing rings. If their sliding surfaces
have scratches or marks, replace the
2265-0501-0010
rings.
Check the lengths of the springs. See T22-93

Work Card
2014-28-01
Checking.
2265-0501-0007O07
5 (11)
HYUNDAI
2265-0501-0010 MAN B&W
Inspect piston rod Inspect the surface of the piston rod.

If small longitudinal scratches have oc-

curred (caused by poorly adapted stuff-
ing box rings), smooth the piston rod
surface carefully with a fine grained car-
borundum stone.
In the case of coarse scratches, it may

prove necessary to machinegrind the
surface in a workshop.
Lubricate the piston rod (in the area

Lubricate piston rod where all the ring units in the stuffing box
will be positioned) with molybdenum di- 2265-0501-0007O08
sulphide (MoS2).
Check lamellas Check the position of the lamellas in the

scraper rings.
In both standard scraper rings and in lap

joint scraper rings the lamellas must be
mounted so that the ends of the lamel-
las are flush with the ends of the scraper
rings.
For details see the sketch.
The lamellas may NOT overlap the gap

NOTE between the scraper rings.
2265-0501-0010
2014-28-01
Work Card
2265-0501-0009O09
6 (11)
HYUNDAI
MAN B&W 2265-0501-0010
Mounting of rings For correct mounting of the sealing and A

scraper rings see the sketch.
1 B
The scraper ring in groove no. 4 must be 2 C
standard type without relief grooves on 3
the underside. 4
The scraper ring in grooves no. 1, 5, 6 5
and 7 must be Lap Joint type with relief 6 Scraper
grooves on the underside. ring
7
Make sure that the guide pins in the
sealing rings in grooves no. 2 and 3 are
mounted correctly.
A
Scraper
ring
B
Sealing
ring
C
No relief
groove
Relief
groove
2265-0501-0007O10
2265-0501-0010
Work Card
2014-28-01
7 (11)
HYUNDAI
2265-0501-0010 MAN B&W
Stuffing box assembly Assemble all the stuffing box ring units
round the piston rod, on the worktable, in

the following way:
• Place the lowermost scraper ring

segments (Lap Joint type) on the
worktable.
• Place the spring round the segments,

and hook the spring ends together.
Repeat this procedure for the next two

Lap Joint type scraper rings and one
standard type scraper ring.
On top of the scraper rings, assemble the 2265-0501-0007O11

two sealing ring units (each consisting of
a 4part and an 8part ring).
Assemble the 8part sealing ring so that the two guide pins face upwards,
place the spring round the segments and, hook the spring ends together.
Assemble the 4part sealing ring above the 8part sealing ring. Push the two
rings together in such a manner that the guide pins in the lower sealing ring en-
gage with the two holes in the upper sealing ring.
Finally, assemble the uppermost scraper ring (Lap Joint type).
Adjust the rings With all rings mounted on the piston rod
adjust the position of the rings to obtain
an equal distance between them. Use
the stuffing box gauge tool to check the
spacing between the rings. This is done
by carefully inserting the teeth of the
gauge tool within the rings and then care-
fully moving the gauge along the springs.
2265-0501-0007O12
2265-0501-0010
2014-28-01
Work Card
8 (11)
HYUNDAI
MAN B&W 2265-0501-0010
Clean stuffing box Clean the halves of the stuffing box housing.

housing
Mount stuffing box Mount the first stuffing box half. Take
housing care not to pinch any of the rings.
Re-check and if necessary adjust the po-

sitions of the rings.
Place the other half of the stuffing box

housing on the worktable, and push it
into position round the rings.
In the middle holes mount and tighten up

the fitted bolts to the torque specified on
the Data Sheet, See Data T22-89.
Mount and tighten the standard bolts to

specified torque, See Data T22-88.
2265-0501-0009O13
Mount the Oring in the stuffing box
groove.
Remove work table Mount eyebolts and wire ropes, and lift
the stuffing box a little.
Remove the worktable and lower the

stuffing box until it rests against the dis-
tance pieces on the piston rod foot.
Remove wire ropes and screws.
2265-0501-0007O14
Mount piston rod T22-85

Re-mount the piston rod shield.
shield T22-84
2265-0501-0010
Work Card
2014-28-01
2265-0501-0009O02
9 (11)
HYUNDAI
2265-0501-0010 MAN B&W
Mounting the screws After overhauling, assemble the stuffing

Piston Rod Stuffing Box • Mounting
box halves on top of four screws.
Mount the two long screws from the

worktable in the stuffing box.
Turn down the short screws so that the

stuffing box lands on the flange.
2265-0501-0009M01
Turn the piston Turn the piston upwards until the stuffing
box is in place in the cylinder frame.
2265-0501-0009M02
Make sure that the two guide pins in the flange enter the guide holes in the bot-
NOTE tom of the cylinder frame.
Mount the screws Mount two screws in the flange through

the holes in the worktable.
2265-0501-0010
2265-0501-0009M03
2014-28-01
Work Card
10 (11)
HYUNDAI
MAN B&W 2265-0501-0010
Remove the worktable Remove the long screws from the stuffing
Piston Rod Stuffing Box • Mounting

box and mount them in the worktable.
Remove the worktable from the piston

rod.
2265-0501-0009M04
Mount all screws Mount and tighten all the inner and outer T22-86
screws for the stuffing box. See Data. T22-87
2265-0501-0009M05
Remove the protect- Remove the protecting rubber cover from

ing rubber the piston rod/crosshead.
Smear the piston rod with molybdenum

disulphide.
Then turn the crankshaft a couple of

revolutions.
If possible: Start up the engine and keep

it running for about fifteen minutes at a
number of revolutions corresponding to
2265-0501-0010
very slow or idle speed.

2014-28-01
Then stop the engine and inspect the pis-

Work Card
ton rod and stuffing box.

2265-0501-0007D01
11 (11)
HYUNDAI
MAN B&W
MAN B&W 2265-0600-0019

Precautions
Cylinder Liner, Data

see 0545-0100
O Shut off fuel oil
Data
T22-107 Cylinder diameter, new 500 mm
T22-108 Piston cleaning ring diameter, new 498.3 mm
T22-109 Piston cleaning ring radial width, new 9.85 mm
T22-111 Cylinder liner, complete 2400 kg
T22-112 Cooling jacket 150 kg
T22-115 PC-ring replacement criteria: - -
- Liner wear * : Install New PC-ring 0-1 mm
- Liner wear * : Install No PC-ring >1 mm
- * : At measuring point no. 5 - -
2013-03-01 - en
2265-0600-0019
Work Card
1 (2)
HYUNDAI
2265-0600-0019 MAN B&W
MAN B&W
Cylinder Liner, Data
Tools
2270-0610 - Measuring tool for cylinder liner
2270-0640 - Lifting tool for cylinder liner
2013-03-01 - en
2265-0600-0019
Work Card
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
Starting with the cylinder liner
Cylinder Liner • Checking

Dismount the cylinder cover, the piston cleaning ring and the piston.
See work card 2265-0301 and 2265-0401.
Clean the cylinder liner and scavenge air ports.
Setting measuring Position the cylinder liner measuring

tool tool.
Measure the cylinder liner with the spe-

cial measuring tool at the positions indi-
cated on the measuring tool. See Data.
T22-107
2265-0601-0001C02
2265-0601-0013
2013-05-07 - en
Work Card
1 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Measurements Take measurements in the fore-and-aft

Cylinder Liner • Checking
and athwartship directions.
Check and assess the condition of the

cylinder liner according to the descrip-
tion given in description 2245-0100. 2265-0601-0001C03
Carefully! Scratch over any scores or marks on the cylinder liner running surface, and re-
move the wear ridges. See overhaul part of this work card.
Lubrication points Check the lubricating points of the cylin-

der by pumping cylinder oil into the liner
via the MOP panel.
Clean any blocked lubricating duct.
2265-0601-0001C06
Piston cleaning (PC) The PC-ring is to be regarded as an integrated part of the liner and it is intend-
ring ed to follow the service life of the liner.
During inspection of the piston and the liner, the PC-ring must also be inspect-
ed.
When the piston is removed, then PC-ring must always be taken up before the
piston. See work card 2265-0401.
If the PC-ring is broken or cracked, replace the ring with a new PC-ring or
PC-ring according to T22-115 in the Data sheet.
2265-0601-0013
2013-05-07 - en
Work Card
2 (12)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
Dismantling the Dismantle the cylinder cover.
Cylinder Liner • Dismantling

cylinder cover See work card 2265-0301.
Discard the sealing ring from the top of

the cylinder liner.
Turn the piston down to enable removal

of wear ridges at the top of the liner.
Dismantle the piston cleaning ring and

the piston.
Fasten the lifting tools Mount the lifting tools in the cylinder
liner.
T22-106
2265-0601-0013D01
Tighten the lifting screws to the torque stated in the Data.

NOTE
Check with a 0.05 mm feeler guage that there is no clearance between the
screws and the cylinder liner.
This must be done whenever the lifting tools are mounted on the liner.
Disconnecting the oil Disconnect - at the exhaust side of the

pipes cylinder -the oil pipes leading from the
cylinder lubricator to the non-return
valves.
2265-0601-0013
2013-05-07 - en
Work Card
2265-0601-0013D02
3 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Cooling water inlet Remove the bolts of the cooling water Exhaust Side
inlet and outlet pipes.
2265-0601-0013D03
Removing the liner Attach the crane hook to the lifting

crossbar.
Hook the chains from the lifting tools on

to the crossbar and lift the cylinder liner
with the cooling jacket out of the cylin-
der frame.
T22-111
Low lifting height in the engine room
NOTE may require the removal of one or more
cylinder cover studs before dismantling
the cylinder liner.
Land the cylinder liner vertically on, for

instance, a couple of planks.
2265-0601-0013D04
2265-0601-0013
2013-05-07 - en
Back to the cylinder Clean the cylinder frame internally, taking special care with the contact surfaces
frame for the cylinder liner at the top of the cylinder frame.
Work Card
4 (12)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
Lifting tools The lifting tools are also used for trans-

porting the cylinder liner.
T22-111
2265-0601-0013D05
2265-0601-0013
2013-05-07 - en
Work Card
5 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Non-return valve Unscrew the nuts on the dummy and

Cylinder Liner • Overhaul
non-return valves and remove the

valves.
Clean and inspect the non-return valves.
2265-0601-0003O01
Preparations Attach two tackles to the crossbar as

shown.
Mount two lifting eyebolts in the cooling

jacket.
Hook the tackles on the lifting eyebolts

on the cooling jacket and haul tight.
Remove the two lifting screws from the

cylinder liner.
Remove the four clamps which fix the

cooling jacket to the cylinder liner.
2265-0601-0013O02
2265-0601-0013
2013-05-07 - en
Work Card
6 (12)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
Removing the Lower the cooling jacket by means of

cooling jacket the tackles, and land it on the wooden
planks.
2265-0601-0013O03
Moving the cylinder Mount the lifting tools on the cylinder

liner from the cooling liner, see data T22-105.
jacket
Lift the cylinder liner away from the
cooling jacket.
Clean the cooling jacket internally.
2265-0601-0013
2013-05-07 - en
Work Card
2265-0601-0013O04
7 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Checking inside the Check and assess the condition of the

liner body cylinder liner according to the descrip-

tion given in description 2245-0100. A B
Carefully scratch over any scores or

marks on the cylinder liner running sur-
face, by means of a rough grindstone C
held in the hand.
Check in the top of the liner for a wear

ridge (where the piston rings reverse
direction). If there is any sign of a wear
ridge, it is necessary to create a groove
by grinding.The groove serves to pre-
vent the build-up of a new wear ridge.
2265-0601-0013O05
Creating the groove It is recommended to use a wear ridge

milling machine to create the groove.
For use of the milling machine, see sup-

plier’s instruction.
2265-0601-0001O04
Alternate groove Alternatively, place an old piston

ring on the top of the piston and turn
to a position that enables the grinding
disc to rest on the old piston ring while
removing the wear ridge. Use a grinding S
disc with a round edge. D
R=4-5 mm
C
2265-0601-0013
Check the distance C before grinding

2013-05-07 - en
to ascertain that the wear ridge was

caused by the top ring at TDC.
Work Card
The maximum depth of the groove is

2265-0601-0013O06
calculated as Smax. = D x 0.0045.
8 (12)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
It is of the utmost importance that the groove is made with a regular rounding
NOTE

as shown in the sketch
O-rings Apply a thin layer of grease on the con-

tact surface for the cooling jacket on the
liner.
Mount the lifting tools on the liner. Lift

the liner a little and pull a new O-rings,
for the cooling jacket, up on the liner as
far as possible. Then place the liner in
the cooling jacket and remove the lifting
tools from the liner. Mount the O-rings
for the cooling jacket in the grooves of
the cylinder liner.
2265-0601-0013O07
Mounting the cooling Lift the cooling jacket into position.

jacket
2265-0601-0013
2013-05-07 - en
Work Card
2265-0601-0013O08
9 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Make sure that the scratch marks in the manoever side of the cylinder liner and
NOTE
cooling jacket coincide.
Fitting the liner Turn the clamps until it fit in the groove
of the liner, and tighten the screws.
Remove the tackles from the lifting

crossbar and the cooling jacket lifting
eyebolts.
2265-0601-0013O09
Mount the dummy and non-return valves for cylinder lubrication. Tighten nuts
and connect the lubricating oil pipes.
2265-0601-0013
2013-05-07 - en
Work Card
10 (12)
HYUNDAI
MAN Diesel
MAN B&W 2265-0601-0013
Returning the cylinder Mount the lifting screws in the cylinder
Cylinder Liner • Mounting

liner liner. See Data T22-105.
Hook the chains from the lifting cross-

bar on to the lifting screws, and lift the
jacket/liner assembly.
Mount the lowermost O-ring and apply

a little lubricating oil on the ring.
T22-111
2265-0601-0013M01
Before mounting Check that the joint surfaces on

the cylinder frame and cylinder liner are
completely clean.
Coat the joint surfaces with permatex or

a similar liquid sealing compound.
Mount the cylinder liner in the cylinder

frame.
T22-112
Mount the water connections on the
cooling jacket.
Remove the lifting tools.

2265-0601-0013
2013-05-07 - en
Work Card
2265-0601-0013M02
11 (12)
HYUNDAI
2265-0601-0013 MAN
MANDiesel
B&W
Studs If one or more cylinder cover studs have

Cylinder Liner • Mounting
been removed during the dismantling

of the cylinder cover, remount the studs
using the stud setter,
see work card 2265-0301.
Gasket Mount new gaskets between the cool-

ing water inlet and outlet pipes and the
cooling jacket. Mount and tighten the
bolts.
2265-0601-0013M04
Lubrication pipes Screw the pipes from the lubricator on
to the non-return valves, but do not
tighten.
Vent the cylinder lubricating system

by pumping all pipes through until oil,
without air bubbles, comes out from the
union pipe/ non-return valve.
When this is in order, tighten the pipes

firmly on the non-return valves and
again pump until it is certain that each
individual lubricating point functions
correctly.
2265-0601-0002M05
Before mounting the Lubricate the inside of the cylinder liner

piston with cylinder lubricating oil and mount
the piston and the piston cleaning ring.
Cylinder cover Mount the sealing ring and the cylinder

cover.
See work card 2265-0301

2265-0601-0013
NOTE Do not apply any kind of lubricant to the

2013-05-07 - en
sealing ring.
Work Card
2265-0601-0013M06
Tighten the upper water connections on
the cooling jacket as soon as the cylinder cover is correctly positioned.
12 (12)
MAN B&W
HYUNDAI
Plate Exhaust Valve Panel Tools

2270-0200-0019
1 (2)
2270- 0200- 0019
HYUNDAI
2270-0200-0019 MAN B&W

Exhaust Valve Panel Tools

029 - Name plate
042 - Tightning template for actuator
054 - Lifting tool
066 - Lifting tool for exhaust valve
080 - Test equipment for exhaust valve
091 - Gauge for exhaust valve spindle
125 - Tool for emergency opening of exhaust valve
150 - Gauge for exhaust valve bottom piece
162 - Lifting tool for exhaust valve
174 - Lifting tool for exhaust vlave roller guide
186 - Grinding ring for exhaust valve bottom piece
257 - Coupling
2270- 0200- 0019
Plate
2 (2)
HYUNDAI
MAN B&W 2270-0220-E002
Exhaust Valve Extra Tools

0802
2270-0220-E002
Plate
'RF,' ( 1 (2)

HYUNDAI
2270-0220-E002 MAN B&W
Item no
Item Qty Designation
0802 - Piston ring opener
Ex h a u s t V a l v e E x r ta T o o l s
2270-0220-E 002
2008-07-29
late
PPla
2 (2) Doc-ID: 2270-0220-E002

HYUNDAI
MAN
MAN Diesel
B&W 2270-0240-0001.0
Exhaust Valve Hydraulic Tools

2270-0240-0001.0
Plate
Doc-ID: 2270-0240-0001.0 1 (2)

HYUNDAI
2270-0240-0001.0 MAN
MANDiesel
B&W

Exhaust Valve Hydraulic Tools

039 - Ball handle
076 - Hex key
088 - Stud setter
2270-0240-0001.0
Plate
2 (2) Doc-ID: 2270-0240-0001.0

2010-08-23 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Cylinder Cover Panel Tools

2270-0300-0006
1 (2)
2270-0300-0006
HYUNDAI
2270-0300-0006 MAN B&W
MAN Diesel

Cylinder Cover Panel Tools

022 - Name plate
046 - Grinding tool for exhaust valve seat
058 - Milling and grinding wheel for fuel valve
060 - Milling and grinding wheel for starting valve
071 - Dismantling lever for fuel valve
095 - Grinding ring for starting valve
105 - Pin wrench for starting valve
130 - Lifting chains for cylinder cover
201 - Handle for sundry types
2270-0300-0006
2010-08-23 - en
Plate
2 (2)
2010-09-06 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Cylinder Cover Hydraulic Tools Spares

2270-0315-0003
1 (2)
2270-0315-0003
HYUNDAI
2270-0315-0003 MAN B&W
MAN Diesel

Cylinder Cover Hydraulic Tools Spares

048 - Ball handle
085 - Hex key
107 - Stud setter
2270-0315-0003
2010-09-06 - en
Plate
2 (2)
2009-04-01
MAN
MAN B&W
HYUNDAI
Diesel
Plate Cylinder Cover Lifting Tools

2270-0350-0002
1 (2)
2270-0350-0002
HYUNDAI
2270-0350-0002 MAN
MANDiesel
B&W

Cylinder Cover Lifting Tools
013 - Lifting tool for cylinder cover

025 - Lifting tool for cylinder cover
2270-0350-0002
2009-04-01
Plate
2 (2)
2013-03-04 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Piston Panel Tools

2270-0400-0028
1 (2)
2270-0400-0028
HYUNDAI
2270-0400-0028 MANB&W
MAN B&W

Piston Panel Tools
014 - Panel for tools ms902

026 - Name plate
040 - Lifting tool for piston rod foot
051 - Lifting tool for cylinder liner
075 - Template, piston top
087 - Distance piece
099 - Cover for stuffing box hole
109 - Mounting tool for stuffing box spring
110 - Pressure test tool for piston
122 - Worktable-stuffing box
134 - Piston ring expander
158 - Guide screw for piston crown
160 - Screw
171 - Pushing tool, seals
205 - Gauge for stuffing box
217 - Measuring tools for ring groove
2270-0400-0028
2013-03-04 - en
Plate
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 2270-0430-0001.0
Piston Guide Tool

018
2270-0430-0001.0
Plate
Doc-ID: 2270-0430-0001.0 1 (2)

HYUNDAI
2270-0430-0001.0 MANDiesel
MAN B&W

Piston Guide Tool
018 - Guide ring for piston

2270-0430-0001.0
Plate
2 (2) Doc-ID: 2270-0430-0001.0

2010-08-29 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Piston Support Tools

2270-0470-0005
1 (2)
2270-0470-0005
HYUNDAI
2270-0470-0005 MAN B&W
MAN Diesel

Piston Support Tools
016 - Support iron for piston

2270-0470-0005
2010-08-29 - en
Plate
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 2270-0480-0001.0
Piston Lifting Tools

010
2270-0480-0001.0
Plate
Doc-ID: 2270-0480-0001.0 1 (2)

HYUNDAI
2270-0480-0001.0 MANDiesel
MAN B&W

Piston Lifting Tools
010 - Lifting tool for piston

2270-0480-0001.0
Plate
2 (2) Doc-ID: 2270-0480-0001.0

HYUNDAI
MAN B&W
MAN Diesel 2270-0610-0001.0
Cylinder Liner Tools

016
2270-0610-0001.0
Plate
Doc-ID: 2270-0610-0001.0 1 (2)

HYUNDAI
2270-0610-0001.0 MANDiesel
MAN B&W

Cylinder Liner Tools
016 - Measuring tool for cylinder liner

2270-0610-0001.0
Plate
2 (2) Doc-ID: 2270-0610-0001.0

HYUNDAI
MAN Diesel
MAN B&W 2270-0640-0002
Cylinder Liner Lifting Tools

2270-0640-0002
2008-07-10
Plate
Doc-ID: 2270-0640-0002 1 (2)

HYUNDAI
2270-0640-0002 MAN
MANDiesel
B&W

Cylinder Liner Lifting Tools
010 - Cross bar for cylinder liner

2270-0640-0002
2008-07-10
Plate
2 (2) Doc-ID: 2270-0640-0002

2012-10-09 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Exhaust Valve, Upper Part

2272-0200-0012
1 (2)
2272-0200-0012
HYUNDAI
2272-0200-0012 MANB&W
MAN B&W

Exhaust Valve, Upper Part
010 - Eye bolt

022 - Screw
034 - Plate
046 - Packing
071 - Orifice plug
083 - Disc
095 - Nut
105 - Safety handrail
129 - Oil cylinder
130 - Stud coupling
142 - Piston actuator, complete
166 - Sealing ring
178 - Piston ring
191 - Piston actuator
201 - Slide
213 - Piston
225 - Spring
237 - Disc
249 - Packing ring
250 - Disc
274 - Screw
298 - Packing
321 - Screw
345 - Flange
357 - Cone
370 - Sliding bearing
382 - Sealing ring
394 - Piston
404 - Sealing ring
2272-0200-0012
2012-10-09 - en
Plate
2 (2)
2012-10-09 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Exhaust Valve, Lower Part

2272-0210-0009
1 (2)
2272-0210-0009
HYUNDAI
2272-0210-0009 MANB&W
MAN B&W

Exhaust Valve, Lower Part
015 - Sealing ring

027 - Screw
039 - Valve housing
040 - Packing
052 - Safety valve
076 - Packing
088 - Cover
111 - Screw
135 - Screw
147 - Cooling water connection
159 - Packing
172 - Screw
184 - Spring pin
196 - Bottom piece
206 - Exhaust valve spindle
231 - O-ring
243 - Sealing ring
267 - Sealing ring
279 - Sealing ring
280 - Screw
292 - Spindle guide
302 - Exhaust valve housing
351 - Thread insert
375 - Non-return valve
387 - Packing ring
399 - Plug screw
2272-0210-0009
2012-10-09 - en
Plate
2 (2)
2009-04-18
MAN
MAN B&W
HYUNDAI
Diesel
Plate Exhaust Valve, Detail

2272-0220-0003
1 (2)
2272-0220-0003
HYUNDAI
2272-0220-0003 MAN
MANDiesel
B&W

Exhaust Valve, Detail
021 - Point screw

033 - Dowel pin
045 - Rod for lift and rotation check
057 - Spring pin
069 - Union nut
070 - Steel pipe
082 - O-ring
094 - Reducing adapter
104 - Spring
116 - Disc
128 - Rod for lift and rotation check, complete
2272-0220-0003
2009-04-18
Plate
2 (2)
2013-02-28 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Exhaust Valve, Upper Part Detail

2272-0230-0009
1 (2)
2272-0230-0009
HYUNDAI
2272-0230-0009 MANB&W
MAN B&W

Exhaust Valve, Upper Part Detail
014 - Drain pipe-exhaust valve

038 - Stud coupling
051 - Stud coupling
109 - Coupling
134 - Main pipe-lubricating oil
2272-0230-0009
2013-02-28 - en
Plate
2 (2)
2009-04-06
MAN
MAN B&W
HYUNDAI
Diesel
Plate Exhaust Valve Pipe

2272-0240-0003
1 (2)
2272-0240-0003
HYUNDAI
2272-0240-0003 MAN
MANDiesel
B&W

Exhaust Valve Pipe
019 - Hydraulic pipe

020 - Retaining ring
032 - O-ring
044 - Retaining ring
056 - Sleeve divided
068 - Sealing ring
081 - Intermediate piece
093 - Sealing ring
103 - Screw
115 - Thrust flange
2272-0240-0003
2009-04-06
Plate
2 (2)
2013-02-21 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Cylinder Cover

2272-0300-0017
1 (2)
2272-0300-0017
HYUNDAI
2272-0300-0017 MANB&W
MAN B&W

Cylinder Cover
014 - Nut
026 - Stud
051 - Cylinder cover
075 - O-ring
099 - Cooling jacket
110 - Nut
122 - Spring housing complete
134 - Stud, fuel valve
158 - Screw
171 - Protective cap
195 - Stud, exhaust valve
217 - Sealing ring
229 - Cooling water connection
230 - Screw
254 - Packing
278 - Screw
2272-0300-0017
2013-02-21 - en
Plate
2 (2)
2010-04-16 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Cylinder Cover Protective Shield

2272-0320-0003
1 (2)
2272-0320-0003
HYUNDAI
2272-0320-0003 MAN B&W
MAN Diesel

Cylinder Cover Protective Shield
025 - Shield
037 - Sound insulation-pvc
050 - Screw
062 - Cam lock washer, stainless*
074 - Nut
086 - Shield
108 - Nut
121 - Screw
2272-0320-0003
2010-04-16 - en

Plate
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 2272-0400-0001.0
Piston
018
126
031
043
055 151
163
067 175
079
080
092
055
102
2272-0400-0001.0
Plate
Doc-ID: 2272-0400-0001.0 1 (2)

HYUNDAI
2272-0400-0001.0 MANDiesel
MAN B&W

Piston
018 - Piston crown

031 - Piston skirt
043 - Flange screw
055 - Locking wire
067 - Screw
079 - Piston rod
080 - D-ring
092 - Screw
102 - Screw
126 - D-ring
151 - Screw
175 - Cooling pipe insert
2272-0400-0001.0

Plate
2 (2) Doc-ID: 2272-0400-0001.0

2012-05-03 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Piston Rings

2272-0420-0002
1 (2)
2272-0420-0002
HYUNDAI
2272-0420-0002 MANB&W
MAN B&W

Piston Rings
017 - Piston ring

029 - Piston ring
030 - Piston ring
042 - Piston ring
2272-0420-0002
2012-05-03 - en
Plate
2 (2)
2011-12-19 - en
MAN B&W
HYUNDAI
Plate Piston Rod Stuffing Box

2272-0500-0010E
2272- 0500- 0010E
1 (2)
HYUNDAI
2272-0500-0010E MAN B&W

Piston Rod Stuffing Box
011 - Stuffing box housing

023 - Fitted bolt
035 - Screw
047 - O-ring
059 - Scraper ring, complete
060 - Sealing ring, complete
096 - Base ring, scraper ring
106 - Lamella
131 - Segment, sealing ring
155 - Segment-sealing ring
179 - Spring pin
192 - Lamella
214 - Flange
226 - Screw
238 - Locking wire
251 - Screw
263 Guide pin
275 Nut
2272- 0500- 0010E
2011-12-19 - en
Plate
2 (2)
HYUNDAI
MAN
MANDiesel
B&W 2272-0600-0010
Cylinder Liner
015
027
206
218
040
064
088
123
135
147
2272-0600-0010
160
2013-03-01 - en
184
Plate
147
1 (4)
HYUNDAI
2272-0600-0010 MAN B&W
MAN Diesel

Cylinder Liner
015 - Piston cleaning ring

027 - Gasket
040 - Cylinder liner
064 - O-ring
088 - O-ring
123 - Packing
135 - Flange
147 - Screw
184 - Clamp
206 - Packing ring
218 - Plug screw
231 - Non-return valve dummy
243 - Studs
255 - Nut
279 - Non-return valv assy
292 - Stud coupling
314 - Distributor block
326 - Screw
338 - Screw
351 - Banjo coupling
2272-0600-0010
2013-03-01 - en
Note:* The Cylinder Liner can not be purchased alone.

Plate
2 (4)
HYUNDAI
MAN
MANDiesel
B&W 2272-0600-0010
Cylinder Liner
231
243
255
A-A
314
326
292 338
243
255
279
351
2272-0600-0010
2013-03-01 - en
Plate
3 (4)
HYUNDAI
2272-0600-0010 MAN B&W
MAN Diesel

Cylinder Liner
015 - Piston cleaning ring

027 - Gasket
040 - Cylinder liner
064 - O-ring
088 - O-ring
123 - Packing
135 - Flange
147 - Screw
184 - Clamp
206 - Packing ring
218 - Plug screw
231 - Non-return valve dummy
243 - Studs
255 - Nut
279 - Non-return valv assy
292 - Stud coupling
314 - Distributor block
326 - Screw
338 - Screw
2272-0600-0010
2013-03-01 - en
Note:* The Cylinder Liner can not be purchased alone.

Plate
4 (4)
HYUNDAI
MAN B&W
Preface Chapter Bearings ............................... .................................. 2540-0100-0001
B ea r i n g s
Description Bearings ............................... ................................... 2540-0100-0003
Alignment of Main Bearings ................. ..................... 2540-0110-0002
Drawing Main Bearing, Thin Shell Design .............. ............... 2555-0105-0002

Crosshead Bearing ....................... .......................... 2555-0110-0003
Crankpin Bearing ...................................................... 2555-0115-0002
Main Bearing Assemblies ................... ..................... 2555-0120-0002
Guide Shoes and Strips .................... ....................... 2555-0125-0004
Thrust Bearing Assembly ................... ..................... 2555-0130-0002
Camshaft Bearing Assemblies ............... ................. 2555-0135-0001.0
Bearing Wear Monitor ..................... ........................ 2555-0136-0002
Propeller Shaft Earthing Device .............. ............... 2555-0137-0002
Inspection of Bearings - Recording Observations .... 2555-0140-0003
Acceptance Criteria for Tin-Aluminium Bearings 2555-0150-0003
with overlayer ............................ ...............................
Report: Crankshaft Deflections - (Autolog) ............... 2555-0175-0003
Cranksh Deflection, Limits .................. ..................... 2555-0180-0004
Check Measurements ..................... ........................ 2555-0185-0002
Work Card Camshaft Bearing, Data .................... ...................... 2565-0100-0003
Camshaft Bearing ........................ ........................... 2565-0101-0002
Crosshead Bearing, Data ................... ...................... 2565-0200-0008
Crosshead Bearing ....................... .......................... 2565-0201-0012
Crankpin Bearing, Data .................... ....................... 2565-0300-0004
Crankpin Bearing ......................... ............................ 2565-0301-0004
Main Bearing, Data ....................... .......................... 2565-0400-0004
Main Bearing, Data ....................... .......................... 2565-0401-0006
Journal Bearing, Data ...................... ....................... 2565-0500-0004
Journal Bearing .......................... ............................. 2565-0501-0005
Thrust Bearing, Data ...................... ......................... 2565-0600-0001
Thrust Bearing ........................... .............................. 2565-0601-0001.0
Tool Plate Bearing Panel Tools ....................... ......................... 2570-0010-0015

Main Bearing Hydraulic Tools ................ ................. 2570-0400-0022
Main Bearing Measuring Tools ............... ................. 2570-0430-0005
Plate Camshaft Bearing ........................ ........................... 2570-0110-0022.0

Crosshead Bearing ....................... ........................... 2570-0200-0001.0
Connecting Rod Bearing ................... ...................... 2570-0300-0002
Main Bearing ............................ ............................... 2570-0400-0004
Thrust Bearing, Segments .................. .................... 2570-0600-0001.0

Thrust Bearing, Miscellaneous ................ ................. 2570-0650-0022
1 (1)
HYUNDAI
MAN B&W 2540-0100-0001
01. Camshaft Bearings
Bearings
The camshaft is carried in bearing assemblies which are fitted in the roller
guide housings. See also Description 2545-0100.
02. Crosshead Bearing
The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
04. Main Bearing
The main bearings consist of steel shells, lined with bearing metal.
06. Thrust Bearing
The thrust bearing serves the purpose of transmitting the axial thrust of the
propeller through propeller shaft and intermediate shafts to the ship’s hull.
The crankshaft is provided with a thrust collar which transmits the thrust to
a number of segments mounted in a thrust shoe on either side of the thrust col-
lar.
The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal cast
onto the wearing faces against the thrust collar. See also Description 2545-0100.
The thrust bearing is lubricated by the pressure lubrication system of the en-
gine. The oil is supplied between the segments through spray pipes and spray
nozzles.
The thrust bearing is provided with alarm, slowdown, and shutdown devices for
low lube oil pressure and high segment temperature. See also Description 7045-
0100.
Stationary engines and geared marine plants:

The crankshaft is provided with a collar for the guide bearing. The purpose
of the guide bearing is to keep the crankshaft in its proper position in the axial
direction. 2540-0100-0001
2008-06-17 - en
Plate
Doc. ID: 2540-0100-0001 1 (1)

HYUNDAI
MAN B&W 2545-0100-0003
1. General Bearing Requirements and Criteria for Evaluation
Bearings
Bearings are vital engine components; therefore, bearing design and choice of
bearing metal is crucial for reliable engine performance.
Bearing design criteria depend on the bearing type and, in general, on:
a. Bearing load
• Static
• Dynamic
b. Bearing load direction
c. Journal orbit movement
d. Revolutions
e. Cooling
f. Expected lifetime
g. Overhaul aspects
h. Space aspects
The compactness of engines and the engine ratings (gas pressure, engine speed
and stroke/bore) influence the magnitude of the specific load on the bearing and
make the correct choice of bearing metals, construction, production quality and,
in certain bearings, the application of overlayer necessary. (See Item 3., ‘Overlay-
ers’).
2. Bearing Metals
2.1 Tin based White Metal
Tin-based white metal is an alloy with minimum 88% tin (Sn), the rest of the alloy
composition is antimony (Sb), copper (Cu), cadmium (Cd) and small amounts of
other elements that are added to improve the fineness of the grain structure and
homogeneity during the solidification process. This is important for the load car-
rying and sliding properties of the alloy. Lead (Pb) content in this alloy composition
is an impurity, as the fatigue strength deteriorates with increasing lead content, which
should not exceed 0.2 % of the cast alloy composition.
2.2 Tin Aluminium (AlSn40)

Tin aluminium is a composition of aluminium (Al) and tin (Sn) where the tin is
trapped in a 3-dimensional mesh of aluminium. AlSn40 is a composition with 40%
tin. The sliding properties of this composition are very similar to those of tin based
white metal but the dynamic loading capacity of this material is higher than tin
2545-0100-0003
based white metals at similar working temperature; this is due to the ideal combi-
2008-10-17
nation of tin and aluminium, where tin provides the good embedability and sliding
Description
properties, while the aluminium mesh functions as an effective load absorber.
Doc-ID: 2545-0100-0003 1 (18)

HYUNDAI
2545-0100-0003 MAN B&W
3. Overlayers, coatings and running-in layers

Bearings
An overlayer is a thin galvanic coating of mainly lead (Pb) and tin (Sn), which is
applied directly on to the white metal or, via a thin galvanically applied intermedi-
ate layer of either Ag or Ni, on to the tin aluminium sliding surface of the bearing.
The overlayer is a soft and ductile coating, its main objective is to ensure good
embedability and conformity between the bearing sliding surface and the pin
surface geometry. Overlayer is mainly used in Cross Head Bearing design
4. Flashlayer, Tin (Sn)

A flash layer is a 100% tin (Sn) layer which is applied galvanically; the thickness
of this layer is only a few µm. The coating of tin flash is applied all over and
functions primarily to prevent corrosion (oxidation) of the bearing. The tin flash
also functions as a dry lubricant when new bearings are installed and when the
crankshaft is turned.
5. Bearing Design
(See Drawings 2555-0100/0105/0110/0120)
Plain bearings for MC-C/ME/ME-C/ME-B engines are manufactured as steel

shells with a sliding surface of white metal or tin aluminium with or without over-
layer/flash layer. Tin aluminium bearings are always of the thin shell design while
the white metal bearings can either be of the thick shell or thin shell design.
The bearing surface is furnished with a centrally placed oil supply groove and
other design features such as smooth run-outs, oil wedges and/or bore reliefs.
5.1 Smooth Runout of Oil Groove

(See Drawings 2555-0100/0105/0120, Fig. B-B)
A smooth runout is the transition geometry between the circumferential oil supply
groove and the bearing sliding surface. This special oil groove transition geo-
metry prevents an oil scraping effect and enhances the hydro-dynamic build-up
of the load carrying oil film towards the loaded area of the bearing (Main bearing
Drawings 2555-0100 and 2555-0105 and crankpin bearing Drawing 2555-0120).
5.2 Bore Relief

(See Drawings 2555-0100/0105/0120, Fig. A-A)
The bearing sliding surface is machined near the mating faces of the upper and
lower shells to create bore reliefs. Their main objective is to compensate for
misalignments which could result in a protruding edge (step) of the lower shell’s
2545-0100-0003
mating face to that of the upper shell. Such a protruding edge can act as an oil
scraper and cause oil starvation. (Main bearing Drawing 2555-0100 and 2555-0105
2008-10-17
and crankpin bearing Drawing 2555-0120).

Description
2 (18) Doc-ID:2545-0100-0003
HYUNDAI
MAN B&W 2545-0100-0003
5.3 Axial Oil Grooves and Oil Wedges
Bearings
(See Drawings 2555-0110 and 2555-0125, Fig. A-A)
Oil grooves and wedges have the following functions:
1. To enhance the oil distribution over the load carrying surfaces.

(The tapered areas give improved oil inlet conditions).
2. Especially in the case of crosshead bearings (Drawing 2555-0110) – to as-

sist the formation of a hydrodynamic oil film between the load carrying
surfaces.
3. To provide oil cooling (oil grooves).
In order to perform these functions, the oil must flow freely from the lubricating
grooves, past the oil wedges, and into the supporting areas – where the oil film
carries the load.
5.4 Thick Shell Bearings

(See Drawing 2555-0100)
This type of bearing has a steel back with the required stiffness
1. To ensure against distortion of the sliding surface geometry, and
2. To support the cast-on white metal in regions where the shell lacks sup-
port, for example in the area of the upper shell mating faces.
The top clearance in this bearing design is adjusted with shims, while the side
clearance is a predetermined result of the summation of the housing bore, shell
wall thickness, journal tolerances, and the influence of the staybolt and bearing
stud tensioning force which deforms the bedplate around the bearing assem-
bly.
Thick shell bearings are typically 30-60 mm thick and used for main bearings
only.
5.5 Thin Shell Bearings

Thin shell bearings have a wall thickness between 2% and 2.5% of the journal
diameter. The steel back does not have the sufficient stiffness to support the cas-
ton bearing metal alone. The bearing must therefore be supported rigidly over its
full length. This type of bearing is manufactured with a circumferential overlength
(crush/nip) which, when the shells are mounted and tightened up, will produce the
required radial pressure between the shell and the bearing housing.
The top and side clearance in this bearing is predetermined and results from a
2545-0100-0003
summation of the housing bore, shell wall thickness, journal/pin diameter toler-
2008-10-17
ances and, for main bearings, the deformation of the bedplate from the staybolt
Description
and bearing stud tensioning force.
Doc-ID: 2545-0100-0003 3 (18)

HYUNDAI
2545-0100-0003 MAN B&W
5.6 Top Clearance

Bearings
Correct top clearance in main bearings, crankpin bearings, and crosshead bear-
ings is a balance between sustaining the required oil flow through the bearing,
hence stabilising the bearing temperature at a level that will ensure the fatigue
strength of the bearing metal and having a geometry, which enhances a proper
oil film build-up and maintenance.
Too high top clearance is often the cause of fatigue cracks.
The bearings are checked in general by measuring the top clearances.
In service, top clearance measurements can be regarded:
1. as a check of the correct re-assembly of the bearing.

For new bearings the clearances should lie within the limits specified in
the maintenance manual.
2. as an indicator to determine the condition of the bearing at a periodic

check without opening up, see Item 7.1, ‘Check without Opening up’.
In both cases, it is vital that the clearance values from the previous check
are available for comparison. Therefore, it is necessary to enter clearances in
the engine log book with the relevant date and engine service hours (see e.g.
Drawing 2555-0140 page 5).
The initial clearances can be read from the testbed results
5.7 Wear
Bearing wear is negligible under normal service conditions, see Item 7.8, ‘Bearing
Wear Rate’. Excessive wear is due to abrasive or corrosive contamination of the
system oil which will affect the roughness of the journal/pin and increase the wear
rate of the bearing. The Spark Erosion phenomenon will lead to highly increased
Main Bearing wear rates, particularly in case of AlSn Main Bearing type.
5.8 Monitoring
The aim of monitoring engine bearings, is to avoid extensive damage to the en-
gine. Monitoring in a wider perspective, has numerous good side-effects. One
in particular is that the well known fact of possible contamination of internal
engine parts, when opening up, is decreased. The systems described in the fol-
lowing are designed to monitor the engine bearings continuously using various
techniques.
5.8.1. Bearing Wear Monitoring (BWM)

The aim of the BWM system is to detect a bearing damage before the lining (Bab-
bitt or Tin-Aluminium) is worn away by lining scuffing (Tin-Aluminium), wiping,
abrasive wear, melting out or extensive fatigue of the lining (Babbitt) and steel to
2545-0100-0003
steel contact occurs. However, the intended effect of the system is not to protect
2008-10-17
the bearing shells as such, but mainly to prevent consequential damage of the
Description
crankshaft and bedplate in case of severe bearing failures.
The principle of the BWM system is to measure the vertical position of the cross
head in bottom dead centre (BDC) (see Drawing 2555-0136). The BWM sys-
tem monitors all three principal crank-train bearings using two proximity sensors
forward/aft per cylinder unit and is placed inside the frame box. Targeting the
4 (18) Doc-ID:2545-0100-0003
HYUNDAI
MAN B&W 2545-0100-0003
guide shoe bottom ends continuously, the sensors measure the distance to the
Bearings
crosshead in BDC. Signals are computed and digitally presented to computer
hardware, from which a useable and easily interpretable interface is presented
to the user. The measuring precision is more than adequate to obtain an alarm
well before steel-to-steel contact in the bearings occur. In case of wear in a main
bearing, in a crankpin bearing or in a crosshead bearing, this vertical position
will reflect the wear. By appropriate signal processing following a MAN Diesel
specification, the system delivers alarm or slow down relay output in the case
of abnormal wear of one or more bearings. As such the system is connected to
the alarm and safety systems. Also refer to Checking and Maintenance Schedule,
duties during Operation, Chapter 0760-0302.
5.8.2. Bearing Temperature Monitoring (BTM)

The BTM system continuously monitors the temperature of the bearings. The
monitoring is performed either by measuring the temperature on the rear side
of the bearing shell directly or by detecting the return oil from each bearing in
the crankcase. In case of a specified temperature is recorded, either a bearing
shell temperature or bearing oil outlet temperature, an alarm is raised. For shell
temperature in main, crankpin and crosshead bearings two high-temperature
alarm levels apply.
The first level alarm is indicated in the alarm panel while the second level acti-
vates a slow down command. For oil outlet temperature in main, crankpin and
crosshead bearings two high temperature alarm levels including deviation alarm
apply. The first level of the high temperature/deviation alarm is indicated in the
alarm panel while the second level activates a slow down command.
5.8.3. Water in Oil Monitoring (WIOM)

Water content in the lubricating oil can be extremely damaging to engine bear-
ings, if significantly exceeding the saturation point of a given system oil, typically
max. 0.2 vol.%; for a short period up to 0.5 vol.%. This is particularly valid for
Tin-Aluminium lined crosshead bearings featuring lead overlay as running layer.
The higher the water content, the faster the wear rate.
The excessive water content will cause the lead overlay in crosshead bearings
to corrode away rapidly. Main and crankpin bearings lined with Babbitt or Tin-
Aluminium may also suffer irreparable damage from water contamination, but the
damage mechanism would be different and not as acute.
The above scenario can be prevented by continuously monitoring eventual water

contamination of the lubricating oil. For this purpose a Water In Oil Monitoring
System is implemented in the engine lub oil system, continuously meassuring the
relative humidity in the system oil. A probe in the oil piping system transmits a
signal to a unit, which calculates the humidity as Water Activity (aw). This method
of calculation has the advantage of being independent of oil type, temperature or
age. The system is connected to the alarmsystem.
2545-0100-0003
2008-10-17
5.8.4. Propeller Shaft Earthing Device

Description
The Propeller Shaft Earthing Device, is a system designed to avoid so called

spark erosion in the engine bearings and journals. The spark erosion phenom-
enon is a result of difference in electrical potential between metal parts. The level
of electrical potential lies generally between 200 – 600 mV on engines without
protection from a Propeller Shaft Earthing Device.
Doc-ID: 2545-0100-0003 5 (18)

HYUNDAI
2545-0100-0003 MAN B&W
In some cases, it has been found that this difference in electrical potential be-
Bearings
tween the hull and the propeller shaft has caused spark erosion on the main
bearings and journals of the engine. To avoid this, a continuous electrical earth-
ing circuit between the propeller and the ships structure, must be established.
This circuit usually exists when the propeller is at a rest, where a metal to metal
contact is made between the shaft and the stern tube liners, or main engine
bearings and journals.
However, whilst the shaft is turning the bearing oil film creates an intermittent
high resistance which effectively insulates the propeller from the hull structure.
Since the propeller presents a relatively large surface area of bare metal, it at-
tracts cathodic protection currents, which tend to discharge by arcing across the
bearing oil film. This can result in spark erosion which eventually leads to pitting
and ‘striping’ of white metal bearing surfaces.
In order to reduce the potential between the propeller shaft (crankshaft) and the
hull (engine structure), thus protecting the engine, an earthing device is installed
on the intermediate shaft, see Drawing 2555-0137. The drawing shows the prin-
cipal components of a Propeller Shaft Earthing Device. As a Condition Monitor
a voltmeter is installed to ensure a continuous display of the shaft/hull potential.
The reading is not to exceed 50 mV. Readings in excess of this value (Alarm limit
= 80 mV>) are indicative of worn bonding brushes or poorly maintained brushgear
and/or sliprings. The system is connected to the alarm system.
5.9 Undersize Bearings

1. Crankpin bearings are thin shell bearings. Due to relatively long production
lead time, the engine builder has a ready stock of semi-produced shells
(blanks) that covers a range from nominal diameter to 3 mm undersize, see
also Item 6.4, ‘Undersize Journals/Pins’. Semi-produced shells for journals
with undersizes lower than 3 mm are not stocked as standard. Furthermore,
undersizes lower than 3 mm can also involve modification such as the bolt
tension, hydraulic tool, etc.
For advice on the application of undersize bearings, it is recommended to

contact MAN Diesel.
2. The main bearings for the MC engine series can be of the thick or thin shell
type; the information under point 1 is also valid here.
3. Crosshead bearings are only available as standard shells, as the recon-

ditioning proposal for offset grinding of the pin (refer to 6.4 2.b) facilitates
the use of standard shells, for MC engines, but not for AlSn40 Cross
Head Bearings.
It is recommended to contact MAN Diesel for advice on such reconditioning.
6. Journals/Pins
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6.1 Surface Roughness

Description
Journal/pin surface roughness is important for the bearing condition.

Increased surface roughness can be caused by:
1. Abrasive damage due to contamination of the system oil.

See also Item 7.4.2.
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2. Corrosive damage due to sea water or other contamination of the system
Bearings
oil (acidic) or oxidation of the journals due to condensate. See also Item
7.4.2.
3. Spark erosion (only known in main bearings). See also Item 6.2, ‘Spark
Erosion’.
4. Scratches caused by manhandling.
With increasing journal/pin roughness, a level will be reached where the oil film
thickness is no longer sufficient, causing metal contact between journal/pin and
the bearing sliding surface. This will cause bearing metal to adhere to the journal/
pin, giving the surface a silvery white appearance and roughening the bearinmg
surface at the same time. When such a condition is observed, the journal/pin
must be reconditioned by polishing, and the roughness of the surface made
acceptable. In extreme cases, the journal/pin must be ground to an undersize
(see Item 6.4, ‘Undersize Journals/Pins’). The bearing shell condition determines
whether exchange of the shells are necessary or not.
6.2 Spark Erosion

Spark erosion is caused by a voltage discharge between the main bearing and
journal surface.
The cause of the potential is the development of a galvanic element between the
ship’s hull, sea water, and the propeller shaft/crankshaft.
The oil film acts as a dielectric. The spark attack in the bearing depends on the
thickness of the oil film and the shaft/hull potential.
Since the hydrodynamic oil film thickness varies through a rotation cycle, the
discharge will take place at roughly the same instant during each rotation cycle,
i.e when the film thickness is at its minimum. The roughening will accordingly be
concentrated in certain areas on the journal surface. However, as the bearings
wear, the position of the spark attack may shift and thus other parts get dam-
aged.
In the early stages, the roughened areas can resemble pitting erosion – but later,
as the roughness increases, the small craters will scrape off and pick up bearing
metal – hence the silvery white appearance.
Therefore, to ensure protection against spark erosion, the potential level must be
kept at maximum 50 mV, which is feasible with a high efficiency earthing device.
If an earthing device is installed, its effectiveness must be checked regularly.
(See also Drawing 2555-0137).
Spark erosion has only been observed in main bearings and main bearing journals.
Regarding repair of the journals, see Item 7.11, ‘Repairs of Journals/Pins’.
The condition of the bearings must be evaluated to determine whether they can
be reconditioned or if they have to be discarded. It is recommended to contact
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MAN Diesel if advice is required.

2008-10-17
Description
6.3 Surface Geometry

Surface geometry defects such as lack of roundness, conicity and misalign-
ment may give rise to operational difficulties. Such abnormal cases of journal/
pin geometry and misalignment may occur after a journal grinding repair.
It is recommended to contact MAN Diesel for advice.
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6.4 Undersize Journals/Pins

Bearings
In case of severe damage to the journal, it may become necessary to recondi-

tion the journal/pin by grinding to an undersize.
1. Main and crankpin journals can be ground to 3 mm undersize; undersize jour-

nals below this value require special investigations of the bearing assembly.
2. In service, crossheads pins can be:
a. Polished to (Dnominal – 0.15 mm) as the minimum diameter.
b. Offset to a maximum of 0.3 mm and ground.
c. Undersize (AlSn40) or repaired by welding.
In both cases, since standard bearings are used, the bearing top clear-
ance will increase depending on the surface condition of the pin to be re-
conditioned. The offset value used for grinding must be stamped clearly
on the pin.
7. Practical Information
7.1 Check without Opening up
Follow the check list in accordance with the programme stated in the Work
Cards. Enter the results in the engine log book. See also Item 7.12, ‘Inspection of
Bearings’.
1. Stop the engine and block the main starting valve and the starting air dis-
tributor and block the starting air reservoir valves.
2. Engage the turning gear.
3. Just after stopping the engine, while the oil is still circulating, check that
uniform oil jets appear from all the oil outlet grooves in the crosshead
bearing lower shell and the guide shoes.
4. Turn the crankthrow for the relevant cylinder unit to a suitable position
and stop the lube oil circulating pump (it is recommended to turn the en-
gine for ½-1 hr with the pumps off to let the oil drip off).
5. a. Check the vertical clearance with a feeler gauge. The change in

clearances must be negligible when compared with the readings
from the last inspection (overhaul). If the total increase in clear-
ance as from new is beyond the tolerance, the bearing should be
inspected.
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b. For guide shoe and guide strip clearances and checking proce-
dure, see Work Card 2565
2008-10-17
Description
6. Examine the sides of the bearing shell, guide shoes and guide strips, and
check for squeezed-out or loosened metal; also look for bearing metal
fragments in the oil pan, see Work Card 2565.
7. In the following cases, the bearings must be dismantled for inspection,

see Item 7.2, ‘Open up Inspection and Overhaul’.
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a. Bearing running hot.
Bearings
b. Oil flow and oil jets uneven, reduced or missing.
c. Increase of clearance since previous reading larger than 0.05 mm.

See also Item 7.8, ‘Bearing Wear Rate’.
d. Bearing metal squeezed out, dislodged or missing at the bearing,

guide shoe or guide strip ends.
e. The oil having been contaminated with e.g. water
If Item 7.a has been observed excessively in crosshead bearings or crankpin

bearings, measure the diameter of the bearing bore in several positions. If the
diameter varies by more than 0.06 mm, send the connecting rod complete to
an authorised repair shop.
If Items 7.a, 7.c or 7.d are observed when inspecting main bearings, we will
recommend to inspect the two adjacent bearing shells, to check for any abnor-
malities.
If item 7.e has been observed, check lead content in oil analysis. If high, open
up Cross Head Bearing
7.2 Open up Inspection and Overhaul

(See Drawing 2555-0140 page 2)
NOTE Record the hydraulic pressure level when the nuts of the bearing cap go loose.
Carefully wipe the running surfaces of the pin/journal and the bearing shell with
a clean rag. Use a powerful lamp for inspection.
Assessment of the metal condition and journal surface is made in accordance

with the directions given below. The results should be entered in the engine log
book. See also Item 7.12, ‘Inspection of Bearings’.
7.3 Types of Damage

The overlayer and bearing metal can exhibit the following types of damage.
1. Tearing of the overlayer (XH bearings) can be due to substandard bonding.

The damage is not confined to specific areas of the bearing surface. The
bearing metal/intermediate layer in the damaged area is seen clearly with a
sharply defined overlayer border. This defect is regarded mainly as a cos-
metic defect, if it is confined to small areas of the bearing surface without
interconnection.
For tin-aluminium bearings, the total area where the intermediate layer is ex-
2545-0100-0003
NOTE posed due to overlayer tearing, wiping or wear must not exceed the maximum
2008-10-17
limit given in Table 1 on Drawing 2555-0150.

Description
Whether the intermediate layer is exposed can be determined if the layer

is of Ni with a knife test, as the knife will leave only a faint or no cut mark
in the intermediate layer, which is very hard.
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2. Wiping of overlayer manifests itself by parts of the overlayer being

Bearings
smeared out. Wiping of overlayer can take place when running-in a new
bearing; however, if the wiping is excessive, the cause must be found and
rectified. One of the major causes of wiping is pin/journal surface rough-
ness and scratches.
See also the NOTE above.
3. Bearing metal wiping is due to metal contact between the sliding surfac-
es which causes increased frictional heat, resulting in plastic deformation
(wiping) (see Item 7.4, ‘Causes of Wiping’). See also Item 7.10.2.
Moderate wiping during the running-in stage is normal, and is considered
as a “cosmetic” problem. See item 7.7 for »dressing-up« wedges.
7.4 Causes of Wiping

1. Hard contact spots, e.g. originating from:
a. Defective pin/journal, bearing, or crosshead guide surfaces.
b. Scraped bearing or guide shoe surfaces.
c. Objects trapped between the housing bore and the back of the
shell.
2. Increased pin/journal surface roughness.
In most cases the increase in roughness will have occurred in service,

and is attributed to:
a. Hard particle ingress:
Hard particle ingress may be due to the malfunction of filters and/

or centrifuges or loosened rust and scales from the pipings. There-
fore, always pay careful attention to oil cleanliness.
b. Corrosive attack:
• Water contamination of the system oil is by far the most found
cause of corrosive attack of bearings.
• If the oil develops a weak acid.
• If strong acid anhydrides are added to the oil which, in combi-
nation with water, will develop acid.
• If salt water contamination of the lube oil is higher than 0.5%.
The water will attack the bearing metal, and result in the forma-
tion of a very hard black tin-oxide encrustation (SnO) which may
scratch and roughen the pin surface. The formation of tin oxide
is intensified by rust from the bottom tank. Therefore, keep the
internal surface clean.
2545-0100-0003
Special care must be taken during piston overhaul to avoid dirt entering Cross-
CAUTION
2008-10-17
Head Pin oil bores.

Description
3. Inadequate lube oil supply.
4. Misalignment.
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7.5 Cracks
Bearings
Crack development is a fatigue phenomenon due to high dynamic stress levels
in local areas of the bearing metal, typically in combination with a weakened
bearing metal.
In the event of excessive local heat input, the fatigue strength of the bearing
metal will decrease, and thermal cracks are likely to develop even below the
normal dynamic stress level. This can typically be found in crankpin and cross
head bearing shells, exceeding 50.000 running hours.
A small cluster of hairline cracks develops into a network of cracks. At an ad-

vanced stage, increased notch effect and the influence of the hydrodynamic oil
pressure will tear the white metal from the steel back and produce loose and
dislodged metal fragments.
7.6 Cause for Cracks

1. Insufficient strength of the bonding between the white metal and the steel
back (tinning or casting error).
2. Crack development after a short working period may be due to a mis-

alignment (e.g. a twist between the bearing cap and housing) or geo-
metric irregularities (e.g. a step between the contact faces of the bearing
shell, or incorrect oil wedge geometry).
3. High local loading: for example, if, during running-in, the load is concen-
trated on a few local high spots of the white metal.
Bearings with cracks can only be repaired temporarily depending on the extent
CAUTION of the damage.
7.7 Repair of Oil Transitions

Wedges, Tangential run out and bore relief.
It is strongly recommended to contact MAN Diesel for advice before starting any
CAUTION repairs. (See also Item 1., ‘General Bearing Requirements and Criteria’.)
Formation of sharp ridges or incorrect inclination of the transition to the bearing

surface will seriously disrupt the flow of oil to the bearing surface, causing oil
starvation at this location.
Oil transitions are reconditioned by carefully cleaning for accumulated metal

with a straight edge or another suitable tool. Oil wedges should be rebuilt to the
required inclination (maximum 1/100) and length, see Drawing 2555-0110.
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Check the transition geometries before installing the bearings, see Item 13.,
CAUTION
2008-10-17
‘Check of Bearings before Installation’.

Description
7.8 Bearing Wear Rate

The reduction of shell thickness in the loaded area of the main, crankpin and
crosshead bearing in a given time interval represents the wear rate of the bear-
ing. Average bearing wear rate based on service experience is 0.01 mm/10,000
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hrs. As long as the wear rate is in the region of this value, the bearing function
Bearings
can be regarded as normal. See also Item 7.1, ‘Check without Opening up’,
point 7.c.).
For white metal cross head bearings, the wear limit is confined to about 50%
reduction of the oil wedge length, see Drawing 2555-0110. Of course, if the
bearing surface is still in good shape, the shell can be used again after the oil
wedges have been extended to normal length. Check also the pin surface con-
dition, see Items 6.1, ‘Surface Roughness’ and 7.9, ‘Surface Roughness (journal/
pin)’.
For tin-aluminium crosshead bearings, see the ‘Note’ in Item 7.3.1.
For further advice, please contact MAN Diesel.
7.9 Surface Roughness (journal/pin)

1. Limits to surface roughness
The surface roughness of the journal/pin should always be within the
specified limits.
a. For main and crankpin journals: 0.4 Ra AlSn 40-layer

• New journals 0.8 Ra WM-layer
• Roughness approaching 1.6 Ra WM-layer
(journal to be reconditioned) 0.8 Ra AlSn 40-layer
b. For crosshead pins: Scratches

OK
• New or repolished 0.05 Ra
• Acceptable in service 0.05-0.1 Ra
• Repolishing if higher than 0.1 Ra
2. Determination of the pin/journal roughness 120°

Measure the roughness with an electronic roughness tester, or
Evaluate the roughness with a RUGOTESTER®, by comparing the surface

of the pin/journal with the specimens on the RUGOTESTER®. When per-
forming this test, the pin surface and the RUGOTESTER® must be thor-
oughly clean and dry. Hold the tester close to the surface and compare
the surfaces. If necessary, use your finger nail to run over the pin/journal
surface and the RUGOTESTER® specimens to compare and determine
the roughness level.
7.10 Repairs of Bearings on the Spot
It is recommended to contact MAN Diesel for advice before starting any repairs.
CAUTION
See also Item 1., ‘General Bearing Requirements and Criteria’).
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1. Overlayer wiping
Description
a. Overlayer wiping and moderate tearing in crosshead bearing lower

shells is not serious, and is remedied by careful use of a scraper.
However, see the ‘Note’ in Item 7.3.1.
b. Hard contact on the edges of crosshead bearings is normally due

to galvanic build-up of the overlayer. This is occasionally seen
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when inspecting newly installed bearings and is remedied by re-
Bearings
lieving these areas with a straight edge or another suitable scrap-
ing tool.
2. Bearing metal squeezed out or wiped:
a. The wiped metal can accumulate in the oil grooves/wedges, run-

out or bore relief where it forms ragged ridges. Such bearings
can normally be used again, provided that the ridges are carefully
removed with a suitable scraping tool and the original geometry is
re-established (see Item 7.7, ‘Repair of Oil Transitions’). High spots
on the bearing surface must be levelled out by light cross-scraping
(90 by 90 degrees).
b. In cases of wiping where the bearing surface geometry is to be re-

established, it is important:
• to assess the condition of the damaged area and, if found nec-
essary, to check the bearing surface for hairline cracks under a
magnifying glass and with a penetrant fluid, if necessary.
• to check the surface roughness of the journal/pin and polish if
necessary.
c. In extreme cases of wiping, the oil wedges in the crosshead bear-

ing may disappear. In that event, the shell should be replaced.
3. For evaluation and repair of spark erosion damage, refer to Item 6.2,
‘Spark Erosion’.
4. Cracked bearing metal surfaces should only be repaired temporarily.

The bearing must be replaced (see Items 7.5, ‘Cracks’ and 7.6, ‘Cause for
Cracks’).
7.11 Repairs of Journals/Pins

1. Crosshead pins
Pin surface roughness should be better than 0.1 Ra (see Item 7.9, ‘Sur-
face Roughness (journal/pin)’). If the Ra value is higher than 0.1 µm, the
pin can often be repolished on the spot, as described below. If the pin is
also scratched, the position and extent of the scratched areas must be
evaluated. If there are also deep scratches, these must be levelled out
carefully with hardbacked polishing paper, or similar, before the polishing
process is started.
Use a steel ruler, or similar, to support the polishing paper, as the fingertips are
CAUTION too flexible.
The surface roughness not counting in scratches after polishing should

be better than 0.1 Ra in the 120° crown. The upper 240° can be accepted
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up to an average roughness of 0.2 Ra including scratches.

2008-10-17
The following methods are recommended for repolishing on site.

Description
a. Polishing with microfinishing film

The polishing process is carried out with a “microfinishing film”,
e.g. 3M aluminium oxide (30 micron,, 15 micron and 5 micron),
which can be recommended as a fairly quick and easy method, al-
though to fully reestablish the pin surface it will often be necessary
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to send the crosshead ashore for regrinding/polishing in an appro-

Bearings
priate mashine.
The microfinishing film can be slung around the pin and drawn to
and fro by hand and, at the same time, moved along the length of
the pin, or it is drawn with the help of a hand drilling machine; in
this case, the ends of the microfilm are connected together with
strong adhesive tape or glued together.
b. Braided hemp rope method

This method is executed with a braided hemp rope and jeweller’s
rouge.
Before the rope is applied all frontending scratches must be re-

moved with fine emery cloth as per 7.11.1.
A mixture of polishing wax and gas oil (forming an abrasive paste

of a suitably soft consistency) is to be applied to the rope at regu-
lar intervals. During the polishing operation, the rope must move
slowly from one end of the pin to the other.
The polishing is continued until the roughness measurement

proves that the surface is adequately smooth (see Item 7.9).
This is a very time consuming operation and, depending on the

surface roughness in prior, about three to six hours may be needed
to complete the polishing.
2. Journals (Main and crankpin journals)
a. The methods for polishing of crosshead pins can also be used here,
and method a) Polishing with microfinishing film, will be the most
suitable method. A 30 micron microfinishing film is recommended
here or 220-270 grade emery cloth of a good quality.
b. Local damage to the journal can also be repaired. The area is to be

ground carefully and the transitions to the journal sliding surface are
to be rounded carefully and polished. We recommend to contact MAN
Diesel for advice before such a repair is carried out. But as temporary
repair, any ridges must be filed or ground to level.
7.12 Inspection of Bearings

Regarding check of bearings before installation, see item 13., ‘Check of Bearings
before Installation’.
For the ship’s own record and to ensure the correct evaluation of the bear-
ings when advice is requested from MAN Diesel, we recommend to follow the
guidelines for inspection, which are stated in Drawing 2555-0140 page 2 to 6.
See the example of an Inspection Record on Drawing 2555-0140 page 5.
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8. Crosshead Bearing Assembly

Description
8.1 Bearing Type

The type of bearing used in the crosshead assembly is a thin shell (insert) bearing
(see Item 5.5, ‘Thin Shell Bearings’). The lower shell is a trimetal shell, i.e. the shell
is composed of a steel back with cast-on white metal and an overlayer coating.
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See also Item 3, ‘Overlayers’. The upper shell is a bimetal shell, as it does not have
Bearings
the overlayer coating; both the upper and lower shells are protected against cor-
rosion with tin flash (see Item 4, ‘Flashlayer, Tin (Sn)’). The upper part can also be
cast into the bearing cap.
8.2 Bearing Function and Configuration

Because of the oscillating movement and low sliding speed of the crosshead
bearing, the hydrodynamic oil film is generated through special oil wedges (see
Item 5.3, ‘Axial Oil Grooves and Oil Wedges’) on either side of the axial oil supply
grooves situated in the loaded area of the bearing. The oil film generated in this
manner can be rather thin. This makes the demands for pin surface roughness
and oil wedge geometry important parameters for the assembly to function. A
further requirement is effective cooling which is ensured by the transverse oil
grooves. The pin surface is superfinished (see Item 7.9 1.b). The lower shell is most
often executed with a special surface geometry (embedded arc) which extends
over a 120 degree arc, and ensures a uniform load distribution on the bearing
surface in contact with the pin. The lower shell is coated with an overlayer (see Item
3., ‘Overlayers’), which enables the pin sliding geometry to conform with the bearing
surface in the embedded arch area.
Another geometry execution is the “Single bore” geometry, which depends on a

fully positive yet small clearance. With “Single bore” the overlayer is omitted.
9. Main Bearing Assembly

The MC/ME/ME-B engine series can be equipped with “Thick shell bearings”
(Item 5.4) or “Thin shell bearings” (Item 5.5).
The bearing type, i.e. “thick shell” or “thin shell” determines the main bearing
housing assembly described below (see table of installed bearing types, Drawing
2555-0100, and housing assemblies, Drawing 2555-0120).
9.1 Thick Shell Bearing Assembly

(See Drawing 2555-0120, Fig. 1)
The tensioning force of a thick shell bearing assembly (Fig. 1) is transferred

from the bearing cap (pos. 1) to the upper shell (pos. 2) and via its mating faces
to the lower shell (pos. 3).
The bearing bore is equipped with the following geometry:
1. central oil supply groove and oil inlet in the upper shell which ends in a
sloping run-out (Item 5.1) in both sides of the lower shell, see Drawing
2555-0100.
2. the bearing bore is furnished with a bore relief (Item 5.2) at the mating
faces of the upper and lower shell, see Drawing 2555-0100.
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9.2 Thin Shell (Insert Bearing) Bearing Assembly

Description
(See Drawing 2555-0120, Fig. 2)
This is a rigid assembly (Fig. 2). The bearing cap (pos. 1) which has an inclined
vertical and horizontal mating face, is wedged into a similar female geometry in
the bedplate (pos. 2), which, when the assembly is pretensioned, will ensure a
positive locking of the cap in the bedplate.
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The lower shell is positioned by means of screws (Pos. 3). During mounting of
Bearings
the lower shell it is very important to check that the screws are fully tightened
to the stops in the bedplate. This is to prevent damage to the screws and shell
during tightening of the bearing cap.
See also Item 5.5, ‘Thin Shell Bearings’ earlier in this section. For information re-
garding inspection and repair, see Item 7, ‘Practical Information’.
10. Crankpin Bearing Assembly

This assembly is equipped with thin shells, and has two or four tensioning
studs, depending on the engine type. Crankpin bearing assemblies with four
studs must be tensioned in parallel, for example first the two forward studs
and then the two aftmost studs; the tensioning may be executed in two or
three steps. If four hydraulic jacks are available only one step is necessary plus
check-step. This procedure is recommended in order to avoid a twist (angular
displacement) of the bearing cap to the mating face on the connecting rod.
The oil supply groove transition to the bearing sliding surface is similar to that
of the main bearing geometry. For information regarding inspection and repair,
see Item 7, ‘Practical Information’.
11. Guide Shoes and Guide Strips

1. The guide shoes, which are mounted on the fore and aft ends of the
crosshead pins, slide between guides and transform the translatory
movement of the piston/piston rod via the connecting rod into a rotational
movement of the crankshaft.
The guide shoe is positioned relative to the crosshead pin with a position-
ing pin screwed into the guide shoe, the end of the positioning pin pro-
trudes into a hole in the crosshead pin and restricts the rotational move-
ment of the crosshead pin when the engine is turned with the piston rod
disconnected.
The guide strips are bolted on to the inner side of the guide shoes and
ensure the correct position of the piston rod in the fore-and-aft direction.
This alignment and the clearance between the guide strips and guide is
made with shims between the list and the guide shoe.
The sliding surfaces of the guide shoes and guide strips are provided
with cast-in white metal and furnished with transverse oil supply grooves
and wedges (see Item 5.3, ‘Axial Oil Grooves and Oil Wedges’).
For inspection of guide shoes and guide strips, see Item 7.1, 7.3.3 and
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7.4.1 a) and b).

2008-10-17
Description
12. Thrust Bearing Assembly

The thrust bearing is a tilting-pad bearing of the Michell type. There are eight
pads (segments) or more placed on each of the forward and aft sides of the
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thrust collar. They are held in place circumferentially by stoppers. The seg-
Bearings
ments can be compared to sliding blocks and are pivoted in such a manner
that they can individually take up the angle of approach necessary for a hydro-
dynamic lubricating wedge. The lubricating/cooling oil is sprayed directly on to
the forward and aft sides of the thrust collar by means of nozzles positioned in
the spaces between the pads. The nozzles are mounted on a semicircular de-
livery pipe.
For clearances and max. acceptable wear, see Work Cards.
13. Check of Bearings before Installation

Clean the bearing shells thoroughly before inspecting.
13.1 Visual Inspection

1. Check the condition of the bearing surfaces for impact marks and burrs.
Repair by scraping if necessary.
2. Check that the transition between the bore relief and the bearing sliding
surface is smooth.
13.2 Check Measurements

Place the shell freely, as illustrated in Drawing 2555-0185, Fig. 1.
Measure the crown thickness, with a ball micrometer gauge. Measure in the
centre line of the shell, 15 millimetres from the forward and aft sides.
Record the measurements as described in Item 7.12, ‘Inspection of Bearings’ and

Drawing 2555-0140 page 2 to 6.
This will facilitate the evaluation of the bearing wear during later overhauls.
13.3 Cautions
As bearing shells are sensitive to deformations, care must be taken during
handling, transport and storage, to avoid damaging the shell geometry and sur-
face.
The shells should be stored resting on one side, and be adequately protected
against corrosion and mechanical damage.
Preferably, keep new bearing shells in the original packing, and check that the
shells are in a good condition, especially if the packing shows signs of damage.
During transport from the store to the engine, avoid any impacts which could
affect the shell geometry.
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14. Camshaft Bearing Assembly

Description
(Drawing 2555-0135)
The camshaft bearing assemblies are positioned between the exhaust cams of
the individual cylinder units. The bearing assembly is of the sadle/bearing-cap
Doc-ID: 2545-0100-0003 17 (18)

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2545-0100-0003 MAN B&W
design. The correct position of the caps is ensured by dowel pins.

Bearings
The bearings used are of the thin shell type without overlayer (Item 5.5).
The mating faces of the lower shell rest against the horizontal partition face in
the cam housing. The wall thickness at the mating faces of the shell is reduced
to ensure that the inner surface of the shell is flush with the bore in the cam
housing.
The transition to the bearing sliding surface is wedge-shaped; this is to ensure

unrestricted oil supply to the bearing sliding surface.
The specific load in the camshaft bearings is low, and the bearings function
trouble free provided that the camshaft lub. oil/Uni-Lube system is well main-
tained, see 3045-0150. However, if practical information is needed, refer to Item
7, ‘Check without opening up’ and ‘Open up inspection and overhaul’.
For clearances, please refer to Work Cards.
2545-0100-0003
2008-10-17
Description
18 (18) Doc-ID:2545-0100-0003
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MAN B&W 2545-0110-0002
1 Alignment
Alignment of Main Bearings

During installation of the engine, intermediate shaft and propeller shaft, the yard
aims to carry out a common alignment, to ensure that the bearing reactions are
kept within the permitted limits, with regard to the different factors which infl uence
the vessel and engine during service.
Factors like the ship’s load condition, permanent sag of the vessel, movements in
sea, wear of bearings etc., makes it necessary to regularly check the alignments:
- Main bearings, see Items 2.1-2.4

- Engine bedplate, see Item 2.5
- Shafts, see Item 2.6.
2 Alignment of Main Bearings
See Drawing 2555-0175 and 2555-0180
The bearing alignment can be checked by deflection measurements (autolog) as

described in the following section.
Example; If two adjacent main bearings at the centre of the engine are placed too
high, then at this point the crankshaft centreline will be lifted to form an arc. This
will cause the intermediate crank throw to deflect in such a way that it “opens”
when turned into bottom position and “closes” in top position.
Since the magnitude of such axial lengthening and shortening increases in propor-
tion to the difference in the height of the bearings, it can be used as a measure of
the bearing alignment.
2.1 Deflection Measurements (autolog)
See Drawings 2555-0175
As the alignment is influenced by the temperature of the engine the deflection

measurements should, for comparison, always be made under nearly the same
temperature and load conditions.
It is recommended to record the actual jacket water and lub. oil temperatures in
Drawings 2555-0175.
Procedure
2012-11-01 - en
2545-0110-0002
Turn the crankpin for the cylinder concerned to Pos. B1, see Fig. 2, Drawing
Description
2555-0175. Place a dial gauge axially in the crank throw, opposite the crankpin,
and at the correct distance from the centre, as illustrated in Fig. 1. The correct
mounting position is marked with punch marks on the crankthrow. Set the dial
gauge to “Zero”.
1 (4)
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2545-0110-0002 MAN B&W
MAN B&W
Make the deflection readings at the positions indicated in Fig. 2.

“Closing” of the crankthrow (compression of the gauge) is regarded as negative

and “Opening” of the crankthrow (expansion of the dial gauge) is regarded as posi-
tive, see Fig. 1.
Since, during the turning, the dial gauge cannot pass the connecting rod at BDC,
the measurement for the bottom position is calculated as the average of the two
adjacent positions (one at each side of BDC).
When making deflection readings for the two rearmost cylinders, the turning gear
should, at each stoppage, be turned a little backwards to ease off the tangential
pressure on the turning wheel teeth. This pressure may otherwise falsify the read-
ings.
Enter the readings in the table Fig. 3. Then calculate the BDC deflections, 1/2
(B1+B2), and note down the result in Fig. 4.
Enter total “vertical deflections” (opening - closing) of the throws, during the turning
from bottom to top position in the table Fig. 5 (T-B).
2.2 Checking the Deflections
See Drawing 2555-0180 and Testbed Report

The results of the deflection measurements (see Drawing 2555-0175, Fig. 5)
should be evaluated with the commisioning test measurements (recorded by the
engine builder in the commisioning test report on site). If re-alignment has been
carried out later on (e.g. following repairs), the results from these measurements
should be used.
Values of permissible “vertical deflections” etc. are shown in Drawing 2555-0180.
The values shown on Drawing 2555-0180 are specifically attributed to

the crankshaft condition, NOT the bearing wear condition.
The values represent theoretical maximum deflection, which the

crankshaft material can sustain, for an unlimited time of operation,
without risking to exceed the stress fatigue limits of the crankshaft.
The values are unlikely to exceed the “permissible from new” in static
condition (turning of the engine).
For bearing wear measurements derived from deflection readings;

2012-11-01 - en
2545-0110-0002
always refer to commissioning test results, and judge the relative

change in deflection over time.
Description
Abnormal/deviating deflection readings should always be investigated

and additional measurements performed, such as Top and Bottom
clearance of adjacent main bearings.
2 (4)
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MAN B&W 2545-0110-0002

2.3 Floating Journals
See also Item 2.2 and Drawing 2555-0180
Use a special bearing feeler gauge to investigate the contact between the main
bearing journals and the lower bearing shells. Check whether the clearance
between journal and lower shell is zero.
If clearance is found between journal and lower bearing shell, the condition of the
shell must be checked and, if found damaged, it must be replaced.
The engine alignment should be checked and adjusted, if necessary.
To obtain correct deflection readings in case one or more journals are not in con-
tact with the lower shell, it is recommended to contact the engine builder.
If the deflection values are within limits and there is bottom clearance found, it may
be possible to install an offset bearing to get a positive bearing reaction.
2.4 Causes of Crankshaft Deflection
1. Excessive wear of main bearings

2. Displacement of bedplate (see ‘Piano Wire Measurements’)
3. Displacement of engine alignment and/or shafting alignment
4. Loose or broken Staybolts.
5. Loose foundation bolts.
6. Wear of shock absorber material.
2.5 Piano Wire Measurements. Bedplate Alignment
A 0.5 mm piano wire is stretched along each side of the bedplate.
The wire is loaded with 400 N horizontal force.
At the centreline of each cross girder the distance is measured between the wire
and the machined faces of the bedplate top outside oil groove.
It will thus be revealed whether the latter has changed its position compared with
the reference measurement from engine installation.
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2545-0110-0002
This measurement requires special equipment available from MAN Diesel & Turbo.
Description
3 (4)
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MAN B&W
2.6 Shafting Alignment, Bearing Load, “Jack-up” Test

This can be checked by measuring the load at:

- the aftermost main bearing
- the intermediate shaft bearings (plummer blocks)
- in the stern tube or generator bearing.
Making these measurements normally requires specialist assistance.
As a reliable evaluation of the shafting alignment measurements requires a good

basis, the best obtainable check can be made if the contractor/supplier or repair-
shop has carried out the alignment based on precalculation of the bearing reac-
tions.
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2545-0110-0002
Description
4 (4)
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2555-0105-0002
Main Bearing, Thin Shell Design

A-A
(Bore Relief)
A
B
B-B
(Tang. Run-out)
Engine types with thin shell main bearing assemblies:

S35ME-B
S40ME-B
S46MC-C
S50ME-C/MC-C
S60ME-C/MC-C
2555-0105-0002
S70ME-C/MC-C
2008-10-16
K80ME-C/MC-C
Drawing
S90ME-C/MC-C
K90-98ME-C/MC-C
Doc-ID: 2555-0105-0002 1 (1)

HYUNDAI
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2555-0110-0003
Crosshead Bearing
A-A
(Oil Wedge) A
A
Extent of oil wedges in crosshead bearing lower shell
Engine Type Extent L [mm] *

S26MC
S/L35MC
S35ME-B
S40ME-B
S42MC
S46MC-C
S/K/L50ME/MC For actual values, refer to
S50ME-C/MC Work Card 2565-0200
S/K/L60ME/MC
2555-0110-0003
S/K/L70ME/MC
2009-01-20
S/K/L80ME/MC
K80ME-C/MC-C
Drawing
K/L90ME/MC
K90-98ME-C/MC-C
* on each side of the axial oil groove
Doc-ID: 2555-0110-0003 1 (1)

HYUNDAI
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2555-0115-0002
Crankpin Bearing
B-B
(Tang. Run-out)
A-A
(Bore Relief)
2555-0115-0002
2008-10-16
Drawing
Doc-ID: 2555-0115-0002 1 (1)

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2555-0120-0002
Main Bearing Assemblies

Fig. 1 Thick Shell
Fig. 2 Thin Shell

2555-0120-0002
2008-10-16
Drawing
Doc-ID: 2555-0120-0002 1 (1)

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2555-0125-0004
Guide Shoes and Strips

2555-0125-0004
2008-10-16
Drawing
Doc-ID: 2555-0125-0004 1 (1)

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MAN B&W 2555-0130-0002
Thrust Bearing Assembly

2555-0130-0002
2008-10-16
Drawing
Doc-ID: 2555-0130-0002 1 (1)

HYUNDAI
MAN B&W 2555-0135-0001.0
Camshaft Bearing Assembling

A
2555-0135-0001.0
2007-12-07
Drawing
Doc-ID: 2555-0135-0001.0 1 (1)

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2555-0136-0002
Bearing Wear Monitoring System (BWM)

Proximity sensors (2 per cylinder, i.e.
one for each guideplane) are placed
on brackets typically mounted on
the Exhaust side structure below
both guide shoes.
The system monitors the variation in

distance between sensor and gui-
de shoe bottom surface, in bottom
dead centre (BDC). The measure-
ments represent the relative wear in
all three crank-train bearings, simul-
taneously.
Via cables, the signals are sent to a

junction box outside the engine and
computed for further use.
Man. side %xh. side
'UIDEæPLANE
'UIDEæSHOE
BOTTOMæSURFACE
0ROXIMITYæSENSORæCONNECTEDæTO
JUNCTIONæBOXæOUTSIDEæENGINE
2555-0136-0002
2008-09-19
Drawing
Doc-ID: 2555-0136-0002 1 (1)

2008-09-19
MAN B&W
HYUNDAI
Doc-ID: 2555-0137-0002
Drawing Propeller Shaft Earthing Device
2555-0137-0002
2555-0137-0002
1 (1)

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2555-0140-0003
Recording of Observations
Inspection of Bearings
References to Work Cards
Inspection without Open-up Inspection
Bearing Type Opening-up and Overhaul
Main bearing 2565-0401 2565-0401
Crankpin bearing 2565-0301 2565-0301
Crosshead bearing 2565-0201 2565-0201
Guide shoes 2565 –
Crosshead guides 2565 –
Thrust bearing – 2565-0601
Camshaft bearing (MC/ME-B) 2565-0101 2565-0101
Use the Inspection Sheet, 2555-0140 page 6. For help, refer to example, 2555-0140
page 5.
A. Inspection without Opening-up

State the following information:
Date / Signature / Engine running hours / Type of inspection / Bearing type (2555-
0140, table 1) / Bearing number / Observation (2555-0140 page 4, Table 3)/ Remarks /
Clearances.
B. Open-up Inspection and Overhaul

State the following information:
Date / Signature / Engine running hours / Type of inspection / Bearing type
(2555-0140, Table 1) / Bearing number / Manufacturer’s logo / Damage to (2555-0140,
Table 2) / Observation (2555-0160 page 4, Table 4) / Site and extent of damage (2555-0140
page 2 and 3) * /Remarks / Clearances / Hydraulic opening pressure / Roughness.
* The site and extent of the damage is determined by:
1. The approx. centre of the damaged area (see examples I, II and III).
The axial location (I) of the centre should be stated in (mm) from the aft end of the
bearing or the journal.
2. The extent of the damage defined by a circle with radius (r); or a rectangle (a, b) or (a, b, +/– c),
(see examples I, II and III).
Note: for isolated cracks, illustration III is used, with the measurement b omitted.
Table 1: Table 2:
Bearing Type Damage
Main Bearing MB Overlayer OL
Crankpin Bearing CRB White Metal WM
Crosshead Bearing CHB Journal J
2555-0140-0003
Guide Shoes GS Pin P

2008-10-17
Crosshead Guides CG Transitions:

Thrust Bearing TB Oil Wedge OW
Drawing
Camshaft Bearing (MC/ME-B) CSB Bore Relief BR

Tang. Run-out TR
Back of Shell BS
Doc-ID: 2555-0140-0003 1 (6)

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Location and size of damage in bearing shells

2555-0140-0003
2008-10-17
Drawing
2 (6) Doc-ID: 2555-0140-0003

HYUNDAI
MAN B&W
2555-0140-0003
Location of damage on pin/journal
d
a
e
sh
ro
C Crosshead pin
(View from aft)
F M A
0
9 3
Main and crank bearing journals
(View from aft)
0
F M A
9 3
6
2
0
F M A
1
9 3
2555-0140-0003
2008-10-17
6
Drawing
1 Main bearing journal
2 Crank pin bearing journal
Doc-ID: 2555-0140-0003 3 (6)

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2555-0140-0003 MAN B&W
Observations
Table 3 I nspecti on wi thout O pening-up (7.1)
C h e ck s Symbol O b s e r va t i o n s
Oil flow OF • OK, similarity
U Uneven
Oil Jets OJ • OK, similarity
(Crosshead, Guide strips) R Reduced
M Missing
TW Twisted
White Metal WM • OK
SQ Squeezed out
CR Cracks
L Loose
M Missing
Crosshead Guides CG • OK
SC Scratches
CO Corrosion
SW Silvery White
Oil Pan OP • OK, clean
WM White metal fragments
Oil Condition OC • OK
DK Dark
WT Water traces
Table 4 Open-up Inspection and Overhaul (7.2)
Checks Symbol Observations Ref.

White Metal WM • OK
W Wiping 7.3 II
HC Hard Contact 7.4
7.7
OS Oil Starvation 7.5
CR Cracks 7.1
CRC Crack Cluster 7.1
L Loose 6.2
M Missing 7.4 B, 6.1
SSE Spark Erosion
CO Corrosion
Overlayer OL • OK 7.3 I
(Crosshead only) TE Tearing 7.3 II
W Wiping
Transitions: • OK 7.7
Oil Wedge OW RR Ragged Ridges 7.7
Bore Relief BR W Wiping 7.10BII
Tang. Run-out TR D Disappeared
2555-0140-0003
Journal/Pin J/P • OK
2008-10-17
SE Spark Erosion 6.2

CO Corrosion 7.4B, 6.1
6.1
SW Silvery White 7.4, 7.11
Drawing
SC Scratches
Back of Shell BS • OK
FR Fretting 7.4
TH Trapped hard Particles 7.4
4 (6) Doc-ID: 2555-0140-0003

2008-10-17
Clearance (mm)
M/V
No.:
Date
Yard:
hours
Type of
pressure
Description of Condition Top
Journal/pin
Hydr. open.
Checked by
inspection 2)
Roughness 3)
Engine running
Fore Aft
MAN B&W
HYUNDAI
Builder:
B ui l t y e a r :
Engine type:
Inspection Records, Example
No.:
Engine
Total
Doc-ID: 2555-0140-0003
CW / CCW 1) Running hours
4)
Date:
Checked by:
4)
4)
1) Engine direction of rotation, seen from aft, must be underllined; CW: Clockwise, CCW: Counter Clockwise
2) Inspection without opening-up: 7.1; Open-up inspection: 7.2
3) It should be stated whether the roughness is measured: M, or evaluated: E.
4) Only to be filled in, if all observations are carried out at the same running hours.
Drawing Inspection of Bearings

2555-0140-0003
2555-0140-0003
5 (6)
Drawing
6 (6)
2555-0140-0003
Clearance (mm)
M/V
No.:
Date
Yard:
hours
Type of
pressure
Description of Condition Top
2555-0140-0003
Journal/pin
Hydr. open.
Checked by
inspection 2)
Roughness 3)
Engine running
Fore Aft
Builder:
B ui l t y e a r :
Engine type:
Inspection Records, Blank
No.:
Engine
Total
Doc-ID: 2555-0140-0003
CW / CCW 1) Running hours
4)
Date:
Checked by:
4)
4)
1) Engine direction of rotation, seen from aft, must be underllined; CW: Clockwise, CCW: Counter Clockwise
2) Inspection without opening-up: 7.1; Open-up inspection: 7.2
3) It should be stated whether the roughness is measured: M, or evaluated: E.
MAN B&W
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4) Only to be filled in, if all observations are carried out at the same running hours.
2008-10-17
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MAN B&W 2555-0150-0003
Crosshead Bearing Lower Shells
Acceptance Crtieria for Tin-Aluminium Bearings with Overlayer

Overlayer
Intermediate layer
Tin-Aluminium
Steel
Engine type Max. allowed exposure (mm2)

26MC 2900
35MC 4300
35ME-B 5700
40ME-B 7500
42MC 6700
46MC-C 8100
50MC-C/ME-C 9600
60MC-C/ME-C 13100
65ME-C 16100
2555-0150-0003
70MC-C/ME-C 17900
2008-10-17
Maximum allowed exposure of the intermediate layer. Values are calculated accord-
Drawing
ing to SL05-460/NHN.
Doc-ID: 2555-0150-0003 1 (1)

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MAN
Autolog
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Drawing Report: Crankshaft Deflections

2555-0175-0003
2555-0175-0003
1 (1)
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MAN B&W 2555-0180-0004
Crankshaft Deflections, Limits

Type Normally obtainable for a new or Realignment Absolute maximum
recently overhauled engine recommended permissible
mm mm mm
1 2 1 2 1 2
S26MC 0.12 0.23 0.31 0.35 0.46 0.46
L35MC/MC-S/MC-E 0.10 0.20 0.27 0.30 0.40 0.40
S35MC 0.17 0.35 0.46 0.52 0.70 0.70
S35MC-C/ME-B9 0.19 0.39 0.52 0.58 0.77 0.77
S40MC-C/ME-B9 0.22 0.44 0.59 0.67 0.89 0.89
L42MC/MC-S/MC-E 0.14 0.28 0.38 0.43 0.57 0.57
S42MC 0.21 0.43 0.57 0.64 0.86 0.86
S46MC-C/MC-C8 0.23 0.46 0.62 0.69 0.93 0.93
ME-B8
K50MC-S 0.12 0.25 0.34 0.38 0.51 0.51
L50MC/MC-E 0.17 0.34 0.45 0.51 0.68 0.68
S50MC/MC-E 0.23 0.46 0.61 0.69 0.92 0.92
S50MC-C/MC-C8 0.23 0.47 0.62 0.70 0.94 0.94
ME-B8/ME-C
S50ME-B9 0.29 0.58 0.77 0.86 1.15 1.15
G50ME-B 0.33 0.66 0.88 0.99 1.32 1.32
K60MC-S 0.15 0.31 0.41 0.46 0.62 0.62
L60MC/MC-E 0.20 0.40 0.54 0.61 0.81 0.81
L60MC-C/MC-C8 0.22 0.45 0.59 0.67 0.89 0.89
ME-C
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2555-0180-0004
S60MC/MC-E 0.27 0.55 0.73 0.82 1.10 1.10

Drawing
S60MC-C/MC-C8 0.28 0.56 0.75 0.84 1.13 1.13

ME-B8/ME-C/ME-GI
S65MC-C/MC-C8 0.33 0.65 0.87 0.98 1.31 1.31
ME-C8/ME-GI
1 (2)
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Type Normally obtainable for a new or Realignment Absolute maximum

recently overhauled engine recommended permissible
Crankshaft Deflections, Limits
mm mm mm
1 2 1 2 1 2
G60ME-C 0.36 0.72 0.95 1.07 1.43 1.43
L70MC/MC-E 0.24 0.48 0.63 0.71 0.95 0.95
L70MC-C/ME-C 0.26 0.53 0.70 0.79 1.05 1.05
ME-C8
S70MC/MC-E 0.32 0.64 0.85 0.96 1.28 1.28
S70MC-C/MC-C8 0.33 0.66 0.88 0.99 1.32 1.32
ME-C/ME-C8/ME-GI
G70ME-C 0.40 0.79 1.05 1.19 1.58 1.58
L80MC/MC-E 0.27 0.54 0.72 0.81 1.08 1.08
S80MC 0.36 0.73 0.97 1.10 1.46 1.46
S80MC-C/ME-C8 0.38 0.76 1.00 1.13 1.50 1.50
S80ME-C9 0.45 0.89 1.20 1.35 1.80 1.80
K80MC/MC-C/MC-S 0.22 0.44 0.58 0.66 0.88 0.88
ME-C6
K80ME-C9 0.29 0.58 0.77 0.87 1.16 1.16
G80ME-C 0.49 0.99 1.31 1.48 1.97 1.97
L90MC/MC-E 0.30 0.60 0.81 0.92 1.22 1.22
K90MC/MC-E 0.25 0.50 0.67 0.75 1.00 1.00
K90MC-S/MC-C/ME- 0.20 0.41 0.54 0.61 0.82 0.82
C
S90MC-C/ME-C 0.36 0.71 0.96 1.08 1.45 1.45
ME-C8
S90ME-C9 0.42 0.83 1.11 1.25 1.66 1.66
K98/MC/ME/ME-7 0.24 0.49 0.65 0.74 0.98 0.98
K98MC-C/MC-S 0.20 0.41 0.54 0.61 0.81 0.81
ME-C/ME-C7
1 Normal for all crank throws
2 Permissible for the foremost crank throw, when the crankshaft fore end is provided with a torsional vibration
damper, tuning wheel or directly coupled to a generator rotor.
Permissible for the aftmost crank throw, when the crankshaft generator end is provided with a flexible coupling.
When judging the alignment on the above “limiting-value”’ basis, make sure that the crankshaft is actually supported in
2013-02-08 - en
2555-0180-0004
the adjacent bearings. (See chapter 2545-0110 ‘Alignment of Main Bearings’ point 2.3 ‘floating journals’).
Drawing
2 (2)
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MAN B&W 2555-0185-0002
Measuring of Crown Thickness
Check Measurements
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2555-0185-0002
Drawing
1 (1)
HYUNDAI
MAN B&W 2565-0100-0003

Precautions
Camshaft Bearing, Data

see 0545-0100
O Shut off fuel oil
Data
T25-01 Screws for bearing cap, tightening torque 125 Nm
T25-03 Clearance between cap/bearing housing 3±0.3 mm
T25-07 Camshaft bearing cap kg
2013-02-04 - en
2565-0100-0003
Work Card
1 (2)
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Camshaft Bearing, Data
Tools
7670-0100 167 Angle union
2013-02-04 - en
2565-0100-0003
Work Card
2 (2)
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B&W 2565-0101-0002
1. Dismount the
Camshaft Bearing • Checking

Dismount the inspection covers from the
inspection covers for front of the camshaft housing.
checking
Check for wiped-out metal at the
bearing ends, and for fragments of metal
in the camshaft housing.
In the event of any signs of anomalies,

the bearing shell must be dismantled for
closer investigation and, if necessary,
the bearing shell must be replaced.
If no anomalies are found during the

visual inspection, dismantling need only
be carried out in connection with Class
surveys.
See Checking and Maintenance
Schedule, Major Overhaul.
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2565-0101-0002
Work Card
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Camshaft Bearing • Dismantling
Before dismantling any camshaft bearings, the main chain must be

relieved of tension by loosening the chain tightener to avoid damaging
engine parts.
1. Dismount the Remove the inspection covers on each

inspection covers side of the bearing from the camshaft
housing.
Dismount the lubricating oil connecting

pipe from the baseplate above the
bearing in question.
Lift the roller guide of the exhaust valve

hydraulic actuator.
2. Remove the bearing Loosen the bearing cap screws through

cap the inspection opening.
Remove the screws from the bearing

cap.
Remove the bearing cap from the

housing.
3. Place the hydraulic Place a hydraulic jack between two

jack pieces of wood in the camshaft housing
underneath the camshaft, close to the
bearing.
Place a dial gauge on the camshaft, and

lift the camshaft 0.20 mm.
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2565-0101-0002
Work Card
2 (5)
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B&W 2565-0101-0002
4. Remove the bearing Press lightly on the upper edge of the

shell shell to turn the shell up over the
Camshaft Bearing • Dismantling

camshaft.
Remove the shell from the camshaft

housing.
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2565-0101-0002
Work Card
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1. Inspect the bearing

Camshaft Bearing • Overhaul
For assessment of the bearing condition,

surface see Chapter 2545-0100, Bearings.
Inspect the entire surface of the bearing

journal for seizures.
If seizures are found on the bearing

journal surface (on account of bearing
breakdown), polish the surface with a
fine carborundum stone to re-establish a
bright and smooth surface.
By closely examining the sliding surface

of the bearing shell visually, an
impression can be formed of whether
the lubrication of the bearing surface has
been insufficient or entirely missing.
Normally, camshaft bearing damage
only occurs due to faulty lubrication.
Measure the thickness of the bearing

shell with a micrometer to check the
amount of wear.
Turning of the engine must not

take place until all camshaft
bearing shells are in place and the
hydraulic jack has been removed
from underneath the camshaft.
2. Clean and lubricate Clean the bearing journal, the bearing

support and the bearing shell.
Coat the bearing journal and the bearing

shell with plenty of lubricating oil. Mount
the shell on the camshaft, and turn it into
place.
2015-01-10 - en
2565-0101-0002
Work Card
4 (5)
HYUNDAI
MAN
MANB&W
B&W 2565-0101-0002
1. Mount the bearing
Camshaft Bearing • Mounting

Relieve the hydraulic jack of pressure to
shell lower the camshaft. Remove the dial
gauge, the pieces of wood and the
hydraulic jack from the camshaft
housing.
2. Mount the bearing Place the bearing cap on the camshaft

cap and mount the outermost bearing cap
screw.
Be careful not to scratch the

camshaft surface.
Tighten the outermost screw lightly by

hand until the clearance given in T25-3
is reached. Then mount and tighten the
innermost screw with a torque spanner.
See data T25-1. This procedure ensures
that the outermost screw will obtain the
correct torque.
Check the torque on the outermost

screw with a torque spanner.
Check the clearance T25-3 on both

sides of the camshaft. Then mount the
lubricating oil pipe.
3. Mount the inspection Clean the camshaft housing and mount

covers the inspection covers.
2015-01-10 - en
2565-0101-0002
Work Card
5 (5)
HYUNDAI
MAN B&W
MAN B&W 2565-0200-0008

Precautions
Crosshead Bearing, Data

see 0545-0100
Data
T14-42 Crosshead complete 950 kg
T22-54 Piston rod/crosshead, tightening torque 600 Nm
Piston rod/crosshead, tightening torque +
T22-61 100/35 Nm/˚
angle
T22-78 Piston complete 1000 kg
T25-12 Crosshead bearing, top clearance max. 0.50 mm
T25-13 Crosshead bearing, top clearance min. 0.15 mm
T25-14 Oil wedge length, L 10 mm
T25-15 Crosshead bearing cap 170 kg
T25-16 Crosshead bearing shell, upper 25 kg
T25-17 Crosshead bearing shell, lower 35 kg
T25-18 Crosshead bearing cap with bearing shell 200 kg
T25-19 Crosshead with piston and guide shoes 2300 kg
2013-03-11 - en
2565-0200-0008
Work Card
1 (2)
HYUNDAI
2565-0200-0008 MAN B&W
MAN B&W
Crosshead Bearing, Data
Tools
1470-0300 041 Wire guide
1470-0300 077 Chain for suspending piston
2013-03-11 - en
2565-0200-0008
Work Card
2 (2)
HYUNDAI
MAN B&W 2565-0201-0012
Tin-Aluminium Bearings
Crosshead Bearing • Checking

The top clearance between the journal and a new bearing shell is the result of a
summation of the production tolerances of the bearing assembly components.
The top clearance for a new bearing will normally be in the range stated in Data.
Note that the figures are to be used for guidance only.
For the top clearance of a specific bearing, see the measurement in the Testbed
Sheet from engine builder.
Open the crankcase door at the relevant cylinder.
Turn the crankthrow concerned to BDC.
2565-0201-0001C02
Clearance Use a selection of Kjaer-feelers to meas-

ure the clearance betweenthe tops of the
crosshead and the bearing shell.
2565-0201-0012
2013-03-04 - en
Work Card
2565-0201-0007C03
1 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Bearing clearance Perform the measurement by inserting a

snitable Kjaer feeler into the space be- T25-12

tween the piston rod and the crosshead T25-13
bearing cap.
Proceed until the space inherent to the

feeler coresponds to the actual clear-
ance. See Data.
2565-0201-0009C03
The difference between the actual clear-

ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing in-
stalled later) must not exceed 0.1 mm. If
so, the crosshead bearing must be disas-
sembled for inspection. See dismantling.
For evaluation of the bearing shell, see de-

2565-0201-0009C04
The wear limit for a crosshead bearing

Bearing wear shell is confined to a 50% reduction of
the oil wedge length L.
If the wear limit exceeds the 50% reduc-

tion, the bearing shell must be replaced
by a new one.
(Oil Wedge)
2565-0201-0012
L
1/2
2013-03-04 - en
Work Card
L
T25-14
2565-0201-0001C05
2 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Alternate checking method:

In case the reason for opening the crosshead bearing is a routine inspection, the
following procedure is sufficient.
Perform the clearance measurement shown in Checking,

section
Mount the two eyebolts and tackles in the top of the crankcase in the fore and
aft direction. Mount two eyebolts in the top of the guideshoes.
Turn to BDC, mount the connecting rod lifting attachments on the connecting
rod. Use tackles to hold the connecting rod in the vertical position.
Unscrew the crosshead bearing cap hydraulic nuts.

For operation of the hydraulic jacks, see work card 7665-0101.
Mount two eyebolts in the bearing

cap and use two small tackles in the
athwartship direction to lift the bearing
cap free of the guidepins and to keep
the bearing cap balanced.
2565-0201-0001C08
2565-0201-0012
2013-03-04 - en
Work Card
3 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Inspection of bearing Use the tackles in the crankcase top to

lift the crosshead and piston high

enough to allow inspection of the lower
crosshead bearing.
Ensure that the crosshead is lifted si-

NOTE multaneously fore and aft, i.e. by placing
marks on the guide planes using a felt T25-19
tipped pen.
If the lower bearing shows no anomalies

the piston and crosshead is lowered
again and the crosshead bearing cap
nuts are mounted.
Recheck the bearing top clearance. Re- 2565-0201-0001C09
move all tools.
If there are any doubt concerning damage to the upper bearing, the bearing has
to be dismantled and checked according to dismantling.
2565-0201-0012
2013-03-04 - en
Work Card
4 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Securing the piston This procedure applies to the following two dismantling situations:
Crosshead Bearing • Dismantling

rod with piston mounted
with piston removed
With piston mounted:
Piston rod foot Turn the crankshaft down far enough to

give access to the nuts and screws on
the piston rod.
2565-0201-0003D01
Securing chains Mount two chains in the inner screw

holes in the top of the crankcase, in the
athwarthship direction, for suspending
the piston rod.
2565-0201-0012
2013-03-04 - en
Work Card
2565-0201-0001D02
5 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Loosen hexagon Loosen and remove the locking wire

screws from
the screws on the piston rod foot. Re-
move the screws.
2565-0201-0001D03
Lifting eyebolts Mount a lifting eyebolt on each side of

the piston rod.
2565-0201-0001D04
2565-0201-0012
2013-03-04 - en
Work Card
6 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Suspend the piston Turn the crosshead to TDC.

rod
Hook the chains to the lifting eyebolts in
the piston rod.
Turn the crosshead downward, and the

piston rod will then remain suspended
from the two chains.
With piston removed: 2565-0201-0001D05
Turn to BDC.
Loosen hydraulic Place the spacer rings around the nuts

nuts and screw the hydraulic jacks on to the
studs.
Loosen the crosshead bearing cap nuts.

For operation of the hydraulic jacks, see
Remove the hydraulic jacks and the

spacer rings, and unscrew the nuts.
T76-1
2565-0201-0001D07
2565-0201-0012
2013-03-04 - en
Work Card
7 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Lifting tool Mount the lifting attachments on the

head of the connecting rod.
2565-0201-0001D08
Bearing cap removal Suspend two tackles from the lifting

brackets, in the athwarthship direction.
2565-0201-0012
2013-03-04 - en
Work Card
2565-0201-0001D09
8 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Lifting tool Mount the lifting tool on the top of the crosshead bearing cap.

Wire guide Mount the wire guide at the top of the
crankcase door frame to prevent dam-
age.
Hook the tackles on to the eyebolts, and

remove the bearing cap from the engine.
Check the upper part of the journal.
T25-18
2565-0201-0002D10
Land the bearing cap Place the bearing cap on one side on a
couple of wooden planks.
Check the bearing shell, see Checking.
T25-18
2565-0201-0001D11
2565-0201-0012
2013-03-04 - en
Work Card
9 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Preparation Fasten tackles to the fixed lifting

brackets on the frame box wall.
2565-0201-0001D12
Land the piston rod If the piston is suspended:
Turn the crosshead upwards until the

piston rod lands on the crosshead. En-
sure that the guide ring in the crosshead
fits correctly in the centre hole of the
piston rod.
Do not remove the chains or lifting eye-

bolts.
2565-0201-0001D13
2565-0201-0012
2013-03-04 - en
Work Card
10 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Attach tackles Turn to TDC and attach the tackle

hooks to the lifting attachments. Haul
the tackles tight.
2565-0201-0001D14
Crosshead supports Mount the two supports for guide shoes

on the web plate.
Carefully turn the crank down towards

the exhaust side, until the guide shoes
rest on the supports.
Adjust the support brackets to the guide

shoes so that the weight of the cross-
head is evenly distributed on the two
supports.
Haul the tackles tight.
2565-0201-0012
2565-0201-0002D15
2013-03-04 - en
Work Card
11 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Free the crankpin Turn the crankthrow carefully towards

BDC while ‘following’ with the tackles,

thus continuously supporting the con-
necting rod.
2565-0201-0001D16
Crosshead journal With the crosshead resting on the supports, check the lower part of the cross-
head journal and the lower bearing shell.
Regarding checking of journal and bearing shells, see description 2545-0100.

2565-0201-0012
2013-03-04 - en
Work Card
12 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Lower bearing shell In cases where it is necessary to remove

the lower bearing shell, tilt the connect-
ing rod towards the doorway on the
camshaft side, using the tackles.
Dismount the locking screws, and turn

the bearing shell.
T25-17
2565-0201-0001D18
2565-0201-0012
2013-03-04 - en
Work Card
13 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Remove bearing shell Lift the bearing shell out of the engine.
Crosshead Bearing • Mounting
With piston mounted/

With piston removed:
Mounting the bearing Mount and secure the bearing shell in

shell the bearing housing.
The excess height X is to ensure the

correct tighteningdown of the bearing
shell and must not be eliminated.
X X
2565-0201-0001M01
2565-0201-0012
2013-03-04 - en
Work Card
14 (18)
HYUNDAI
MAN B&W 2565-0201-0012
Raise the connecting Raise the connecting rod to an upright

rod position.
Turn to TDC while ‘following’ with the

tackles, for assembling the crosshead
and the connecting rod.
Take care that the bearing studs do not

NOTE damage the crosshead.
Take care that the guide shoes do not

damage the bearing shell.
Lubricate the crosshead bearing with

clean lube oil before “landing” the cross-
head journal in the bearing. 2565-0201-0001M02
Remove the supports Remove the supports from the web

plates.
Remove the tackles from the crosshead.
Turn the crank throw to BDC.
If the piston is mounted, slowly turn

down until it is fully suspended from the
chains.
2565-0201-0012
2565-0201-0002M03
2013-03-04 - en
Work Card
15 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Land the bearing cap Lift the bearing cap into the engine.
Lower the bearing cap onto the cross-

head and remove the tackles. Remove
the lifting attachments from the con-
necting rod and the wire guide from the
door frame.
T25-18
2565-0201-0001M04
Hydraulic nuts Tighten all four crosshead bearing cap

nuts simultaneously. See Data.
For operation of hydraulic jacks, see

Mount the piston.

See work card 2265-0401, Mounting.
T76-2
2565-0201-0001M05
2565-0201-0012
2013-03-04 - en
Work Card
16 (18)
HYUNDAI
MAN B&W 2565-0201-0012
With piston mounted:

Land the piston rod Turn the crosshead upwards until the
piston rod lands on the crosshead. En-
sure that the guide ring in the crosshead
fits correctly in the centre hole of the
piston rod.
2565-0201-0001M07
Unhook the chains Unhook the chains from the lifting eye-
bolts in the piston rod. Remove the
chains and eyebolts from the top of the
crankcase, from the piston rod and from
the crosshead bearing cap.
2565-0201-0001M08
2565-0201-0012
2013-03-04 - en
Work Card
17 (18)
HYUNDAI
2565-0201-0012 MAN B&W
Tighten hexagon Turn down to BDC, tighten the

screws screws in the piston rod, and lock with

locking wire.
Apply the locking wire in such a way that

the wire is tightened if a screw works
loose.
2565-0201-0001M09
2565-0201-0012
2013-03-04 - en
Work Card
18 (18)
HYUNDAI
MAN B&W 2565-0300-0004

Precautions
Cr a n k p i n B ea r i n g , Da t a
see 0545-0100
Data
T14-54 Connecting rod complete 2420 kg
T25-22 Crankpin bearing clearance, max. 0.70 mm
T25-23 Crankpin bearing clearance, min. 0.30 mm
T25-25 Crankpin bearing, upper shell 21 kg
T25-26 Crankpin bearing, lower shell 18 kg
T25-27 Crankpin bearing cap + shell + bearing studs 160 kg
T25-28 Piston + Crosshead + Connecting Rod 2000 kg
2 0 1 3 -0 3 -1 1 - e n
2565-0300-0004
W o r k Ca r d
1 (2)
HYUNDAI
2565-0300-0004 MAN B&W
MAN B&W
Crankpin Bearing, Data
Tools
1470-0300 041 Wire guide
2013-03-11 - en
2565-0300-0004
Work Card
2 (2)
HYUNDAI
MAN B&W 2565-0301-0004
Bottom Clearance
Crankpin Bearing • Checking

The bottom clearance between the journal and a new bearing shell is the result
of a summation of the production tolerances of the bearing assembly compo-
nents.
For the bottom clearance of a specific bearing, see the measurement in the Ad-
justment Sheet in Volume 4.
Open the crankcase door at the relevant

cylinder.
Turn the crank concerned to BDC.
2565-0301-0001C02
2565-0301-0004
2009-06-18 - en
Work Card
1 (10)
HYUNDAI
2565-0301-0004 MAN B&W
Measurement Measure the clearance in the crankpin

Crankpin Bearing • Checking
bearing by inserting a feeler gauge at

the bottom of the bearing shell in both
sides.
See Data for bottom clearance.
The difference between the actual

clearance measurement and the meas-
urement recorded in the Adjustment
Sheet (or the clearance noted for a new
bearing installed later) must not exceed
0.05 mm. If so, the crankpin bearing
must be disassembled for inspection.
See Dismantling.
T25-22
T25-23
2565-0301-0001C03
Bearing shell wear The wear limit for the crankpin

bearing shells is based on an evaluation
of the bearing condition at the time of
inspection.
An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.
For further external inspection of

the crankpin bearing, see Section
2545-0100.
2565-0301-0004
2009-06-18 - en
Work Card
T25-25
2565-0301-0001C05
2 (10)
HYUNDAI
MAN B&W 2565-0301-0004
Preparation Suspend two tackles from the lifting
Crankpin Bearing • Dismantling

brackets, in the athwartship direction.
Mount the wire guide in the top of the

crankcase door opening.
2565-0301-0001D01
Turn the crank to

Mount eyebolts in each side of the
TDC
crankpin bearing cap and, using shack-
les and wire ropes, hook on the tackles T76-1
and haul tight.
Loosen the crankpin bearing stud nuts,

using the hydraulic jacks.
For operation of the hydraulic jacks, see

Workcard 7665-0101.
Remove the hydraulic jacks and the

nuts.
Fit the protective screws on top of the

studs. The protective screws are found
on the tool panel.
2565-0301-0004
2009-06-18 - en
Work Card
2565-0301-0001D02
3 (10)
HYUNDAI
2565-0301-0004 MAN B&W
Bearing cap Lower the bearing cap while seeing T25-27

carefully that the studs do not damage

the crankpin journal.
Land the bearing cap on a couple of

planks placed in the oil pan.
Inspect the bearing shell.
2565-0301-0001D03
Removal If the bearing shell needs to be replaced,

remove the whole bearing cap from the T25-27
crankcase.
Suspend a tackle outside the engine

above the crankcase door opening.
Turn the crankthrow to the exhaust side

to give space for lifting out the crankpin
bearing cap.
Using the tackle from the frame box

inside wall, together with the tackle sus-
pended outside the engine, lift the bear-
ing cap out of the crankcase.
2565-0301-0001D04
2565-0301-0004
2009-06-18 - en
Work Card
4 (10)
HYUNDAI
MAN B&W 2565-0301-0004
Bearing shell Place the bearing cap on one side on a T2526

couple of planks.
Dismount the bearing shell lock screws

and replace the bearing shell by a new
one, if necessary.
The bearing shells must be replaced in 2565-0301-0003D05

pairs. If only one of the shells needs re-
placement, MAN Diesel should be con-
tacted for advise beforehand.
Crosshead support Turn to TDC.
Mount the two supports for guide shoes

on the webplates. T25-28
Carefully turn the crank to the camshaft

side and down until the guide shoes rest
on the supports.
Adjust the support brackets to the guide

shoes so that the weight of the cross-
head is evenly distributed on the two
supports.
2565-0301-0002D06
2565-0301-0004
2009-06-18 - en
Work Card
5 (10)
HYUNDAI
2565-0301-0004 MAN B&W
Connecting rod Mount a lifting attachment for securing

the connecting rod at the lower end, on

the camshaft side.
Hook the tackle on to the lifting attach-

ment.
2565-0301-0001D07
Bearing shell Carefully turn the crankshaft down-

inspection wards, while ‘following’ with the tackle,
making sure that the upper part of the
bearing comes completely clear of the
recess in the crankshaft when the parts
begin to ‘separate’.
If necessary suspend a second tackle

from the bracket below the doorway.
Continue turning the crankshaft until the

bearing surface can be freely inspected.
Inspect the bearing shell surface and the

crankpin journal.
2565-0301-0001D08
2565-0301-0004
2009-06-18 - en
Work Card
6 (10)
HYUNDAI
MAN B&W 2565-0301-0004
Bearing shell If it is necessary to replace the bearing

replacement shell, proceed as follows:
Turn the crankshaft to horizontal posi-

tion.
Release the tackle so that the connect-

ing rod is hanging freely.
2565-0301-0001D09
Removal of bearing Dismount the bearing shell lock

shell screws.
Lower the bearing shell and remove it

from the crankcase.
T25-25
2565-0301-0001D10
2565-0301-0004
2009-06-18 - en
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7 (10)
HYUNDAI
2565-0301-0004 MAN B&W
Inspection of bearing If necessary, replace the bearing shells

Crankpin Bearing • Mounting
shell with new ones. The bearing shells must

be replaced in pairs.
Bearing shells of three mm undersize

are available as spares in case of journal
rectification.
Coat the bearing shell surfaces and the

journal with clean oil. 2565-0301-0001M01
The excess height X is to ensure the

correct tighteningdown of the bearing
shell, and must not be eliminated.
Mounting of bearing Lift the upper bearing shell for the

shell crankpin concerned into the crankcase.
Carefully lift the bearing shell into posi-

tion in the connecting rod, and mount
the lock screws.
T25-25
2565-0301-0001M02
2565-0301-0004
2009-06-18 - en
Work Card
8 (10)
HYUNDAI
MAN B&W 2565-0301-0004
Connecting rod Hook the tackle on to a lifting pipe under

assembly the gallery platform and on to the lifting
attachment on the connecting rod, and
haul tight.
Carefully turn the crankshaft upwards,

while following up with the tackle, mak-
ing sure that the upper part of the bear-
ing enters the recess in the crankshaft
when the parts turn together.
Remove the tackle and the lifting attach-

ment from the connecting rod.
2565-0301-0001M03
Crosshead support Turn the crosshead to TDC.
Remove the guide shoe support brack-

ets from the crosshead guides.
2565-0301-0002M05
2565-0301-0004
2009-06-18 - en
Work Card
9 (10)
HYUNDAI
2565-0301-0004 MAN B&W
Landing the bearing Suspend the tackles from the lifting

T25-27
cap brackets in the side of the frame box.
Lift the bearing cap assembly into the

crankcase and land it on a couple of
planks placed in the oil pan.
Remove the wire guide tool from the

engine.
2565-0301-0001M05
Bearing cap assem- Hook the tackles on to the wire ropes

bly and lift the bearing cap into position
against the connecting rod.
Check that the protective screws are still

fitted on the studs.
During mounting, take care that the

studs do not damage the crankpin
NOTE journal, and check that the guide pins
mounted in the bearing cap enter the-
holes in the connecting rod.
Remove the protective screws.
Mount the nuts and, by means of spacer

rings and hydraulic jacks, tighten the T76-2
crankpin bearing cap. See Data.
2565-0301-0001M06
For operation of hydraulic jacks, see

Workcard 7665-0101.
Remove the tackles from the side of the frame box.

2565-0301-0004
2009-06-18 - en
Work Card
10 (10)
HYUNDAI
MAN B&W
MAN B&W 2565-0400-0004

Precautions
Main Bearing, Data

see 0545-0100
Data
T25-30 Main bearing, top clearance max. 0.65 mm
T25-31 Main bearing, top clearance min. 0.30 mm
T25-32 Main bearing cap 270 kg
T25-33 Main bearing shell, upper 17 kg
T25-34 Main bearing shell, lower 19 kg
2013-02-05 - en
2565-0400-0004
Work Card
1 (2)
HYUNDAI
2565-0400-0004 MAN B&W
MAN B&W
Main Bearing, Data
Tools
1070-1030 - Crankshaft tools
1470-0300 041 Wire guide
2570-0010 045 Pulley for wire for main bearing
2570-0010 070 Lifting tool for main bearing cap
2570-0010 082 Dismantling tool for main bearing shell
2570-0010 128 Retaining tool for main bearing shell
2570-0010 177 Mounting tool for thin bearing shell
2570-0010 189 Lifting tool for main bearing shell
2570-0400 - Main bearing hydraulic tools
2570-0430 - Main bearing measuring tools
2013-02-05 - en
2565-0400-0004
Work Card
2 (2)
HYUNDAI
MAN B&W 2565-0401-0006
General
Main Bearing • Checking

The condition of the main bearings (and the journal bearing) can be checked
by:
• Deflection readings
• Visual checking
• Edge checking and
• Measuring of top clearance.
Crankshaft deflection readings
Crankshaft deflection readings should be taken while the ship is afloat (i.e. not
while in dry dock).
As the alignment is influenced by the engine temperature as well as the loading

conditions, deflection measurements should, for comparison purposes, always
be made under nearly the same temperature and load conditions.
1. Place a dial gauge axially in the

crank throw opposite the crank
pin, as illustrated on the sketch.
The correct position is marked
with punch marks on the crank
throw.
See also Description 2545-0101.
2565-0401-0006
2565-0401-0001C01
2009-06-23
Work Card
Doc-ID: 2565-0401-0006 1 (27)

HYUNDAI
2565-0401-0006 MAN B&W
2. “Closing” of the crank throw “Positive” (+)

(compression of the gauge) is

regarded as negative (–) and
“opening” as positive (+).
“Negative” (-)
2565-0401-0001C02
3. Set the dial gauge to zero while in T

B1 position near BDC. Whilst turn
ing clockwise, take readings when
the throw passes the positions:
B1 (near bottom) C E
C (camshaft side)
T (top)
E (exhaust side) B1 B2
B
B2 (near bottom)
1/2 (B2+B1) = B Looking forward

B1
C
T
E
B2
2565-0401-0006
½ (B1+B2)=B
2009-06-23
2565-0401-0001C03
Work Card
2 (27) Doc-ID: 2565-0401-0006

HYUNDAI
MAN B&W 2565-0401-0006
4. When taking deflection readings

for the three aftmost cylinders, the
turning gear should, at each stop
page, be turned slightly back
wards to ease off the tangential
pressure on the turning wheel
teeth. Otherwise, this pressure
may falsify the readings.
For evaluation of the crankshaft de-

flection readings, see Description
2545-0100.
If the crankshaft deflection (align

ment indicator) is approaching the
tolerance limits (see Description
2545-0100), the two adjacent main
bearings must be checked for
wear. See next page for checking
of main bearing.
2565-0401-0001C04
If the bearings are found to be in
good order, MAN Diesel or the
engine manufacturer must be
contacted for checking of the bedplate alignment.
As reference, use the “after seatrial” deflection table.
The condition of the bearing can be checked as follows:
5. Visually look for bearing metal

fragments in the oil pan, and
check the filters for metal frag
ments.
Such fragments can be from the

crosshead, guide shoe or crank
pin bearings. If fragments are
found, the damaged bearing can
be found by edge checking with
a blade feeler.
General
Bearing damage usually propagates
rather quickly towards the edge
of the bearing where, eventually, it
2565-0401-0001C05
causes chips to be broken off, which
2565-0401-0006
means that loose pieces of white

2009-06-23
metal can fall down into the crankcase beneath the bearing support.
Work Card
Large, thick pieces will normally be found during a crankcase inspection, and
small, thin pieces can enter the filter. A check of the bearing edges together
with inspection of the crankcase and the filter normally provides a good indica
tion of the bearing condition.
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2565-0401-0006 MAN B&W
Checking the bearing edges

6. Bearing edges can be checked

with a blade feeler that can fol
low the bearing edge against the
journal all the way round on each
side. If white metal is missing
on the edge, the tip of the blade
feeler will enter the hole, thus
locating the damage. In most
cases this hole can be seen with
the naked eye as a dark spot
when using a strong flashlight.
Hole in
the edge
2565-0401-0001C06
7. The No. 1 and the two aftmost main bearings are difficult to access on the
whole circumference on each side, but it is often possible to bend the blade
feeler to suit the situation and, thus, reach as far round as possible.
2565-0401-0006
2009-06-23
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MAN B&W 2565-0401-0006
Wirefeeler

8. It is rather easy to make a
<1.2 mm
blade feeler (see sketch). The >0.7 mm 7-10 mm
feeler should be made from a 1
piece of steel wire (e.g. a weld
ing rod) approx. 0.61 m long
depending on the engine type,
and 2-3 mm thick. Approx.
7-10 mm of the wire should be
bent to an angle of approx.
65° to form a “feeler tip”. Grind
the tip smooth to obtain the
60-70
shape and dimension shown
on the sketch. Note that the
thickness of the white metal is 2-3 mm
approx. 1.5 mm, which is why
500-1000
the tip should be less than
1.2 mm thick, and bigger than
the max. top clearance. At the
other end of the tip, a “handle”
should be made by bending Wire feeler
a hook or similar in the same
direction as the tip.
The above dimensions of the

“wire-feeler” are guideline
NOTE values and may depend on
the engine type as well as indi 2565-0401-0001C08
vidual, personal designs.
9. If there is too large a difference

in the crankshaft deflection read
ings (autolog) check the clearance
in the individual bearings.
Bearing clearance checks

should also be carried out during
timebased overhauls and sur
veys.
If there is a suspicion of a dam

aged bearing, it is recommended
2565-0401-0006
to edge check the bearing, with

2009-06-23
out opening up.

Work Card
256504010001C09
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10. Before measuring, check that the

feeler blades are in good condi

tion without damaged or missing
blades.
The feeler is inserted along the

crank throw. When the feeler
touches on the journal, it is hori
zontally pushed against the clear
ance. Make sure that the feeler is
in contact with the bearing shell
before pushing the feeler blades
maximum 20 mm into the gap.
2565-0401-0001C10
11. The clearance is measured at

both the fore and the aft part of
the bearing.
The crank throw adjacent to the

bearing must be turned away
from TDC in order to provide suf
ficient room to perform the clear
ance measurement correctly.
The bearing clearances for a new

NOTE bearing stated in Data (see Data
2565-0400) are for guidance pur
poses only.
2565-0401-0001C11
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MAN B&W 2565-0401-0006
12. Note the following.

When a feeler blade with a rec
tangular cross section is used
to measure a curved clearance,
the resulting measured clearance
CM will be smaller than the actual
clearance CA. The difference be
tween CA and CM may be 0.03 to
0.005 mm.
Consequently, when the clear

ance stated in the datasheet is
0.25 mm the measured clearance
may be 0.20 mm and still be cor
rect.
Cm Ca
2565-0401-0001C12
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13. For example: During inspection 0,15 - 0,20 mm

a 0.35 mm feeler blade could en

ter the clearance, but a 0.40 mm
feeler blade could not. This 0,15 mm
means that the real clearance is
larger than 0.35 mm, but smaller
than 0.45 mm.
This is illustrated in the table

below:
GO NO GO 2565-0401-0001C13
T25-30 = 0.40 0.35 0.4

T25-31 = 0.20 0.15 0.10
The main purpose of scheduled main bearing clearance measurements is to

ascertain the relative wear of the bearing. See Description 2545-0100.
NOTE Note that the bearing clearances stated in the data sheet are for guidance
purposes only.
14. The difference between the actual

clearance measurement and the meas
urement recorded in the adjustment
sheet (or the clearance noted for a new
bearing installed later) must not exceed
0.10 mm. If it does, see Description
2545-0100.
For evaluation of the bearing, see

Description 2545-0100
Description 2545-0100.
If the bearing needs to be disassembled

for inspection, see Dismantling.
2565-0401-0006
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MAN B&W 2565-0401-0006
Positioning the crankshaft
Main Bearing • Dismantling

1. Dismantling of main bearing. Aftmost main bearing (= Journal bearing)
The bearings are divided into two

categories:
• main bearings
• aftmost main bearing, often re

ferred to as the “Journal bear
ing”
Main bearings
Thrust bearing
2565-0401-0001D01
2. Before any dismantling, check and note

down the main bearing top clearances
and crankshaft deflection readings for
the cylinder unit concerned.
2565-0401-0006
2565-0401-0001D02
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2565-0401-0006 MAN B&W
3. Turn the crank throw to the EXH-SIDE MAN-SIDE

position shown on the sketch and

in such a way that the top of the
studs are flush with the crank
throw.
Be sure that the crosshead for

the neighbouring cylinder is in a
NOTE higher position than for the cylin
der you are working on, otherwise
it will be impossible to lift the cap.
2565-0401-0001D03
Oil pipes
4. Disconnect the lubricating oil pipe

from the main pipe.
On some engines, the oil pipes for

NOTE the Axial Vibration Damper (AVD)
have to be removed together with
the oil pipe on main bearing No. 1.
Some engines have temperature

sensors fitted to the main, cross
NOTE head, and crankpin bearings.
These sensors must be carefully
handled to avoid damage.
2565-0401-0001D04
2565-0401-0006
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MAN B&W 2565-0401-0006
5. Mount the extension studs, the

spacers, the hydraulic jacks and
the nuts on the extension studs.
Loosen the main bearing stud
nuts, using the hydraulic jacks.
For operation of the hydraulic
jacks, see workcard 7665-0101
T76-1
2565-0401-0006D05
6. Remove the hydraulic main bear

ing tools from the engine. -010
1
7665
Unscrew and remove the nuts
from the main bearing studs.
Remove the rectangular nuts

washers from the bearing cap.
2565-0401-0006
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2565-0401-0001D06
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7. Mount the lifting tool on the main

bearing cap.
Install the pulley on the webplate

over the main bearing, and fix the
wire rope from the lifting tool in
the pulley.
Fit an eyebolt in one of the

threaded holes on the opposite
webplate. 2565-0401-0001D07
8. Install the wire guide as shown.
Move the lifting pipes below the

platform to the relevant cylinder. B A
Fit tackles in the following posi
tions: D
A + B: Two 1ton chain tackles,

below the platform.
C: One 1ton chain tackle.

C
D: One ½ton chain tackle, in
the eyebolt on the opposite
webplate.
2565-0401-0001D08
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MAN B&W 2565-0401-0006

P
D
9. Attach the wire rope from the

lifting tool to tackle A. A
Use tackle A to lift the main bear

ing cap free of the studs.
Owing to space limitations below

NOTE the web-plate, it might be neces
sary to remove the eyebolt from
the lifting tool.
2565-0401-0001D09
10. Pull the bearing cap clear of

the crosshead guides by using
chain tackle D.
A
T25-32
2565-0401-0001D10
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A
11. Attach tackle B to the eyebolt B
in the centre of the lifting tool.
Remove the balancing handle

from the main bearing cap lifting
tool. D
Tighten tackle B, and release
tackles A and D.
When released, remove tackle A 2565-0401-0001D11

from the wire rope and the wire
rope from the pulley.
T25-32
B
12. Lift the bearing cap out of the en
gine and land it on the gallery.
2565-0401-0001D12
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MAN B&W 2565-0401-0006

13. Mount the bearing shell lifting
tool on the upper main bearing
shell and lift the shell out of the
engine.
T25-33
2565-0401-0001D13
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14. If the crankshaft is turned without

the bearing cap installed, use the
two stops to prevent the lower
shell from being rolled out.
2565-0401-0001D14
15. Place the crosspiece in the bed

plate with the ends resting on the
cross girders, and position the
hydraulic jacks beneath the crank
webs as shown.
Tighten the screws against the

crank webs and compress the
jacks.
Connect the hydraulic jacks to the

highpressure pump, and raise
the pressure until the crankshaft
has been lifted 0.20.5 mm, but
not higher than the clearance in
the two adjacent bearings.
Note down the pressure for later

reference.
2565-0401-0006
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2565-0401-0001D15
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MAN B&W 2565-0401-0006

16. Remove the locking screws.
Place the dismantling tool on top

of the lower bearing shell. Make
sure that the flap on the dismant-
ling tool enters the oil groove in
the bearing shell.
2565-0401-0001D16
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2565-0401-0006 MAN B&W
min
0.1 mm
17. Check that there is min. 0.1 mm

clearance between journal and
bearing shell, or between bearing
shell and main bearing support, in
both sides of the journal.
EXH CAM
The feeler blade must be inserted

minimum 60 mm into the gap to
NOTE pass the bore relief in the bearing
Min. 60 mm
shell.
If the clearance is less than 0.1

mm, move the crosspiece side
ways until clearance is obtained.
Normally, adjustment needs to be
50150 mm to the exhaust side
(the side where the clearance is
missing).
256504010001D17
The lower shell must be lifted out to the side with the most clearance, which
is normally the fuel pump side.
NOTE
18. If repositioning of the crosspiece

does not ensure a vertical lift,
place a 5ton jack between the
side wall and the crank throw, to
correct the journal position in this
way.
If it is available, note down the

pressure applied to the jack. This
data is used to ensure that the
crankshaft is in the same position
2565-0401-0006
when the new bearing is installed.

2009-06-23
Work Card
It is recommended that the crank

shaft lifting tool is only removed if
NOTE it is urgently necessary, and then
only after the main bearing shell 2565-0401-0001D18
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HYUNDAI
MAN B&W 2565-0401-0006
has been reinstalled.

19. Pull the lower shell round and
up until it lies over the main bear
ing journal. Never use a tackle
larger than 0.5 ton.
It is recommended to hold a foot

or hand on the wire rope, to tight
NOTE en it up and observe whether the
shell is sticking.
2565-0401-0001D20
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2565-0401-0006 MAN B&W
20. Take out the lower shell from the

engine in the same way as the
upper shell, i.e. using the lifting
tool.
T25-43
2565-0401-0001D21
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MAN B&W 2565-0401-0006
Main Bearing • Overhaul

1. Clean and inspect the bearing
shells.
For judging the condition of the
bearing, see Description
2545-0100.
If a bearing is damaged and re

placement of one or two bearing
shells is necessary, contact MAN
Diesel for advice.
2565-0401-0001O01
2. Before remounting:
• Check the bearing support for damage and burrs. If damage is found,
contact MAN Diesel for advice.

• Make sure that all parts are clean, use nonfluffy cloth to clean between
journal and main bearing support.
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2565-0401-0006 MAN B&W
Main Bearing • Mounting
• Lubricate the bearing journal, the main bearing support and the back of
the lower shell.
Installation of bearing shells T25-34

1. Lubricate the journal and the
bearing support with clean oil
Using the bearing shell lifting

tool, lift the lower bearing shell
into the crankcase and land it on
the crankshaft journal.
2565-0401-0001M01
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MAN B&W 2565-0401-0006

2. Position the guide tool for the
lower bearing shell on the main
bearing support. Remove the
lifting tool from the bearing shell.
Place the lower bearing shell on

the journal and push it down by
hand.
To ensure that the shell is cor

rectly installed, check that the
distance from the main bearing
support to the shell is equal in
both sides.
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3. Fit the locking screws in the

bearing support.
Lower the crankshaft and re

move the hydraulic jacks and
the crosspiece from below the
crankshaft.
Wipe clear the contact surfaces

between the upper and the
lower bearing shells with a non-
fluffy piece of cloth.
2565-0401-0001M03
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4. Land the upper bearing shell
on the main journal in the same
way as the lower bearing shell.
Make sure that none of the

edges of the upper bearing
shell are resting on the edge of
the bearing support.
If necessary, place the special

tool between the studs and
press the shell into place.
Clean the contact surfaces

between the bearing support
and the bearing cap. Make sure
that no oil is left on the contact
surfaces.
2565-0401-0001M04
5. Mount the lifting tool on the

bearing cap.
Using the tackles and pulleys,

lift the cap into the crankcase in
reverse order to dismantling.
See Dismantling.
Be sure that the cap lands cor

rectly and that the spring pin in
NOTE the asembly surface enters the
2565-0401-0001M05
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2565-0401-0006 MAN B&W
hole in the bearing cap. T25-32

6. Mount the lifting tool on the

bearing cap using the lifting tool B
and the tackles, lift the bearing
cap into the crankcase in the
reverse order to dismantling.
See Dismantling.
Using the pulleys installed in

side the crankcase, move the
bearing cap into position verti
cally above the main bearing
upper shell in the reverse order
to dismantling.
2565-0401-0001M06
7. Mount the hydraulic jacks.
Use the hydraulic jacks to fully

tighten the nuts on both sides
of the bearing cap.
For tightening pressure, see

Data.
For operation of the hydraulic T76-2
jacks, see Workcard 7665-0101.
2565-0401-0006
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8. Measure the clearance between

the upper main bearing shell
and the crankshaft journal, see
Checking, and note down for later
reference.
Compare the clearance with the

required clearance as stated in
Data. If necessary, the bearing
cap and the upper bearing shell
must be dismantled and the
number of shims readjusted.
Connect the lubricating oil pipe

from the main pipe.
Connect the lubricating oil pipe

from the main pipe.
The engine may be equipped

with a bearing wear monitoring
(BWM) system. If the bracket for
the BWM probe has been dis
mantled, re-mount the bracket
and re-adjust the BWM system
according to the manufacturer’s
instructions.
2565-0401-0001M13
9. Remove all the tools from the

engine.

NOTE that no tools, shackles or rags
are left behind.
2565-0401-0006
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MAN B&W 2565-0500-0004

Precautions
Journal Bearing, Data

see 0545-0100
Data
T25-40 Journal bearing, top clearance max. 0.65 mm
T25-41 Journal bearing, top clearance min. 0.3 mm
T25-42 Journal bearing cap 270 kg
T25-43 Upper bearing shell 17 kg
T25-44 Lower bearing shell 19 kg
T25-45 End cover 160 kg
2013-02-05 - en
2565-0500-0004
Work Card
1 (2)
HYUNDAI
2565-0500-0004 MAN B&W
MAN B&W
Journal Bearing, Data
Tools
1070-1040 - Thrust shaft tools
2570-0010 070 Lifting tool for main bearing cap
2570-0010 128 Retaining tool for main bearing shell
2570-0010 177 Mounting tool for thin bearing shell
2570-0010 189 Lifting tool for main bearing shell
2570-0400 - Main bearing hydraulic tools
2570-0430 - Main bearing measuring tools
2013-02-05 - en
2565-0500-0004
Work Card
2 (2)
HYUNDAI
MAN B&W 2565-0501-0005
Aftmost main bearing (=Jurnal bearing)

1. Check the journal bearing in the
Journal Bearing • Checking

same way as the remaining main
bearings, see Workcard
2565-0401.
Main bearing
Thrusat bearing
2565-0501-0001C01
2. Write down the journal bearing clearances.
2565-0401-0001D02
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3. Also check the journal bearing

Journal Bearing • Checking
by visually searching the area

underneath the bearing support
for bearing material.
2565-0501-0001C03
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MAN B&W 2565-0501-0005
1. Dismount the screws for the end cover.
Journal Bearing • Dismantling

Mount a tackle above the end cover.
Remove the end cover, T25-45.
2. Disconnect the lubricating oil pipe

from the main pipe.
Remove the protective shield for

the thrust bearing.
Turn the crank throw for the aft-

most cylinder to horizontal posi-
tion. Remove other piping if nec-
essary.
2565-0501-0005D02
3. Mount the extention studs, the

spacers, the hydraulic jacks and
the nuts on the bearing stud nuts,
using the hydraulic jacks.
T76-1
2565-0501-0005
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4. For operation of the hydraulic

101
tools, see Workcard 7665-0
7665-0101.
2565-0501-0001D04
5. Remove the hydraulic main bearing tools from the engine
Unscrew and remove the nuts from the bearing studs.
As piping may vary, the amount of piping necessary to be removed may

NOTE also vary.
6. Mount the lifting attachment on the

journal bearing cap, and lift the cap
out of the engine using the tackle.
Use a pull lift mounted on the oppo-

T25-42
site webplate to guide the vertical lift.
2565-0501-0005
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MAN B&W 2565-0501-0005
7. Mount a tackle on the lifting

beam on the exhaust side en-
gine gallery.
Lift the journal bearing cap out

through the cutout in the engine
wall in the exhaust side.
2565-0501-0001D07
8. Mount the lifting attachment on

the upper shell, and lift the shell
out of the engine.
T25-43
2565-0501-0001D08
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9. Place the crosspiece under the

turning wheel as shown. Mount a

dial gauge to measure the lift of
the crankshaft.
Tighten the screw against the

turning wheel and compress the
jacks.
Connect the hydraulic jacks to the

highpressure pump, and raise
the pressure until the crankshaft
has been lifted 0.20.5 mm, but
max. the clearance in the adja-
cent bearing.
2565-0501-0001D09
10. Dismount the locking screws.
Place the dismantling tool on

top of the lower bearing shell.
Make sure that the flap on the
dismantling tool enters the oil
groove in the bearing shell.
Pull the lower bearing shell

round and upwards until it lies
over the bearing journal. Never
use a tackle larger than ½ton.
2565-0501-0001D10
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11. Take the lower shell out of the

engine in the same way as the up-
per shell, i.e. using the lifting tool.
T25-44
2565-0501-0001D11
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1. Clean and inspect the bearing

Journal Bearing • Overhaul
shells. It is recommended that

the main bearing shells be re-
placed in pairs.
If it is nevertheless desired to
replace only one shell, this re-
quires a careful evaluation of the
condition of the shell that is to be
reinstalled.
See Instruction book, Chapter
2545.
For advice on replacing individual

bearing shells, it is recommend- 2565-0501-0001O01
ed to contact MAN Diesel A/S or
the engine builder.
2. Before remounting:
• Check the bearing support for damage and burrs. If damage is

found, contact MAN Diesel for advice.
• Make sure that all parts are clean, use nonfluffy cloth to clean
between journal and bearing support.
• Lubricate the bearing journal, the bearing support and the back
of the shell, with main engine lubricating oil.
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1. Lubricate the journal, the lower
Journal Bearing • Mounting

bearing shell and the bearing sup-
port with clean oil.
Using the bearing shell lifting tool,

lift the lower bearing shell into
T25-44
the crankcase and land it on the
crankshaft journal.
2565-0501-0001M01
2. Position the guide tool for the

lower bearing shell on the bear-
ing support. Remove the lifting
tool from the bearing shell.
Lubricate the journal, the lower

bearing shell and the bearing
support with clean oil.
Place the lower bearing shell on

the journal and push it down by
hand.
To ensure that the shell is cor-

rectly mounted, check that the
2565-0501-0001M02
distance from the bearing sup-
port to the shell is equal in both sides.
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3. Remove the guide tool when the

lower bearing shell has been

mounted.
Mount the locking screws in the

bearing support.
Lower the crankshaft and re-

move the hydraulic jacks and
the crosspiece from under the
crankshaft.
Wipe the contact surfaces

between the upper and the
lower bearing shells clean with a
nonfluffy piece of cloth.
2565-0501-0001M03
4. Land the upper bearing shell on

the main journal in the same way
as the lower bearing shell.
Make sure that none of the edg-

es of the upper bearing shell are
resting on the edge of the bear-
ing support.
If necessary, place the special

tool between the studs and
press the shell into place.
Clean the contact surfaces be-

tween the bearing support and
2565-0501-0001M02
the bearing cap. Make sure that
no oil is left on the contact surfaces.
2565-0501-0005
2009-06-25
Work Card
10 (13) Doc-ID: 2565-0501-0005

HYUNDAI
MAN B&W 2565-0501-0005
5. Mount the lifting tool on the bearing cap. Using the lifting tool and the tack-

les, lift the bearing cap into the crank casing in reverse order to dismantling.
6.
Be sure that the cap lands cor-

NOTE rectly and that the guide pin in
the assembly surface enters the
hole in the bearing cap.
2565-0501-0001M06
7. Mount the nuts, the spacer rings,

the hydraulic jacks, and tighten
the nuts.
See Data.

tools,
T76-2
2565-0501-0005
2009-06-25
Work Card
2565-0401-0006M11
Doc-ID: 2565-0501-0005 11 (13)

HYUNDAI
2565-0501-0005 MAN B&W
8.
Before removing the hydraulic

NOTE jacks, check the top clearance
between the upper bearing shell
and the journal.
T25-40
T25-41
See Workcard 2565-0401, how to
NOTE use feeler blades.
256504010001M08
9. Remove all tools from the engine.

NOTE that there are no tools, shackles
or rags left behind.
256504010001M09
2565-0501-0005
2009-06-25
Work Card
12 (13) Doc-ID: 2565-0501-0005

HYUNDAI
MAN B&W 2565-0501-0005
10. Mount all disassembled piping,

and mount the end cover.
2565-0501-0001M10
2565-0501-0005
2009-06-25
Work Card
Doc-ID: 2565-0501-0005 13 (13)

HYUNDAI
MAN B&W
MAN B&W 2565-0600-0001

Precautions
Thrust Bearing, Data

see 0545-0100
Data
T25-45 End cover 117 kg
T25-48 Thrust bearing segment 18 kg
T25-49 Segment stopper 15 kg
2013-02-20 - en
2565-0600-0001
Work Card
1 (2)
HYUNDAI
2565-0600-0001 MAN B&W
MAN B&W
Thrust Bearing, Data
Tools
2570-0010 104 Tool for turning out segments
2570-0020 - Segment stopper hydraulic tools
2013-02-20 - en
2565-0600-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 2565-0601-0001.0
The clearance in the thrust bearing was measured during testbed trials of the
Thrust Bearings • Checking

engine and noted down in the ‘Adjustment Sheet’. See description 6345-0100.
For a new engine the clearance is 0.51.0 mm, and for an engine in service it
must not exceed 2.0 mm.
In service it is only necessary to measure the wear of the thrust bearing pads,
and to inspect for white metal below the thrust bearing.
1. To measure the wear in the thrust

bearing, it is necessary to dis
mount the foremost segment
stopper.
For dismantling the segment stop-
per, see Dismantling.
A wear groove of 1 mm is posi

tioned in the uppermost thrust
segment. (The segment with ther
mometers).
2565-0601-0001C01
2. To measure the wear, the thrust

segment has to be pressed
against the thrust cam, to eliminate
any gap, i.e. by using a suitable
crowbar on the back of the seg
ment.
If a feeler gauge of 0.1 mm is not

able to enter the groove (the wear
is more than 0.9 mm), the thrust
bearing must be overhauled.
2565-0601-0001.0
2013-03-13
Work Card
2565-0601-0001C02
Doc-ID: 2565-0601-0001.0 1 (6)

HYUNDAI
2565-0601-0001.0 MAN B&W
3. Note down the wear for later reference.

Thrust Bearings • Checking
2565-0601-0001C03
2565-0601-0001.0
2013-03-13
Work Card
2 (6) Doc-ID: 2565-0601-0001.0

HYUNDAI
MAN B&W 2565-0601-0001.0
1. Remove the end cover of the engine.
Thrust Bearings • Dismantling

Remove the lub. oil pipe from the
thrust segments.
If necessary, remove the lub. oil pipe T2545

for the aftmost main bearing shell.
2565-0301-0001D01
2. Remove the protective shields

from the thrust collar.
T2549
Loosen and remove the nuts from
the segment stoppers. T761
jacks, see Workcard 7665-0101.
Screw an eye bolt into the stop

pers that are to be removed.
Suspend a tackle above each

stopper and hook the tackle on
to the eye bolt.
Remove the stoppers from the

chain drive above the thrust seg
ments (ahead or astern) that are to 2565-0601-0001D02
be taken out.
2565-0601-0001.0
2013-03-13
Work Card
Doc-ID: 2565-0601-0001.0 3 (6)

HYUNDAI
2565-0601-0001.0 MAN B&W
3. Suspend a tackle from the chain

Thrust Bearings • Dismantling
tightener bracket above the seg

ments which are to be removed.
For turningup the thrust seg

ments, mount the segment tool
on the thrust collar.
2565-0601-0001D03
4. Turn up the segments by turn

ing the engine, and remove them
from the chain casing.
T24-48
Do not remove all the segments

NOTE from the bearing at the same
time.
The “last” segment can be turned

out to the opposite side, or new
segments can be fitted on top of
2565-0601-0001D04
the segment tool.
2565-0601-0001.0
2013-03-13
Work Card
4 (6) Doc-ID: 2565-0601-0001.0

HYUNDAI
MAN B&W 2565-0601-0001.0
1. Land the segment on the journal

T25-48
Thrust Bearings • Mounting

and remove the eye bolt from the
segment.
Turn the shaft a little. Land the next

segment. Repeat this process until
all segments have been mounted.
2565-0601-0001M01
2. After the last segment has been

mounted, turn the segment tool
up and dismount it.
2565-0601-0001M02
2565-0601-0001.0
2013-03-13
Work Card
Doc-ID: 2565-0601-0001.0 5 (6)

HYUNDAI
2565-0601-0001.0 MAN B&W
3. Mount the protective shields for the

Thrust Bearings • Mounting
thrust collar.
4. Mount the segment stoppers.
Mount the hydraulic jacks and tighten the nuts on the stoppers.
See data T76-2.
5. Mount the lub. oil pipe for the thrust

segments.
If dismantled, mount the lub. oil pipe

for the aftmost main bearing.
2565-0601-0001M05
6. Mount the end cover.

2565-0601-0001.0
2013-03-13
Work Card
6 (6) Doc-ID: 2565-0601-0001.0

2013-02-06 - en
MAN B&W
HYUNDAI
Plate B ea r i n g P a n el To o l s
2570-0010-0015
1 (2)
2570-0010-0015
HYUNDAI
2570-0010-0015 MAN B&W
Item no
B ea r i n g P a n el To o l s

021 - Name plate
045 - Pulley for wire for main bearing
070 - Lifting tool for main bearing cap
082 - Dismantling tool for main bearing shell
094 - Mounting tool for thin bearing shell
104 - Tool for turning out segments
128 - Retaining tool for main bearing shell
130 - Lifting tool for relief valve
177 - Mounting tool for thin bearing shell
189 - Lifting tool for main bearing shell
307 - Tool for turning out segments
2570-0010-0015
2013-02-06 - en
Plate
2 (2)
2014-08-28 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Main Bearing Hydraulic Tools
1 (2)
2570-0400-0022
2570-0400-0022
HYUNDAI
2570-0400-0022 MAN
MANB&W
B&W
Item No. Qty Item Designation

Main Bearing Hydraulic Tools

248 - Stud setter
273 - Tommy bar
307 - Hex key
320 - Lifting tool
332 - Extension stud for hydraulic jack
344 - Nut
370 - Instruction plate
2014-08-28 - en
2570-0400-0022
Plate
2 (2)
2010-08-29 - en
MAN
MANDiesel
B&W
HYUNDAI
Plate Main Bearing Measuring Tools

2570-0430-0005
1 (2)
2570-0430-0005
HYUNDAI
2570-0430-0005 MAN B&W
MAN Diesel

Main Bearing Measuring Tools
013 - Feeler gauge set

025 - Feeler gauge set
062 - Feeler gauge, 0.05mm
300 - Spare tip for feeler gauge, 0.05mm
2570-0430-0005
2010-08-29 - en
Plate
2 (2)
2014-10-14 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Camshaft Bearing

2572-0110-0022
1 (2)
2572-0110-0022
HYUNDAI
2572-0110-0022 MANMAN
B&WB&W
Item No. Qty Item Designation

Camshaft Bearing
017 - Cam lock washer 1)

029 - Screw
030 - Sealing ring
042 - Straight screwith conn
054 - Connecting piece
078 - High pressure pipe
113 - Screw
125 - Guide pin
149 - Drain pipe, complete
150 - Stud coupling
162 - T-coupling
174 - Adjustable elbow coupling
186 - Sealing ring
198 - Base plate
208 - Sealing ring
221 - Straight screwith conn
233 - Connecting piece
269 - Nut
270 - Stud
282 - Stud
294 - Connecting pipe
304 - Packing ring
316 - O-ring
328 - Plug screw
341 - Packing ring
353 - Elbow connection
365 - Bearing cap
377 - Bearing shell
389 - Flange screw
390 - Bearing cap
400 - Guide pin
412 - Guide disc
424 - Bearing shell
Note: 1)
* Cam lock washers are to be supplied by MAN Diesel
Turbo only.
2014-10-14 - en
2572-0110-0022
Plate
2 (2)
HYUNDAI
MAN B&W 2572-0200-0001.0
Crosshead Bearing
1472-0300
1472-0300
028
016
041
2572-0200-0001.0
1472-0300
Plate
Doc-ID: 2572-0200-0001.0 1 (2)

HYUNDAI
2572-0200-0001.0 MAN B&W

Crosshead Bearing
016 - Crosshead bearing, complete

028 - Crosshead bearing shell, upper*
041 - Crosshead bearing shell, lower*
2572-0200-0001.0
Note: * To be ordered as a complete part only.

Plate
2 (2) Doc-ID: 2572-0200-0001.0

HYUNDAI
MAN Diesel
MAN B&W 2572-0300-0002
Connecting Rod Bearing

2572-0300-0002
2008-08-19
Plate
Doc-ID: 2572-0300-0002 1 (2)

HYUNDAI
2572-0300-0002 MANDiesel
MAN B&W

Connecting Rod Bearing
021 - Connecting rod bearing, complete

033 - Connecting rod bearing shell, upper*
045 - Connecting rod bearing shell, lower*
2572-0300-0002
2008-08-19
Note: * To be ordered as a complete part only.

Plate
2 (2) Doc-ID: 2572-0300-0002

2012-05-31 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Main Bearing

2572-0400-0004
1 (2)
2572-0400-0004
HYUNDAI
2572-0400-0004 MANB&W
MAN B&W

Main Bearing
013 - Main bearing, complete*

025 - Main bearing, upper shell
037 - Main bearing, lower shell
2572-0400-0004
2012-05-31 - en
Note: * When ordering, please specify between which cylinders the bearings are mounted.
Plate
2 (2)
HYUNDAI
MAN Diesel
MAN B&W 2572-0600-0001.0
Thrust Bearing, Segments

2572-0600-0001.0
Plate
Doc-ID: 2572-0600-0001.0 1 (2)

HYUNDAI
2572-0600-0001.0 MANDiesel
MAN B&W

Thrust Bearing, Segments
010 - Segment
022 - Segment*
2572-0600-0001.0
Note: * More units are installed. They are identical.

Plate
2 (2) Doc-ID: 2572-0600-0001.0

2013-02-19 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Thrust Bearing, Miscellaneous

2572-0650-0022
1 (2)
2572-0650-0022
HYUNDAI
2572-0650-0022 MANB&W
MAN B&W

Thrust Bearing, Miscellaneous
013 - Scraper ring housing, complete

037 - Screw
050 - Scraper ring housing, upper
062 - Fitted bolt
074 - Screw
121 - Scraper ring housing, lower
133 - Plug screw
157 - Lubricating oil pipe
169 - Screw
182 - Stopper segment
194 - Stopper segment
241 - Screw
277 - Screw
289 - Flange
312 - Nut
324 - Stud
336 - Screw
361 - Spray pipe
373 - Spray pipe
419 - Stud
444 - Spring
468 - Dowel
493 - Oil throw ring, complete
527 - Spray nozzle
540 - Spray nozzle
564 - Spray nozzle
2572-0650-0022
2013-02-19 - en
Plate
2 (2)
HYUNDAI
MAN B&W
Preface Chapter Lubricating Oil System ..................... ..................... 3040-0100-0001
Lubricating Oil System

Description Cylinder Lubrication ....................... ....................... 3045-0110-0009
Circulating Oil and Oil System ............... ............... 3045-0120-0002
Maintenance of Circulating Oil System ......... ......... 3045-0130-0005
Turbocharger Lubrication ................... ................... 3045-0140-0002
Camshaft Lubrication for Engines with Uni-Lube 3045-0160-0002
System ................................ ................................
Drawing Cylinder Lubricating Oil Pipes ................ ................ 3055-0110-0002
Circulatiing Oil System - Outside Engine (Engines 3055-0115-0002
with Uni-Lube System) ..................... .....................
Circulatiing Oil System - Inside Engine ......... ......... 3055-0125-0002
Flushing of Main Lubricating Oil System - Location 3055-0130-000
of Chackbag and Blank Flanges .............. ..............
Cleaning System - Stuffing Box Drain Oil (Option) . 3055-0135-0002
Camshaft Lubricating Oil Pipes (Engine with Uni- 3055-0140-0002
Lube System) ............................ ............................
Flushing of Camshaft Lubricating Oil System .... .... 3055-0150-0002
Turbocharger Lubrating Oil Pipes ............. ............. 3055-0155-0002
Work Card Lubricating Oil, Data ....................... ....................... 3065-0150-0001
Lubricating Oil ........................... ........................... 3065-0151-0001
Cylinder Lubricator, Data .................... ................... 3065-0600-0001
Cylinder Lubricator ........................ ........................ 3065-0601-000
Plate Cylinder Lubricator ........................ ........................ 3072-0600-0007
Cylinder Lubricator ........................ ........................ 3072-0700-0023
Table of contents
1 (1)
HYUNDAI
MAN B&W
MAN B&W 3040-0100-0001
Cylinder Lubricators

The engine is equipped with electronically controlled cylinder lubricators for lubri-
cation of the running surface of liners and rings.
See chapter 3045-0110.

2012-11-05 - en
3040-0100-0001
Preface
1 (1)
HYUNDAI
MAN
MANB&W
B&W 3045-0110-0009
Cylinder Lubrication
1 Lubricators
Each cylinder liner has a number of lubricating quills, through which oil is intro-
duced from the Lubricators.
There are three different types of lubricators available for B&W engines:
▪ ME-lubricators (integrated with the ME engine ECS system).
▪ Alpha lubricators for MC engines.
▪ Mechanical lubricators for MC engines.
For the specific lubricator system installed, please see individual instruction book.
The oil is pumped into the cylinder (via non-return valves) when the piston rings
pass the lubricating orifices, during the upward stroke.
2 Cylinder Oil Film

The purpose of cylinder lubrication is as follows:
1. To create a hydrodynamic oil film separating the piston rings from the liner. The
oil amount needed to create an oil film is more or less independent of the fuel
being used. Measurements of the oil film have also revealed that when the feed
rate for optimum oil film is reached no further increase of the oil film is obtained
from an increase of the feed rate, the optimum is kept safely down to a feed rate of
0.60 g/kWh.
2. To clean the piston rings, ring lands and ring grooves. Cleaning of piston rings,
ring lands and grooves is essential, and relies on the detergency properties of the
cylinder oil. All approved cylinder oils fulfil the requirements, even at a feed rate as
low as 0.60 g/kWh.
3. Control of cylinder liner corrosion, i.e. neutralisation of sulphuric acid. The com-
bustion process creates highly corrosive sulphuric acids depending on the sulphur
content in the fuel. To obtain an optimal corrosive level of the cylinder liner, the
ACC factor for the cylinder oil feed rate must be set according to instructions. The
ACC (Adaptive Cylinder oil Control) concept ensures a correct cylinder oil feed rate
level in relation to the fuel oil Sulphur content.
If a satisfactory cylinder condition is to be achieved, it is of vital importance that the
oil film is intact. Therefore, the following conditions must be fulfilled:
1. The cylinder lubricators must be correctly timed.
2. The cylinder oil type and BN must be selected in accordance with the fuel being
burned.
3. New liners and piston rings must be carefully run-in, see drawing 2255-0125.
4. The oil feed-rate (dosage) under normal service must be in accordance with the
engine builder’s recommendations. Furthermore, the dosage feed rate must be
adjusted in accordance with the service experience for the actual trade (obtained
from the scavenge port inspections).
3 Cylinder Oils
2014-01-31 - en
3045-0110-0009
The tables below indicates international brands of cylinder oils that have been tes-
ted in service with acceptable results, and some of the oils have also given long
Description
term satisfactory serivce during heavy fuel operation in MAN B&W engines.
Do not consider the list complete, as oils from other companies can be equally
suitable. Further information can be obtained by contacting the engine builder or
MAN Diesel & Turbo, Copenhagen.
1 (2)
HYUNDAI
3045-0110-0009 MANB&W
MAN B&W
MAN Diesel & Turbo recommend the use of cylinder oils with the following main
properties:
Cylinder Lubrication
▪ SAE 50 viscisity
▪ High detergency
▪ Alkalinity (BN) must be chosen according to the applied fuel sulpher content
and engine design
For Mark 8.1 engines and higher the following oils are recommended:
Cylinder oils
Oil company Oil name Specified BN level
Aegean Alfacylo 540 LS 40
Alfacylo 100 HS 100
BP CL-DX 405 40
Energol CL 100 ACC 100
Castrol Cyltech 40SX 40
Cyltech CL 100 ACC 100
Chevron Taro special HT LS 40 40
Taro Special HT 100 100
ExxonMobil Mobilgard L540 40
Mobilgard 5100 100
Gulf Oil Marine Gulfsea Cylcare DCA 5040H 40
Gulfsea Cylcare 50100 100
JX Nippon Oil & Marine C405 40
Energy
MC-1005-8* internal code 100
Lukoil Navigo 40 MCL 40
Navigo 100 MCL 100
2014-01-31 - en
3045-0110-0009
Shell Alexia S6 100

Description
Sinopec Marine Cylinder Oil 5040 40

Total Talusia LS 40 40
Talusia Universal 100 100
2 (2)
HYUNDAI
MAN B&W
MAN B&W 3045-0120-0002
1 Circulating Oil
Circulating Oil and Oil System

Lubricating and cooling oil
Rust and oxidation inhibited engine oils, of the SAE 30 viscosity grade, should be
chosen.
In order to keep the crankcase and piston cooling space clean of deposits, the oils
should have adequate dispersancy/detergency properties.
Alkaline circulating oils are generally superior in this respect.
The international brands of oils listed below have all given satisfactory service in
one or more MAN diesel engine installation(s).
Company Circulating oil SAE 30, BN 5-10

BP Energol OE-HT30
Castrol Marine CDX 30
Chevron Veritas 800 Marine 30
Exxon Mobil Mobilgard 300
Shell Melina S 30
Total Atlanta Marine D3005
The list must not be considered complete, and oils from other companies may be
equally suitable.
Further information can be obtained by contacting the engine builder or MAN Die-
sel & Turbo.
2 Circulating Oil System
One of the pumps (1) draws the oil from the bottom tank and forces it through the
lub. oil cooler (2), the filter (3) with an absolute fineness of minimum 50 μm (0.05
mm) (40 μm, 0.04 mm for AlSn40 bearings) corresponding to a nominal fineness of
approx. 30 μm at a retaining rate of 90%) and thereafter delivers it to the engine
via the flange RU.
RU The main part of the oil is, via the telescopic pipe, sent to the piston cooling manifold,
2012-10-31 - en
3045-0120-0002
where it is distributed between piston cooling and bearing lubrication. From the
crosshead bearings, the oil flows through bores in the connecting rods, to the crank-
Description
pin bearings.
The remaining oil goes to lubrication of the main bearings, thrust bearing, camshaft
(not ME/ME-C engines) and turbocharger.
1 (3)
HYUNDAI
3045-0120-0002 MAN B&W
MAN B&W
The relative amounts of oil flowing to the piston cooling manifold, and to the main
bearings, are regulated by a butterfly valve, or an orifice plate. The oil distribution
inside the engine is shown on Drawing 3055-0125.
Circulating Oil Pressure: See 7045-0100.
3 Circulating Oil Failure
3.1 Cooling Oil Failure
The piston cooling oil is supplied via the telescopic pipe fixed to a bracket on the
crosshead. From here it is distributed to the crosshead bearing, guide shoes,
crankpin, bearing and to the piston crown.
Failing supply of piston cooling oil, to one or more pistons, can cause heavy oil
coke deposits in the cooling chambers. This will result in reduced cooling, thus
increasing the material temperature above the design level.
In such cases, to avoid damage to the piston crowns, the cylinder loads should be
reduced immediately (see slow-down below), and the respective pistons pulled at
the first opportunity, for cleaning of the cooling chambers.
Cooling oil failure will cause alarm and slow-down of the engine. See 7045-0100.
For CPP-plants with a shaft generator coupled to the grid, an auxiliary engine will
be started automatically and coupled to the grid before the shaft generator is dis-
connected and the engine speed reduced. See Drawing 6655-0120, ‘Sequence
Diagram’.
After remedying a cooling oil failure, it must be checked (with the circulating oil
pump running) that the cooling oil connections in the crankcase do not leak, and
that the oil outlets from the crosshead, crankpin bearings, and piston cooling, are
in order.
3.2 Lubricating Oil Failure
If the lub. oil pressure falls below the pressures stated in 7045-0100, the engine’s
safety equipment shall reduce the speed to slow down level, respectively stop the
engine when the SHUT DOWN oil pressure level has been reached.
For CPP-plants with a shaft generator coupled to the grid, an auxiliary engine will
be started automatically and coupled to the grid before the shaft generator is dis-
connected and the engine speed reduced. See 6655-0120, ‘Sequence Diagram’.
2012-10-31 - en
3045-0120-0002
Find and remedy the cause of the pressure drop.

Description
2 (3)
HYUNDAI
MAN B&W
MAN B&W 3045-0120-0002
A likely cause of pressure drop, is worn-out bearings, causing

the filters to clog.
Check for traces of melted white metal in the crankcase and oil pan. See also Sec-
tion 6645-0100.
“Feel over” 15-30 minutes after starting, again one hour later, and fi nally also after
reaching full load (see also Section 6645-0120).
2012-10-31 - en
3045-0120-0002
Description
3 (3)
HYUNDAI
MAN B&W
MAN B&W 3045-0130-0005
1 Oil System Cleanliness
Maintenance of the Circulating Oil

In a new oil system, as well as in a system which has been drained owing to repair
or oil change, the utmost care must be taken to avoid the ingress and presence of
abrasive particles, because filters and centrifuges will only remove these slowly,
and some are therefore bound to find their way into bearings etc.
For this reason - prior to filling-up the system - careful cleaning of pipes, coolers
and storage tank is strongly recommended.
2 Cleaning the Circulating Oil System
The recommendations below are based on our experience, and laid out in order to
give the contractor/supplier and operators the best possible advice regarding the
avoidance of mishaps to a new engine, or after a major repair.
The instruction given in this book is an abbreviated version of our flushing proce-
dure used prior to shoptrial. A copy of the complete flushing procedure is available
through MAN Diesel & Turbo or the engine builder.
2.1 Cleaning before filling-up
In order to reduce the risk of bearing damage, the normal careful manual cleaning
of the crankcase, oil pan, pipes and storage tank, is naturally very important.
However, it is equally important that the system pipes and components, between
the filter(s) and the bearings, are also carefully cleaned for removal of “welding
spray” and oxide scales.
If the pipes have been sand blasted, and thereafter thoroughly cleaned or “acid-
washed”, then this ought to be followed by “washing-out” with an alkaline liquid,
and immediately afterwards the surfaces should be protected against corrosion.
In addition, particles may also appear in the circulating oil coolers, and therefore
we recommend that these are also thoroughly cleaned.
2.2 Flushing Procedure, Main Lub. Oil System
Regarding flushing of the camshaft lub. oil pipes:

Engines with Uni-lube system, see Section 3045-0160.
Experience has shown that both during and after such general cleaning, airborne
abrasive particles can still enter the circulating oil system. For this reason it is nec-
2012-11-07 - en
3045-0130-0005
essary to flush the whole system by continuously circulating the oil - while bypass-
Description
ing the engine bearings, etc.
This is done to remove any remaining abrasive particles, and, before the oil is
again led through the bearings, it is important to definitely ascertain that the sys-
tem and the oil have been cleaned adequately.
1 (12)
HYUNDAI
3045-0130-0005 MAN B&W
MAN B&W
During flushing (as well as during the preceding manual cleaning) the bearings
must be effectively protected against the entry of dirt.
The methods employed to obtain effective particle removal during the oil circula-
tion depend upon the actual plant installations, especially upon the filter(s) type,
lub. oil centrifuges and the bottom tank layout.
Cleaning is carried out by using the lub. oil centrifuges and by pumping the oil
through the filter. A special flushing filter, with fineness down to 10 μm, is often
used as a supplement to or replacement of the system filter.
The following items are by-passed by blanking off with special blanks:
a. The main bearings
b. The crossheads
c. The thrust bearing
d. The turbocharger(s)
e. The axial vibration damper.
f. The torsional vibration damper (if installed)
g. The moment compensators (if installed)
h. The chain drive
See also Drawing 3055-0130 page 1.
It is possible for dirt to enter the crosshead bearings due to the design of the open
bearing cap. It is therefore essential to cover the bearing cap with rubber shielding
throughout the flushing sequence.
As the circulating oil cannot by-pass the bottom tank, the whole oil content should
partake in the flushing.
During the flushing, the oil should be heated to 60-65°C and circulated using the
full capacity of the pump to ensure that all protective agents inside the pipes and
components are removed.
It is essential to obtain an oil velocity which causes a turbulent flow in the pipes
that are being flushed.
Turbulent flow is obtained with a Reynold number of 3000 and above.
Re = x 1000, where
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Re = Reynold number
Description
V = Average flow velocity (m/s)

v = Kinematic viscosity (cSt)
D = Pipe inner diameter (mm)
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The preheating can be carried out, for instance, by filling the waterside of the cir-

culating oil cooler (between the valves before and after the cooler) with fresh water
and then leading steam into this space. During the process the deaerating pipe
must be open, and the amount of steam held at such a level that the pressure in
the cooler is kept low.
In order to obtain a representative control of the cleanliness of the oil system dur-
ing flushing, "control bags" are used (e.g. 100 mm wide by 400 mm long, but with
an area of not less than 1000 cm2, and made from 0.050 mm filter gauze). Pro-
posals for checkbag housings are shown on Drawing 3055-0130 page 2..
To ensure cleanliness of the oil system after the filter, two bags are placed in the
system, one at the end of the main lub. oil line for the telescopic pipes, and one at
the end of the main lub. oil line for the bearings.
To ensure cleanliness of the oil itself, another bag is fed with circulating oil from a
connection stub on the underside of a horizontal part of the main pipe between
circulating oil pump and main filter. This bag should be fitted to the end of a 25
mm plastic hose and hung in the crankcase.
At intervals of approx. two hours, the bags are examined for retained particles,
whereafter they are cleaned and suspended again, without disturbing the oil circu-
lation in the main system.
The oil flow through the "control bags" should be sufficient to ensure that they are
continuously filled with oil. The correct flow is obtained by restrictions on the bag
supply pipes.
The max. recommended pressure differential across the check bag is 1 bar, or in
accordance with information from the check bag supplier.
On condition that the oil has been circulated with the full capacity of the main
pump, the oil and system cleanliness is judged sufficient when, for two hours, no
abrasive particles have been collected.
As a supplement, and for reference during later inspections, we recommend that

in parallel to using the checkbag, the cleanliness of the lub. oil is checked by parti-
cle counting, in order to find particle concentration, size and type of impurities.
When using particle counting, flushing should not be accepted as being complete
until the cleanliness is found to be within the range in ISO 4406 level ≤19/15 (cor-
responding to NAS 1638, Class 10).
In order to improve the cleanliness, it is recommended that the circulating oil cen-
trifuges are in operation during the flushing procedure. The centrifuge preheaters
ought to be used to keep the oil heated to the proper level.
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3045-0130-0005
Description
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If the centrifuges are used without the circulating oil pumps

running, then they will only draw relatively clean oil, because,
on account of low oil velocity, the particles will be able to settle
at different places within the system.
A portable vibrator or hammer should be used on the outside of the lub. oil pipes
during flushing in order to loosen any impurities in the piping system. The vibrator
is to be moved one metre at least every 10 minutes in order not to risk fatigue fail-
ures in piping and welds.
A flushing log, see Drawing 3055-0130 page 3, is to be used during flushing and
for later reference.
As a large amount of foreign particles and dirt will normally settle in the bottom
tank during and after the flushing (low flow velocity), it is recommended that the oil
in the bottom tank is pumped to a separate tank via a 10 μm filter, and then the
storage tank is again cleaned manually. The oil should be returned to the tank via
the 10 μm filter.
If this storage tank cleaning is not carried out, blocking up of the filters can fre-
quently occur during the first service period, because settled particles can be dis-
persed again:
a. due to the oil temperature being higher than that during flushing,
b. due to actual engine vibrations.
Important: When only a visual inspection of the lub. oil is carried out, it is important
to realise that the smallest particle size which is detectable by the human eye is
approx. 0.04 mm.
During running of the engine, the lub. oil film thickness in the bearings becomes as
low as 0.005 mm or even lower. Consequently, visual inspection of the oil cannot
protect the bearings from ingress of harmful particles. It is recommended to
inspect the lub. oil in accordance with ISO 4406.
3 Circulating Oil Treatment
3.1 General
Circulating oil cleaning, during engine operation, is carried out by means of an

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inline oil filter, the centrifuges, and possibly by-pass filter, if installed, as illustrated
3045-0130-0005
on Drawing 3055-0115.
Description
The engine as such consumes about 0.1 g/kWh of circulating lub. oil, which must
be compensated for by adding new lub. oil.
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It is this continuous and necessary refreshing of the oil that will control the BN and

viscosity on an acceptable equilibrium level as a result of the fact that the oil con-
sumed is with elevated figures and the new oil supplied has standard data.
In order to obtain effective separation in the centrifuges, it is important that the flow
rate and the temperature are adjusted to their optimum, as described in the follow-
ing.
3.2 The Centrifuging Process
Efficient oil cleaning relies on the principle that - provided the through-put is ade-
quate and the treatment is effective - an equilibrium condition can be reached,
where the engine contamination rate is balanced by the centrifuge separation rate
i.e.:
Contaminant quantity added to the oil per hour = contaminant quantity removed
by the centrifuge per hour.
It is the purpose of the centrifuging process to ensure that this equilibrium condi-
tion is reached, with the oil insolubles content being as low as possible.
Since the cleaning efficiency of the centrifuge is largely dependent upon the flow-
rate, it is very important that this is optimised.
The above considerations are further explained in the following.
3.3 The System Volume, in Relation to the Centrifuging Process
As mentioned above, a centrifuge working on a charge of oil will, in principle, after

a certain time, remove an amount of contamination material per hour which is
equal to the amount of contamination material produced by the engine in the same
span of time.
This means that the system (engine, oil and centrifuges) is in equilibrium at a cer-
tain level of oil contamination (Peq) which is usually measured as pentane insolu-
bles %.
In a small oil system (small vol-

ume), the equilibrium level will
be reached sooner than in a
large system (Fig. 1) - but the
final contamination level will be
the same for both systems -
because in this respect the sys-
tem oil acts only as a carrier of
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3045-0130-0005
contamination material.
Description
A centrifuge can be operated at greatly varying flow rates (Q).
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Practical experience has

revealed that the content of

pentane insolubles, before and
after the centrifuge, is related to
the flow rate as shown in Fig. 2.
Fig. 2 illustrates that the

amount of pentane insolubles
removed will decrease with ris-
ing Q.
It can be seen that:

a. At low Q, only a small portion of the oil is passing the centrifuge/hour, but is being
cleaned effectively.
b. At high Q, a large quantity of oil is passing the centrifuge/hour, but the cleaning is
less effective.
Thus, by correctly adjusting the

flow rate, an optimal equilibrium
cleaning level can be obtained
(Fig. 3).
This minimum contamination

level is obtained by employing a
suitable flow rate that is only a
fraction of the stated maximum
capacity of the centrifuge (see
the centrifuge manual).
3.4 Guidance Flow Rates
The ability of the system oil to “carry” contamination products is expressed by its
detergency/dispersancy level.
This means that a given content of contamination - for instance 1 % pentane

insolubles - will, in a detergent oil, be present as smaller, but more numerous parti-
cles than in a straight oil.
Furthermore, the particles in the detergent oil will be surrounded by additives,

which results in a specific gravity very close to that of the oil itself, thereby hamper-
ing particle settling in the centrifuge.
This influences the position of
the minimum in Fig. 3, as illus-
trated in Fig. 4.
As can be seen, the equilibrium

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3045-0130-0005
level in a detergent oil will be

higher than in a straight oil, and
Description
the optimum flow rate will be

lower.
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However, since the most important factor is the particle size (risk of scratching and
wear of the bearing journals), the above-mentioned difference in equilibrium levels

is of relatively minor importance, and the following guidance figures can be used:
In general,
a. the optimum centrifuge flow rate for a detergent oil is about 20-25% of the maxi-
mum centrifuge capacity,
b. whereas, for a straight oil, it is about 50-60%.
c. This means that for most system oils of today, which incorporate a certain deter-
gency, the optimum will be at about 30-40% of the maximum centrifuge capacity.
The preheating temperature should be about 80°C.
4 Oil Deterioration
4.1 General
Oil seldom loses its ability to lubricate, i.e. to form an oil film which reduces friction,
but it can become corrosive.
If this happens, the bearing journals can be attacked, such that their surfaces
become too rough, and thereby cause wiping of the white metal.
In such cases, not only must the bearing metal be renewed, but also the journals
(silvery white from adhering white metal) will have to be re-polished.
Lubricating oil corrosiveness is either due to advanced oxidation of the oil itself
(Total Acid Number, TAN) or to the presence of inorganic acids (Strong Acid Num-
ber, SAN). See further on in this Section.
In both cases the presence of water will multiply the effect, especially an influx of
salt water.
4.2 Oxidation of Oils
At normal service temperature the rate of oxidation is insignificant, but the follow-
ing three factors will accelerate the process:
4.2.1 High Temperature
The temperature level will generally increase if the coolers are not effective.
Local high-temperature areas will arise in pistons, if circulation is not continued for
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3045-0130-0005
about 15 minutes after stopping the engine.

Description
The same will occur in electrical preheaters, if circulation is not continued for 5
minutes after the heating has been stopped, or if the heater is only partly filled with
oil (insufficient venting).
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4.2.2 Air Admixture

Good venting of the bottom tank should be arranged.
The total oil quantity should be such that it is not circulated more than about 15-18
times per hour. This ensures that sufficient time exists for deaeration during the
period of “rest” in the bottom tanks.
It is important that the whole oil content takes part in the circulation, i.e. stagnant
oil should be avoided.
4.2.3 Catalytic Action
Oxidation will be considerably accelerated if oxidation catalysts are present in the

oil.
In this respect, wear particles of copper are especially bad, but also ferrous wear
particles and rust are active.
In addition, lacquer and varnish-like oxidation products of the oil itself have an
accelerating effect. Therefore, continuous cleaning is important to keep the
“sludge” content low.
As water will evaporate from the warm oil in the bottom tank, and condense on the
tank ceiling, rust is apt to develop here and fall into the oil, thereby tending to
accelerate oxidation. This is the reason for advocating the measures mention in
Section 6645-0100, concerning cleaning and rust prevention.
4.3 Signs of Deterioration
If oxidation becomes grave, prompt action is necessary because the final stages of
deterioration can develop and accelerate very quickly, i.e. within one or two
weeks.
Even if this seldom happens, it is prudent to be acquainted with the following signs
of deterioration, which may occur singly or in combinations.
• The sludge precipitation in the centrifuge multiplies.
• The smell of the oil becomes bad (acrid or pungent).
• Machined surfaces in crankcase become coffee-brown (thin layer of lacquer).
• Paint in crankcase peels off, or blisters.
• Excessive carbon deposits (coke) are formed in piston cooling chambers.
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In serious cases of oil deterioration, the system should be cleaned and flushed
Description
thoroughly, before fresh oil is filled into it.
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4.4 Water in the Oil

Water contamination of the circulating oil should always be avoided.
The presence of water, especially salt water, will:

• accelerate oil oxidation (tend to form organic and inorganic acids)
• tend to corrode machined surfaces and thereby increase the roughness of bearing
journals and piston rods, etc. (see e.g. Section 2545-0100)
• tend to form tin-oxide on white metal (see Section 2545-0100).
In addition, freshwater contamination can enhance the conditions for bacteriologi-

cal attack.
For alkaline oils, a minor increase in the freshwater content is not immediately det-
rimental, as long as the engine is running, although it should, as quickly as possi-
ble, be reduced again to below 0.2% water content.
If the engine is stopped with excess water in the oil, then once every hour, it
should be turned a little more than 1/2 revolution (to stop in different positions),
while the oil circulation and centrifuging (at preheating temperature) continue to
remove the water. This is particularly important in the case of salt water ingress.
Water in the oil may be noted by “dew” formation on the sight glasses, or by a
milky appearance of the oil.
Its presence can also be ascertained by heating a piece of glass, or a soldering

iron, to 200-300°C and immersing it in an oil sample. If there is a hissing sound,
water is present.
If a large quantity of (sea) water has entered the oil system, it may be profitable to
suck up sedimented water from the bottom of the tank. Taste the water for salt.
In extreme cases it may be necessary to remove the oil/water mixture, and clean
and/or flush the system, before filling up again with the cleaned oil, or the new oil.
4.5 Check of Oil Condition
As described in items 4.3 and 4.4, the on site surveillance of oil condition involves
keeping a check of:
• alterations in separated sludge amount
• appearance and smell of the oil
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• “dew” on sight glasses

Description
• lacquer formation on machined surfaces

• paint peeling and/or blistering
• “hissing” test
• carbon deposits in piston crown.
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In addition to the above, oil samples should be sent ashore for analysis at least
every three months. The samples should be taken while the engine is running, and
from a test cock on a main pipe through which the oil is circulating.
Kits for rapid on-board analyses are available from the oil suppliers. However, such
kits can only be considered as supplementary and should not replace laboratory
analyses.
5 Circulating Oil: Analyses and Characteristic Properties
Used-oil analysis is most often carried out at oil company laboratories. It is normal
service for these to remark upon the oil condition, based upon the analysis results.
The report usually covers the following characteristics:
Property Remarks Guiding Limits for

used oils
Oil Type Alkaline detergent (for 2-stroke engines)
Specific Gravity Usually 0.90-0.98. Mainly used for identification of ±5%
the oil. (of initial value)
Viscosity The viscosity increases with oil oxidation, and also max. + 40%
by contamination with cylinder oil, heavy fuel, or min.-15%
water. A decrease in the viscosity may be due to (of initial value)
dilution with diesel oil.
Flash Point Lowest temperature at which the oil gives off a min. 180°C
(open cup) combustible vapour. Gives an indication of possible
fuel oil contamination.
TAN This expresses the total content of organic and max. 2
(Total Acid Num- inorganic acids in the oil. Organic (or weak) acids
ber) are due to oxidation. TAN = SAN + Weak acid num-
ber.
SAN This expresses the amount of inorganic (or strong) 0
(Strong Acid acids in the oil. These are usually sulphuric acid
Number) from the combustion chamber, or hydrochloric acid
arising from salt water (ought to be stated in the
analysis). SAN makes the oil corrosive (especially if
water is present) and should be zero.
Alkalinity/BN Gives the alkalinity level in oils containing acid neu- max.+ 100%
(Base Number) tralizing additives. See also Service Letter min.-30%
SL02-408/KEA. (of initial values)
Water Risky if TAN and SAN are high. Salt water has a fresh: 0.2%
higher corrosive effect than freshwater. See previ- (0.5% for short
ous point 4.4. Also refer to SL05-460/NHN periods)
Saline: trace
Conradsen Residue from incomplete combustion, or cracked max. + 3%
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3045-0130-0005
Carbon lubricating and cylinder oil.

Description
Ash Some additives leave ash, which may thereby be max. + 2%

used to indicate the amount of additives in the oil.
The ash can also consist of wear particles, sand
and rust. The ash content of a used oil can only be
evaluated by comparison with the ash content of
the unused oil.
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Property Remarks Guiding Limits for

used oils

Insolubles Usually stated as pentane/heptane and benzene Non-coagulated
insolubles. The amount of insoluble ingredients in pentane insolu-
the oil is checked as follows: Equal parts of the oil bles max. 2%
sample are diluted with benzene (C6H6) and normal
Non-coagulated
pentane (C5H12 ) or heptane (C7H14). As oxidized oil
benzene insolu-
(lacquer and varnish-like components) is only solu- bles max. 1%
ble in benzene, and not in pentane or heptane, the
difference in the amount of insolubles is indicative of
the degree of oil oxidation. The benzene insolubles
are the solid contaminants.
The above limiting values are given for reference/guidance purposes only.
The assessment of oil condition can seldom be based on the value of a single
parameter, i.e. it is usually important, and necessary, to base the evaluation on the
overall analysis specification.
For qualified advice, we recommend consultation with the oil company or engine
builder.
6 Cleaning of Drain Oil from Piston Rod Stuffing Boxes
See Drawing 3055-0135
The oil which is drained off from the piston rod stuffing boxes is mainly circulating
oil with an admixture of partly-used cylinder oil and, as such, it contains sludge
from the scavenge air space. In general, this oil can be re-used if thoroughly
cleaned.
Drawing 3055-0135 shows the cleaning installations. (Option)
The drain oil is collected in tank No. 1. When the tank is nearly full, the oil is trans-
ferred, via the centrifuge, to tank No. 2, and thereafter, via the centrifuge, recircula-
ted a number of times.
When centrifuging the stuffing box drain oil, the flow-rate should be decreased to
about 50% of what is normally used for the circulating oil, and the preheating tem-
perature raised to about 90°C. This is because, in general, the drain oil is a little
more viscous than the circulating oil, and also because part of the contamination
products consist of oxidized cylinder oil, with a specific gravity which does not dif-
fer much from that of the circulating oil itself.
Water-washing should only be carried out if recommended by the oil supplier.

Finally, the centrifuged oil, in tank No. 2, should be filtered a number of times
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3045-0130-0005
through the cellulose fine filter, at a temperature of 60-80°C.

Description
This will remove any very fine soot and oxidation products not taken out by the
centrifuging, and thus make the oil suitable for returning to the circulating system.
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Provided that the circulating oil is an alkaline detergent type, it is not necessary to
analyse each charge of cleaned drain oil before it is returned to the system. Regu-
lar sampling and analysis of the circulating oil and drain oil will be sufficient.
If, however, the circulating oil is not alkaline, all the cleaned drain oil should be
checked for acidity, for instance by means of an analysis kit, before it is returned to
the system.
The “total acid number” (TAN) should not exceed 2. See also Item 5, ‘Circulating
Oil: Analyses & Characteristic Properties’. If the TAN exceeds 2, the particular
charge of drain oil should be disposed of.
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Description
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1 MAN Diesel & Turbo T/C, System Details
Turbocharger Lubrication
The lub. oil system for the MAN Diesel & Turbo type of turbocharger is shown sep-
arately on Drawing 3055-0155.
The system is supplied from the main lub. oil system.

See also Drawing 3055-0125.
The oil is discharged to the main lub. oil system. The discharge line is connected
to the venting pipe, E, which leads to open air.
See also Drawing 3055-0115.
In case of failing lub. oil supply from the main lub. oil system, e.g. due to a power
black-out or defects in the system, the engine will stop due to shut-down. Lubrica-
tion of the turbocharger bearings is ensured by a separate tank.
The tank is mounted on top of the turbocharger, and is able to supply lub. oil until
the rotor is at a standstill, or until the lub.oil supply is re-established.
2 MET T/C, System Details
The MET turborchargers are also lubricated via the main lub. oil system. See
description of turbocharger lub. oil system in Item 1 ‘MAN Diesel & Turbo T/C,
System Details’.
3 ABB TPL T/C, System Details
The ABB TPL turbochargers are designed either with an integrated lub. oil system
or with a similar system as MDT TC. Please refer to the relevant ABB TPL-instruc-
tion manual.
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Description
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1. System details
with Uni-Lube System

Camshaft Lubrication for Engines
See Drawing 3055-0140
The camshaft bearings and the exhaust roller guides are lubricated by the main
lub. oil pumps.
The exhaust valve actuators also receive oil from the main lub. oil system.
Booster pumps are installed in order to increase the oil inlet pressure.
From the bearings, roller guides and exhaust valve actuators, the oil drains to
the bottom of the bearing housings, where a suitable oil level is maintained to
lubricate the running surfaces of the cams. From here, the lub. oil is drained
back to the bottom tank.
2. Pressure Adjustment
1. Start the main lub. oil pumps and booster pump No. 1.
2. Set the pump by-pass valve to open at the maximum working pressure of
the pump - not, however, below 3 bar.
Adjust in steps (while the outlet valve is slowly closed and opened) until
the pressure, with closed valve, has the above-mentioned value.
Adjust booster pump No. 2, using the same method.
3. Adjust the pressure control valve fitted at the end of the inlet pipe, so as
to obtain the pressure indicated in the Guidance Value Automation sec-
tion 7045.
4. When the engine is running, it may become necessary to readjust the

pressure control valve, to maintain the required pressure.
3. Flushing Procedure
Follow these instructions together with the instructions given in ‘Maintenance of

CAUTION the circulating oil’, Item 2.2 ‘Flushing procedure’.
1. Remove the inspection hole cover of each camshaft roller guide section.
2. Remove the oil inlet pipes to all camshaft roller guide sections and ex-
haust valve actuators, see Drawing 3055-0150. Also blank off to governor
drive/starting air distributor, etc. Inspect internal cleanliness of all opened
pipes.
3045-0160-0002
3. Connect a flexible hose with a valve to the open end of the lub. oil pipes
2008-07-28
at point (B) of each cylinder unit. See also Drawing 3055-0150.

Description
4. Suspend the flexible hoses through the open inspection hole into the cor-
responding camshaft section.
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5. Keep the booster pumps running during the flushing procedure.

with Uni-Lube System
Camshaft Lubrication for Engines
6. In order to monitor the cleanliness of the system while the flushing is in

progress, a 50 micron checkbag may be fitted to the end of the flexible
hoses in the outmost cylinder unit.
Regarding recommended design of the checkbag housing, see Drawing

3055-0130.
7. After flushing, open the lub. oil blank flanges and any other possible
“blind ends” for inspection and manual cleaning.
8. Use the flushing log, Drawing 3055-0130, during flushing and for later ref-
erence.
3045-0160-0002
2008-07-28
Description
2 (2) Doc-ID:3045-0160-0002
HYUNDAI
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Cylinder Lubricating Oil Pipes

Fig. 1
Deck
Filling pipe
Cylinder oil storage or

service tank
Level
Min. 3000mm
alarm
LS 8212 AL
Heater with set
point of 40°C
TI
Min. 2000mm
Small box for

Insulation
heater element
AC
Fig. 2
3055-0110-0002
2008-08-14
Drawing
Doc-ID: 3055-0110-0002 1 (1)

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MAN
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B&W
Drawing Circulating Oil System (Outside Engine)

3055-0115-0002
3055-0115-0002
1 (1)
2008-08-07
MAN B&W
HYUNDAI
Aft. Fore.
Doc-ID: 3055-0125-0002
The letters refer to the List of Flanges
Item no. refer to “Guidance Value Automation”
Drawing Circulating Oil System (Inside Engine)

3055-0125-0002
3055-0125-0002
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Location of Checkbag and Blank Flanges
Flushing of Main Lubricating Oil System

Lube oil inlet to exhaust valve
and fuel pump actuator and for
some engines also camshafts
3
7
RU
Common
Iub. oil inlet
Manometer
Oil
sample
Protection apron Checkbag Flexible hose
housing
3
4
Man hole
2
Checkbag
housing
3
6 Manometer
8
5
1 Flexible
hose
Oil sampIe
Blanking off pipes:
1. Main bearing by-pass blanks

3055-0130-0002
See Page 2.
2. Cnosshead bearings by-pass blanks
2008-08-08
3. Blank-off Thrust bearing Manometer, max. recommended

4. Blank-off or by-pass axial vibration damper pressure before checkbag: 1 bar o.
Drawing
5. Blank-off torsional vibration damper or in accordance with information

6. Blank-off forward moment compensator chain drive from the checkbag supplier.
7. Blank-off or by-pass turbocharger
8. Blank-off PTO-PTI power gear
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Dimension of Checkbag and Blank Flanges

Sketch of check- Alternative check- Checkbag monofil

bag housing: bag (Inside engine): filter cloth: 50 μm.
!PPROXIMATE
DIMENSIONS
0LATEæWELDED

TO HOUSING
v #HECKBAG FRAME

v 0IPE STUB

The holes in the checkbag frame are,

in our experience to be approx 5 mm.
in diameter, to avoid damage to the
checkbag and too high pressure drop.
The above filter components can be delivered from MAN Diesel A/S
Blank flanges for flushing:
A) Blank at main bearings

$
$
(

B) Blank between telescopic pipes and crossheads
D $IAMETER D
3055-0130-0002
$ $IAMETER æ$
2008-08-08
$
(

Drawing
$IAMETER D
D
2 (3) Doc-ID: 3055-0130-0002

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MAN B&W 3055-0130-0002
Flushing Log
Flushing of Main Lubricating Oil System

M/V: Engine Type: System: Checked by:
Builder: En g in e N o. : M.E. Lub. Oil
Yard: No . : B u i lt y e ar : Da t e :
Info Pumps Filters Absolute/fineness Centrifuge Magnet Filter

Centrifugal Maker : Maker:
Maker:
Screw Main : xm Type:
Maker: Type : Type: Other Filters
Type: By-pass : xm Capacity: Maker:
Capacity: Type : Type:
Filter Unit (if used) xm L.O. System
Type: Temp. Press. Pump 1-2 Purifier Filter Check
Maker: [C] [bar] Unit No.
at &
Inspection of Checked by Date Time Run- Run- Start/ Start/
pump ISO
start ning ning stop stop
& Code
Pipes: & hours hours running running
M.E.
stop per total hours hours
Tanks: day
Date: Remarks
3055-0130-0002
2008-08-08
Sign. Inspector: Yard/Engine builder Total flushing hrs.: Final cleanliness:

Check bags ISO 4406 Code
Drawing
Recording of pump running hrs. with ½hr.

Cleaning and replacement of filters to be recorded under remarks.
Accepted flushing cleanliness level: Clean check bags after 2 hrs. (ISO 4406 Code qª19/15)
Doc-ID: 3055-0130-0002 3 (3)

2012-11-09 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Cleaning System, Stuffiing Box Drain Oil (Option)

3055-0135-0002
3055-0135-0002
1 (1)
2008-10-17
p
g
MAN B&W
HYUNDAI
System oil inlet

Cyl. 1
Engines with Uni Lube System
Exhaust valve actuator
Connected to frame box
Fuel pump
Booster
pumps
Doc-ID: 3055-0140-0002
PT PS
8101 8102
Y
Engine
Uni lubrication system
Drawing Camshaft Lubricating Oil Pipes

3055-0140-0002
3055-0140-0002
1 (1)
HYUNDAI
MAN B&W 3055-0150-0002
Flushing of Camshaft Lubricating Oil System

*
*
*
3055-0150-0002
2008-10-17
Drawing
* Also valid for engines with Uni lube system
Doc-ID: 3055-0150-0002 1 (1)

HYUNDAI
MAN B&W
MAN B&W 3055-0155-0002
MAN Turbocharger
Turbocharger Lubricating Oil Pipes

MET Turbocharger
ABB TPL Turbocharger

2012-11-09 - en
3055-0155-0002
Drawing
1 (1)
HYUNDAI
MAN B&W
MAN B&W 3065-0150-0001

Precautions
Lubricating Oil, Data

see 0545-0100
O Shut off fuel oil
O Lock the turbocharger rotors
Data
T30-08 Maximum water content lub.oil 0.2 %
2013-03-05 - en
3065-0150-0001
Work Card
1 (2)
HYUNDAI
3065-0150-0001 MAN B&W
MAN B&W
Lubricating Oil, Data
Tools
2013-03-05 - en
3065-0150-0001
Work Card
2 (2)
HYUNDAI
MAN B&W 3065-0151-0001
Lub. oil checking Lubricating oil is to be checked for water content and other contaminants
Lubricating Oil • Checking

weekly.
Lub. oil samples In addition to the on board surveillance

of the lubricating oil condition.
See description 3045-0130.
Oil samples must be sent ashore for

analysis at least every three months.
The samples should be taken while the

engine is running, and from a test cock
on a main pipe through which the oil is
circulating.
3065-0151-0001C02
3065-0151-0001
2013-03-13 - en
Work Card
1 (1)
HYUNDAI
MAN
MANB&W
B&W 3065-0600-0001
Cylinder Lubricators, Data

Precautions O Shut off starting air supply - At starting air receiver
see 0545-0100
Data
- Table is empty on purpose. No Data needed. - -
Tools
2270-0400 171 Pushing tool for seals
4570-0540 126 Special screw
2014-10-27 - en
3065-0600-0001
Work Card
1 (1)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
Check of oil injection
Cylinder Lubricators • Checking

1. The MOP control Activate the lubricator test sequence on
panel the MOP control panel, and check that
the lubricators concerned are operating
correctly by watching through the covers
for scavenge port inspection.
Turn the piston concerned to BDC and

check inside the liner with a mirror and a
powerful light source that all lubrication
points are working properly.
For use of the MOP Panel, see

description 6645-0190.
2. With running engine The system is automatically checked.
The Engine Control System will generate

an alarm if faults occur.
Additionally, it is possible to check the

pressure shocks from the injection of the
lubricators on each lubricator pipe by
feeling with a hand.
If in doubt, disconnect the pipe at the

cylinder liner to observe the oil flow.
2014-02-20 - en
3065-0601-0009
Work Card
1 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
Before dismantling
Cylinder Lubricators • Dismantling
The engine must be stopped and blocked before dismantling a lubricator. Stop the cylinder lubricating oil
supply.
Close the hydraulic power supply to the lubricator as described in Procedure 4565-0301. Check with a
pressure gauge that there is no hydraulic pressure in the lubricator.
1. The supply valve Close the supply valve for cylinder

lubricating oil. Remove the electrical plug
for the lubricator.
2. Cylinder supply Check that the cylinder supply is closed.
Disconnect the cylinder oil supply pipe.
Disconnect the drain pipe if installed.
2014-02-20 - en
3065-0601-0009
Work Card
2 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
3. Remove the cover of Unscrew the top cover screws and

the lubricator disconnect the cover with pertaining
Cylinder Lubricators • Dismantling

pipes.
Unscrew the four screws on the top that

fix the lubricator to the hydraulic cylinder
unit.
Lift the lubricator clear of the cylinder

unit.
4. 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
• Dismount the lubricator as described

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

in the mounting part of this procedure.
2014-02-20 - en
3065-0601-0009
Work Card
3 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
1. Remove the O-ring

Cylinder Lubricators • Overhaul
Place the lubricator in a bench vice with

soft “jaws”. Remove the adjusting screw
with bushings. Discard the O-ring from
the adjusting screw.
2. The cylinder block Push down the cylinder block and

remove the four screws from the cylinder
block.
2014-02-20 - en
3065-0601-0009
Work Card
4 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
3. Overhaul dismantling Pull up the cylinder block.

Remove the springs and actuator piston
with plungers.
Remove and discard the O-ring from the

cylinder block.
4. Non-return valves Screw out the non-return valves and

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

compressed air.
2014-02-20 - en
3065-0601-0009
Work Card
5 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
5. General inspections Inspect the plungers, actuator piston

and cylinder block for wear, using a
magnifying glass.
6. Place new sealing If the sealing ring needs to be replaced,

ring on the cone proceed as follows:
Slide the cone for the sealing ring onto

the actuator piston so that only the
lowermost groove is exposed. Place a
new sealing ring on the uppermost part
of the cone.
2014-02-20 - en
3065-0601-0009
Work Card
6 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
7. Use the pushing tool Push the pushing tool over the cone
thus pushing the sealing ring down to

the lowest groove, then remove both
tools.
8. Mount the non-return Push the compressor over the ring so

valve that the sealing ring goes back to its
original form and into the groove.
2014-02-20 - en
3065-0601-0009
Work Card
7 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
9. Non-return valve Fit the non-return valve with new O-

rings.
Mount the non-return valves in the

cylinder block.
2014-02-20 - en
3065-0601-0009
Work Card
8 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
10. The cylinder block Fit the cylinder block with a new O-ring.
Pre-assemble the cylinder block with the

actuator piston and plungers to ensure
correct guidance of the plungers, before
finally assembling the cylinder block unit.
Mount the spring and press down the

actuator piston with plungers. Mount the
special screw supplied with the test
equipment for accumulators to keep the
spring compressed.
2014-02-20 - en
3065-0601-0009
Work Card
9 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
11. The terminal box Remove the cover from the terminal box,
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.
Clean the housing with diesel oil or

kerosene and dry with a non-fluffy cloth.
12. Discard the O-rings Turn the lubricator upside down in the
vice.
Unscrew the solenoid valve.
Discard the O-rings.
2014-02-20 - en
3065-0601-0009
Work Card
10 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
13. Remember ! Before mounting the feedback sensor,

check that the sensor is flush with the

sensor 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 depth gauge of a calliper)
that the end of the feedback sensor
does not protrude into the actuator
piston cylinder.
14. Mount the terminal Mount the terminal box.

box Connect the wires and mount the cover
on the terminal box.
15. Solenoid Valve Disassemble and clean the valve.
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be
replaced by a new one.
2014-02-20 - en
3065-0601-0009
Lubricate the slide with oil and check

Work Card
that the slide can move lightly with a

good fit in the housing.
Assemble the valve.
11 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
16. Mounting the Mount the solenoid valve fitted with new
solenoid valve O-rings. Coat the O-rings with a little
grease to keep the rings in place during

mounting.
17. Cylinder block Mount the cylinder block assembly in the

assembly and cylinder housing.
cylinder housing
Check that the spring pin engages
correctly with the cylinder block
assembly.
Mount the screws and tighten the block

to the housing.
Remove the special screw.
2014-02-20 - en
3065-0601-0009
Work Card
12 (14)
HYUNDAI
MAN
MANB&W
B&W 3065-0601-0009
18. New O-ring and Mount the adjusting screw fitted with a
distance bushing new O-ring and the distance bushing.

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.
Cover all surfaces with a thin
layer of oil.
2014-02-20 - en
3065-0601-0009
Work Card
13 (14)
HYUNDAI
3065-0601-0009 MANB&W
MAN B&W
1. New O-ring on the

Cylinder Lubricators • Mounting
Mount new O-rings on the lubricator and

lubricator on the cover with pipes.
Use a little clean grease to keep the O-

rings in place during mounting.
Tighten the top cover screws in the end

of the lubricator to the pipe connection.
2. Mounting the Mount the lubricator and tighten the

lubricator and screws on the hydraulic cylinder unit.
cylinder oil supply
pipe Mount the cylinder oil supply pipe.
Mount the drain pipe.
Open for the cylinder lubrication oil

supply
3. Finally Mount the electrical plug.
Open the hydraulic oil supply.
See Procedure 4565-0601.
Open the valve for cylinder lubricating oil

supply.
When possible, test the pre-lubrication

of the cylinder on the MOP panel.
2014-02-20 - en
3065-0601-0009
Work Card
14 (14)
2013-01-07 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Cylinder Lubricator

3072-0600-0007
1 (2)
3072-0600-0007
HYUNDAI
3072-0600-0007 MANB&W
MAN B&W

Cylinder Lubricator
021 - Screw
033 - Spacer tubular
045 - O-ring
057 - Adjusting screw
070 - O-ring
082 - Inductive sensor
094 - O-ring
104 - Plug screw
116 - Cylinder housing
141 - Plug screw
153 - Screw
165 - Cover
177 - Straight stud coupling
190 - Cylinder block
200 - O-ring
212 - O-ring
236 - O-ring
248 - Screw
261 - Plug
273 - Plug
285 - Housing
297 - Cable
307 - Quick coupling, minimess
344 - 3/2-way solenoid valve
356 - Screw
368 - Spring
381 - Sealing ring
393 - Actuator piston
403 - Plunger
3072-0600-0007
2013-01-07 - en
Plate
2 (2)
2013-02-21 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Chain Drive Lubrication

3072-0700-0023
1 (2)
3072-0700-0023
HYUNDAI
3072-0700-0023 MANB&W
MAN B&W

Chain Drive Lubrication
013 - Lubricating pipe

037 - Spray pipe
049 - T-coupling
074 - Screw
098 - Nut
108 - Spray pipe
133 - Spray pipe
170 - Spray pipe
216 - Spray pipe
241 - Spray pipe
289 - Screw
312 - Spray pipe
336 - Nut
348 - Screw
385 - Screw
407 - Screw
3072-0700-0023
2013-02-21 - en
Plate
2 (2)
HYUNDAI
MAN B&W
Preface Chapter Compressed Air System ... ........................................ 3440-0100-0001
Compressed Air System

Drawing Starting Air System ... ................................................ 3455-0100-0002
Work Card Starting Air Valve, Data ... ........................................... 3465-0200-0005

Starting Air Valve .... .................................................... 3465-0201-0004
Starting Air Distributor, Data .... ................................... 3465-0500-0001
Starting Air Distributor ... ............................................ 3465-0501-0003
Plate Starting Air System, Reduction Station .... ................... 3472-0140-0001

Starting Air System, Air Reciever ... ............................ 3472-0150-0001.0
Starting Air Valve .... .................................................... 3472-0200-0004
Main Starting Air Valve ... ........................................... 3472-0300-0005
Starting Air Distributor ... ............................................ 3472-0500-0001.0
Starting Air Safety Cap .... ........................................... 3472-0900-0012
Control Air System ... ................................................. 3472-0250-0002
Table of contents
1 (1)
HYUNDAI
MAN B&W 3440-0100-0001
01. Starting Air System

The starting air system consists of the manoeuvring system and the starting air
components, which comprise:
• Main Starting Valve
• Starting Air Distributor
• Starting Valves
The manoeuvring system is of electric/pneumatic design. See also Drawing

7055-150.
02. Starting Valve
The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled

by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now flows from the starting
air pipe to the cylinder.
When the starting period is finished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.
The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.
03. Main Starting Valve
The main starting valve is interposed in the starting air main pipe. The main
starting valve consists of a large ball valve and, optionally, a smaller ball valve
for slow-turning prior to starting the engine, which is fitted as a by pass for the
large valve. Both valves are operated by pneumatic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted for set-
ting the slow-turning speed.
Furthermore, a non-return valve is incorporated to prevent blowback in the

event of excessive pressure in the starting air line.
3440-0100-0001
Preface Chapter
The main starting valve is equipped with a blocking device consisting of a plate
��
2008-06-17 - en
which, by means of a hand-wheel, can be made to block the actuators.
The ball valves and their actuators are, together with the non-return valve and
blocking device, built together to form a unit.
Doc. ID: 3440-0100-0001 (2)

HYUNDAI
3440-0100-0001 MAN B&W
During all inspections of the engine, the blocking device of the main
WARNING starting valve must be in the BLOCKED position.

The only exception is when the starting valves are being tested for
tightness, in which case the blocking device of the main starting valve
must be in the WORKING position and the shutoff valve for the start-
ing air distributor must be in the CLOSED position. See Drawing 7055-
0150.
05. Starting Air Distributor
The starting air distributor controls the opening and the closing of the starting
valves.
09. Safety Cap in Starting Air Line
Each starting valve inlet pipe is provided with a safety cap. The safety cap
consists of a bursting disc enclosed by a perforated cylinder and a perforated
cover in order to protect any bystanders, in the event of a burst.
The cover is provided with a check plate, which shows if the bursting disc has
been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst,
and fit a new disc.
If a new disc is not available immediately, turn the cover in relation to the cyl-
inder, in order to reduce the leakage of starting air. Fit a new bursting disc and
return the cover to the open position at the first opportunity.
3440-0100-0001
Preface Chapter
��
2008-06-17 - en
(2) Doc. ID: 3440-0100-0001

2012-12-07 - en
MAN
MAN B&W
HYUNDAI
B&W
Drawing Starting Air System

3455-0100-0002
3455-0100-0002
1 (1)
HYUNDAI
MAN B&W
MAN B&W 3465-0200-0005

Precautions
Starting Air Valve, Data

see 0545-0100
Data
T34-01 Piston tightening torque 110 Nm
T34-02 Valve tightening torque 240 Nm
T34-04 Starting air valve 20 kg
Tools
2270-0300 095 Grinding ring for starting valve
2270-0300 201 Handle for sundry types
2013-05-06 - en
3465-0200-0005
Work Card
1 (1)
HYUNDAI
MAN B&W 3465-0201-0004
Air Valve
Starting Air Valve • Dismantling

Shut off the starting air and
control air inlet.
Dismount the control air pipes.
Unscrew the fixing nuts of the start-

ing valve flange.
3465-0201-0001D01
Pull the starting air valve out of the T34-4

cylinder cover and remove it from
the engine.
3465-0201-0001D02
3465-0201-0004
2009-06-25
Work Card
Doc-ID: 3465-0201-0004 1 (9)

HYUNDAI
3465-0201-0004 MAN B&W
Top cover Remove the top cover fixing screws

Starting Air Valve • Overhaul
and remove the cover.
Remove and discard the gasket.
3465-0201-0003O01
3465-0201-0004
2009-06-25
Work Card
2 (9) Doc-ID: 3465-0201-0004

HYUNDAI
MAN B&W 3465-0201-0004
Dismantling the valve Screw off the valve spindle nut and

remove the valve spindle from the valve
housing.
Take out the piston, distance pipe, valve

spring, and the liner.
Remove and discard the O-ring.
3465-0201-0003O02
3465-0201-0004
2009-06-25
Work Card
Doc-ID: 3465-0201-0004 3 (9)

HYUNDAI
3465-0201-0004 MAN B&W
Grind the valve hous- Grind the valve housing

ing seating and seating with the grinding ring af-

ter applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle

and housing to match, using the
face wrench to rotate the valve CARBORUNDUM
spindle. No. 200
Carborundum No. 500.
CARBORUNDUM
No. 500
3465-0201-0003O03
3465-0201-0004
2009-06-25
Work Card
4 (9) Doc-ID: 3465-0201-0004

HYUNDAI
MAN B&W 3465-0201-0004
Assemble the valve Thoroughly clean all parts before reas-

housing parts sembling the valve.
Lubricate all internal parts (sliding sur-

faces) with, for instance, Molybdenum
Disulphide, MoS2.
Tighten and lock the First mount the valve spindle, then
screws the distance pipe, the spring and the
piston.
3465-0201-0003O05
3465-0201-0004
2009-06-25
Work Card
Doc-ID: 3465-0201-0004 5 (9)

HYUNDAI
3465-0201-0004 MAN B&W
Mount the valve spin- Mount the nut on the valve spindle
dle nut and tighten the nut, see Data T34-1. T34-1
3465-0201-0003O06
3465-0201-0004
2009-06-25
Work Card
6 (9) Doc-ID: 3465-0201-0004

HYUNDAI
MAN B&W 3465-0201-0004
Valve tightening Place a new gasket on the valve

housing.
Mount and tighten the top cover.
Before mounting of If the starting air valve is not to be mount-

the valve ed in the engine immediately after the
overhaul, all openings of the valve should
be covered with plastic to prevent dirt
from entering the valve during storage.
3465-0201-0003O07
3465-0201-0004
2009-06-25
Work Card
Doc-ID: 3465-0201-0004 7 (9)

HYUNDAI
3465-0201-0004 MAN B&W
Starting valve bore Carefully clean the starting

Starting Air Valve • Mounting
valve bore in the cylinder cover

and, if necessary, recondition the
seat for the starting
valve in the bore.
If not already done, replace the O-

ring on the overhauled valve and
lubricate with Neverseize or Molyb-
denum Disulphide, MoS2.
3465-0201-0003M01
Mount the valve Mount the valve in the cylinder T34-4

cover.
3465-0201-0004
2009-06-25
Work Card
3465-0201-0001M02
8 (9) Doc-ID: 3465-0201-0004

HYUNDAI
MAN B&W 3465-0201-0004
Control air pipe Mount the nuts and tighten-up T34-2
Starting Air Valve • Mounting

to specified torque.
See Data T34-2.
Mount the control air pipes and

turn on starting air and control air.
3465-0201-0001M03
3465-0201-0004
2009-06-25
Work Card
Doc-ID: 3465-0201-0004 9 (9)

HYUNDAI
MAN B&W
MAN B&W 3465-0500-0001

Precautions
Starting Air Distributor, Data

see 0545-0100
Data
T34-07 Gear wheel on camshaft, tightening torque 90 Nm
Clearance between gear wheel and bushing:
T34-08 0.9-1.6 mm
Min - Max.
Clearance with roller in outermost position:Min
T34-09 1.0-3.0 mm
- Max.
Clearance with roller in innermost position:Min
T34-10 1.0-2.0 mm
- Max.
2013-02-20 - en
3465-0500-0001
Work Card
1 (2)
HYUNDAI
3465-0500-0001 MAN B&W
MAN B&W
Starting Air Distributor, Data
Tools
2013-02-20 - en
3465-0500-0001
Work Card
2 (2)
HYUNDAI
MAN B&W
MAN Diesel 3465-0501-0003
1. Turn the engine in AHEAD direction
Starting Air Distributor • Checking

to bring the piston of cylinder
No. 1 to TDC.
Check with the pin gauge.
3465-0501-0003C01
Starting Air Distributor

2. Remove the plug screw and
gasket from the side of the
distributor housing, and insert
check pin K in slot S.
S
If pin K is not available, use the
cylindrical end of a drill of a suit-
able size.
K S
3465-0501-0003C02
3. If the check pin cannot enter the slot, i.e. if the slot is not aligned with the
hole in the distributor housing, the air distributor must be adjusted. See next
part of this Procedure.
3465-0501-0003
Work Card
2009-06-26
Doc-ID: 3465-0501-0003 1 (4)

HYUNDAI
3465-0501-0003 MAN B&W
1. Turn the engine in AHEAD direc-

Starting Air Distributor • Adjustment
tion to bring the piston of cylin-

der 1 to TDC.
Check with the pin gauge.
3465-0501-0003C01
2. Remove the end cover of the

camshaft housing, along with the
starting air distributor, from the
engine. S
Remove the plug screw and gas-
ket from the side of the distribu-
tor housing, and insert check pin
K in slot S.
Turn the loosened gear wheel by

hand until check pin K enters slot
S in the disc and keep it there.
K S
3465-0501-0003C02
3465-0501-0003
Work Card
2009-06-26
2 (4) Doc-ID: 3465-0501-0003

HYUNDAI
MAN B&W
MAN Diesel 3465-0501-0003
3. Check and, if necessary, adjust

the clearance T34-8
between the gear wheel and the
bushing.
T34-8
3465-0501-0003A03
4. Remove the lower half of the

gearwheel drive cover. Mount the
upper half of the gearwheel drive
cover with the complete starting
ait distrubutor after loosing the
gearwheel on the camshaft, and
then engage the two gearwheels
by turning the wheel on the cam-
shaft.
Tighten and lock the gear wheel

screws on the camshaft, see
Data, T34-7.
Mount the lower half of the gear

wheel drive cover.
T34-7
3465-0501-0003A04
3465-0501-0003
Work Card
2009-06-26
Doc-ID: 3465-0501-0003 3 (4)

HYUNDAI
3465-0501-0003 MAN B&W
5. Remove check pin K from the K

distributor housing and mount

the gasket and plug screw.
S
3465-0501-0003A05
6. Check the clearance between

the roller and the two interlock-
ing valves with the roller in its
innermost and outermost posi-
tions, respectively (ASTERN and
AHEAD).
T34-10
T34-9
3465-0501-0003A06
3465-0501-0003
Work Card
2009-06-26
4 (4) Doc-ID: 3465-0501-0003

2008-10-03
MAN B&W
HYUNDAI
MAN Diesel
Doc-ID: 3472-0140-0001
Plate Starting Air System, Reduction Station
3472-0140-0001
1 (2)
3472-0140-0001
HYUNDAI
3472-0140-0001 MAN
MANDiesel
B&W

Starting Air System, Reduction Station

029 - Plate
030 - Adjustable T-coupling
042 - Adjustable straight coupling
054 - Reducing valve
066 - Steel pipe
078 - Stud
091 - Nut
125 - Ball valve
149 - Adjustable L-coupling
162 - Copper pipe
186 - Safety valve
198 - Reducing adaptor, male/female
208 - Adjustable T-coupling
221 - Bracket, complete
233 - Filter unit
270 - Ball valve
304 - Precision steel pipe
341 - Adjustable L-coupling
3472-0140-0001
2008-10-03
Plate
2 (2) Doc-ID: 3472-0140-0001

HYUNDAI
MAN
MAN Diesel
B&W 3472-0150-0001.0
Starting Air System, Air Reciever

3472-0150-0001.0
Plate
Doc-ID: 3472-0150-0001.0 1 (2)

HYUNDAI
3472-0150-0001.0 MAN
MAN Diesel
B&W

Starting Air System, Air Reciever
011 - Nut
023 - Plug screw
035 - Packing ring
060 - Air reciever
084 - Drain valve
096 - Clamp
3472-0150-0001.0
Plate
2 (2) Doc-ID: 3472-0150-0001.0

2009-04-20
MAN
MAN B&W
HYUNDAI
Diesel
Plate Starting Air Valve

3472-0200-0004
1 (2)
3472-0200-0004
HYUNDAI
3472-0200-0004 MAN
MANDiesel
B&W

Starting Air Valve
012 - Screw
024 - Cover
048 - Piston
061 - Spring
073 - Distance pipe
085 - Liner
097 - Packing
107 - Valve housing
119 - Sealing ring
120 - Valve spindle
3472-0200-0004
2009-04-20
Plate
2 (2)
HYUNDAI
MAN B&W 3472-0300-0005
Main Starting Valve

016
028
041
053
028
065 340
352
364
376
388
089 411
090 423
435
447
100 459 531
543
460 555
112 472
161
136 173
148 197
161
173
185 232
244
579
303 580
315
197 220 256

207 232
148 244
136
496 281
506 256
3472-0300-0005
��
2011-03-12 - en
256
268
281
Plate
1 (4)
HYUNDAI
3472-0300-0005 MAN B&W

Main Starting Valve
016 - Screw
028 - Switch
041 - Washer
053 - Screw
065 - Distance pipe
089 - Screw
090 - Plate for components
100 - Spindle
112 - Ball valve with actuator
136 - Plug screw
148 - Packing ring
161 - Plug screw
173 - Packing ring
185 - Intermediate piece
197 - Packing ring
207 - Stud
220 - Nut
232 - Screw
244 - Nut
256 - Packing ring
268 - Starting air pipe
281 - Screw
303 - Screw
315 - Ball valve with actuator
340 - Nut
352 - Washer
364 - Handwheel
376 - Pin
388 - Locking plate
411 - Spring
423 - Split pin
435 - Key ring
447 - Chain
459 - Nut
460 - Screw
472 - Nut
496 - Screw
506 - Screw
531 - Housing
3472-0300-0005

��
2011-03-12 - en
List continues on page 4

Plate
2 (4)
HYUNDAI
MAN B&W 3472-0300-0005
Main Starting Valve

016
028
041
053
028
065 340
352
364
376
388
089 411
090 423
435
447
100 459 531
543
460 555
112 472
161
136 173
148 197
161
173
185 232
244
579
303 580
315
197 220 256

207 232
148 244
136
496 281
506 256
3472-0300-0005
��
2011-03-12 - en
256
268
281
Plate
3 (4)
HYUNDAI
3472-0300-0005 MAN B&W

Main Starting Valve
555 - Housing
579 - Disc
3472-0300-0005
��
2011-03-12 - en
Plate
4 (4)
HYUNDAI
MAN Diesel
MAN B&W 3472-0500-0001.0
Starting Air Distributor

3472-0500-0001.0
Plate
Doc-ID: 3472-0500-0001.0 1 (2)

HYUNDAI
3472-0500-0001.0 MAN B&W
Item no
St a r t i n g A i r Di s t r i b u t o r
013 - Gearwheel
020 - Sealing ring
025 - Nut, low
037 - Locking washer for nut
050 Key
062 - Shaft
074 Bracket
086 - Screw
108 - Piston ring
121 - Reversing disc
157 - Spring pin
169 - Fitted bolt
182 - 3/2-way valve, pneumatic
194 - Screw
204 - Distributor disc
216 - Sealing ring
241 - Bushing
253 - Tapered dowel
265 - Tapered dowel
277 - Distributor housing
289 - Spring pin
290 - Stud
336 - Screw
348 - Packing ring
373 - Cover, start air distributor
385 - Nut
419 - Air cylinder
420 - Fitted bolt
432 - Bracket
444 - Screw
456 - Washer
3472-0500-0001.0
Plate
2 (2) Doc-ID: 3472-0500-0001.0

2012-09-26 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Starting Air Safety Cap

3472-0900-0012
1 (2)
3472-0900-0012
HYUNDAI
3472-0900-0012 MANB&W
MAN B&W

Starting Air Safety Cap
018 - Packing ring

031 - Screw
043 - Screw
079 - Packing ring
102 - Fitted bolt
114 - Check plate
126 - Bursting cap cover
138 - Hollow-point screw
163 - Washer
175 - Wing nut
187 - Perforated cylinder
199 - Bursting disc
209 - Housing
222 - Safety cap
234 - Packing ring
258 - Screw
271 - Nut
295 - Bursting cap, complete
3472-0900-0012
2012-09-26 - en
Plate
2 (2)
2013-01-21 - en
MAN
MANB&W
B&W
HYUNDAI
Plate Control Air System

3472-0250-0002
1 (2)
3472-0250-0002
HYUNDAI
3472-0250-0002 MANB&W
MAN B&W

Control Air System
015 - 3/2-way valve

3472-0250-0002
2013-01-21 - en
Plate
2 (2)

Man B& W G50me-B, Volume I

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HYUNDAI

In accordance with Chapter I of the code of Federal Regulations, Part

MAN Diesel & Turbo

Copyright © MAN Diesel & Turbo

Preface Introduction .............................. ............................. 0220-0100-0001

Table of Content and Introduction

24-hour hotline number:

Deviations from a MAN Diesel product may be found in a specific plant.

Reliable and economical operation of the MAN Diesel product is conditional

Furthermore, to ensure optimum efficiency, reliability and lifetime of the product

3. The manual structure

Each chapter is made up from several document types e.g. 1065-0100-0001.

Examples of document types are as follows.

70-90 - Spare part plates.

The last 4 digits form the edition number.

Designations in a Workcard starting with a “T” or “F” refer to the information

5. Referring to this manual

Piston - 2265-0401-0028 - Page 2

Example: Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028-017 -

In order to ensure up-to-date manuals on operation and maintenance,

Further details may be found in:

 Plant Installation Drawings

 Shop trial report

 Sea trial report

 EIAPP Technical File

11. Responsible publisher

Table of Content & Introduction

Preface Chapter Safety ................................. ................................. 0540-0100-0002

Tool Plate Safety Equipment ......................... ......................... 0570-0100-0001

2 Engine Room Staff

Operation & Maintenance of MAN B&W engines is to be carried out by qualified

Minimum safety equipment requirements:

3. Boiler suit or other protective wear.

Keep clear of the space below a crane with load.

When operating the turning gear it is important to note the following:

Block the switch or place a “Do not touch” sign.

5 Entering the Crankcase or Cylinder

Working in the crankcase is minimum a two-man job, and good comunication

Remove any oil spil at once.

easily inflammable and should be renewed. See also description 6645-0290,

Ample working light should be permanently installed at appropriate places in the

While handling harmful materials it is important to secure proper ventilation and

In the event of leaks or spillage, spread binding agents immediately. Disposal of

Keep lifting equipment clear of sharp edges.

Make sure to attach the load correctly on the crane hook.

Always keep clear of the space below a crane with load.

Use of working air requires safety goggles and gloves.

Avoid blowing pressurised air directly at skin.

First aid measures in the event of skin contact:

Beware of hot surfaces and use gloves.

17 Safety Precautions at Maintenance

18 Data Sheet Signs

Warning signs Mandatory action signs

Explosive material Wear ear protection

Drop (fall) Wear eye protection

Slippery surface Wear safety footwear

Electricity Wear protective

Overhead load Wear face shield

Hot surface Wear head protec-

Example: Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028-017 -

Plant Installation Drawings

Shop trial report

Sea trial report

EIAPP Technical File