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MAN Energy Solutions

5G40ME-C9.6

Name: MAN Energy Solutions 5G40ME-C9.6
Brand: MAN Energy Solutions
SKU: OSE-38442

The MAN 5G40ME-C9.6 is a high‑speed, five‑cylinder, two‑stroke main engine delivering 8 550 kW at 146 rpm, distinguished by its hydraulic camshaft system and advanced electronic control for low specific fuel consumption.

8550.0 kW

Power

Engine Specifications

Cylinders

400 mm

Bore

1860 mm

Stroke

8,550 kW

MCR Power

146.0 rpm

MCR RPM

2-stroke

Stroke Type

Family: MAN Energy Solutions ME/ME-C · Tier: Tier III · Fuel: HFO, VLSFO, MDO

Inspector Detail

▸

Designation decoded

5 = number of cylinders, G = Green Ultra Long Stroke, 40 = 400 mm bore, ME-C = MAN Electronically controlled Mark C, 9.6 = Mark 9.6 control generation.

Background

The ME-C series is MAN's standard line of electronically controlled 2-stroke crosshead engines for conventional fuel (HFO/VLSFO/MGO). The G40 platform with Ultra Long Stroke (1860mm, S/B=4.65) addresses small bulkers, feeder containerships and coastal vessels. 5 cylinders is the minimum configuration for balanced operation.

Calculated metrics

Stroke To Bore Ratio

4.65

Inspector checklist

Fuel System

Fuel pumps and valves: plunger condition, nozzle opening pressure, spray pattern
Fuel pre-heating: correct viscosity at the injector with HFO/VLSFO (12-15 cSt)
Fuel quality: check VLSFO compatibility (cat fines, asphaltenes, stability)
Separators: cleaning efficiency for cat fines (<15 ppm Al+Si after separator)

Running Gear and Tribology

Cylinder liners: document liner wear rate, honing pattern present?, BN matched to sulfur content
Piston rings: gap measurement, running surface condition at scavenge port inspection
Crosshead bearing: S/B=4.65 gives high side forces, LI reading critical with 5 cylinders
Stuffing box: log drainage quantities, oil contamination in the scavenge air area

ME Control (Hydraulics)

HPS: 300 bar, oil quality ISO 4406, filter dP
FIVA valves: fuel injection and exhaust valve actuation, timing
CCU: software version, calibration, alarms

Scavenge Air and Turbocharger

Scavenge air cooler: fouling, condensate drainage
Turbocharger: bearing clearance, vibration, cleaning intervals (water washing)
Document scavenge air pressure at various loads

Logbook reference values

Parameter	Expected	Deviation means
Exhaust gas temperature per cylinder	320-420°C (HFO, load-dependent)	>25°C spread: injector, timing or compression
Scavenge air pressure	1.5-3.0 bar (load-dependent)	Low: turbocharger fouling, cooler contamination
Cylinder oil consumption	0.7-1.2 g/kWh (BN depends on sulfur content)	Too high: waste; too low: liner wear
OMD	<2.5% LEL	Rise: stuffing box, piston

Common Failure Modes

Cat fine damage to the liner

Symptoms: Accelerated liner wear, piston ring wear, metallic debris in scavenge air

Causes: Inadequate fuel treatment, Separator not efficient, VLSFO with high cat fine content

Preventive: Cat fines after separator <15 ppm, check bunker analysis; at >60 ppm in the bunker, increase separator throughput.

Liner corrosion (cold corrosion)

Symptoms: Unusually high liner wear (>0.1 mm/1000 op. hours), cloverleafing

Causes: Cylinder oil BN too low for the current sulfur content, Cylinder wall temperature too low at part load, VLSFO with low sulfur but high acidity

Preventive: Adjust BN to sulfur content: HFO S>1.5% BN70-100, VLSFO S<0.5% BN25-40. Increase feed rate at part load.

FIVA valve malfunction

Symptoms: Timing deviation, Pmax spread, alarm in CCU

Causes: Oil contamination in the hydraulic system, Valve seat wear, Electrical actuation fault

Preventive: Regularly check HPS oil quality, overhaul FIVA every 16000-24000 op. hours.

Expert tips

💡 5 cylinders is the minimum configuration — mass balance is not ideal. Observe torsional vibration behavior at various loads, especially during slow steaming.
💡 G40 with S/B=4.65: long stroke with a small bore — crosshead inspection is more important than for S variants.
💡 On small engines (400mm bore) scavenge port inspection is easier — use it to regularly visually check piston rings and liner.

Related components

Turbocharger (compact unit) Scavenge air cooler Fuel separators Alpha Lubricator HPS oil quality

Classification & regulatory

IMO Tier II standard. When operating in ECAs: VLSFO (<0.5% S) or scrubber required. EEDI requirements for newbuildings.

Reference content for inspector orientation. Always verify against manufacturer's manual, latest service letters and class society requirements.

Other Cylinder Configurations 50

Components & Design

Alpha Lubricator Control MAN Energy Solutions

MAN Alpha Lubricator Mk III

Feed rate 0.6-1.2 g/kWh depending on fuel sulfur. Monitor via Alpha ACC (Adaptive Cylinder lubrication Control).

Lead time: 6 wk

25.0 kg

Crankcase Oil Mist Detector Schaller Automation

Schaller Visatron VN215+ OMD

SOLAS mandatory. Test weekly. Clean sensor optics every 4,000 hrs. Replace reference cell every 2 years.

Lead time: 2 wk

8.0 kg

Crosshead Bearing MAN Energy Solutions

MAN Crosshead Bearing (thin-shell, white metal)

Inspect at 16,000 hrs. Check bearing clearance. Monitor via bearing temperature and oil analysis.

Lead time: 12 wk

380.0 kg

Cylinder Liner MAN Energy Solutions

MAN ME-C Cylinder Liner (bore-cooled)

Wear monitoring via calibration. Max wear 0.8% of bore. Replace typically at 32,000-60,000 hrs.

Lead time: 16 wk

3500.0 kg

Engine Control Unit (ECU / ECS) MAN Energy Solutions

MAN ECS (Engine Control System)

Dual-redundant ECU. Software updates via MAN PrimeServ. Keep backup CCU on board.

Lead time: 8 wk

45.0 kg

Exhaust Valve (& Valve Seat) MAN Energy Solutions

MAN Exhaust Valve (Nimonic/Stellite)

Overhaul at 8,000-12,000 hrs. Stellite-faced seat. Grinding/lapping at overhaul. Check spindle guide clearance.

Lead time: 8 wk

320.0 kg

FIVA Valve (ME-type) MAN Energy Solutions

MAN FIVA Valve (ME-C)

FIVA = Fuel Injection Valve Actuator. Overhaul at 8,000 hrs. Critical for timing accuracy.

Lead time: 8 wk

35.0 kg

Fuel Booster Module (ME-type) MAN Energy Solutions

MAN Fuel Booster Module

Overhaul at 16,000 hrs. Pressure test fuel pipes. Check plunger wear with micrometer.

Lead time: 12 wk

450.0 kg

Fuel Valve (Injector) MAN Energy Solutions

MAN ME-C Fuel Valve Assembly

Overhaul every 4,000-8,000 hrs. Pressure test after overhaul. Nozzle replacement at 8,000 hrs.

Lead time: 4 wk

85.0 kg

Governor (Electronic/Woodward) Woodward

Woodward 723PLUS Digital Governor

Electronic governor integrated with ECS on ME engines. Firmware updates via Woodward service.

Lead time: 4 wk

15.0 kg

Hydraulic Cylinder Unit (HCU) MAN Energy Solutions

MAN HCU (ME-C type, per cylinder)

One HCU per cylinder. FIVA valve overhaul at 8,000 hrs. Booster overhaul at 16,000 hrs.

Lead time: 12 wk

1200.0 kg

Hydraulic Power Supply (HPS) MAN Energy Solutions

MAN HPS Unit (ME-C)

Servo oil SAE 30 / System oil. Filter change every 4000 hrs. Monitor servo oil pressure.

Lead time: 16 wk

2800.0 kg

Main Bearings MAN Energy Solutions

MAN Main Bearing Shells (white metal/tri-metal)

Inspect at 16,000 hrs. Jack up crankshaft for clearance measurement. Replace at signs of overlay fatigue.

Lead time: 8 wk

250.0 kg

PMI (Pressure Measurement Indicator) MAN Energy Solutions

MAN PMI Sensor System

Online cylinder pressure monitoring. Calibrate sensors annually. Essential for combustion optimization.

Lead time: 4 wk

5.0 kg

Piston Crown MAN Energy Solutions

MAN ME-C Piston Crown (bore-cooled Cr-Mo steel)

Inspect at 16,000 hrs. Pull piston at 16,000-24,000 hrs. Check cooling bores with borescope.

Lead time: 16 wk

1800.0 kg

Piston Ring Pack MAN Energy Solutions

MAN Piston Ring Set (CPR / AL rings)

CPR (Controlled Pressure Relief) top ring. Replace at 8,000-16,000 hrs depending on wear.

Lead time: 4 wk

60.0 kg

Scavenge Air Cooler MAN Energy Solutions

MAN Scavenge Air Cooler (plate-type)

Clean air side every 4,000-8,000 hrs (chemical/HP water). Monitor pressure drop and charge air temp.

Lead time: 16 wk

5500.0 kg

Turbocharger Unit (ABB/MHI/Napier) ABB Turbocharging

ABB A175-L Turbocharger

Overhaul at 12,000-16,000 hrs. Water washing every 24-100 hrs depending on load.

Lead time: 12 wk

4500.0 kg

Technical Data

unified from engine model True

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Manuals

operating
MAN B&W ME/ME-C/ME-B Engine Operation (OM-ME-C)
MAN Energy Solutions
maintenance
MAN B&W ME/ME-C Maintenance Manual (MM-ME-C)
MAN Energy Solutions
spare_parts
MAN B&W ME/ME-C Illustrated Parts Catalogue (IPC-ME-C)
MAN Energy Solutions
service_letter
SL-ME Service Letters Collection (SL-ME)
MAN Energy Solutions
technical_data
MAN CEAS Engine Calculation Tool (CEAS)
MAN Energy Solutions

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Equipment Model #38442 · ✓ still in production