Exhaust Valve: S35MC Data

S35MC Exhaust Valve 108-2
Data
SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S35MC
07
108-2 Exhaust Valve
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
Shut off fuel oil
10–120 Nm
X Shut off lubricating oil
X Lock turbocharger rotors
2 x M10, 2 x M12
Data
Ref. Description Value Unit

D-1 Exhaust valve, complete 195 kg
D-2 Exhaust valve housing 110 kg 4 x 1 m, 1 x 3 m
D-3 Oil cylinder 26 kg
D-4 Air cylinder 11 kg
D-5 Spindle 15 kg
D-6 Bottom piece 15 kg
D-7 Oil cylinder,
inside diameter max. 50.2 mm
D-8 Piston rings, min. thickness 2.0 mm
D-9 Min. distance to piston 47.0 mm
D-10 Max. distance to piston 51.2 mm
D-11 Min. diameter of spindle stem 39.8 mm
D-12 Tightening torque, oil cylinder 110 Nm
D-13 Tightening torque,
orifice plug 50 Nm
D-14 Tightening torque,
safety valve 50 Nm
D-15 Opening pressure,
safety valve 21 bar
D-16 Grinding angle –
valve spindle 30.2 °
D-17 Grinding angle –
bottom piece 30.0 °
D-18 Max. grinding of seat 2.3 mm
D-19 Gap of bottom piece 0.5 mm
D-20 Max. burn-off of spindle 6.0 mm
D-21 Max. grinding of spindle 2.0 mm
D-22 Hydraulic pressure
– dismantling 900-990 bar
D-23 Hydraulic pressure
– mounting 900 bar
D-24 Max. diameter, top 40.4 mm
D-25 Max. diameter, bottom 41.8 mm
When referring to this page, please quote Data Sheet 108-2 Edition 07 Page 1 (2)
MAN B&W Diesel A/S
108-2 Exhaust Valve S35MC
Data
Plate
90851
1849864-9
Spare Parts
Plate – Item No. Description Qty

90801-xxx 049 Gasket 1
90801-xxx 108 Spring washer 10
90801-xxx 145 Guide ring 1
90801-xxx 157 Sealing ring 1
90801-xxx 182 O-ring 1
90801-xxx 265 O-ring 1
90801-xxx 290 O-ring 1
90801-xxx 300 Sealing ring 2
90801-xxx 336 Disc 1
90801-xxx 361 Piston ring 2
90801-xxx 420 O-ring 1
90801-xxx 456 O-ring 2
90801-xxx 814 O-ring 1
Page 2 (2) When referring to this page, please quote Data Sheet 108-2 Edition 07
MAN B&W Diesel A/S
S35MC Exhaust Valve 908-2.1
Checking
Exhaust Valve
S35MC
210
Checking
908-2.1
1.
1. Before mounting an overhauled exhaust
valve in the engine, it is recommended to
check the valve as follows:
• Lift up the valve with the engine room D-1

crane (which makes the valve open).
• Connect compressed air to the pneu-

matic piston. The valve should now
close.
• Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3, to
ensure that there is a clearance between
the outer parts of the seating faces of
valve housing and the spindle.
See Procedure 908-2.3.
BM908-2.0 101 30
• After shutting-off the compressed air
supply and releasing the vent plug screw
located just above the ball cock on the air
cylinder, the exhaust valve should open.
• After doing this a couple of times, leave

the valve closed and shut-off the com-
pressed air. The valve should remain
closed for at least fifteen minutes.
When referring to this page, please quote Procedure 908-2.1 Edition 210 Page 1 (19)
MAN B&W Diesel A/S
908-2.2 Exhaust Valve S35MC
Dismantling
Dismantling
908-2.2
1. 1. Close the cooling water inlet and outlet, and

drain the exhaust valve.
Dismount the high-pressure pipe for the hy-

draulic valve actuation.
Disconnect the cooling water outlet pipe

from the exhaust valve.
Dismount the return oil pipe from the ex-

haust valve.
BM908-2.2 207 01
2. Dismount the air pipes for the sealing air ar-

rangement and the pneumatic exhaust
valve.
3. Remove the plate jacket with insulation

2. from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the inlet pipe of the exhaust receiver.
Note!
The two lowermost screws need only be

loosened, not removed.
BM908-2.2 207 02
3.
BM908-2.2 207 03
Page 2 (19) When referring to this page, please quote Procedure 908-2.2 Edition 210
MAN B&W Diesel A/S
Dismantling
4. Remove the protective caps from the ex- 4.

haust valve studs, and mount the four hy-
draulic jacks.
Connect the high-pressure pump to the

jacks by means of the distributor block and
four high-pressure hoses.
Bleed the hydraulic system and raise the

pressure as stated in Data. Then loosen
and remove the nuts. D-22
See Procedure 913-1.
BM908-2.2 207 04
5. Attach the crane to the lifting tool fitted on
top of the valve and lift the exhaust valve
away.
Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat- 5.
ing and sealing surfaces of the bore, if re-
quired.
For overhaul of the exhaust valve, see Pro- D-1

cedure 908-2.3.
BM908-2.2 207 05
MAN B&W Diesel A/S
Overhaul
Overhaul
908-2.3
1. 1. Place the exhaust valve on a wooden sup-

port on the platform.
D-3
Remove any pipes or hoses still connected
to the exhaust valve.
Remove the four nuts from the oil cylinder.
2. Lift away and place the oil cylinder on a

wooden support.
Dismount and inspect the O-rings and the

thrust piece of the hydraulic high-pressure
BM908-2.0 101 01
pipe for marks.
Replace the O-rings and thrust piece, if

necessary.
2. Check that the exhaust valve rotation indi-

cator can slide freely in its tube.
3. Loosen and remove the plug screw from the

oil cylinder to gain access to the orifice
plug.
Unscrew and clean the orifice plug.
Check and clean the bore for the orifice

plug in the oil cylinder.
BG908-2.0 99 02
3.
BG908-2.0 99 03
MAN B&W Diesel A/S
Overhaul
4. Place the oil cylinder in a horizontal posi- 4.

tion. D-7
Remove the piston.
Inspect the bore of the oil cylinder for scor-

ing and check its measurements.
BG908-2.0 99 04
If the diameter of the bore exceeds the val-
ue stated in Data, send the oil cylinder to
an MAN B&W authorized workshop for re-
pair.
5.
5. Release the vent plug screw located just
above the ball cock on the air cylinder to let
the air escape from below the piston.
Remove the four screws from the flange on

top of the air piston and dismount the
flange.
Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring.
6. Pass lifting straps through the four bores of

the valve housing and lift the valve housing
clear of the valve spindle.
BG908-2.0 99 05
Take care – when the internal O-ring in the

air piston and the internal rings for the seal-
ing arrangement at the bottom of the air cyl-
inder pass the groove for the conical ring at
the top of the spindle. 6.
D-2
BM908-2.0 101 06
D-5
MAN B&W Diesel A/S
Overhaul
7. 7. Unscrew and remove the lock screws which

retain the bottom piece. Lift the valve hous-
ing approx. 10 mm.
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 O-rings from the bottom piece

and clean all the cooling bores.
Bottom piece:
8. Inspect the seating of the bottom piece

carefully for damage and check with the
bottom piece template.
Note!
Before using the bottom piece template,

thoroughly clean the contact faces on the
D-6
BM908-2.0 101 07
valve housing seat with a steel brush.
All measurements should be taken at four

diametrically opposite points on the cir-
cumference of the bottom piece seating.
8.
Take measurements G 2 and G3, using a

feeler gauge. Compare the results with the
figures stated in Data D-18 and D-19.
9. IF burn marks are visible on the bottom

piece seating OR G3 does not equal D-19,
THEN the valve housing seat must be
ground.
IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN the bottom
piece seating must not be ground, regard-
less of burn marks or G3. Instead the bot-
tom piece must be reconditioned.
Contact MAN B&W Diesel for advice on re-

conditioning.
D-17
HC908-2.0 117 08
MAN B&W Diesel A/S
Overhaul
10. If it is necessary to grind the seating, pro- 10.

ceed as follows:
Mount the support grinder on the slide rest

of the lathe and attach a dial gauge to the
support grinder. Mount the grinding tem-
plate in the centre chuck as shown.
Adjust the angle of the slide rest as stated

in Data. Let the point of the dial gauge slide
across the surface of the grinding template
marked: Bottom Piece.
Fine-adjust the angle of the slide rest until

a deviation no larger than 0.03 mm is ob- D-17
served when sliding the dial gauge across
the surface of the grinding template.
Note!
As the grinding angle is very important to

the operation of the exhaust valve, make
absolutely sure to adjust the slide rest
correctly.
GM908-2.0 120 10
Remove the grinding template and the dial

gauge. Mount the bottom piece in the cen-
tre chuck as shown. Use a dial gauge to
check that the bottom piece is perfectly
centered.
Regarding the use of the support grinder,

see separate instructions from the support
grinder manufacturer.
During grinding, use the bottom piece tem-

plate frequently to ensure that maximum
grinding is not exceeded, see step 9.
After grinding, inspect the bottom piece

seating again, using a feeler gauge and the
bottom piece template, to measure how
much has been ground away.
Grind the recess so that gap G3 equals

D-19 as stated on the Data sheet.
MAN B&W Diesel A/S
Overhaul
11. Valve spindle
11. Inspect the seating of the valve spindle for

burn marks.
Check the burn-off F1 of the valve spindle

by measuring at each of the points A, B, C,
D and E, indicated by means of notches in
the spindle template.
Note!
Before using the spindle template, clean

the contact faces on the valve spindle
thoroughly with a steel brush.
HC908-2.0 117 11
All measurements should be taken at four

diametrically opposite points on the cir-
cumference of the valve spindle.
12. 12. Measure gap G 1 between the spindle tem-

plate and the seating of the spindle.
13. IF burn marks are visible on the seating of

the spindle, the valve must be ground.
IF gap G1 exceeds the max. value D-21,

see Data, OR the burn-off F1 exceeds the
max. burn-off D-20, the spindle must not be
ground. Instead the spindle must be recon-
ditioned.
Contact MAN B&W Diesel for advice on re-

KC908-2.0 107 08
D-16 conditioning.
MAN B&W Diesel A/S
Overhaul
14. Mount the support grinder on the slide rest 14.

of the lathe and attach a dial gauge to the
support grinder. Mount the grinding tem-
plate in the centre chuck as shown.
Adjust the angle of the slide rest as stated D-16

in Data. Let the point of the dial gauge slide
across the surface of the grinding template
marked: Spindle.
Fine-adjust the angle of the slide rest until

a deviation no larger than 0.03 mm is ob-
served when sliding the dial gauge across
the surface of the grinding template.
GM908-2.0 120 14
Note!
As the grinding angle is very important to

15.
the operation of the exhaust valve, make
absolutely sure to adjust the slide rest
correctly.
Remove the grinding template and the dial

gauge. Mount the spindle in the centre
chuck as shown. Use a dial gauge to check
that the spindle is perfectly centered D-11
Regarding the use of the support grinder,
see separate instructions from the support
grinder manufacturer.
During grinding, measure gap G 1 frequent-

ly. The max. grinding of the spindle, see
Data, must not be exceeded.
If the max. grinding limit is reached, and

GM908-2.0 96 09
burn marks are still visible on the seating of

the spindle, contact MAN B&W Diesel for
advice on reconditioning.
15. Check the spindle stem for wear in the area

between 220 mm and 292 mm measured
from the top of the spindle.
If the stem diameter is less than stated in

Data, or the hard facing layer is worn away,
contact MAN B&W Diesel for advice.
MAN B&W Diesel A/S
Overhaul
16. 16. Dismount the air piston from the air cylin-
D-7 der, and check the teflon guide ring and te-
flon sealing ring for wear.
Dismount the sealing air control box from

the air cylinder/valve housing.
D-4
Mount two eye bolts in the air cylinder and
dismount the air cylinder.
Remove the cooling water inlet pipe and the

covers from the exhaust valve housing. In-
spect and, if necessary, clean the inside of
the exhaust valve housing.
Blow through the sealing air pipe in the top

of the exhaust valve housing with com-
pressed air.
17. Clean the air cylinder and check the run-

ning surface for wear or possible scores.
Remove the four screws inside the air cyl-

BM908-2.0 101 11
inder.
Dismount and check the flanges and the

sealing rings of the sealing air arrange-
17. ment.
D-4 Fit new O-rings and sealing rings when
mounting the flanges inside the air cylinder.
Make sure to mount the sealing rings cor-

rectly, see the sketch.
Mount and tighten the four screws.

BM908-2.3 207 17
MAN B&W Diesel A/S
Overhaul
18. Remove and discard the O-ring from the air 18.
cylinder.
Dismount the safety valve housing.
Remove and discard the O-ring from the

safety valve housing.
19. Remove the safety valve from the safety

valve housing and place the valve in the
pressure testing device.
Connect the testing device with the high-

pressure pump by means of a hose.
Check the opening pressure, see Data.
BG908-2.0 99 14
If the opening pressure is not correct, loos-
en the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated. 19.
Tighten the lock nut and test the opening

pressure once more.
20. Mount a new mild steel ring inside the safe- D-4
ty valve housing and an O-ring in the
groove at the end of the safety valve hous-
ing.
Mount the safety valve in the housing and

mount the protective cap.
AM908-2.0 98 16
20.
DG908-2.0 91 15
D-14
MAN B&W Diesel A/S
Overhaul
21. 21. Inspect the bushing in the spindle guide for

wear. See Data.
If necessary, dismantle and replace the

bushing.
22. Mount new O-rings on the bottom piece.
Mount the bottom piece on the valve hous-

D-24 ing and secure with the screws.
Mount the valve spindle in the valve hous-

ing.
D-25
Mount the covers and the cooling water in-
let fitted with new packings on the exhaust
valve housing.
BG908-2.0 99 17
22.
D-2
BM908-2.0 101 18
D-6
MAN B&W Diesel A/S
Overhaul
23. Lubricate the spindle with camshaft lubri- 23.

cating oil.
Mount a new O-ring in the groove at the top D-4

of the exhaust valve housing.
Guide the air cylinder down over the valve

spindle. Make sure that the guide pins enter
the air cylinder correctly.
Note!
To avoid damage, take great care when

the internal rings (well-coated with ordi-
nary lube oil) pass the groove for the con-
ical locking ring.
24. Remove the filter plug screw from the seal-

ing air control unit.
Clean and check the filter plug screw, and

BM908-2.0 101 19
replace the O-ring.
After checking, re-mount the filter plug

screw.
24.
Loosen and remove the screws and cover
the sealing air valve spindle in the control
unit.
Remove the valve spindle and check the

sealing rings and the spring. If necessary,
replace them.
After checking, mount the valve spindle and

spring, and tighten the cover.
KB908-2.0 110 29
MAN B&W Diesel A/S
Overhaul
25. 25. Examine the sealing rings of the air piston.

If it is necessary to replace the rings, cut
them and remove them.
Be careful not to damage the edges of

the ring grooves in the piston.
Mount the new O-ring in the groove of the

air piston.
Caution!
Before mounting, heat the new teflon

AM908-2.0 98 12
rings in 100°C hot water for at least five

minutes.
When mounting the teflon rings, be care-

26. ful not to damage the running surfaces.
After mounting, compress the teflon rings

by means of the conical ring. This is done
by pressing the air piston through the con-
ical ring.
26. Pour a little lubricating oil into the air cylin-

der around the valve spindle.
Mount a new O-ring in the groove on the

outside of the air cylinder.
Fit the conical guide ring for the air piston

on the air cylinder.
Lower the air piston over the valve spindle

down into the air cylinder.
Caution!
To avoid damage, take great care when

the internal sealing ring in the air piston
passes the groove for the conical locking
ring.
Remove the conical guide ring from the air

cylinder.
BM908-2.0 101 20
MAN B&W Diesel A/S
Overhaul
27. Mount the conical locking ring and lift the 27.
air piston up around the locking ring.
Remove the eye bolts.
Mount the flange on top of the air piston

and, by means of the four screws, tighten
the air piston and the flange together.
28. Remove the piston rings from the oil piston

and check them for wear.
If the thickness of the rings has worn down

to the minimum, see Data, discard the rings
BG908-2.0 99 21
and mount new ones.
Check that the TOP mark on the piston

rings faces upwards, when mounting.
28.
29. Mount the piston on top of the spindle and
check the functioning of the damper piston.
Connect compressed air supply to the

space below the air piston, so as to keep
the valve closed, and to keep the air cylin-
der in close contact with the valve housing.
Place the measuring tool on the air cylinder D-8

across the piston.
BG908-2.0 99 22
29.
BM908-2.0 101 23
MAN B&W Diesel A/S
Overhaul
30. 30. Check the mesh of the damper piston by

checking the distance from the upper edge
D-9 of the crossbar to the top of the damper pis-
ton. See Data.
D-10 If the measurement is outside the value
stated in Data, adjustment must take place
by changing the disc in the damper piston
as follows:
31. Place the piston in the special tool.
Press out the disc with the centre screw.

BG908-2.0 99 24
If necessary, change also the spring and

the piston.
32. Assemble the damper piston with the new

31. disc in the special tool.
Place the piston upside down in the tool

and press the disc into place in the piston.
Check the mesh once more, repeating

points 22 and 23.
MA908-2.0 103 25
32.
S8211427.WPG
MAN B&W Diesel A/S
Overhaul
33. After carefully cleaning and visually check- 33.

ing all the parts, assemble the parts and
mount the piston, orifice plug and sealing
rings in the oil cylinder. See Data. D-13
34. Mount the overhauled oil cylinder on top of
the air cylinder.
Mount and tighten the nuts. See Data.
Disconnect the compressed air.
35. Blow through the orifice pipe in the exhaust

valve housing with compressed air to re-
BG908-2.0 99 27
move any obstructions. Also blow through
the pipes of the sealing air control unit.
Mount the sealing air control unit on the air

cylinder. 34.
D-3
D-12
BM908-2.0 101 28
35.
D-1
BM908-2.0 101 29
MAN B&W Diesel A/S
Mounting
Mounting
908-2.4
1. 1. After fitting new O-rings on the seat and the

water connection, lift the overhauled ex-
haust valve.
D-1
Lubricate the O-rings and the threads of the
studs with molybdenum disulphide (MoS 2).
AIR Mount a new sealing ring in the groove of

the compensator.
Place a new sealing ring (packing) on top

of the cylinder cover.
MoS2 Position the valve in the cylinder cover

bore, guiding it in accordance with the ex-
haust flanges and the water connection.
Note!
Before mounting the valve on the engine,

connect compressed air to the pneumatic
piston to keep the exhaust valve closed
BM908-2.4 210 01
during the mounting.
2. Mount the nuts and the hydraulic jacks.

Raise the pressure to the value indicated in
2. Data and tighten up the nuts.
D-23
Relieve the system of pressure, remove the
hydraulic jacks and the high-pressure hose,
and fit the protective caps.
BM908-2.2 207 04
MAN B&W Diesel A/S
Mounting
3. Connect the intermediate pipe to the flange 3.

at the exhaust receiver.
Attach the insulation jacket.
4. Mount the cooling water outlet pipe on the

exhaust valve.
Mount the high-pressure pipe and the re-

turn oil pipe.
5. Mount the pipe for the sealing air arrange-

ment and the air pipe for the pneumatic ex-
BM908-2.4 207 03
haust valve.
Open the lub. oil supply and the cooling wa-

ter supply to the exhaust valve.
Disconnect the compressed air and con- 4.

nect the normal air supply.
Caution!
The air supply to the exhaust valve must

always be connected before starting the
camshaft oil pumps.
This is very important, because other-

wise the valve will open more than
intended.
BN908-2.4 207 04
5.
BM908-2.4 207 05
MAN B&W Diesel A/S

Exhaust Valve: S35MC Data

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S35MC Exhaust Valve 108-2

SAFETY PRECAUTIONS Standard Tools: See Section 913

Ref. Description Value Unit

Plate – Item No. Description Qty

• Lift up the valve with the engine room D-1

• Connect compressed air to the pneu-

• Check that a 1.0 mm feeler gauge can be

• After doing this a couple of times, leave

1. 1. Close the cooling water inlet and outlet, and

Dismount the high-pressure pipe for the hy-

Disconnect the cooling water outlet pipe

Dismount the return oil pipe from the ex-

2. Dismount the air pipes for the sealing air ar-

3. Remove the plate jacket with insulation

The two lowermost screws need only be

4. Remove the protective caps from the ex- 4.

Connect the high-pressure pump to the

Bleed the hydraulic system and raise the

Carefully clean the exhaust valve bore in

For overhaul of the exhaust valve, see Pro- D-1

1. 1. Place the exhaust valve on a wooden sup-

Remove the four nuts from the oil cylinder.

2. Lift away and place the oil cylinder on a

Dismount and inspect the O-rings and the

pipe for marks.

Replace the O-rings and thrust piece, if

2. Check that the exhaust valve rotation indi-

3. Loosen and remove the plug screw from the

Unscrew and clean the orifice plug.

Check and clean the bore for the orifice

4. Place the oil cylinder in a horizontal posi- 4.

Inspect the bore of the oil cylinder for scor-

Remove the four screws from the flange on

Loosen the air piston from the conical lock-

6. Pass lifting straps through the four bores of

Take care – when the internal O-ring in the

7. 7. Unscrew and remove the lock screws which

If the bottom piece has become stuck, use

Remove the O-rings from the bottom piece

8. Inspect the seating of the bottom piece

Before using the bottom piece template,

valve housing seat with a steel brush.

All measurements should be taken at four

Take measurements G 2 and G3, using a

9. IF burn marks are visible on the bottom

IF the template rests on the lower surface

Contact MAN B&W Diesel for advice on re-

10. If it is necessary to grind the seating, pro- 10.

Mount the support grinder on the slide rest

Adjust the angle of the slide rest as stated

Fine-adjust the angle of the slide rest until

As the grinding angle is very important to

Remove the grinding template and the dial

Regarding the use of the support grinder,

During grinding, use the bottom piece tem-

After grinding, inspect the bottom piece

Grind the recess so that gap G3 equals

11. Valve spindle

11. Inspect the seating of the valve spindle for

Check the burn-off F1 of the valve spindle

Before using the spindle template, clean

All measurements should be taken at four

12. 12. Measure gap G 1 between the spindle tem-