Detroit Diesel V-71 Series Engines V6 V8 V12 V16 Cylinders Complete Workshop Service Repair Manual

DETROIT DIESEL V-71 Service Manual Sections 1-3 D __ e_T_R_o_•_T_~-!-~-0-~-~- .o-~---- ~ 3400 Outer Drive. West I Detroit. Michigan 48239-4001 Telephone. 313-592-5000 Telex 4320091 I TWX: 810-221-1649 Fax· 313-592-7288 6SE193 69090 Det ro it Diesel Corporation Lltho In USA

FOREWORD Thi manual contains in truction on the overhaul, maintenance and operat ion of the ba ic V- 71 Detroit D ie el Engi ne . Fu ll bene fi t of the long life and dependability built into the e engine can be realized thro ugh proper operation and maintenance. Of equal importance i the u e of proper procedure during engine overhaul. Pe onnel responsible for engine operation and maintenance hould tudy the ection of the manual pertaining to their particular dutie . imilarly, before beginning a repair or overhaul job, the erviceman hould read the manual carefully to familiarize him elf with the part or uba embli of the engine with which he ' ill be concerned. The information, pecification and illu trarion in thi. publication are ba ed on the information in effect at the time of approval for printing. Thi publication i revi ed and reprinted periodically. It i recommended that u er contact an authorized Detroit Di el Corporation ervi e Outlet for information on the latest revi ion . he right i r erved to make changes at any time without obligation. TNEWCAMP MANUALS

CAUTION To reduce the chance of per onal injury and/or property damage, the following inst.ructions must be carefully observed . Proper ervice and repair are important to the safety of the service tecbnician and the safe, reliable operation of the engine. If part replacement is necessary, the part mu t be replaced with one of the ame part number or with an equivalent part. Do not u ea replacement part of lesser quality. The ervice procedures recommended by Detroit Diesel Corporation and described in this service manual are effective method of performing ervice and repair. Some of these procedures require the use of tools specially designed for the purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not recommended by Detroit Diesel Corporation, must first determine that neither his safety nor the safe operation of the engine will be jeopardized by the replacement part, service procedure or tool selected. It i important to note that thi manual contain ariou "Caution " and " otices' that mu t be carefully observed in order to reduce the ri k of personal injury during ervice or repair or the po sibility that improper service or repair may damage the engine or render it unsafe. It is also important to understand that the e 'Caution " and "Notices" are not exhau tive, because it is impos ible for Detroit Diesel Corporation to warn of all the possible hazardou consequences that might result from failure to follow these instruction .

TABLE OF CONTENTS SUBJECT SECTION GENERAL INFORMATION AND CAUTIONS ENGINE (less major assemblies) 1 FUEL SYSTEM AND GOVERNORS 2 AIR INTAKE SYSTEM 3 LUBRICATION SYSTEM 4 COOLING SYSTEM 5 EXHAUST SYSTEM 6 ELECTRICAL EQUIPMENT, INSTRUMENTS AND PROTECTIVE SYSTEMS 7 POWER TAKEOFF AND TORQMATIC CONVERTER 8 TRANSMISSIONS 9 SPECIAL EQUIPMENT 1 2 OPERATION 13 TUNE-UP 14 PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND STORAGE 1 5 © 1989 Detroit Diesel Corporation October, 1989 TNEWCAMP MANUALS

General Information DETROIT DIESEL V-71 SCOPE AND USE OF THE MANUAL Thi manual covers the basic V-71 Diesel Engine built by the Detroit Diesel Corporation. Complete instruction on operation, adju tment (tune-up), preventive maintenance and lubrication, and repair (in.eluding complete overhaul) are covered. The manual was written primarily for persons ervicing and overhauling the engine and, in addition, contain all of the instruction es ential to the operators and u er . Basic maintenance and overhaul. procedures are common co all V -7 1 engines and therefore, apply to all V- 71 model . The manual is divided into numbered ections. The first ection covers the engine (le major as. emblie ). The following ections cover a complete system such a the fuel system, lubrication sy tern or air system. Each ection is divided into ubsections which contain complete maintenance and operating instruction for a pecitic . uba sembly on the engine. For example, Section l, which cover the basic engine, contain ubsection I. I pertaining to the cylinder block, sub ection 1.2 covering the cylinder head, etc. The subject and ections are listed in the Table of Content on the preceding page. Page are numbered consecutively, tarting with a new Page I at the beginning of each ubsection. The illustration are also numbered consecutively, beginning with a new Fig. 1 at the start of each subsection. Information regarding a general subject, such as the lubrication sy tern, can best be located by using the Table of Contents. Opposite each ubject in the Table of Contents i a section number which regi ter \ itha tab printed on the fir t page of each section throughout the manual. Information on a specific subassembly or acces ory can then be found by con ulting the list of contents on the first page of the section. For example the cylinder liner is part of the basic engine. Therefore, it will be found in Section 1. Looking down the list of contents on the first page of Section 1, the cylinder liner is found to bejn ubsection 1.6.3. An Alphabetical Index at the back of the manual has been provided a an additional aid for locating information. SERVICE PARTS AVAILABILITY Genuine Detroit Diesel service parts are available from authorized Detroit Die el distributor and ervice dealers throughout the world. A complete list of all distributor and dealers i available in the Worldwide Di tributor and Dealer Directory 6SE280. This publication can be ordered from any authorized di tributor. CLEARANCES AND TORQUE SPECIFICATIONS Clearance of new part and ~ ear limit on used part are listed in tabular form at the end of each e tion throughout the manual. It hould be pecifically noted that the ' New Part ·" clearance apply only when all new part are used at the point where lhe various specification apply. This al o applies to reference within the text of the manual. The column entitled ''Limits" Ii t the amount of wear or increa e in clearance which can be tolerated in u ed engine parts and till a ure ·atisfactory performance. It hould be emphasized that the figures given as "Limits' must be quaJjfied by the judgment of personnel respon ible for in, tailing new part . These wear limits are in geoeraJ, Ii ted only for the parts more rrequently replaced in engine overhaul work. For additional information, refer 10 the paragraph entitled Jn pection under General Procedures in this ection. Bolt, nut and stud torque pecification are al ·o Ii ted in tabular form at the end of each ection. •PARTS REPLACEMENT Before in talling a new or u ed part, check it thoroughly to make . ure il i the proper part for the job. The quality of the replacement part must be equivalent to the quality of the original Detroit Die el component being replaced and mu t meet DOC specification for new or reusable part . Part mu t al o be clean and not phy icaJly damaged or defective. For example, bolt and bolt hole thread must not be damaged or di . torted. Gasketing must have all holes completely punched through with no re idual gasket material left clinging to the top or bottom. Flatne. and fit pecification in the service manual must be tri tly adhered to. CAUTION: Failure to inspect parts thoroughly before installation, failure to install the proper parts, or failure to install parts properly can result in component or engine malfunction and/or damage and may also result in personal injury. Page 4 October, 1989 © Detroit Diesel Corporation

-- DETROIT DIESEL V-71 General Information PRINCIPLES OF OPERATION The die el engine is an internal combustion power unit, in which the heat of fuel i converted into work in the cylinder of the engine. In the diesel engine, air alone is compressed in the cylinder; then, after the air has been compressed, a charge of fuel is sprayed into the cylinder and ignition is accomplished by the heat of compression. The Two-Cycle Principle In the two-cycle engine, intake and exhau t take place during part of the compres ion . and power strokes re pectively (Fig. 1). In contrast, a four-cycle engine require four piston strokes to complete an operating cycle; thus, during one half of its operation, the four-cycle engine functions merely as an air pump. A blower is provided to force air into the cylinder for expelling the exhaust gases and to upply the cylinders with fresh air for combustion. The cylinder wall contains a row of ports which are above the piston when it i at the bottom of it troke. These ports admit the air from the blower into the cylinder as soon a the rim of the piston uncover the ports (Fig. I - Scavenging). AIR AIR SCAVENGING COMPRESSION The unidirectional flow of air toward the exhaust valves produces a scavenging effect, leaving the cylinders full of clean air when the piston again covers the inlet ports. A the piston continue on the upward stroke, the exhaust valve close and the charge of fresh air i subjected to compression (Fig. l - Compre sion). Shortly before the piston reaches its highest po ition, the required amount of fuel is prayed into the combu tion chamber by the unit fuel injector (Fig. I - Power). The inten e heat generated during the high compres ion of the air ignite the fine fuel pray immediately. The combu tion continues until the fuel injected has been burned. The re ulting pressure forces the piston downward on its power stroke. The exhau t valve are again opened when the pi ton is about halfway down, allowing rhe burned gases to e cape into the exhau t manifold (Fig. I - Exhaust). Shortly thereafter, the downward moving pi ton uncover the inlet ports and the cylinder i again wept with clean cavenging air. Thi entire combu tion cycle i completed in each cylinder for each revolution of the crank haft, or, in other words, in two strokes; hence, it is a "two- troke cycle". AIR AIR POWER EXHAUST 1 2240 Fig. 1 - The Two-Stroke Cycle © Detroit Diesel Corporation October, 1989 Page 5 TNEWCAMP MANUALS

General Information DETROIT DIESEL V-71 GENERAL DESCRIPTION The two-cycle diesel engines covered in this manual are produced in 6 8, 12 and 16 cylinder models having the a.me bore and stroke and many of the major working parts uch as injectors pistons, connecting rods, cylinder liner and other part that are interchangeable. AU cylinder blocks are ymmetrical in design thu permitting oil cooler or starter installation on the same ide or on opposite ides of the engine, depending upon the installation requirements. The engines are built with right-band or left-hand crankshaft rotation. For example the crankshaft in an RC engine, viewed from the flywheel end will rotate counterclockwise the oil cooler will be mounted on the right-hand ·ide of the engine and the starter will be on the left-hand ide (Fig. 2). The meaning of each digit in the model numbering ystem is hown in Fig. 2. The letter Lor R indicates left or right-band engine rotation as viewed from the front of the engine. The letter A, B, C or D designate the location of the tarter and oil cooler as viewed from the rear of the engine. Each engine is equipped with oil coolers, lubricating oil filters fuel oil strainer, fuel oil filter, air cleaner or ilencer, governor, heat exchanger and raw water pump or fan and radiator, and tarting motor. Full pres ure lubrication is upplied to all main, connecting rod and cam haft bearings, and to other moving part within the engine. A gear-type pump draw oil from the oil pan through an intake creen, through the oil filter, and then to the oil cooler. From the oil cooler, the oil flow through pas age that connect with the oil galleries in the cylinder block and cylinder head for distribution to the bearing , rocker arm mechanism and other functional parts. Coolant is circulated through the engine by a centrifugaJ- type water pump. Heat i removed from tbe coolant, which circulat in a clo ed y tern, by the radiator or heat exchanger. Control of the engine temperature is accompli hed by thermo tats which regulate the flow of the coolant within the cooling system. Fuel i drawn from the supply tank through the fuel strainer by a gear-type fuel pump. It i then forced through a ftlter and into the fuel inlet manifold in the cylinder heads and to the injector . Excess fuel i returned to the upply tank through the fuel outlet manifold and connecting lines. Since the fuel is con tantly circulating through the injectors it erv to cool the injector and also carries off any air in the fuel y tern. Air for cavenging and combustion is supplied by a blower which pump air into the engine cylinder via the air box and cylinder liner port . AU air entering the blower first passes through an air cleaner or ilencer. Engine starting i provided by a either a hydraulic pt electric tarting sy ·tern. The electric starting motor is energized by a storage battery. A battery-charging generator, with a suitable voltage regulator erves to keep the battery charged. Engine speed i regulated by a mechanical or hydraulic type engine governor, depending upon the engine application. Page 6 October, 1989 © Detroit Diesel Corporation

DETROIT DIESEL V-71 SEllES 71 V ENGINES 7 NUMBER OF CYLINDERS 0 8 2 APPLICATION DESIGNATION (see below l APPLICATION DESIGNATIONS : 7081-7200 MAllNE 7083-7200 INDUSTRIAL F-F 7084 - 7200 POWER-BASE 7085-7200 GENERATOR 7087-1000 VEHICLE F·F 708_!·7000 VEHICLE H BASIC ENGINE ARRANGEMENTS : lololion : L Cleftl and R lrightl designatH rotation viewed from th1t front of the engine Type: A-B·C-D designate• location of starter and oil cooler 01 viewed from the ~ CllywhHll end . Cyllnd r Bonk: left ond right cylinder bonlts ore de · termlned from ~ of engine . LA IXXXX-1 XXXI LB lXXXX· 2XXXI IA l XXXX-S XXX I RB IXXXX- 6XXX I - General Information 7 2 0 1 BASIC ENGINE AHANGEMENT AND DllVE SHAFT IOTATION ltH belowl DESIGN VARIATION hub lowl SPECIFIC MODEL NUMBER DESIGN VARIATIONS : 7082 - 7000 7082- 7100 7082 - 7200 7082-7300 7082 - 7400 7082-7500 7087 - 7600 7087 · 7100 7087 ·7!00 7087 · 7!00 V-7 1 " N " ENGINE 2 VALVE HEAD ENGINE 4 VALVE HEAD ENGINE TURBOCHARGED ENGINE TURBO·AFTERCOOLED ENGINE CUSTOMER SPEC. ENGINE CONSTANT HORSEPOWER ECONOMY (TAE) (CALIFORNIA CERTIFIED) CONSTANT HORSEPOWER ( TT } CONSTANT HORSEPOWER f TTA ) (CALIFORNIA CERTIFIED) CONSTANT HORSEPOWER ECONOMY (TTAE ) (CALIFORNIA CERTIFIED) DRIVE SHAFT ROTATIONS : 7242 - 0200 7242-9200 LEFT-HAND RIGHT-HAND Dtive shaft rolatlon ; thoft rotation on multiple units b det ermi ned from rhe reor of rhe unit. lC IXXXX - 3XXX I lD lXXXX·4XXXl RC lXXXX· 7XXX I RD IXXXX-8XXX I All ABOVE VIEWS FROM REAR Of ENGINE l ·l 1 •73 Fig. 2 - Model Numbering, Rotation and Accessory Arrangements © Detroit Diesel Corporation October, 1989 Page 7 TNEWCAMP MANUALS

Genera I Information 6V FRONT 0 0) ~ lot z z 0 < o( CV CID CID I- I- :t: II.. ~ w @ .... © Ci ( ) FIRING ORDER RH-1L - 3R - 3L-2R-2L-1 R LH-1 l -1 R-2L-2R-3L-3R c 8V FRONT 0 Q) 0 0 @ @ © © FIRING ORDER ) RH -1 l- 3R-3L - 4R . 4L. 2R - 2L -1 R LH -1 L-1 R-2l-2R -4l-4R-3l - 3R ~ z < CID .... II.. w _, c 12V FRONT 0 0 0 0 0 0 0 © © @ © © FIRING ORDER ) RH- ll - 5l - 3R-4R - 3l .4L - 2R - 6R- 2L . 6L-1 R .5R LH.1 l- 5R-1 R-6L - 2L -6R- 2R- AL . JL • .4R -3R-5l DETROIT DIESEL V-71 :lot z < <ID .... .... w _, ( 16V FRONT CD CD 0 0 @ 0 © © © © © © 0 0 © ® FIRING ORDER ) RH - 1L - 2R - 8L -6R - 2L - 4R- 6L - 5R . 4L . 3R. 5L . 7R -3L-1 R. 7l . 8R 11750 LH .1 L- SR -ll -1 R-3l -7R - 5L- 3R . 4l - 5 R- 6l - 4R - 2L - 6R - 8l - 2R Fig. 3 - V-71 Cylinder Designation and Firing Order GENERAL SPECIFICATIONS Type ................. ... ............ . .. .. ..... . .. . Number of Cylinders , .. . .. ... .... .... .. . .. .. ...... .. . Bore (inches) .. . ..... . .......... . ..... . ............ . Bore (mm) ........... . ................ . ........... . troke (inch ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke (mm) .......... . ................ . .. . ........ . Compres ion Ratio Normal) (Standard & Turbo.) ....... . Compression Ratio (Normal) ("N " Engine ) ...... . ..... . Total Displacement - cubic inche ....... . .. . ......... . Total Displacement - liter . .. . .. . ...... .. .... .. .. . . . . Number of Main Bearings . . ............ . ............ . 6V 2 Cycle 6 4.25 108 5 127 17 to I 18.7 to l 426 6.99 4 Page 8 October, 1989 SV 2 Cycle 8 4. 25 108 5 127 17 to I 18 .7 to 1 568 9.32 5 12V 2 Cycle 12 4.25 108 5 127 17 to I 18.7 to l 852 13 .97 7 16V 2 Cycle 16 4.25 108 5 127 17 to 1 18 .7 to I 1136 18 .63 10 © Detroit Diesel Corporation

DETROIT DIESEL V-71 General Information ENGINE MODEL, SERIAL NUMBER AND OPTION PLATE The engine erial number and model number arc tamped on the cylinder block in the following location (a viewed from Lhe flywheel end): The left side, upper front corner of current 6V and 8V cylinder block (Fig. 4) and the right ide, upper rear comer of current I 2V and l 6V block and former 6V and 8V block . Fig. 4 - Typical BV-71 Engine Serial Number and Model Number Option Plate (Metal Labels) An option plate, atta hed LO one of the val e rocker c ver , carrie the engine erial number and model number and, in addition, lj any optional equipment u ed on the engine (Fig. 5). On-highway vehicle engine also carry an exhau t emi sion certification label next to the option plate. It i eparate from the option plat and i mounted permanently in the option plate retainer. The current label in lude information relating to an engine family for the maximum fuel injector ize and ma imum peed. Due to Federal regulation , c.he exhau t cmi ion plate hould not be removed from c.he rocker er. Refer to Section 14 for further information regarding cmi i n regulation . Fig. 5 - Option Plate ltltJ OOTOOfT 0tU4• j ~ . \g •n:u ae"'otr ;;'"'@ L-6650 Fig. 6 - Typical Option Label With any order for part , the engine model number and erial number mu t be given. In addition if a type number is shown on the option plate covering the equipment required this number h uld al o be included on the parts order. AU group of part u ed on a unic are tandard for the engine model unles otherwi e Ii ted on the option plate. Power takeoff embli , torque con erter , marine gear , etc. ma al o carry name plates. The information on the e name plate i al o u eful when ordering repla ement part for the e a embli . •Option Plate (Paper Labels) A new paper/ laminate engine option label (Fig. 6) has replaced the metal option plate. In conjunction with the ne~ ption label the folio' ing paper/laminate label are al o being u ed: bar code labels for engine erial number and cu tomer pecification number; emissions label c~ hen applicable) and disclaimer label. Di tributor ' ill provide their own label(·) in order to notify the cu ·tomer f any di tributor-made change lo Detroc Diesel- manufa tured engines. Di tributor- lyped label( ) will indicate the di tributor name, addre and the group/type re i ion that reflect their changes to engine a originally manufactured b Detroit Diesel. Attaching Lables Label mu t be pla ed on rocker cover . Label are de igned to fit in the ame pace provided for the former tamped or current ca. t rocker cover option plate holder. © Detroit Diesel Corporation October, 1989 Page 9 TNEWCAMP MANUALS

Detroit Diesel V-71 Series Engines V6 V8 V12 V16 Cylinders Complete Workshop Service Repair Manual

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