EMD 710 Series G3B G3C Diesel Engine Workshop Service Manual

710G3B/G3C SERIES TURBOCHARGED ENGINE WORKSHOP MANUAL Third Edition, July 1999 Document Part Number E00109EP Electro-Motive Division General Motors Corporation La Grange, Illinois 60525 USA Telephone: 708-387-6000 Tele-Fax: 708-387-5795

© Copyright 1999 Electro-Motive Division, General Motors Corporation. All rights reserved. Neither this document, nor any part thereof, may be reproduced without the expressed written consent of the Electro-Motive Division. Contact EMD Service Publications Office.

CONTENTS III 0 Contents PREFACE ......................................................................................................................................... v SECTION 0. GENERAL ENGINE INFORMATION ....................................................................... vii SECTION 1. CRANKCASE AND OIL PAN.................................................................................. 1-1 SECTION 2. CYLINDER HEAD AND ACCESSORIES ............................................................... 2-1 SECTION 3. PISTON ASSEMBLY AND CONNECTING RODS ................................................. 3-1 SECTION 4. CYLINDER LINER ................................................................................................... 4-1 SECTION 5. CYLINDER POWER ASSEMBLY ........................................................................... 5-1 SECTION 6. CRANKSHAFT ASSEMBLY AND ACCESSORY DRIVE GEAR TRAIN ............... 6-1 SECTION 7. CAMSHAFT GEAR TRAIN, AUXILIARY DRIVE, AND CAMSHAFT ASSEMBLIES.......................................................................................................... 7-1 SECTION 8. AIR INTAKE AND EXHAUST SYSTEMS ............................................................... 8-1 SECTION 9. LUBRICATING OIL SYSTEM ................................................................................. 9-1 SECTION 10. COOLING SYSTEM ............................................................................................ 10-1 SECTION 11. FUEL OIL SYSTEM .............................................................................................. 11-1 SECTION 12. ENGINE CONTROLS ........................................................................................... 12-1 SECTION 12A. GOVERNOR ................................................................................................................. 12A-1 SECTION 12B. EMDEC SYSTEM ......................................................................................................... 12B-1 SECTION 13. PROTECTIVE DEVICES ...................................................................................... 13-1 SECTION 14. STARTING SYSTEM ............................................................................................ 14-1 SECTION 15. TROUBLESHOOTING ......................................................................................... 15-1 Appendix A. METRIC CONVERSION ........................................................................................ A-1

IV 710G3B ENGINE MAINTENANCE MANUAL

PREFACE v 0 PREFACE FORWORD This manual contains maintenance information for the 8, 12, 16, and 20-cylinder Model 710G3B and 710G3C series diesel engines. The material describes the basic engine and common extra equipment. However, the coverage of any particular system or component does not imply that the equipment is part of any specific order. The illustrations generally depict a typical 16-cylinder engine model as representative of the location, size, and relative shape of various components and accessories. Some of the illustrations used may NOT be of actual components or accessories applied to a specific engine, but have been used as typical or representative examples where actual visual appearance will NOT affect positioning or placement during reassembly. Special tools, referred to in the text and shown in many of the illustrations, are not supplied with the engine, but are available on order. File numbers contained in this manual represent detailed drawings for the construc- tion of fabricated tooling. These drawings are available from Electro-Motive Service Department. SERVICE DATA PAGES References, specifications, and a list of service equipment are presented as Service Data at the end of most sections. Clearance and dimensional limits listed in Service Data are defined as follows: • Minimum, maximum, and tolerance measurements are provided as service limits for requalified parts. At the time of engine overhaul or any time unscheduled maintenance is performed, the service limits should not be exceeded. Engine components within these limits may be reused with the assurance that they will perform satisfactorily until the next scheduled overhaul. These limits are NOT to be used as a basis for component change-out on a running engine. METRIC MEASUREMENT Units of measurement appearing in this manual are shown in metric units and U.S. standard units. A conversion table is provided in Appendix A to convert U.S. standard units to metric units. NOTE These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the Electro-Motive Division.

EMD 710 Series G3B G3C Diesel Engine Workshop Service Manual

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