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.

vi Engine Maintenance Manual Figure 0-1. Three-Quarter Left Front View, 16-Cylinder . Figure 0-2. Three-Quarter Left Rear View, 16-Cylinder . F43068 F43069

PREFACE vii 0

viii Engine Maintenance Manual

GENERAL ENGINE INFORMATION ix 0 ENGINE INFORMATION Table Of Contents DESCRIPTION............................................................................................................................................... x OPERATION .................................................................................................................................................. x ARRANGEMENT ........................................................................................................................................ xii SERIAL NUMBERS .................................................................................................................................... xii PAINTING ................................................................................................................................................... xiv SERVICE DATA - ENGINE INFORMATION........................................................................................... xv SPECIFICATIONS .................................................................................................................................... xv RATINGS ................................................................................................................................................... xv WEIGHTS ................................................................................................................................................. xvi TORQUE VALUES ................................................................................................................................... xviii TOP DECK.............................................................................................................................................. xviii TURBOCHARGER END ......................................................................................................................... xix CRANKCASE AND OIL PAN.................................................................................................................. xx EXTERNALLY THREADED FASTENERS ............................................................................................ xxii EQUIPMENT LIST ................................................................................................................................... xxiii

x ENGINE MAINTENANCE MANUAL DESCRIPTION The turbocharged diesel engines are “V” type two-cycle engines incorporating the advantages of low weight per horsepower, positive scavenging air system, solid unit injection, and high compression. OPERATION In a two-cycle engine, each cylinder completes a power cycle in one revolution of the crankshaft. The piston does not function as an air pump during one crankshaft revolution as is the case in a four-cycle engine which requires two revolu- tions of the crankshaft to complete one power stroke in each cylinder. A separate means is provided in a two-cycle engine to supply the needed air and to purge the combustion gases from the cylinder. The engine is equipped with a turbocharger, shown schematically in Figure 0-3., “Schematic Illustration Of Engine Operation” on page -xi , to efficiently provide the air needed for combustion and scavenging. The turbocharger provides an air supply greater than that provided by positive displacement blowers used on other model engines. During engine operation, the turbocharger utilizes heat energy in the exhaust from the engine as well as power from the camshaft gear train to drive the turbine. However, when exhaust heat energy is sufficient to drive the turbine alone, the gear drive is disengaged by an overrunning clutch. The turbine then drives a centrifugal blower which furnishes air to the engine. The air from the centrifugal blower is raised to a higher pressure and likewise to a higher temperature. It is desirable to reduce the air temperature to increase its density before it enters the air box surrounding the cylinders. The air temperature is reduced by passing it through the aftercoolers as shown in Figure 0-3., “Schematic Illustration Of Engine Operation” on page -xi. Thus cooled, air of greater comparable weight and having more oxygen is available to the engine. Assuming that the piston is at the bottom of its stroke and just starting up, the air intake ports and the exhaust valves will be open. Air under pressure enters the cylinder through the liner ports, pushes the exhaust gases, remaining from the previous power stroke, out through the exhaust valves and fills the cylinder with a fresh supply of air. When the piston is 45° after bottom dead center, the air intake ports will be closed by the piston. Shortly after the air intake ports are closed, the exhaust valves will also be closed, and the fresh air will be trapped in the cylinder. Closing the exhaust valves after the intake air ports provides for the greatest efficiency in cylinder scavenging of combustion gases.

EMD 710 Series G3B G3C Diesel Engine Workshop Service Manual

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