ii c I c Q I\ L! CJ / c/ c, G c c1 C G c3 G c G G G G G General Motors Electro-Motive G c Model 567,645,and 71 0 Series Diesel Engine G e, G G C c G G (i G 6 0 G G c ti c c c G c G G c c G G c G 0 c; c Acknowledgements c. Gi This course was prepared by International Technical Services, a division of 984326 Ontario Inc., in Q cooperation with the General .\lotors Locomotive Group Customer Training Center, Technical Publications Dept. and Engineering Departments. 6, The course content is based partialy on previous publications produced by the Training Center, and pardy c on information gathered by the Training Center from Electro-Motive's Service and Engineering Departments. The contents of Chapter 7 were extracted from the EMD document, The Electro-Motive Turbocharger by c; William Badurski. 0 G 0 0 Developed in Cooperation with the General Motors Locomotive Group c ElectdMotive Customer Training Center. G c c G Copyright, April, 1997 The content ofthis document is the property ofInternational Technical Services, a division of984326 Ontario Inc.. All rights reserved. Neither this document, nor any part thereof, may be regroduced or stored by any means without c the expressed written consent of984326 Ontario Inc. Contact International Technical Services, 572 Wellington Street, C London Ontario Canada, N6A 3R3 Tel(519)439 -2362, Fax 675-1868 Internet:[email protected]. L Second Edition - Revision 1 - August 1997 G c lntro - iii <-I c C 6 G G c c 6 c ci 6 G c 0 G G /ABLE OF bONTENTS G c G c Chapter 7 EMD Technical Publications & History G EMD History ...................................................................... 1 .1 G Engine Development ...................................................... 1 .4 Locomotive Development .............................................. 1 ,5 0 EMD Technical Publications ........................................... 1 .9 C Locomotive Service Manual (LSM) ................................ 1 .9 C Engine Maintenance Manual ..................................... 1 .1 1 Maintenance Instructions ........................................... 1 .1 3 . - C Service Pointers ............................................................ 1 . 14 G e Chapter 2 Diesel Engine Theory G Introduction ..................................................................... 2.1 G Engine Operating Cycles ............................................... 2.1 Four Stroke Engine .......................................................... 2.2 c. Two Stroke Engine ........................................................... 2.5 G General Engine Arrangement .................................... 2.10 Internal Pressure Division ............................................. 2.1 3 C Serial Numbers ............................................................. 2.14 G G G ITS Locomotive Training Series - Student Text Intro - v -*. I Chapter 3 Engine Components and Construction Physical Layout .......................................................................... 3.1 567-645-710 Engine Evolution .................................................... 3.4 3 Cross Sectional Engine Diagram .............................................. 3.4 Components .............................................................................. 3.5 3 Crankcase .................................................................................. 3.5 Crankcase Comparison ............................................................ 3.8 Main Bearings and Crankshaft ............................................... 3 .lo *d Crankshaft ................................................................................ 3.11 Torsional Dampers ................................................................... 3-12 3 Types of Oil Pans ...................................................................... 3.15 3 Power Packs (Assemblies) ....................................................... 3.16 Cylinder Liner ........................................................................... 3.16 3 Piston and Rings ....................................................................... 3.18 3 Piston Carrier ............................................................................ 3.19 Connecting Rods ..................................................................... 3.21 k3 Cylinder Head .......................................................................... 3-22 Rocker Arm Assembly .............................................................. 3.23 3 Hold Down Crab System ......................................................... 3.24 3 Head Seat Ring ........................................................................ 3.27 Camshafts ................................................................................ 3.27 3 Clutch/Spring Drive Gear ........................................................ 3.32 LJ Accessory Drive ........................................................................ 3.33 Engine Model Comparison 645 - 71 0 ..................................... 3.34 (3 13 cs Chapter 4 Fuel System 3 Introduction ................................................................................ 4.1 bd supply ......................................................................................... 4.1 Delivery ....................................................................................... 4-4 3 Unit Injector System ................................................................... 4.5 u Injector Operation ..................................................................... 4.6 Injection Control ........................................................................ 4.8 3 EMDEC Injection Control ........................................................... 4.8 u EMDEC Fuel Flow and System Components ............................ 4.9 Electronic Fuel Control ............................................................ 4.12 u) Fuel System Troubleshooting .................................................. 4.16 EMDEC System Maintenance ................................................. 4.19 3 Fuel System Troubleshooting EMDEC ..................................... 4.20 lntro .vl ElectrrjMotive Model 567. 645 8t 71 0 Series Diesel Engines Ir . c c C c G c c c Chapter 5 Cooling System Ci Introduction ................................................................................. 5.1 Blower Type Cooling System ...................................................... 5.4 G System Pressurization .................................................................. 5.4 c Operating Water Level ............................................................... 5.5 Coolant ....................................................................................... 5.5 c. Water Pumps ............................................................................... 5.6 Low Water Shutdown .................................................................. 5.7 e Radiators ..................................................................................... 5.8 0 System Maintenance ............................................................... 5.10 G Cooling System Troubleshooting ............................................. 5.12 c Chapter 6 Lube Oil System G c. Introduction ................................................................................. 6.1 Main Lubricating System ............................................................ 6.2 G Piston Cooling Oil System ........................................................... 6.3 Scavenenging Oil System .......................................................... 6.4 G Oil Gauge .................................................................................... 6.4 G Piston Cooling Oil Pressure ......................................................... 6.4 Scavenging Oil Strainer .............................................................. 6.5 G Scavenging Oil Pump ................................................................. 6.5 0 Lube Oil Filter ............................................................................... 6.6 Lube Oil Cooler ........................................................................... 6.7 c Lube Oil Strainer Housing ........................................................... 6.7 Main & Piston Cooling Strainers (Fine) ...................................... 6.8 c Main Lube and Piston Cooling Pump ........................................ 6.8 c Lube Oil Pressure Relief Valve .................................................... 6.9 Turbocharger Oil Filter ............................................................. -6.10 0 Soakback System ...................................................................... 6.10 G Lube Oil Separator (Turbo and Blower) .................................. 6.11 System Maintenance ............................................................... 6.12 c Lube Oil System Troubleshooting ............................................ ,6.14 c Prelubrication of Engines .......................................................... 6.22 G e Chapter 7 Air Intake and Exhaust Systems C Introduction ................................................................................. 7.1 Turbochargers ............................................................................. 7.1 G C c ITS Locomotive Training Series -Student Text lntro .vii c 3 Chapter 7 Component Familiarization ....................................................... 7.2 cont’d Doweling Assembly. ................................................................... 7.4 Main Housing “Cradle” Gasket Area .......................................