Troubleshoot the 63V53/6V53T Detriot Engine 63H34D01 / Version MOSC 01 Oct 2004

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

091-63H30

MOSC

Tracked Vehicle Mechanic(BNCOC)

Task Number

Task Title

INDIVIDUAL 091-63H-3008 (*) 091-63H-3136 (*) 091-63H-3137 (*) Perform Diagnostics on Unit Type Injection System on a M113 Series Track Vehicle Perform Diagnostics on a Track Vehicle Engine (M113/M88A1/M993/M48A5) Perform Diagnostics on a Fuel System on a Track Vehicle (M113/M88A1/M993/M48A5)
Task Title

Reinforced Task(s) Academic Hours

Task Number

The academic hours required to teach this lesson are as follows:

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

13 hrs 0 hrs 0 hrs 13 hrs

Hours

/ Conference / Discussion

Lesson No.

Testing
(to include test review)

N/A
Lesson Title

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions

Lesson Number

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the USA, CASCOM, Training Directorate foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.

References

Number

Title

Date

Additional Information

TM 11-6625-3199-14

TM 9-2350-261-10

TM 9-2350-261-20-1

TM 9-2350-261-20-2

TM 9-2350-261-20-3

TM 9-2350-277-10

Operators, Unit, Intermediate Direct Support, and General Support Maintenance Manual for Digital Multimeter AN/PSM-45A (NSN 6625-01-265-6000) Operator's Manual for Carrier, Personnel, FullTracked, Armored, M113A2 (NSN 2350-01068-4077); Carrier, Command Post, Light: Tracked M577A2 (235001-068-4089) (Reprinted w/ Basic Incl 1-5) (This item included on EM 0040 and EM 0078 Unit Maintenance Manual for Carrier, Personnel, Full-Tracked, Armored, M113A2 (NSN 2350-01-068-4077); Carrier, Command Post, Light: Tracked M577A2 (2350-01-068-4089) (Reprinted w/ Basic Incl 1-4)(This item included on EM 0040 and EM 0078) Unit Maintenance Manual for Carrier, Personnel, Full-Tracked, Armored, M113A2 (NSN 2350-01-068-4077); Carrier, Command Post, Light: Tracked M577A2 (2350-01-068-4089) (Reprinted w/ Basic Incl 1-4)(This item included on EM 0040 and EM 0078) Unit Maintenance Manual for Carrier, Personnel, Full Tracked, Armored, M113A2, (NSN 2350-01-068-4077); Carrier, Command Post, Light Tracked, M577A2, (2350-01-068-4089); Carrier, Mortar, 107-MM, M30, Self- Propelled, M106A2, Operator's Manual for Carrier, Personnel, Full Tracked, Armored, M113A3 Carrier, Command Post, Light , Tracked, M577A3

15 Dec 1988

12 Jul 1990

11 Jul 1990

11 Jul 1990

11 Jul 1990

02 Jan 2001

TM 9-2350-277-20-1

TM 9-2350-277-20-2

TM 9-2350-277-20-3

TM 9-2350-277-20-4

TM 9-2815-205-34

Carrier, Anti-Tank (TOW) Full, Tracked, Armored, M901A3; M981A3; M1059A3; M1064A3; (This Item is Included on EM 0040) Unit Maintenance Manual for Carrier, Personnel, Full-Tracked, Armored, M113A3 (NSN 2350-01-219-7577) (EIC: AEY) Carrier, Command Post, Light Tracked, M577A3 (2350-01-3696085) (EIC: AE7) Carrier, Smoke Generator, Full Tracked, M1059A3 Unit Maintenance for Carrier, Personnel, Full Tracked, Armored M113A3 (NSN 2350-01219-7577) Carrier, Command Post, Light Tracked, M577A3 (235001-369-6085) Carrier, Anti-Tank (TOW), Full Tracked, Armored, M901A3 (2350-01-3697253) Carrier, Unit Maintenance for Carrier, Personnel, Full Tracked, Armored M113A3 (NSN 2350-01219-7577) Carrier, Command Post, Light Tracked, M577A3 (235001-369-6085) Carrier, Anti-Tank (TOW), Full Tracked, Armored, M901A3 (2350-01-3697253) Carrier, Unit Maintenance for Carrier, Personnel, Full Tracked, Armored M113A3 (NSN 2350-01219-7577) Carrier, Command Post, Light Tracked, M577A3 (235001-369-6085) Carrier, Anti-Tank (TOW), Full Tracked, Armored, M901A3 (2350-01-3697253) Carrier, Direct and General Support Maintenance Manual for Engine w/Container Model 50635299 (NSN 2815-00-1245390) (2815-01-2957458); Engine w/Container Model 50635392 (2815-01-246-

02 Jan 2001

02 Jan 2001

02 Jan 2001

02 Jan 2001

21 Aug 1992

TM 9-4910-571-12&P

0903) (This Item is Included on EM 0040, em 0076, Em 0078) Operator's and Organizational Maintenance Manual Including Repair Parts and Special Tools List for Simplified Test Equipment for Internal Combustion Engines (Reprinted W/Basic Incl C1-2)(This Item is Included on EM 0068)

25 Mar 1988

Student Study Assignments Instructor Requirements Additional Support Personnel Requirements Equipment Required for Instruction

None for this lesson.

One instructor per group.

Stu Ratio

Name

Qty

Man Hours

None
Id Name Stu Ratio Instr Ratio

Spt

Qty

Exp

2350-01-068-4077 CARRIER, PERSONNEL, FULL TRACKED 2350-01-219-7577 CARRIER, PERSONNEL, FULL TRACKED 4910-00-357-5342 TABLE, WORK, AUTOMOTIVE MAINTENANC 4910-00-387-9592 PAN, DRAIN 4910-00-754-0654 SHOP EQUIPMENT, AUTOMOTIVE VEHICL 5180-01-481-8389 TOOL KIT, GENERAL MECHANIC'S 5210-00-538-8465 GAGE, INJECTOR RACK 5210-01-091-8354 GAGE, INJECTOR RACK 5210-01-242-4091 GAGE, INJECTOR TIMIN 70210N Computer; Mirco Laptop portable AC/DC W/Battery pack *ZX7024 Industry Standard Laptop Computer *ZX7043 Projector, Light. High Resolution *ZX9055 Industry Standard Light Pro Screen *ZX9061 Wireless Mouse

1:4 1:4 1:4 1:4 1:16 1:4 1:4 1:4 1:4 1:4

No No No No No No No No No No

0 0 0 0 0 0 0 0 0 0

No No No Yes No No No No No No

1:16 1:16 1:16 1:16

No No No No

0 0 0 0

No No No No

* Before Id indicates a TADSS Materials Required

Instructor Materials: 63H34D01 Slides 63H34D01 Student Handout 1 63H34D01 Practical Exercise Procedures and Solutions Computer w/projector References Equipment Student Materials: 63H34D01 Student Handout 1 63H34D01 Practical Exercise Procedures and DA Form 2404. References Equipment

Classroom, Training Area, and Range Requirements Ammunition Requirements Instructional Guidance

General Instruction Building Vehicle Maintenance Instructional Building

Id

Name

Exp

Stu Ratio

Instr Ratio

Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

Proponent Lesson Plan Approvals

Name

Rank

Position

Date

Gerard, Gregory Deilus, John

GS-11 GS-12

Military Analyst Military Analyst

01 Oct 2004 01 Oct 2004

SECTION II.

INTRODUCTION

Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Small Group Instruction (SGI)
Motivator

As a maintenance supervisor, you will be required to supervise and perform diagnostic procedures, tune-up adjustment, and fuel system repair of the Detroit Diesel Engine.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action:

Terminal Learning Objective

Troubleshoot the Unit Type Injection System on a M113 Series Track Vehicle In a classroom environment given an applicable vehicle; general mechanic's tool kit; additional tools; TMDE; equipment as indicated in the appropriate technical manuals: a maintenance request or equipment inspection worksheet describing equipment malfunctions; and applicable references. IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Conditions:

Standards:

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position. Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work

Risk Assessment Level

Level Environmental Considerations

sheet must be present at time of instruction.

NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment from damage.

When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.
Evaluation

Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34D04, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34D05, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to perform diagnostic procedures, tune-up, adjustments and repair on the 6V53/6V53T Detroit Diesel Engine.

Instructional Lead-In

SECTION III.

PRESENTATION

1.

Learning Step / Activity 1. Identify the characteristics of the 6V53/6V53T Detroit Diesel Engine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: NOTE: Show Slide 1. Issue 63H34D01, Suppl 4, and TM 9-2815-205-34 to students and have them follow along with slide presentation. Show Slide 2. a. Introduction: The 6V53T engine provides power for a variety of military equipment to include: cargo, personnel, recovery vehicles, self-propelled mortars, flamethrowers, missile carriers, and light armored vehicles. Specifically, the 6V53T engine powers the M113 (FOV). Conference / Discussion 1:16 1 hr 20 mins Small Group Instruction (SGI)

NOTE: NOTE: NOTE:

Show Slide 3 & 4. Refer students to TM 9-2815-205-34, page 1-3 to follow along. Show Slide 5. b. Equipment Description: The 6V53T engine is a 6-cylinder, fuel injected, 2-cycle, V-type liquid cooled diesel engine, with wet cylinder liners. It is an internal combustion engine that converts the heat in the fuel into useful torque within the engine cylinders. The various components of the engine transmit this torque to the flywheel as output energy.

NOTE:

Show Slide 6. c. Equipment Description: Numbering of the cylinders is one, two, and three from the front (accessory end) of the engine, on both banks. When determining position of a component on the engine (left or right), view the engine from the rear or flywheel. The firing order of this engine is: 1L, 3R, 3L, 2R, 2L, and 1R. As viewed from the front of the engine, this engine rotates clockwise.

NOTE: NOTE: NOTE: NOTE: along.

Show Slide 7: Front Right View Show Slide 8: Left Rear View Show Slide 9. Refer students to TM 9-2815-205-34, page 1-7 thru 1-9 to follow d. Component Locations:

(1) Water Pump-Mounted on the top of the oil cooler and driven by belts from the camshaft front pulley. It circulates coolant through the cylinder block, cylinder heads, and oil cooler. (2) Valve Rocker Covers- Encloses the valve and injector rocker arm mechanisms located on top of cylinder heads. (3) Engine Oil Cooler- Mounted on lower left side of the engine block. It uses engine coolant to cool the engine oil. Models 5063-5299 NS 5063-5392 have the transmission coolers in the same housing.

(4) Exhaust Manifolds-Attached directly to the cylinder heads. For all except model 5063-5299, they route exhaust gases through attached exhaust piping to the turbocharger. (5) Liquid Level Gage (Oil) Rod- On model 5063-5299, it is mounted on the left rear of the cylinder head. On model 5063-5392, it is mounted on the right rear of the cylinder head. On models 5063-5393 and 5063-539L, it is mounted on the right front of the cylinder head. On models 5063-5395, 5063-5398, and 5063-539F, it is mounted on the middle of the right cylinder head. It measures the liquid level in the oil pan. (6) Thermostat and Housing Assembly-Mounted on the front of the left cylinder head and connected to the right cylinder head with a crossover tube. It controls coolant temperature by restricting coolant flow to the radiator. NOTE: Show Slide 10. (7) Transmission Oil Cooler-Models 5063-5393 and 5063-539L has a separate transmission oil cooler mounted on the side of the engine block. NOTE: Show Slide 11. (8) Oil Filter-Mounted on the lower left side of the engine block for all except model 5063-5392. Model 5063-5392, has it mounted near the left rear cylinder head. It filters the engine lubrication oil. (9) Governor- Mounted on the rear end of the blower and driven from a blower drive gear. It is used to control the idle and maximum engine operating speeds. (10) Oil Pan-Mounted on the bottom of the cylinder block. It provides a reservoir for engine oil. (11) Starter- Mounted on right side of the flywheel housing. It is an electric starter and engages the flywheel ring gear.

(12) Flywheel- Mounted on the rear of the crankshaft. It is used to provide true alignment of transmission flex plate. (13) Fuel Strainer-On model 5063-5299, it is remote mounted. On model 5063-5392, it is mounted near the left rear corner of the engine. On models 5063-5393 and 5063-539L, it is mounted on the lower right side. On models 5063-5395, 5063-5398, and 5063-539F, it is mounted near the right rear corner of the engine. It filters fuel to the fuel pump. (14) Fuel Filter-Mounted adjacent to the fuel strainer. It filters fuel to the fuel inlet manifold. (15) Turbocharger- Mounted on the rear of the engine (models 5063-5393, 5063-5395, 5063-5398, 5063-539F, and 5063539L) or on the blower (model 5392). It increases engine power by delivering high-pressure air to the blower using exhaust gas energy. Model 5063-5299 has no turbocharger. NOTE: Show Slide 12.

(16) Fuel Pump- Attached to the flywheel housing and driven off the right side camshaft gear. It supplies low-pressure fuel to the fuel inlet manifolds in the cylinder heads. (17) Blower-Mounted on top of the cylinder block. It supplies a constant volume of fresh air per revolution to the cylinders. (18) Cylinder heads-Mounted on top of each cylinder bank. They contain fuel manifolds; exhaust valves, injectors, and injector and valve operating mechanisms. NOTE: NOTE: Show Slide 13. Refer students to TM 9-2815-205-34, page 1-13 & 14, to follow along. e. Principles of Operation: The diesel engine is an internal combustion power unit where the heat energy of fuel is converted into working energy inside the cylinder. In a diesel engine, air alone is compressed in the cylinder. After compression, a charge of fuel is sprayed into the cylinder where ignition is accomplished by the heat of compression.

NOTE:

Show Slide 14. (1) Fuel System- The fuel pump draws fuel from the vehicle tank through the strainer and forces it through the filter. From the filter, fuel goes through the fuel inlet passage in the cylinder head and fuel tubes into the injectors. The fuel passes through a filter element within the injector to a chamber where it is metered, displaced, and atomized through the injector tip into the combustion chamber and excess fuel not injected cools the injector and returns to the tank.

10

NOTE: NOTE:

Show Slide 15: discuss the flow of fuel through the engine. Show Slide 16. (2) Lubrication System-The gear type oil pump is bolted to the back of the lower front cover and is driven directly by the crankshaft. Lubricating oil is picked up from the oil pan by the pump. From the pump, it passes from the lower front cover through short gallery passages in the cylinder block to the oil filter adapter plate. From the adapter plate, oil flows through the oil filter, through the oil cooler, back through the lower front cover, and into the cylinder block oil galleries for distribution to the various engine bearings.

NOTE: NOTE:

Show Slide 17: discuss the flow of oil through the engine. Show Slide 18. (3) Cooling System-The water pump takes coolant from the radiator and circulates it through the oil cooler, cylinder block, and cylinder heads to the thermostat housing. During the warm-up period, the thermostat blocks the flow of coolant to the radiator (below 160 degree Fahrenheit). With the thermostat closed, the pump circulates the coolant through the bypass system to the cylinder block and cylinder head. As coolant reaches approximately 160 degrees Fahrenheit, the thermostat opens and the coolant then passes through the radiator for cooling.

NOTE: NOTE:

Show Slide 19: Discuss the flow of coolant through the engine. Show Slide 20. (4) Air Induction-The blower forces air into the cylinder (called scavenging) and sweeps out the burned gases through the exhaust valve ports. This air also cools the internal engine parts, particularly the exhaust valves. The turbocharger forces additional pressurized air into the cylinders (called supercharging) to allow burning of more fuel for additional power.

NOTE: NOTE: NOTE:

Show Slide 21: Discuss the flow of air through the engine. Show Slide 22: Discuss the engine cylinder sleeve. Show Slide 23. (5) Electrical System- The electrical system consists of a starter, air box heater, and related wiring. (a) Starter- The starter is equipped with a shift lever and solenoid plunger, totally enclosed to protect it against dirt, and a Sprague-overrunning clutch. Pressing the starting switch energizes the starter solenoid, which engages the starter pinion with the teeth of the flywheel

11

ring gear. The starter drives the pinion and rotates the engine. When the engine begins to operate, the sprag clutch permits the pinion to overrun on its shaft until the starting switch is released, which prevents over speeding of the starter. (b) Air box heater-heat the air entering the cylinder to assists in ignition of fuel at low ambient temperatures. A fuel and air mixture is sprayed into the air box and a spark ignites a flame. The flame heats the incoming engine air, which is fed directly into the cylinder. (c) Related wiring-assorted harnesses that carry power and ground to various components. NOTE: Show Slide 24. (6) The gear train-The gear train consists of a crankshaft gear, idler gear, fuel pump drive gear, and two camshaft gears. Model 5063-5393 also has a hydraulic pump drive gear. The camshaft gears mesh with each other and run at the same speed as the crankshaft gear. The stamped timing marks on the face of the gears show proper timing. NOTE: NOTE: Show Slide 25: Discuss the function of the gear train. Show Slide 26. (7) The limiting-speed, mechanical governor is mounted between the blower and flywheel housing. The governor holds the injector racks in the advanced fuel position for starting when the speed control lever is in the idle position. Immediately after starting, the governor moves the injector racks to control idle and maximum engine speed during operation. NOTE: NOTE: NOTE: along. Show Slide 27: Point out the location of the governor. Show Slide 28. Refer students to TM 9-2815-205-34, page 1-14 & 15, to follow f. Operational description: A two-stroke engine completes one cycle (intake, compression, power, and exhaust) every time the piston goes up and down. Up being one stroke and down being the return stroke. The air intake and exhaust functions are accomplished during the compression and power strokes.

NOTE:

Show Slide 29. (1) Scavenging- the blower forces air into the cylinders and sweeps out the exhaust gases to supply the cylinder with fresh air for combustion. When the top of the piston moves down and uncovers the ports, air in the air box is forced through the ports. The air then flows towards the exhaust

12

valves and produces a scavenging effect, leaving the cylinder full of fresh air when the piston returns and covers the ports. NOTE: Show Slide 30. (2) Compression- As the piston continues its upward stroke; it compresses the charge of fresh air. Just before the piston reaches its highest point, top dead center, the fuel injectors injects the required amount of fuel into the cylinder. The heat created during compression of the air ignites the fine spray immediately, and combustion continues until the fuel air mixture burns completely. NOTE: Show Slide 31. (3) Power- The resulting pressure forces the piston downward on its power stroke. The exhaust valves open approximately halfway down allowing the burned gasses to escape into the exhaust manifold. Shortly thereafter, the downward moving piston uncovers the inlet ports sweeping the cylinder with fresh scavenging air. This entire cycle takes one revolution of the crankshaft or two strokes. NOTE: Show Slide 32. (4) Exhaust-When the piston is halfway down, the exhaust valve open and most of the high pressure exhausts gases escape. Shortly thereafter, the piston drop below the inlet ports in the cylinder wall. Pressurized air is then forced through the cylinder. During this process, the remaining exhaust gases are removed (or scavenged) from the cylinder. NOTE: NOTE: 2. Show Slide 33: Discuss the exhaust system.

Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Identify the troubleshooting and adjustment procedures of the 6V53/6V53T Diesel Engine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: Conference / Discussion 1:16 1 hr 20 mins Small Group Instruction (SGI)

Refer Students to TM 9-2815-205-34, page 4-7, to follow along. Show Slide 34. a. Engine Adjustments: The Intervals and Adjustment Sequence: (1) Intervals- following any engine repair performs the adjustments specified in Par 4-3.b.

13

(2) Adjustment sequence- when performing adjustments on an engine in service, check various settings for possible changes from previous adjustments. However, if the cylinder head, governor, or fuel injectors have been removed or replaced, also check specific preliminary adjustments before starting engine. NOTE: Show Slide 35. b. Adjustment Sequence- the preliminary adjustments consist of the first four steps in the following sequence. The remaining items complete the list of engine adjustments to be performed. (1) Exhaust valve clearance. (2) Fuel injector timing adjustment. (3) Governor gap adjustment. (4) Fuel injector control tube adjustment. NOTE: Show Slide 36. (5) Throttle delay adjustment. (6) Starting aid screw adjustment. (7) Maximum no-load speed adjustment. (8) Idle speed adjustment. (9) Buffer screw adjustment. NOTE: NOTE: Show Slide 37. Refer students to TM 9-2815-205-34, page 4-8, to follow along. c. Engine Tune-up Procedures(1) Exhaust valve clearance adjustment: (a) Rotate crankshaft until injector follower is fully depressed on cylinder to be adjusted. (b) .025-.027 cold & .023-.025 hot engine. NOTE: NOTE: Show Slide 38. Refer students to TM 9-2815-205-34, page 4-10, to follow along. d. Fuel injector timing adjustment- the fuel injector enables starting directly on diesel fuel and permits the use of a simple, open combustion chamber. High-pressure fuel lines, air-fuel mixing, or vaporizing devices are required.

14

NOTE:

Show Slide 39. (1) The fuel injector: (a) Creates the high fuel pressure required for efficient injection. (b) Meters and injects fuel in the exact amount required to handle the load on the engine. (c) Atomizes the fuel for mixing with the air in the cylinder. (d) Permits continuous fuel flow.

NOTE:

Show Slide 40. e. Fuel Injector Timing Adjustment: (a) Rotate crankshaft until exhaust valve stem are fully depressed on cylinder to be timed. (b) A 1.496-inch timing gage for model 5063-5392 & 5393. (c) A 1.460-inch timing gage for models 5063-5299, 50635395, 5063-5398, and 5063-539F.

NOTE: NOTE:

Show Slide 41. Refer students to TM 9-2815-205-34, page 4-11, to follow along. f. Governor Gap Adjustment(1) Extend buffer screw 5/8, start engine and adjust idle to 500600 RPM. (2) Start and run engine 1100-1300 with differential lever and check gap between low-speed and high-speed plunger with a thickness gage .002-.004 inch.

NOTE: NOTE: NOTE:

Show Slide 42: Discuss the Governor Gap Adjustment. Show Slide 43. Refer students to TM 9-2815-205-34, page 4-14, to follow along. f. Injector Control Tube Adjustment: Purpose: It controls the amount of fuel injected into the cylinder. (1) Adjust No. 3L or 3R injector control lever first to establish the guide for adjusting remaining injector control lever.

15

(2) Loosen and back out six adjusting screw. Remove opposite control lever clevis and cotter pin. Turn screw until slight movement is felt on speed control lever or roll up on injector control tube. NOTE: CAUTION: Show Slide 44. Once 3L and 3R injector control levers are adjusted, do not alter their settings. Make further adjustments only on remaining injector control rack levers. Show Slide 45 & 46: Discuss the Injector Control Tube Adjustment. Show Slide 47. Refer students to TM 9-2815-205-34, page 4-18, to follow along. g. Throttle Delay Adjustment-Purpose: It retards full fuel injection when the engine accelerates, reducing exhaust smoke and improving fuel economy. (1) Fill delay with clean engine oil. Insert delay timing gage on 2R injector. (2) Align delay piston flush with throttle delay cylinder. NOTE: NOTE: NOTE: Show Slide 48: Discuss Throttle Delay Valve Show Slide 49. Refer students to TM 9-2815-205-34, page 4-18, to follow along. h. Starting Aid Screw Adjustment- Hold starting aid screw and loosen locknut. Insert starting aid gage on 3R injector rack. Prevent the gap adjusting screw from turning and adjust starting aid screw with a 0.345-inch gage.

NOTE: NOTE: NOTE:

NOTE: NOTE:

Show Slide 50. Refer students to TM 9-2815-205-34, page 4-20, to follow along. i. Maximum No-Load Speed Adjustment(1) To adjust engine start with five 0.010-inch shims and 0.078 inch shims in governor spring pack. (2) Back out buffer 5/8 inch and place control lever in FULL FUEL position. Maximum speed should be 2965 RPM.

NOTE: NOTE:

Show Slide 51. Removing shims will decrease engine speed and adding shims will increase engine speed. Each 0.010 inch shim will change engine speed approximately 10 RPM. Show Slide 52.

NOTE:

16

NOTE:

Refer students to TM 9-2815-205-34, page 4-21, to follow along. j. Idle Speed Adjustment(1) Place speed control lever in idle position of 600-650 RPM. (2) Adjust idle screw to obtain 15 RPM below recommended idle speed and stop engine.

NOTE: NOTE: NOTE:

Show Slide 53: Discuss the Idle Speed Adjustment. Show Slide 54. Refer students to TM 9-2815-205-34, page 4-22, to follow along. k. Buffer Screw Adjustment(1) Start engine and place speed control lever in FULL FUEL and record maximum no-load speed. (2) Do not increase engine idle speed more than 15 RPM with buffer screw. (3) Place speed control lever in idle position and turn buffer screw until it contact differential lever as lightly as possible and eliminates engine roll.

NOTE: NOTE: 3.

Show Slide 55: Discuss Buffer Screw Adjustment.

Conduct a check on learning and summarize the learning activity. Learning Step / Activity 3. Perform diagnostic procedures, tune-up, adjustments and repair on the 6V53/6V53T Detroit Diesel Engine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Conference / Discussion 1:4 10 hrs Programmed Instruction

Conduct the practical exercise IAW 63H34D01, Suppl 1, Practical Exercise. Divide class into groups for the Practical Exercise. Issue to the group 63H34D01, Suppl 1, Practical Exercise Procedures. Issue to the group, 63H34D01, Suppl 1, DA Form 2404. Restate safety requirements.

NOTE:

Conduct a check on learning and summarize the learning activity.

17

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Small Group Instruction (SGI)

Check on Learning

Determine if the students have learned the material presented by soliciting student questions and explanations. Ask the students questions and correct misunderstandings. NOTE: Show Slides 56, 57, and 58: Ask the following questions to check on learning. Q. What is the purpose of the fuel injector? A. It meters, displaces and atomizes fuel for the cylinders. Q. What purpose does the turbocharger serve? A. Provide pressurized air to the blower. Q. The electrical system consists of what components? A. The starter, air box heater, and assorted wiring.

Review / Summarize Lesson

NOTE:

Show Slide 59: Review the TLO and then summarize the lesson.

18

SECTION V. Testing Requirements

STUDENT EVALUATION
NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan.

Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34D04, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34D05, Job Performance Test, the student must achieve a GO and complete the test within one hour.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

19

Appendix C - Practical Exercises and Solutions PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 63H34D01 version MOSC PRACTICAL EXERCISE SHEET 63H34D01 SUPPL. 1
Title Lesson Number / Title Introduction Motivator

Troubleshoot the 63V53/6V53T Detriot Engine 63H34D01 version MOSC / Troubleshoot the 63V53/6V53T Detriot Engine

As a maintenance supervisor, you will be required to supervise and perform diagnostic procedures, tune-up adjustment, and fuel system repair of the Detroit Diesel Engine.
NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: Troubleshoot the Unit Type Injection System on a M113 Series Track Conditions:

Terminal Learning Objective

Vehicle In a classroom environment given an applicable vehicle; general mechanic's tool kit; additional tools; TMDE; equipment as indicated in the appropriate technical manuals: a maintenance request or equipment inspection worksheet describing equipment malfunctions; and applicable references. IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Standards:

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

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Risk Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons. Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34D04, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34D05, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to perform diagnostic procedures, tune-up, adjustments and repair on the 6V53/6V53T Detroit Diesel Engine.
Instructor Materials:

Environmental Considerations

Evaluation

Instructional Lead-In Resource Requirements

63H34D01 Slides 63H34D01 Student Handout 1 63H34D01 Practical Exercise Procedures and Solutions Computer w/projector References Equipment

Student Materials:

63H34D01 Student Handout 1 63H34D01 Practical Exercise Procedures and DA Form 2404. References Equipment
Special Instructions Procedures

a. NOTE:

Locate the solution to the fault found on 63H34D01, Suppl 1, DA Form 2404 to troubleshoot the 6V53/6V53T Detroit Diesel Engine. read and closely followed to

Stop, make sure all caution and warning statements are ensure no damage to personnel or equipment. b. c.

Make sure ALL equipment conditions have been done before performing task. Perform the task IAW the Technical Manual.

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d. e. f. g. h. i. CAUTION:

Once the removal procedures have been performed, stop and notify instructor. Proceed with the installation procedures. Stop, have instructor check your work. Ensure that all follow-on tasks have been completed. Stop, have instructor check your work. Perform the Engine adjustment procedures IAW the Technical Manual.

Ensure that hearing protection is worn whenever starting the engine. Also make sure that the master power switch is in the OFF position before connecting/disconnecting any electrical connections to prevent damage to equipment and possible harm to individuals. j. k. l. Before starting the engine have the instructor check your work. Ensure that keyways are in line before connecting any electrical connections to prevent damage to the connectors. After all engine adjustments have been performed, stop and have instructor check your work.

m. Fill out DA Form 2404 and turn it into the instructor. n. o. p. q. After completing the task, clean up around work area. Inform instructor when you are done, for further instructions, and wait to get directions for your next task. Turn in all tools and equipment and clean work area. Wait to be directed to your next class.

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EQUIPMENT INSPECTION AND MAINTENANCE WORKSHEET For use of this form, see DA PAM 738-750 and 738-751; the proponent agency is DCSLOG 2. NOMENCLATURE AND MODEL 1. ORGANIZATION Armored Personnel Carrier M113A2/A3 HHC 143d ORD BN 5. DATE 6. TYPE INSPECTION d. HOT b. HOURS c.ROUNDS 4a.MILES 3. REGISTRATION/SERIAL/NSN Initial STARTS FIRED 187 M416 61236 7. APPLICABLE REFERENCE TM DATE TM NUMBER Aug 92 9-2815-205-34 COLUMN a-Enter TM item number. COLUMN b-Enter the applicable condition status symbol. COLUMN c-Enter deficiencies and shortcomings. TM NUMBER TM DATE

COLUMN d-Show corrective action for deficiency or shortcoming listed in Column c. COLUMN e-Individual ascertaining completed corrective action initial in this column. STATUS SYMBOLS DIAGONAL (/)-Indicates a material defect other than a deficiency which X-Indicates a deficiency in the equipment that places it in an inoperable must be corrected to increase efficiency or to make the item completely status. serviceable. CIRCLED X-Indicates a deficiency, however, the equipment may be LAST NAME INITIAL IN BLACK, BLUE-BLACK INK, OR PENCILoperated under specific limitations as directed by higher authority or as Indicates that a completely satisfactory condition exists. prescribed locally, until corrective action can be accomplished. FOR AIRCRAFT-Status symbols will be recorded in red. HORIZONTAL DASH(-)-Indicates that a required inspection, component replacement, maintenance operation check, or test flight is due but has not been accomplished, or an overdue MWO has not been accomplished. ALL INSPECTIONS AND EQUIPMENT CONDITIONS RECORDED ON THIS FORM HAVE BEEN DETERMINED IN ACCORDANCE WITH DIAGNOSTIC PROCEDURES AND STANDARDS IN THE TM CITED HEREON. 9a.SIGNATURE Maintenance Supervisor 9b.TIME 10.MANHOUR 8b.TIME 8a.SIGNATURE Person(s)performing inspection S REQUIRED SGT GREY 10:00 TM ITEM NO. a STATUS b X DEFICIENCIES AND SHORTCOMINGS c LEFT SIDE HEAD GASKET UNSERVICABLE CORRECTIVE ACTION d INITIAL WHEN CORRECTED e

DA

FORM 1APR7 9

2404

Replaces edition of 1 Jan 64, which will be used

Feedback Requirements

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SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34D01 SUPPL. 1 NOTE: Verify students have located the task to replace the Cylinder Head Assembly Removal/Installation in TM 9-2815-205-34, page 3-132, as per fault found on 63H34D01 Suppl 1, DA Form 2404 (Left Cylinder Head Gasket Unserviceable.). Make sure students read and understand all caution and warnings. a. Divide students into groups and direct them to their workstations. b. NOTE: Make sure all students understand the rules of the shop, especially to notify instructor whenever starting the vehicle.

Make sure all equipment conditions are met before students start task of replacing the cylinder head gasket. c. Inform students to notify instructor whenever a task has been accomplished for the equipment conditions.

NOTE:

Make sure that students insure that a drain pan is used whenever a fuel or oil line is disconnected. d. e. f. g. Have students perform the task of removing the cylinder head & gasket. Perform task, Inspect cylinder head. After the head and gasket have been removed, have students perform the task of installing the cylinder head & gasket. Inform students that all follow on tasks must be performed before the engine can be started.

NOTE: NOTE:

When all steps have been performed the instructor must check the engine for serviceability and complete installation correctness. Before the engine is operated make sure all personnel are wearing hearing protection, and that the area is well vented. h. i. j. k. l. Inform the students that before the engine can be operated the engine adjustments must be performed as specified in Paragraph 4-3.b, page 4-7, TM 9-2815-205-34. After completion of the steps for the engine adjustments have been completed, make sure that all follow-on steps have been done. Inform groups to annotate corrective action and turn in Suppl 3 to the instructor. Check work area for cleanliness, vehicle for serviceability and that all tools and equipment have been put away. Schedule and provide immediate feedback in the context to the material presented: and correct students misunderstandings. Provide remedial training as needed.

m. Direct students to next lesson.

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