63H34D01 Student Handout 1

7/27/2019 63H34D01 Student Handout 1

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TROUBLESHOOT

THE 6V53/6V53TDETROIT DIESEL

ENGINE

TROUBLESHOOT

THE 6V53/6V53TDETROIT DIESEL

ENGINE

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INTRODUCTIONThe 6V53T engine provides power for a

variety of military equipment to include:

cargo, personnel, recovery vehicles, self-

propelled mortars, flame throwers,

missile carriers, and light armored

vehicles. Specifically, the 6V53T engine

powers the M113 family of vehicles

(FOV).

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M113A3 FOV

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M113A3

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EQUIPMENT DESCRIPTION

6- CYLINDER , FUEL INJECTED

V- TYPE, LIQUID COOLED

53- cu. in per cylinder (Total displacement318.)

T-Turbocharged

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EQUIPMENT DESCRIPTION

(CONT.)Numbering of the cylinders is one, two,and three from the front (accessory end)of the engine, on both banks. Whendetermining position of a component onthe engine (left or right), view the enginefrom the rear or flywheel. The firingorder of this engine is: 1L, 3R, 3L, 2R,

2L, and 1R. As viewed from the front ofthe engine, this engine rotates clockwise.

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7Right Front View

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Left Rear View

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COMPONENT

LOCATIONSA. Water Pump

B. Valve Rocker

Covers

C. Engine Oil Cooler

D. Exhaust Manifolds

E. Liquid Level Gage

Rod

F. Thermostat &

Housing Assembly

A

B

C

D

E

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COMPONENT LOCATIONS CONT.

G. Transmission Oil Cooler

G.

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COMPONENT

LOCATIONSCONT.

H. Oil Filter

I. Governor

J. Oil Pan

K. Starter

L. Flywheel

M. Fuel Strainer

N. Fuel Filter

O. Turbocharger

H

I

J

K

L

M

NO

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PQ

R

COMPONENT

LOCATIONS

CONT.

P. Fuel Pump

Q. Blower

R. Cylinder

Heads

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ENGINE SYSTEMS

The diesel engine is an internalcombustion power unit where the heat

energy of fuel is converted into workingenergy inside the cylinder. In a dieselengine, air alone is compressed in thecylinder. After compression, a charge offuel is sprayed into the cylinder whereignition is accomplished by the heat ofcompression.

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FUEL SYSTEMThe fuel pump draws fuel from the vehicletank through the strainer and forces itthrough the filter. From the filter, fuel goesthrough the fuel inlet passage in the cylinderhead and fuel tubes into the injectors. Thefuel passes through a filter element within theinjector to a chamber where it is metered,displaced, and atomized through the injectortip into the combustion chamber and excessfuel not injected cools the injector and returnsto the tank.

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LUBRICATION SYSTEMThe gear type oil pump is bolted to the backof the lower front cover and is driven directlyby the crankshaft. Lubricating oil is picked

up from the oil pan by the pump. From thepump, it passes from the lower front coverthrough short gallery passages in the cylinderblock to the oil filter adapter plate. From theadapter plate, oil flows through the oil filter,through the oil cooler, back through the lowerfront cover, and into the cylinder block oilgalleries for distribution to the various enginebearing.

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COOLING SYSTEMThe 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.

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AIR INDUCTIONThe 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.

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AIR INDUCTION

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COMBUSTION CYLINDER

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ELECTRICAL SYSTEM

The electrical system consists of:

A. THE STARTER

B. THE AIR BOX HEATER

C. ALL RELATED WIRING

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GEAR TRAIN

The gear train consists of a crankshaftgear, idler gear, fuel pump drive gear,and two camshaft gears. Model 5063-5393 also has a hydraulic pump drivegear. The camshaft gears mesh witheach other and run at the same speed as

the crankshaft gear. The stamped timingmarks on the face of the gears showproper timing.

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GOVERNORThe limiting-speed, mechanical governoris mounted between the blower andflywheel housing. The governor holdsthe injector racks in the advanced fuelposition for starting when the speedcontrol lever is in the idle position.Immediately after starting, the governormoves the injector racks to control idleand maximum engine speed duringoperation.

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Engine Stop

Throttle Lev

Buffer screw

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TWO STROKE(CYCLE)

ENGINEA two stroke engine completes one cycle(intake, compression, power, and

exhaust) every time the piston goes upand down. Up being one stroke anddown being the return stroke. The airintake and exhaust functions areaccomplished during the compressionand power strokes.

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SCAVENGINGThe blower forces air into the cylinders andsweeps out the exhaust gases to supply thecylinder with fresh air for combustion. Whenthe top of the piston moves down anduncovers the ports, air in the air box is forcedthrough the ports. The air then flows towardsthe exhaust valves and produces a scavengingeffect, leaving the cylinder full of fresh airwhen the piston returns and covers the ports.

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COMPRESSIONAs the piston continues its upwardstroke, it compresses the charge of freshair. Just before the piston reaches itshighest point, top dead center, the fuelinjectors injects the required amount offuel into the cylinder. The heat createdduring compression of the air ignites the

fine spray immediately, and combustioncontinues until the fuel air mixtureburns completely.

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POWERThe resulting pressure forces the pistondownward on its power stroke. Theexhaust valves open approximately half-

way down allowing the burned gasses toescape into the exhaust manifold. Shortlythereafter, the downward moving pistonuncovers the inlet ports sweeping thecylinder with fresh scavenging air. Thisentire cycle takes one revolution of thecrankshaft or two strokes.

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When the piston is halfway down, the

exhaust valve open and most of the high

pressure exhaust 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.

EXHAUST

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INTAKE AIR COMPRESSION

POWEREXHAUST

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ENGINE ADJUSTMENT

The Intervals and Adjustment Sequence:

a. Intervals following any engine repair, perform

adjustments specified in Par 4-3.b.b. Adjustment sequence when performing

adjustments on an engine in service, check varioussettings for possible changes from previousadjustments. However, if the cylinder head,governor, or fuel injectors have been removed orreplaced, also check specific preliminaryadjustments before starting engine.

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ADJUSTMENT

SEQUENCE The preliminary adjustments consist of the

first four steps in the following sequence. Theremaining items complete the list of engineadjustments to be performed.

1. Exhaust valve clearance

2. Fuel injector timing adjustment

3. Governor gap adjustment

4. Fuel injector control tube adjustment

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ADJUSTMENT

SEQUENCE CONT.

5. Throttle delay adjustment

6. Starting aid screw adjustment

7. Maximum no-load speed adjustment

8. Idle speed adjustment

9. Buffer screw adjustment

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EXHAUST VALVE

CLEARANCE ADJUSTMENTA. rotate crankshaftuntil injector

follower is fullydepressed oncylinder to beadjusted.

B. .025-.027 cold &.023-.025 hot engine

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FUEL INJECTOR TIMING

ADJUSTMENTThe 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.

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ADJUSTMENT CONT.The fuel injector:

1. Creates the high fuel pressurerequired for efficient injection.

2. Meters and injects fuel in the exactamount required to handle the load onthe engine.

3. Atomizes the fuel for mixing with theair in the cylinder.

4. Permits continuous fuel flow.

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ADJUSTMENT

A. Rotate crankshaft until exhaust valve stem

are fully depressed on cylinder to be timed.B. 1.496 inch timing gage for model 5063-5392

& 5393.

C. 1.460 inch timing gage for models 5063-5299, 5063-5395, 5063-5398, and 5063-539F.

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GOVERNOR GAP

ADJUSTMENT

A. Extend buffer screw 5/8, start engineand adjust idle to 500-600 RPM.

B. Start and run engine 1100-1300 withdifferential lever and check gap betweenlow-speed and high-speed plunger witha thickness gage .002-.004 inch.

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GOVERNOR GAP

ADJUSTMENT

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INJECTOR CONTROL TUBE

ADJUSTMENTPurpose: It controls the amount of fuel

injected into the cylinder.

A. Adjust No. 3L or 3R injector control leverfirst to establish a guide for adjustingremaining injector control lever.

B. Loosen and back out six adjusting screw.Remove opposite control lever clevis andcotter pin. Turn screw until slight movementis felt on speed control lever or roll up oninjector control tube.

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INJECTOR CONTROL TUBE

ADJUSTMENT CONT.ATTENTION:Once 3L and 3R injector

control levers are adjusted, do not alter their

settings. Make further adjustments only on

remaining injector control rack levers.

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CONTROL TUBE

ADJUSTMENT

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CONTROL TUBE

ADJUSTMENT

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THROTTLE DELAY

ADJUSTMENTPurpose: It retards full fuel injectionwhen the engine accelerates, reducingexhaust smoke and improving fueleconomy.

A. Fill delay with clean engine oil. Insertdelay timing gage on 2R injector.

B. Align delay piston flush with throttledelay cylinder.

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THROTTLE DELAY VALVE

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STARTING AID SCREW

ADJUSTMENTA. Hold starting aid screw and loosenlocknut. Insert starting aid gage on 3Rinjector rack. Prevent gap adjusting screwfrom turning and adjust starting aid screwwith a 0.345 inch gage.

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MAXIMUM NO-LOAD

SPEED ADJUSTMENT

A. to adjust engine start with five0.010 inch shims and 0.078 inchshims in governor spring pack.

B. Back out buffer 5/8 inch and placecontrol lever in FULL FUELposition. Maximum speed should be2965 RPM.

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MAXIMUM NO-LOAD SPED

ADJUSTMENT CONT.NOTE: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.

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IDLE SPEED

ADJUSTMENT

A. Place speed control lever in idleposition of 600-650 RPM.

B. Adjust idle screw to obtain 15

RPM below recommended idle

speed and stop engine.

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IDLE SPEED ADJUSTMENT

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BUFFER SCREW

ADJUSTMENTA. Start engine and place speed control lever in

FULL FUEL and record maximum no-loadspeed.

B. Do not increase engine idle speed more than15 RPM with buffer screw.

C. Place speed control lever in idle position

and turn buffer screw until it contactdifferential lever as lightly as possible andeliminates engine roll.

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BUFFER SCREW

ADJUSTMENT

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SUMMARYIn this lesson you were

introduced to the

6V53/6V53T engine, its

characteristics, component

locations and tune-up

procedures.

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CHECK ON LEARNING

Q. What is the purpose of the fuel

injector ?

A. It meters, displaces and atomizes

the fuel for the cylinders.

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CHECK ON LEARNING

CONT.

Q. What purpose does the turbochargerserve?

A. Provide pressurized air for

combustion.

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CHECK ON LEARNING

CONT.Q. The electrical system consists of what

components?

A. The starter, air box heater, and

assorted wiring.

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63H34D01 Student Handout 1