63H34E05 Student Handout 1

7/27/2019 63H34E05 Student Handout 1

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TROUBLESHOOTTROUBLESHOOT

THE VTATHE VTA--903T903T

DIESEL ENGINEDIESEL ENGINE

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MLRSVEHICLESVEHICLES

M2/M3

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FEATURESFEATURES

--VV--8 engine design8 engine design

--FourFour--cycle operation uses compression ignitioncycle operation uses compression ignition

--Filtered fuel system has fuel pump and governorFiltered fuel system has fuel pump and governor

--Engine working parts are pressure lubricatedEngine working parts are pressure lubricated

--Centrifugal pump circulates engine coolantCentrifugal pump circulates engine coolant

--Turbocharger forces additional air into combustionTurbocharger forces additional air into combustion

chambers to increase horsepower and efficiency.chambers to increase horsepower and efficiency.

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TABULATED DATATABULATED DATA

--Model is VTAModel is VTA--903T, Manufactured by Cummins903T, Manufactured by Cummins

Engine Company, INC.Engine Company, INC.

--Four cycle, valve in head design with compressionFour cycle, valve in head design with compression

ignitionignition

--Right hand (clockwise) rotationRight hand (clockwise) rotation

--800 RPM800 RPM ++ idleidle

--2970 RPM2970 RPM ++70 max governed speed70 max governed speed

--PT (type D) fuel injectorPT (type D) fuel injector

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MAJOR COMPONENTSMAJOR COMPONENTS

AftercoolerAftercooler

TurbochargerTurbocharger

Vibration DamperVibration Damper

Oil panOil pan

Air Intake ManifoldAir Intake Manifold

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MAJOR COMPONENTSMAJOR COMPONENTSTransmission FluidTransmission Fluid

CoolerCooler

Fuel PumpFuel Pump

FlywheelFlywheel

Starter MotorStarter Motor

Engine Oil CoolerEngine Oil Cooler

Exhaust ManifoldsExhaust Manifolds

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VTAVTA--903T903T

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Mounting Bracket

Drain Valve

10 Micron Fuel Filter

FUEL FILTERFUEL FILTER

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FUEL FILTERFUEL FILTER

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10500 TO 600 HP CONVERSION

VTA 903TVTA 903T______________________________________

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Throttle Position

Sensor (TPS)

Rail Pressure Sensor(RPS)Electronic Control

Module (ECM)

PT Pump

Electronic Fuel

Control (EFC) Valve

Magnetic PickUp/Engine Speed

Sensor

CENTRY SYSTEMCENTRY SYSTEM

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CENTRY PT PUMPCENTRY PT PUMP

Electronic Fuel

Control (EFC) Valve

Rail Pressure Sensor

(RPS)

3W100

Manual Fuel Shutoff

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PT PUMPPT PUMP

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Throttle PositionSensor (TPS)

Electronic ControlModule (ECM)

Data-Link Connector

3W101

3W100

Fault Lamp Bulkhead

Connector W/Cap

P1

J1P5

ELECTRONIC CONTROLELECTRONIC CONTROL

MODULE (ECM)MODULE (ECM) --THROTTLETHROTTLEPOSITION SENSOR (TPS)POSITION SENSOR (TPS)

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ECM/TPSECM/TPS

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Dual Inductive

Pickups

ENGINE SPEED SENSORENGINE SPEED SENSOR

(ESS)(ESS)

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ENGINE SPEED SENSORENGINE SPEED SENSOR

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P1J1

P3

P2

1W101

J1

3A100

J1

Connects to

J19 on IEDB

Connects to

3W100 (P1)1W100

WIRE HARNESS 1W100WIRE HARNESS 1W100

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P1

E14

P9

P5

Connects to

1W100 (J1)

Connects to

3W101 (J1)

3W100

P3

P2

P4 P7

E1 E2E11

J1

P8

P6E13

Connects toFSCV

Connects toMagnet Clutch

Connects toEngine Speed

Sensor

Connects toEFC Valve

Connects toTransmission

Connects toRPS

Connects toTPS


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Connects to

3W100 (P5)

Connects to

ECM3W101

J1

Connects toOptional Fault

Lamp(used duringGround Hop)

P1

P10

Sensor ReturnLine Fuses


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3W1013W101

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J19 (1W100P1)

J4 (1W4P1)

J3 (1W3P1)

J12 (1W1P2)

J9 (1W5P1)

J13 (1W13P1)

J1 (1W1P1)

J2 (1W2P1)

J8 (1W8P1)

J7 (1W7P1)

J6 (1W6P1)

J14 (Launcher)

J15 (Launcher)

J16-18 (Future Use)

IMPROVED ELECTRONICIMPROVED ELECTRONIC

DISTRIBUTION BOX (IEDB)DISTRIBUTION BOX (IEDB)

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IEDBIEDB

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CENTRY Fault Light

Cooling Fan Override

Switch

Air Flow Sensor

FAULT LIGHT LOCATIONFAULT LIGHT LOCATION

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FAULT LIGHTFAULT LIGHT

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1. Turn on Master Power

Switch. (See TM 9-

1450-646-10)

2. Toggle diagnostic

switch momentarily.

3. Read fault code.

4. Toggle diagnostic

switch momentarily.

5. Read fault code.

5 Blinks

One

Second

Pause

1 Blink

One

Second

Pause

4 Blinks

Fault Code 514

NOTE

The engine must be running while reading fault codes.

Every time the Master Power Switch is turned on the yellow

fault lamp will flash for one to two seconds as part of the

normal power-up process. If the lamp stays lit or startsflashing steady, then there is an active fault code.

If the same fault c ode repeats there is only one fault code. Ifa new fault code appears t oggle the fault code switch untill

the original fault code reapears then all fault c odes have

been identified.Sample

Procedures:

FAULT CODE LIGHTFAULT CODE LIGHT

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FAULT CODESFAULT CODES

Measured engine speed exceeded calibration engineMeasured engine speed exceeded calibration engine

over speed RPM settingover speed RPM setting

234234

Low voltage detected at throttle position signal pinLow voltage detected at throttle position signal pin

#19 of the ECM#19 of the ECM

132132

High voltage detected at throttle position signal pinHigh voltage detected at throttle position signal pin

#19 of the ECM connector#19 of the ECM connector

131131

One Engine Speed Sensor (ESS) signal lostOne Engine Speed Sensor (ESS) signal lost121121

Both Engine Speed Sensor (ESS) signals lostBoth Engine Speed Sensor (ESS) signals lost115115

An internal ECM fault has been detectedAn internal ECM fault has been detected111111

ECM memory checksum error. EEPROM memoryECM memory checksum error. EEPROM memory

checksum errorchecksum error

341 or341 or

342342

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High voltage detected at rail pressure signal pin #High voltage detected at rail pressure signal pin #

14 of the ECM connector14 of the ECM connector

451451

Low voltage detected at RPS Sensor +5 volt supplyLow voltage detected at RPS Sensor +5 volt supply

pin # 11 of the ECM connectorpin # 11 of the ECM connector

444444

Low voltage detected at TPS Sensor +5 volt supplyLow voltage detected at TPS Sensor +5 volt supplypin # 13 of the ECM connectorpin # 13 of the ECM connector

443443

Battery being charged to an over voltage conditionBattery being charged to an over voltage condition442442

ECM input voltage fell below 16.4 voltsECM input voltage fell below 16.4 volts441441

EEPROM write errorEEPROM write error353353

FAULT CODESFAULT CODES

Low voltage detected at rail pressure signal pin # 14Low voltage detected at rail pressure signal pin # 14

of the ECM connectorof the ECM connector

452452

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ECM detected high or constant rail pressure whenECM detected high or constant rail pressure when

other engine parameters indicated pressure shouldother engine parameters indicated pressure should

be fluctuatingbe fluctuating

554554

Low rail pressure detected when ECM commandingLow rail pressure detected when ECM commanding

high pressure. EFC stuck in closed, high inlethigh pressure. EFC stuck in closed, high inlet

restriction or low pump supply pressurerestriction or low pump supply pressure

552552

ECM does not have a calibration in its memory orECM does not have a calibration in its memory or

there is an internal microprocessorthere is an internal microprocessor

525525

High rail pressure detected when ECM isHigh rail pressure detected when ECM is

commanding low pressure (EFC valvecommanding low pressure (EFC valve

mechanically stuck open)mechanically stuck open)

514514

Low current or open circuit in EFC circuit detectedLow current or open circuit in EFC circuit detected511511

EFC valve has either lost power or been shorted outEFC valve has either lost power or been shorted out455455

FAULT CODESFAULT CODES ______________________________________

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Documents

63H34E05 Student Handout 1