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
WIRE HARNESS 3W100WIRE HARNESS 3W100
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Connects to
3W100 (P5)
Connects to
ECM3W101
J1
Connects toOptional Fault
Lamp(used duringGround Hop)
P1
P10
Sensor ReturnLine Fuses
WIRE HARNESS 3W101WIRE HARNESS 3W101
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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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