Troubleshoot the VTA-903T Diesel Engine 63H34E05 / 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-3007 (*) 091-63H-3137 (*) Perform Diagnostics on Pressure Timed (PT) Injection System on a M993 Track Vehicle Perform Diagnostics on a Fuel System on a Track Vehicle (M113/M88A1/M993/M48A5)
Task Title

Reinforced Task(s) Academic Hours

Task Number

091-109-0006

Maintain Equipment Inspection and Maintenance Worksheet (DA Form 2404) and (DA Form 5988-E)

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

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

1 hr 4 hrs 0 hrs 0 hrs 5 hrs

Hours

/ Conference / Discussion / Practical Exercise (Performance)

Lesson No.

Testing
(to include test review)

1 hr 4 hrs

25 mins 25 mins

63H34E07 version MOSC 63H34E08 version MOSC

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions

Lesson Number

Lesson Title

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 9-1450-646-10

TM 9-1450-646-20-1

TM 9-1450-646-20-2

TM 9-1450-646-20-3

TM 9-1450-646-20-4

TM 9-1450-646-20-5

TM 9-1450-646-34

TM 9-2815-219-34

Operator's Manual For Carrier, Multiple Rocket Launch System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-11) (This item is included on EM 0062) Unit Maintenance For Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-6) (This item is included on EM 0062) Unit Maintenance For Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-7) (This item is included on EM 0062) Unit Maintenance For Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-7) (This item is included on EM 0062) Unit Maintenance For Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-7) (This item is included on EM 0062) Unit Maintenance For Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) (Reprinted w/ Basic Incl C1-7) (This item is included on EM 0062) Intermediate Direct Support and Intermediate General Support Maintenance for Carrier, Multiple Launch Rocket System, M993 (NSN 2350-01-091-5405) Direct Support and General Support Maintenance Manual for Engine, Diesel: Liquid Cooled, V-Type, 8 Cylinder, Turbocharged (Cummins Model VTA903T)w/Engine Container Assembly (NSN 2815-01-105-6445)

03 Aug 1984

01 Jul 1988

07 Jul 1988

08 Jul 1998

08 Jul 1988

08 Jul 1988

11 Mar 1988

20 Dec 1984

TM 9-4910-571-12&P

(This is Included on EM 0043 & EM 0062) 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

2350-01-091-5405 CARRIER, CARGO 4910-00-357-5342 TABLE, WORK, AUTOMOTIVE MAINTENANC 4910-00-754-0654 SHOP EQUIPMENT, AUTOMOTIVE VEHICL 4910-01-115-6284 STAND, MAINTENANCE, AUTOMOTIVE ENG 4910-01-222-6589 ANALYZER SET, ENGINE 5180-01-483-0249 TOOL KIT, GENERAL MECHANIC'S 6625-01-265-6000 MULTIMETER 6625-01-493-8984 TEST SET, ELECTRONIC SYSTEMS *ZX7024 Industry Standard Laptop Computer * Before Id indicates a TADSS

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

No No No No No No No No No

0 0 0 0 0 0 0 0 1

No No No No No No No No No

Materials Required

Instructor Materials: 63H34E05, Suppl 1, Practical Exercise 63H34E05, Suppl 2, Practical Exercise 63H34E05, Student Handout 1 63H34E05, Slides References Equipment Student Materials: 63H34E05, Suppl 1, Practical Exercise procedures and Suppl 1, DA Form 2404

63H34E05, Suppl 2, Practical Exercise procedures and Suppl 2, DA Form 2404 63H34E05, Student Handout 1 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

To keep the engine in top running condition it needs to be adjusted periodically. Knowing how to adjust it properly is every soldiers job.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action: Conditions:

Terminal Learning Objective

Perform Diagnostics on the VTA-901T Diesel Engine. In a classroom environment given an applicable vehicle; general mechanic's tool kit; additional tools; TMDE; equipment as indicated in the technical manuals; a maintenance request or equipment inspection worksheet describing equipment malfunctions and other applicable publications.

Standards:

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.

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 sheet must be present at time of instruction.

Risk Assessment Level

Environmental Considerations

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 63H34E07, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34E08, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to perform diagnostic procedures on the Cummins VTA-903T diesel engine.

Instructional Lead-In

SECTION III.

PRESENTATION

1.

Learning Step / Activity 1. Identify the characteristics and location of components on the VTA903T diesel engine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: NOTE: Show Slide 1. Refer students to TM 9-2815-219-34, page 1-2 & 1-3 and follow along. Show Slide 2. a. Equipment Description: (1) Characteristics(a) Provides primary power for the IFV/CFV and MLRS Carrier. (b) Provides power to PTO and the generator. NOTE: Show Slide 3. (2) Capabilities and features(a) V-8 engine design. (b) Four-cycle operation uses compression ignition. (c) Filtered fuel system has fuel pump and governor. (d) Engine working parts are pressure lubricated. (e) Centrifugal pump circulates engine coolant. (f) Turbocharger forces additional air into combustion chambers to increase horsepower and efficiency. NOTE: Show Slide 4. (3) Tabulated Data(a) Manufactured by Cummins Engine Co. Inc. (b) Model is VTA-903T (c) Four cycle, valve in head design with compression ignition. (d) Right hand (clockwise) rotation Conference / Discussion 1:16 20 mins Small Group Instruction (SGI)

(e) 800 RPM + idle (f) 2970 RPM +70 max governed speed (g) 2450 lb. Weight (h) PT (type D) fuel injector NOTE: NOTE: b. Refer students to TM 9-2815-219-34, page 1-4 to follow along. Show Slide 5. Location and Description of Major Components: (1) Aftercooler-The aftercooler cools the hot air from the turbocharger before it goes into the air intake manifold. This helps the engine operate more efficiently. (2) Turbocharger- The turbocharger, driven by exhaust gases, forces combustion air into the engine cylinders. This produces more horsepower for a given amount of fuel. (3) Vibration Damper- The vibration damper is mounted on the front of the crankshaft and helps absorb engine vibrations. (4) Oil pan- the oil pan is a one-piece, deep sump; aluminum casting that holds oil after it passes through the engine. (5) Air Intake Manifold- The left and right air intake manifolds carry compressed air from the aftercooler to the cylinder heads. NOTE: NOTE: Refer students to TM 9-2815-219-34, page 1-5 to follow along. Show Slide 6. (6) Transmission Fluid Cooler- The transmission fluid cooler is a water-oil heat exchanger. It cools the hydraulic fluid used in the vehicle transmission. (7) Fuel Pump- A pressure time (PT) air fuel control (AFC) pump delivers fuel to the cylinders according to engine speed. (8) Flywheel- The flywheel, mounted at the rear of the crankshaft, helps smooth engine power strokes. The starter ring gear fits around the rim of the flywheel. (9) Starter Motor- The starter motor engages the starter ring gear on the flywheel to start the engine. (10) Engine Oil Cooler- The engine oil cooler is a water-oil heat exchanger. It cools the engine lubricating oil. (11) Exhaust Manifolds- The left and right exhaust manifolds route exhaust gases from the cylinders to the turbocharger.

NOTE: NOTE:

Show Slide 7, and point out actual locations on engine. Show Slide 8 and 9. (12) Fuel Filter- Mounted on the engine access door

NOTE: c.

Show Slide 10. Differences between engines: There are two different types of engines used in the MLRS. The first is the Cummins V-type, Turbocharged, and After-cooled (VTA) -903 Tactical (T) 500 horsepower, used on base MLRS and earlier versions of the A1. The second type will be standard for MLRSA1 models and it is the Cummins V-type 600 horsepower or big cam engine. The differences all deal with horsepower. The changes are(1) 3 camshaft- used to increased torque. (2) Improved Intake System-coolant flows through the after cooler cooling the air making it denser. (3) Aerodynamic Exhaust System-provide less restriction for exhausts gases. (4) HT5C Turbocharger-larger turbo to facilitate increased airflow. (5) Engine Lubrication System- uses a 7 gallon pan to hold 1.5 more gallons of oil for cooling and lubricating, a 40 GPM oil pump which is more efficient, tube and fin oil cooler is added to cool engine oil, and oil is injected directly onto the bottom of piston to cool it better. (6) Cold Start System preheats fuel for better combustion.

NOTE: 2.

Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Identify the characteristics and function of the CENTRY System. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Conference / Discussion 1:16 20 mins Small Group Instruction (SGI)

Show Slide 11. a. CENTRY System: The Centry System is an all speed electronic engine fuel control system capable of precisely controlling the engine to a preset RPM by programming the Electronic Control Module. The Centry System has a built-in monitoring diagnostics that will alert the Operator/Maintainer via a fault lamp. The fault lamp will either flash or stay steady depending on the severity of the fault detected. The fault codes can be assessed using the fault lamp. More in-depth diagnosis can be performed with the troubleshooting procedures supplied in the MSD.

b. NOTE:

Components of CENTRY System:

Show Slide 12 and 13. (1) CENTRY PT Fuel Pump- includes the fuel block, which adapts the new Fuel Shut-Off Valve (FSOV). The Centry PT Pump provides the regulation of fuel through the input and assistance of the Rail Pressure Sensor (RPS) and Electronic Fuel Control (EFC) valve. The PT Pump is located in front of the power plant above the transmission interface assembly. (2) Electronic Fuel Control Valve (EFC)- Meters fuel into the engine proportional to a direct current voltage signal received from the ECM. The EFC Valve is located within the PT Pump. (3) Engine Fuel Rail Pressure Sensor (RPS)- Converts engine fuel rail pressure into a proportional direct current voltage sensed by the ECM. The RPS is attached to the fuel block located on top of the PT Pump.

NOTE:

Show Slide 14 and 15. (4). Electronic Control Module (ECM)- Mounted to a bracket attached to the transmission Interface Assembly (IA). Additionally, this bracket provides mounting capabilities for the TPS and 3W100 to 3W101 connection. The ECM receives Throttle Position Sensor, Engine Speed Sensor, and Rail Pressure Sensor inputs. It uses sensor inputs and an application specific calibration, stored in memory, to provide an output to the EFC valve for fuel metering. (5). Throttle Position Sensor (TPS)- Mounted to the same bracket as the ECM. The TPS converts rotational displacement of a shaft, which is mechanically connected to the accelerator pedal, into a proportional direct current of voltage that is sensed by the ECM.

NOTE:

Show Slide 16 and 17. (6). Magnetic Pick Up/Engine Speed Sensor (ESS)- A dual inductive pickup provides a signal proportional to engine RPM to the ECM. The ESS is located on the right side of the flywheel housing.

NOTE:

Show Slide 18. (7). Wire Harness 1W100- this harness connects from J19 on the Improved Electronic Distribution Box (IEDB) to 3W100 (P1). Interfaces include J1 of 1W101 (FSCV Bypass Switch) and J1 of 3A100 (Fault Lamp).

NOTE:

Show Slide 19.

10

(8). Wire Harness 3W100- connects from J1 of 1W100 to J1 of 3W101. Interfaces include E1, E2, and E11 (Electronic Fuel Control Valve), P4 and P7 (Engine Speed Sensor), P2 (Magnetic Clutch Assembly), P3 (Fan Speed Control Valve), P9 and E4 (Data Link), P6 and E13 (Throttle Position Sensor), P8 (Rail Pressure Sensor) and J1 (TEC Transmission). NOTE: Show Slide 20 and 21. (9) Wire Harness 3W101- connects from P5 of 3W100 to P1 of ECM. 3W101 houses the sensor return line. NOTE: Show Slide 22 and 23. (10) Improved Electronic Distribution Box (IEDB)- additional connectors were added to the distribution box to accommodate. The CENTRY System. The connectors are the J14 through J19. J16 and J17 are not used at this time. NOTE: Show Slide 24 and 25. (11) CENTRY Fault Light and Switch- located inside the engine access door, the fault light and switch are used to display faults diagnosed by the CENTRY Fault System. This is accomplished by a series of blinking lights and pauses. NOTE: NOTE: Show Slide 26. Every time the Master Power switch is turned ON the yellow fault lamp will flash for one or two seconds as part of the normal powerup. If the lamp stays lit or starts flashing steady, there is an active fault code. It is imperative that when stopping the engine the user will use the fuel cutoff handle and NOT turn master power to the OFF position. Failure to do this will result in a loss of non-critical fault codes present in the ECM. c. Follow the Steps below to read a fault code: (1) Turn on Master Power Switch. (2) Depress diagnostic switch momentarily. (3) Read fault code. (4) Depress diagnostic switch momentarily. NOTE: If the same fault code repeats there is only one fault code. If a new fault code appears toggle the fault code switch until the original fault code reappears then all fault codes have been identified. (5) Read fault code. NOTE: Show Slides 27 thru 29 and discuss the fault codes.

11

NOTE: 3.

Conduct a check on learning and summarize the learning activity. Learning Step / Activity 3. Troubleshoot the VTA-903T Diesel Engine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Practical Exercise (Performance) 1:4 4 hrs Small Group Instruction (SGI)

Conduct the practical exercise IAW 63H34E05, Suppl 1, Practical Exercise. Once the first practical exercise has been completed conduct another practical exercise IAW 63H34E05, Suppl 2. Divide class into groups for the Practical Exercise. Issue to the group 63H34E05, Suppl 1, Procedures and DA Form 2404. The task for the first practical exercise is: Adjust The Intake, Exhaust Valves, and Fuel Injectors. Once the first practical exercise has been completed issue to the students 63H34E05, Suppl 2, Procedures and DA Form 2404. The fault for the second practical exercise is: CENTRY System fault #121 (One Engine Speed Sensor (ESS) signal lost). Restate safety requirements.

NOTE:

Conduct a check on learning and summarize the learning activity.

12

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:12 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. Q. What function does the ESS perform? A. Provides an RPM signal to the ECM for the CENTRY system. Q. What is the purpose of the Aftercooler? A. Cools the hot air from the turbocharger before it goes into the air intake manifold. This helps the engine operate more efficiently. Q. What are some of the differences between the 500hp and the 600hp engines? A. Bigger cam, larger turbo, aerodynamic exhaust, improved intake, larger oil pan and more efficient pump (larger), and a cold start system.

Review / Summarize Lesson

13

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 63H34E07, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34E08, 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.

Rapid, immediate feedback is essential to effective learning.

14

Appendix C - Practical Exercises and Solutions PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 63H34E05 version MOSC PRACTICAL EXERCISE SHEET 63H34E05 SUPPL. 1
Title Lesson Number / Title Introduction Motivator

Adjust valves and injectors. 63H34E05 version MOSC / Troubleshoot the VTA-903T Diesel Engine

To keep the engine in top running condition it needs to be adjusted periodically. Knowing how to adjust it properly is every soldiers job.
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: Perform Diagnostics on the VTA-901T Diesel Engine. Conditions: In a classroom environment given an applicable vehicle; general

Terminal Learning Objective

mechanic's tool kit; additional tools; TMDE; equipment as indicated in the technical manuals; a maintenance request or equipment inspection worksheet describing equipment malfunctions and other applicable publications.
Standards:

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.

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

Risk Assessment

D-1

Assessment

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 63H34E07, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34E08, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to perform diagnostic procedures on the Cummins VTA-903T diesel engine.
Instructor Materials:

Environmental Considerations

Evaluation

Instructional Lead-In Resource Requirements

63H34E05, Suppl 1, Practical Exercise 63H34E05, Suppl 2, Practical Exercise 63H34E05, Student Handout 1 63H34E05, Slides References Equipment
Student Materials:

63H34E05, Suppl 1, Practical Exercise procedures and Suppl 1, DA Form 2404 63H34E05, Suppl 2, Practical Exercise procedures and Suppl 2, DA Form 2404 63H34E05, Student Handout 1 References Equipment
Special Instructions Procedures

a. NOTE:

Locate the faults annotated on 63H34E05, Suppl 1, DA Form 2404 in the applicable technical manual. read and closely followed to

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

Make sure ALL equipment conditions have been done before performing task.

NOTE: make

Attention: Ensure that hearing protection is worn whenever starting the engine. Also 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. c. Perform the task of adjust the intake and exhaust valves and the task of adjust the fuel injectors at the same time.

D-2

NOTE:

The 1-6 TDC mark is NOT used for alignment. d. Make sure that the cylinders are aligned before adjusting any components.

NOTE:

Only torque the nuts and bolts to one-half specified torque. This is only for the training environment. e. f. Once the troubleshooting procedure has been completed, stop and notify instructor to verify work Ensure that all follow-on tasks have been completed.

NOTE:

Stop, have instructor check your work. g. h. i. j. After all engine adjustments have been performed, stop and have instructor check your work. Fill out DA Form 2404 and turn it into the instructor. After completing the task, clean up around work area. Inform instructor when you are done and for further instructions, and wait to get directions for your next task.

D-3

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 Carrier, Armored, M993, MLRS HHC 143d ORD BN 5. DATE 6. TYPE INSPECTION d. HOT b. HOURS c.ROUNDS 4a.MILES 3. REGISTRATION/SERIAL/NSN PMCS STARTS FIRED 183 M923 35256 7. APPLICABLE REFERENCE TM DATE TM NUMBER Dec 84 9-2815-219-34 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 11:00 SSG Johnson TM STATUS ITEM NO. b a X DEFICIENCIES AND SHORTCOMINGS c INTAKE VALVES AND INJECTORS OUT OF ADJUSTMENT CORRECTIVE ACTION d INITIAL WHEN CORRECTED e

DA

FORM 1APR79

2404

Replaces edition of 1 Jan 64, which will be used

Feedback Requirements

Rapid, immediate feedback is essential to effective learning.

D-4

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34E05 SUPPL. 1 a. Verify students have located the task to Adjust Intake and Exhaust Valves and the task of Adjust Fuel Injectors, (both tasks can be performed at the same time), in TM 9-2815-219-34, page 3-281, (adjust intake and exhaust valves), and TM 9-2815-21934, page 3-142, (adjust fuel injectors), as per fault found on 63H34E05 Suppl 1, DA Form 2404 (Intake Valves and Injectors out of adjustment). Make sure students read and understand all caution and warnings. Divide students into groups and direct them to their workstations. Make sure all students understand the rules of the shop, especially to notify instructor whenever starting the vehicle.

b. c. NOTE:

Make sure all equipment conditions are met before students start task of Adjusting Intake Valves and Fuel Injectors. d. 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. e. f. Have students perform the task of adjusting the intake and exhaust valves and adjusting the fuel injectors. Make sure that cylinders are aligned before continuing with each step.

NOTE:

The 1-6 TDC mark should not be used when aligning cylinders. g. Adjust each valve in the proper sequence according to the manual.

NOTE:

Perform each torque adjustment to only one-half of the specified torque. This is for the training environment only. h. I. j. The adjustment of the fuel injectors is the same for all cylinders. Sequence of adjustment is the same as the firing order: 1,5,4,8,6,3,7,2. When in position, the dial indicator should be as close to the rocker arm as possible, but not touching it. Inform students that all follow on tasks must be performed before the task is completed.

NOTE: NOTE:

When all steps have been performed the instructor must check the engine for serviceability and complete installation correctness. Before any engine is operated make sure all personnel are wearing hearing protection, and that the area is well vented. k. l. Inform groups to annotate corrective action and turn in Suppl 1 to the instructor. Check work area for cleanliness, vehicle for serviceability and that all tools and equipment have been put away. Direct students to next Practical Exercise.

D-5

PRACTICAL EXERCISE SHEET 63H34E05 SUPPL. 2

Title Lesson Number / Title Introduction Motivator

Troubleshoot the VTA-903T Diesel Engine. 63H34E05 version MOSC / Troubleshoot the VTA-903T Diesel Engine

To keep the engine in top running condition it needs to be adjusted periodically. Knowing how to adjust it properly is every soldiers job.
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: Perform Diagnostics on the VTA-901T Diesel Engine. Conditions: In a classroom environment given an applicable vehicle; general

Terminal Learning Objective

mechanic's tool kit; additional tools; TMDE; equipment as indicated in the technical manuals; a maintenance request or equipment inspection worksheet describing equipment malfunctions and other applicable publications.
Standards:

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.

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 sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid,

Risk Assessment

Environmental Considerations

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Considerations

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 63H34E07, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34E08, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to perform diagnostic procedures on the Cummins VTA-903T diesel engine.
Instructor Materials:

Evaluation

Instructional Lead-In Resource Requirements

63H34E05, Suppl 1, Practical Exercise 63H34E05, Suppl 2, Practical Exercise 63H34E05, Student Handout 1 63H34E05, Slides References Equipment
Student Materials:

63H34E05, Suppl 1, Practical Exercise procedures and Suppl 1, DA Form 2404 63H34E05, Suppl 2, Practical Exercise procedures and Suppl 2, DA Form 2404 63H34E05, Student Handout 1 References Equipment
Special Instructions Procedures

a. Locate the CENTRY System fault light and verify if any faults are present in the vehicle. NOTE: Stop, make sure all caution and warning statements are ensure no damage to personnel or equipment. read and closely followed to

b. Make sure ALL equipment conditions have been done before performing task. NOTE: Attention: 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. c. Perform the task IAW the IETM. d. Ensure that keyways are in line before connecting any electrical connections to prevent damage to the connectors. e. Once the troubleshooting procedure has been completed, stop and notify instructor to verify work

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f.

Ensure that all follow-on tasks have been completed.

g. Stop, have instructor check your work. h. Before starting the engine have the instructor check your work. i. j. After all engine adjustments have been performed, stop and have instructor check your work. Fill out DA Form 2404 and turn it into the instructor.

k. After completing the task, clean up around work area. l. Inform instructor when you are done, for further instructions, and wait to get directions for your next task.

m. Turn in all tools and equipment and clean work area. n. 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 Carrier, Armored, M993, MLRS HHC 143d ORD BN 5. DATE 6. TYPE INSPECTION d. HOT b. HOURS c.ROUNDS 4a.MILES 3. REGISTRATION/SERIAL/NSN PMCS STARTS FIRED 183 M923 35256 7. APPLICABLE REFERENCE TM DATE TM NUMBER Dec 84 9-2815-219-34 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 11:00 SSG Johnson TM STATUS ITEM NO. b a X DEFICIENCIES AND SHORTCOMINGS c Fault light on CENTRY System CORRECTIVE ACTION d INITIAL WHEN CORRECTED e

DA

FORM 1APR79

2404

Replaces edition of 1 Jan 64, which will be used

Feedback Requirements

Rapid, immediate feedback is essential to effective learning.

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SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34E05 SUPPL. 2 a. Verify students have checked the CENTRY System to determine if there is a fault. The fault light should blink with the fault of #121, (One Engine Speed Sensor (ESS) signal lost). Verify students locate fault listing in IETM # 0208-2 M993A1 (MLRS) for the specified fault. Make sure students read and understand all caution and warnings. Divide students into groups and direct them to their workstations. Make sure all students understand the rules of the shop, especially to notify instructor whenever starting the vehicle.

b. c. NOTE:

Make sure all equipment conditions are met before students start task of troubleshooting fault #121. d. 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. e. Have students perform the task IAW MLRS IETM.

NOTE:

Make sure master power is OFF before connecting or disconnecting any electrical connections. j. Inform students that all follow on tasks must be performed before the task is completed.

NOTE: NOTE:

When all steps have been performed the instructor must check the engine for serviceability and complete installation correctness. Before any engine is operated make sure all personnel are wearing hearing protection, and that the area is well vented. k. l. Inform groups to annotate corrective action and turn in Suppl 2 to the instructor. Check work area for cleanliness, vehicle for serviceability and that all tools and equipment have been put away.

m. Direct students to next lesson.

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