Description

►►► Medium & Heavy Duty Truck Engines, Fuel & Computerized Management Systems




Section 1 Diesel Engine Fundamentals . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction 3 n Role of the Trucking Industry and the Truck Technician 4
n The Truck Technician of the Twenty-First Century 5 n Training and the Truck
Technician 7 n Customer Service and Professionalism 9 n Qualifications
and Careers for the Truck Technician 12 n Professional Associations 13
n Proprietary Associations 13 n Defining Engines by Displacement 13
n Engine Oems and Market Share 14 n Health, Safety, and a Green
Environment 14 n VIN 15
Hand and Shop Tools, Precision Tools, and Units of Measurement . . . . . . . . 17
Introduction 18 n Hand Tools 18 n Precision Measuring Tools 23
n Shop Tools 31 n Fastener Grades and Torques 35 n The Metric System
and English/Metric Conversion 37 n Workplace Organization 39
Personal and Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Personal Safety Equipment 44 n Workplace Hazards and Safety
Regulations 46 n Emergencies 47 n Osha 48 n Safety Hotlines 51
Engine Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Introduction 55 n Key Engine Terms 55 n The Diesel Cycle 57
n The Two-Stroke Cycle Diesel Engine 59 n The Otto Cycle 61 n Engine Systems
and Circuits 62 n Advanced Engine Terms 63
History of the Heat Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Introduction 68 n History of the Modern Diesel Engine 68
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Introduction 80 n Definitions and Formulae 80 n Engine Configuration,
Engine Speed, and Torsional Forces 87 n How Much Power Do You Need? 88
Engine Powertrain Components . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Introduction 91 n Piston Assemblies 91 n Piston Rings 99 n Connecting
Rods 105 n Crankshafts and Bearings 109 n Rod and Main Bearings 113
n Vibration Dampers 116 n Flywheels 118
Engine Feedback Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Introduction 125 n Timing Gears 125 n Camshafts 129 n Valve and
Injector Trains 132 n Cylinder Head Valves 136
Engine Housing Components . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Introduction 148 n Engine Cylinder Block 148 n Cylinder Heads 155
n Intake and Exhaust Manifolds 158
Engine Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Introduction 164 n Engine Lubricating Oil 165 n Lubrication System Components
172 n Interpreting Oil Analyses 181 n Lubricating Circuit Problems 184
Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Introduction 189 n Engine Coolant 191 n Cooling System Components 197
n Filters 201 n Coolant Monitoring Circuit 202 n Thermostats 203
n Cooling Fans 205 n Cooling System Problems 210 n Cooling System
Management 211 n Coolant Heaters 211
Engine Breathing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Introduction 216 n Breathing Components 218 n Air Intake System
Components 219 n Turbochargers 221 n Charge Air Heat Exchangers 228
n Exhaust Gas Recirculation 230 n Valve Design and Breathing 232
n Exhaust System Components 234 n Breathing Circuit Sensors 236
Engine Retarders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Introduction 240 n Principles of Operation 241 n Exhaust Brakes 242
n Internal Compression Brakes 243 n Caterpillar Brakesaver 249
Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Introduction 254 n Start-Up and Engine Break-In 254 n Air Intake System
Maintenance 256 n Engine Lube Service 258 n Cooling System Service 261
n Fuel System Maintenance 263 n Selective Catalytic Reduction 268
n Diesel Particulate Filter Service 270
Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines . . . . 273
Introduction 274 n Service Literature 274 n Removal of an Engine
from a Vehicle 274 n Engine Disassembly 276 n Cleaning And
Inspecting Components 279 n Engine Reassembly Guidelines 279
Diesel Engine Run-In and Performance Testing . . . . . . . . . . . . . . . . . 294
Introduction 295 n Rebuilt Engine Run-In Procedure 295 n Chassis
Dynamometer Testing 298 n Engine Dynamome
Chemistry and Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Introduction 311 n Basic Chemistry 311 n Properties of Some Common
Elements 315 n Properties of Some Mixtures and Compounds 317
n Combustion 318 n The Actual Combustion Cycle in a Diesel Engine 321
Diesel Fuel Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Introduction 326 n Fuel Terminology 326 n Petroleum 329 n Diesel Fuel
Characteristics 331 n Fuel Storage, Fuel Deterioration, and Performance 335
Fuel Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Introduction 341 n Fuel Subsystem Objectives 341 n Fuel Tanks 342
n Fuel Filters 345 n Fuel Charging/Transfer Pumps 352 n Complete
Fuel Circuit 356
Fuel Injection Basics and Governor Principles . . . . . . . . . . . . . . . . . . 359
Overview of Diesel Fuel Injection Principles 360 n Engine Management
Objectives 363 n Delivery, Injection, and Combustion 364 n Governing
Objectives 366 n Oem Management Systems 369
Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Introduction 376 n Single Orifice Nozzles 377 n Multiple Orifice Nozzles 379
n Electrohydraulic Injectors 382 n Nozzle Testing and Reconditioning 385
n Nozzle Troubleshooting 389 n Ehi Testing and Reconditioning 390
Port-Helix Metering Injection Pumps . . . . . . . . . . . . . . . . . . . . . . 397
Introduction 398 n Technical Description 399 n Injection Pump Components
404 n Governor Trim Devices 408 n Timing Injection Pumps to an
Engine 409 n Phasing and Calibration 413 n Critical System Pressure Values 414
n Electronic Port-Helix Metering 414 n Electronic Pump-to-Engine Timing 419
Inlet-Metering Rotary Distributor Pumps . . . . . . . . . . . . . . . . . . . . 423
Introduction 424 n Roosa Master 424 n Opposed-Plunger, Inlet-Metering
Injection Pumps 424 n Opposed-Plunger, Inlet-Metering Pump Summary 432
Sleeve-Metering Rotary Distributor Pumps . . . . . . . . . . . . . . . . . . . 434
Introduction 435 n Sleeve-Metering, Single Plunger Distributor Pumps 435
n Ve Pump Electronic Controls 445
Single-Actuator Eui Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Introduction 451 n System Overview 452 n Ecm 453 n Eui Operation 455
n Calibration Codes 459 n Understanding Irt 460 n Multiple Injection
Events 460 n Servicing and Diagnostics 462 n Celect Plus Euis 467
n Bench Testing Euis 471
Dual Actuator Eui Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Introduction 475 n System Overview 477 n Input Circuit 479
n Management Electronics 479 n Output Circuit 484 n Installation
of a Delphi E3 Eui 487 n Bench Testing E3 Injectors 489
Caterpillar and Navistar Heui . . . . . . . . . . . . . . . . . . . . . . . . . . 492
Introduction 493 n Principles of Operation 494 n Fuel Supply System 495
n Injection Actuation System 495 n Heui Injector 497 n Heui Electronic
Management and Switching 502 n Heui Diagnostics 506
Electronic Unit Pump (Eup ) Systems . . . . . . . . . . . . . . . . . . . . . . . 511
Introduction 512 n System Overview 513 n Fuel Subsystem 513
n Input Circuit 515 n Engine Controllers and Management Electronics 516
n Electronic Unit Pumps 517
Cummins Hpi -Tp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Introduction 526 n Tp Hydraulic Equation 526 n Engine Management
Electronics 527 n Fuel System Components 527 n Overhead
Adjustments 533 n Troubleshooting Isx 535
Common Rail Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
Introduction 539 n Cr Subsystems and Components 541 n Cr Management
Electronics 541 n Cr Fuel Routing Circuit 543 n Diagnosing Cr System Problems 557
Amplified Common Rail Systems . . . . . . . . . . . . . . . . . . . . . . . . . 561
Introduction 562 n ACRS Applications and Generations 562 n Acrs Circuit
Layout 563 n Acrs Hadi 568 n Acrs Service Procedures 572
Section 3 Engine Management, Alternate Power,
and Emissions . . . . . . . . . . . . . . . . . 579
Review of Electrical and Electronics Fundamentals . . . . . . . . . . . . . . . 580
Introduction 581 n Atomic Structure and Electron Movement 582
n Conductors and Insulators 584 n Current Flow 585 n Magnetism 586
n Electromagnetism 587 n Electrical Current Characteristics and Sources of
Electricity 589 n Electrical Circuits and Ohms Law 591 n Capacitance 595
n Coils and Transformers 596 n Semiconductors 597 n Diodes 597
n Transistors 600 n Testing Semiconductors 602 n Photonic Devices 602
n Using Electronic Signals 603
Networking, Communications, and Telematics . . . . . . . . . . . . . . . . . 611
Introduction 612 n Networking 612 n The Internet 612 n Lans and Intranet
Systems 613 n The Telecommunications System 613 n Electronic Onboard
Recorders 621 n Data Mining Using Telematics 622
Vehicle Computer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
Introduction 627 n Input Circuit 632 n Ecms and the Processing Cycle 639
n Output Circuit 643 n Ecm Programming 645 n Engine Management Systems
Est s and Sis s ������������������������������������������������������������������������������������������������������ 650
Introduction 651 n Digital Multimeters 653 n Generic Est 664 n Connecting Oem
Est s to the Data Bus 667 n Electronic Troubleshooting 669 n Data Bus Codes and
Protocols 671 n Hd-Obd 674 n Generic Siss, Est s, and Diagnostic Software 675
Electrical Wiring, Connector, and Terminal Repair . . . . . . . . . . . . . . . 678
Introduction 679 n Sae Wiring Standards 679 n Connector Assembly and
Repair 682 n Splicing Guidelines 687 n Circuit Protection Devices 689
n Relays 690 n Troubleshooting Techniques 692
Multiplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
Introduction 700 n Multiplexing, Clients, and Servers 701 n Multiplexing
Basics 701 n Accessing the Data Bus 711 n Diagnosing Bus Faults 714
Biodiesel and Alternate Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . 718
Introduction 719 n Biodiesel 720 n Fuel Alternatives for Engines 723
n Natural Gases 724 n Liquefied Petroleum Gas 729 n Alcohol-Based
Fuels (Methanol/Ethanol) 730
Electric, Electric Hybrid, and Hydraulic Hybrid Drives . . . . . . . . . . . . . . 734
Introduction 735 n Batteries and Ultracapacitors 736 n Electricity 738
n Hybrid Electric Vehicles 739 n Hydraulic Hybrids 742 n Fuel Cells 744
Bosch Edc Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Introduction 751 n Bosch Diesel Systems 751 n Edc Management
Logic 752 n Block Diagrams 754 n Making the Connection 757
Caterpillar Engine Management Systems . . . . . . . . . . . . . . . . . . . . 759
Introduction 760 n Acert 761 n Adem Electronics 761 n Input
Circuit 763 n Ecm 763 n System Diagnostics and Communications 767
Cummins Management Systems . . . . . . . . . . . . . . . . . . . . . . . . . 772
Introduction 773 n System Overview 774 n Input Circuit 774
n Electronic Control Module (Ecm) 775 n System Troubleshooting and
Engine Testing 778
Detroit Diesel Electronic Controls (Ddec ) . . . . . . . . . . . . . . . . . . . . 782
Introduction 783 n Emissions Management 785 n Input Circuit 787
n Governor Options 790 n Diagnostic Tools 791 n Ddec Features 794
Navistar Diamond Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
Introduction 799 n Diamond Logic Controls 800 n Ecm Diagnostics 803
Paccar Engine Management Systems . . . . . . . . . . . . . . . . . . . . . . 807
Introduction 808 n Paccar Electronics 809 n System Diagnostics and
Communications 811
Volvo and Mack Engine Management . . . . . . . . . . . . . . . . . . . . . . 813
Introduction 814 n V-Mac and Vectro Electronics 816
Emissions Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
Introduction 825 n Pollutants 826 n Epa Certification Testing 828
n Diesel Engine Emissions Controls 830 n Diesel Particulate Filters (Dpfs) 834
n Selective Catalytic Reduction (Scr) 840
Servicing and Maintenance of Exhaust Aftertreatment Systems . . . . . . . . . 847
Introduction 848 n Visible Smoke Emission: Legacy Engines 848
n Exhaust Gas Recirculation (Egr) Systems 849 n Diesel Particulate Filters
(Dpfs) 853 n Selective Catalytic Reduction (Scr) 856
n Field Testing of Smoke Density 858
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865
Introduction 866 n Structured Failure Analysis 866 n Principles of Failure
Analysis 867 n Component Failures 873 n Common Abuses of Engines
and Fuel Systems 893
Troubleshooting and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 896
Introduction 897 n Troubleshooting Tools 897 n Smoke Analysis 898
n Troubleshooting Guidelines 901 n Quick Reference Diagnostic Charts 911
Technical Support 918 n Hd-Obd 920

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