SEAN BENNETT MEDIUM & HEAVY DUTY TRUCK ENGINES FUEL & COMPUTERIZED MANAGEMENT SYSTEMS MANUAL – PDF DOWNLOAD
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SEAN BENNETT MEDIUM & HEAVY DUTY TRUCK ENGINES FUEL & COMPUTERIZED MANAGEMENT SYSTEMS MANUAL – PDF DOWNLOAD
- My personal technical background is trucks. However, because this book has over the years been adopted by many diesel programs that cater to heavy-equipment, agricultural, marine, and stationary diesel engines, a broader-based approach has been used since the publication of the first edition. Although this has not changed the book title, it has meant including engine and fuel system technology that has never been used in truck applications—
- or may be regarded as obsolete by the truck community. In this fifth edition, although I have abbreviated or eliminated coverage of some of the older hydromechanical systems, materials on a couple of key hydromechanical fuel systems have been retained to accommodate the learning outcomes of those programs using the book for non-truck programs, and for the requirements of certification testing.
- It should be added that the port-helix pump-line-nozzle (PLN) fuel system continues to be used on a majority of trailer reefer systems produced today, and they are both EPA and CARB compliant because of their specified power ratings. HANDS-ON LEARNING An objective of this book is to keep it 100% current with the changes mandated for commercial diesel engines meeting EPA Tier 4 emissions, and to do so recognizing that mechanical technicians tend to learn by doing rather than by reading.
- Although the emphasis is vocational, with the objective of mastering hands-on repair technology, understanding how and why systems function is crucial to developing skilled technicians. Truck and diesel technology program graduates will ultimately target a broad spectrum of employers with diverse needs.
- The technical skill sets required by small fleets, major fleets, independent garages, construction sites, and OEM dealerships vary enormously, and while the fleet technician may never do anything more involved than servicing engines, OEM technicians will diagnose, recondition, and test engines on a regular basis.
- The challenge to college diesel programs—and this textbook—is to meet those diverse requirements in a single package.
TABLE OF CONTENTS:
SEAN BENNETT MEDIUM & HEAVY DUTY TRUCK ENGINES FUEL & COMPUTERIZED MANAGEMENT SYSTEMS MANUAL – PDF DOWNLOAD
Cover …………………………………………………………………………………………………………………….. 1
Title……………………………………………………………………………………………………………………………….. 2
Statement……………………………………………………………………………………………………………………………. 3
Copyright ……………………………………………………………………………………………………………… 4
Contents ……………………………………………………………………………………………………………….. 5
Preface……………………………………………………………………………………………………………………………… 11
Supplemets ……………………………………………………………………………………………………………. 14
Acknowledgments………………………………………………………………………………………………………………………. 16
Section 1: Diesel Engine Fundamentals ……………………………………………………………. 18
Ch 1: Introduction ………………………………………………………………………………………….. 20
Ch 1: Objectives ………………………………………………………………………………………….. 20
Ch 1: Key Terms ……………………………………………………………………………………………. 20
Ch 1: Introduction ………………………………………………………………………………………. 21
Role of the Trucking Industry and the Truck Technician ………………………. 23
The Truck Technician of the Twenty-First Century …………………………………. 24
Training and the Truck Technician ……………………………………………………………. 27
Customer Service and Professionalism ………………………………………………………. 29
Qualifications and Careers for the Truck Technician ……………………………. 32
Professional Associations ………………………………………………………………………….. 33
Proprietary Associations ……………………………………………………………………………. 34
Defining Engines by Displacement ……………………………………………………………… 34
Engine Oems and Market Share …………………………………………………………………….. 34
Health, Safety, and a Green Environment …………………………………………………. 35
VIN …………………………………………………………………………………………………………………. 35
Ch 1: Summary ……………………………………………………………………………………………….. 36
Ch 1: Review Exercises ……………………………………………………………………………….. 36
Ch 2: Hand and Shop Tools, Precision Tools, and Units of Measurement …. 38
Ch 2: Objectives ………………………………………………………………………………………….. 38
Ch 2: Key Terms ……………………………………………………………………………………………. 38
Ch 2: Introduction ……………………………………………………………………………………………………………. 39
Hand Tools …………………………………………………………………………………………………….. 39
Precision Measuring Tools ………………………………………………………………………….. 45
Fasteners ………………………………………………………………………………………………………. 62
Fastener Grades and Classes ………………………………………………………………………. 62
Adhesives and Chemical Sealing Materials ……………………………………………….. 69
The Metric System and English/Metric Conversion …………………………………… 70
Workplace Organization ……………………………………………………………………………….. 72
Ch 2: Summary ……………………………………………………………………………………………….. 73
Ch 2: Review Questions ……………………………………………………………………………….. 74
Ch 3: Personal and Safety Awareness ……………………………………………………………. 76
Ch 3: Objectives ………………………………………………………………………………………….. 76
Ch 3: Key Terms ……………………………………………………………………………………………. 76
Personal Protective Equipment …………………………………………………………………… 77
Workplace Hazards and Safety Regulations ……………………………………………….. 79
Emergencies …………………………………………………………………………………………………… 81
Osha ……………………………………………………………………………………………………………….. 82
Safety Hotlines ……………………………………………………………………………………………. 86
Ch 3: Review Exercises ……………………………………………………………………………….. 87
Ch 3: Review Questions ……………………………………………………………………………….. 87
Ch 4: Engine Basics ………………………………………………………………………………………… 89
Ch 4: Objectives ………………………………………………………………………………………….. 89
Ch 4: Key Terms ……………………………………………………………………………………………. 89
Ch 4: Introduction ………………………………………………………………………………………. 90
Key Engine Terms ………………………………………………………………………………………….. 90
The Diesel Cycle ………………………………………………………………………………………….. 93
The Two-Stroke Cycle Diesel Engine ………………………………………………………….. 96
The Otto Cycle ……………………………………………………………………………………………… 97
Engine Systems and Circuits ………………………………………………………………………. 98
Advanced Engine Terms …………………………………………………………………………………. 99
Ch 4: Summary ……………………………………………………………………………………………….. 102
Ch 4: Review Questions ……………………………………………………………………………….. 102
Ch 5: History of the Heat Engine …………………………………………………………………. 104
Ch 5: Objectives ………………………………………………………………………………………….. 104
Ch 5: Key Terms ……………………………………………………………………………………………. 104
Ch 5: Introduction ………………………………………………………………………………………. 105
History of the Modern Diesel Engine ………………………………………………………… 106
Ch 5: Summary ……………………………………………………………………………………………….. 115
Ch 5: Review Question …………………………………………………………………………………. 116
Ch 6: Power ………………………………………………………………………………………………………. 117
Ch 6: Objectives ………………………………………………………………………………………….. 117
Ch 6: Key Terms ……………………………………………………………………………………………. 117
Ch 6: Introduction ………………………………………………………………………………………. 118
Definitions and Formulae ……………………………………………………………………………. 118
Engine Configuration, Engine Speed, and Torsional Forces …………………… 126
How Much Power Do You Need? ………………………………………………………………………. 126
Ch 6: Summary ……………………………………………………………………………………………….. 127
Ch 6: Review Questions ……………………………………………………………………………….. 128
Ch 7: Engine Powertrain Components ……………………………………………………………… 130
Ch 7: Objectiives ………………………………………………………………………………………… 130
Ch 7: Key Terms ……………………………………………………………………………………………. 131
Ch 7: Introduction ………………………………………………………………………………………. 131
Piston Assemblies ………………………………………………………………………………………… 131
Piston Rings …………………………………………………………………………………………………. 141
Connecting Rods ……………………………………………………………………………………………. 147
Crankshafts and Bearings ……………………………………………………………………………. 151
Rod and Main Bearings …………………………………………………………………………………. 156
Vibration Dampers ………………………………………………………………………………………… 160
Flywheels ………………………………………………………………………………………………………. 162
Ch 7: Summary ……………………………………………………………………………………………….. 164
Ch 7: Review Questions ……………………………………………………………………………….. 165
Ch 8: Engine Feedback Assembly …………………………………………………………………….. 167
Ch 8: Objectives ………………………………………………………………………………………….. 167
Ch 8: Key Terms ……………………………………………………………………………………………. 167
Ch 8: Introduction ………………………………………………………………………………………. 168
Timing Gears …………………………………………………………………………………………………. 168
Camshafts ………………………………………………………………………………………………………. 172
Valve and Injector Trains ………………………………………………………………………….. 177
Cylinder Head Valves …………………………………………………………………………………… 181
Ch 8: Summary ……………………………………………………………………………………………….. 190
Ch 8: Review Questions ……………………………………………………………………………….. 191
Ch 9: Engine Housing Components …………………………………………………………………… 193
Ch 9: Objectives ………………………………………………………………………………………….. 193
Ch 9: Key Terms ……………………………………………………………………………………………. 193
Ch 9: Introduction ………………………………………………………………………………………. 194
Engine Cylinder Block …………………………………………………………………………………. 194
Cylinder Heads ……………………………………………………………………………………………… 202
Intake and Exhaust Manifolds …………………………………………………………………….. 205
Ch 9: Summary ……………………………………………………………………………………………….. 208
Ch 9: Review Questions ……………………………………………………………………………….. 209
Ch 10: Engine Lubrication Systems ……………………………………………………………….. 211
Ch 10: Objectives ………………………………………………………………………………………… 211
Ch 10: Key Terms ………………………………………………………………………………………….. 211
Ch 10: Introduction …………………………………………………………………………………….. 212
Engine Lubricating Oil ……………………………………………………………………………….. 214
Lubrication System Components …………………………………………………………………… 221
Interpreting Oil Analyses ………………………………………………………………………….. 233
Lubricating Circuit Problems …………………………………………………………………….. 236
Ch 10: Summary ……………………………………………………………………………………………… 237
Ch 10: Review Questions ……………………………………………………………………………… 238
Ch 11: Engine Cooling Systems ………………………………………………………………………. 241
Ch 11: Objectives ………………………………………………………………………………………… 241
Ch 11: Key Terms ………………………………………………………………………………………….. 242
Ch 11: Introduction …………………………………………………………………………………….. 242
Engine Coolant ……………………………………………………………………………………………… 244
Cooling System Components ………………………………………………………………………….. 251
Repairing Leaks ……………………………………………………………………………………………. 254
Filters ………………………………………………………………………………………………………….. 258
Coolant Monitoring Circuit ………………………………………………………………………… 258
Thermostats …………………………………………………………………………………………………… 259
Cooling Fans …………………………………………………………………………………………………. 262
Cooling System Problems ……………………………………………………………………………… 268
Cooling System Management ………………………………………………………………………….. 270
Coolant Heaters ……………………………………………………………………………………………. 270
Ch 11: Summary ……………………………………………………………………………………………… 271
Ch 11: Review Questions ……………………………………………………………………………… 273
Ch 12: Engine Breathing …………………………………………………………………………………. 275
Ch 12: Objectives ………………………………………………………………………………………… 275
Ch 12: Key Terms ………………………………………………………………………………………….. 276
Ch 12: Introduction …………………………………………………………………………………….. 276
Gas Flow in Breathing Circuit …………………………………………………………………… 276
Breathing Components …………………………………………………………………………………… 279
Air Intake System Components …………………………………………………………………….. 279
Turbochargers ……………………………………………………………………………………………….. 281
Charge Air Heat Exchangers ………………………………………………………………………… 291
Air-To-Air Heat Exchangers ………………………………………………………………………… 292
Exhaust Gas Recirculation ………………………………………………………………………….. 293
Valve Design and Breathing ………………………………………………………………………… 296
Exhaust System Components ………………………………………………………………………….. 297
Breathing Circuit Sensors ………………………………………………………………………….. 300
Ch 12: Summary ……………………………………………………………………………………………… 301
Ch 12: Review Questions ……………………………………………………………………………… 302
Ch 13: Engine Retarders …………………………………………………………………………………. 305
Ch 13: Objectives ………………………………………………………………………………………… 305
Ch 13: Key Terms ………………………………………………………………………………………….. 305
Ch 13: Introduction …………………………………………………………………………………….. 306
Energy Conversion in Air Brakes ……………………………………………………………….. 306
Principles of Operation ……………………………………………………………………………… 307
Exhaust Brakes ……………………………………………………………………………………………… 309
Internal Compression Brakes ………………………………………………………………………. 310
Bus Requests to Engine Breakes …………………………………………………………………. 317
Ch 13: Summary ……………………………………………………………………………………………… 317
Ch 13: Review Questions ……………………………………………………………………………… 318
Ch 14: Servicing and Maintenance …………………………………………………………………. 320
Ch 14: Objectives ………………………………………………………………………………………… 320
Ch 14: Key Terms ………………………………………………………………………………………….. 320
Ch 14: Introduction …………………………………………………………………………………….. 321
Startup and Engine Break-In ………………………………………………………………………. 322
Air Intake System Maintenance …………………………………………………………………… 323
Engine Lube Service …………………………………………………………………………………….. 325
Cooling System Service ……………………………………………………………………………….. 330
Fuel System Maintenance ……………………………………………………………………………… 332
Selective Catalytic Reduction …………………………………………………………………… 338
Diesel Particulate Filter Service ……………………………………………………………. 341
Ch 14: Summary ……………………………………………………………………………………………… 342
Ch 14: Review Questions ……………………………………………………………………………… 343
Ch 15: Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines ……………………………………………………… 344
Ch 15: Objectives ………………………………………………………………………………………… 344
Ch 15: Key Terms ………………………………………………………………………………………….. 344
Ch 15: Introduction …………………………………………………………………………………….. 345
Service Literature ………………………………………………………………………………………. 345
Removal of an Engine from a Vehicle ………………………………………………………… 345
Engine Disassembly ………………………………………………………………………………………. 348
Cleaning and Inspecting Components ………………………………………………………….. 352
Engine Reassembly Guidelines …………………………………………………………………….. 352
Ch 15: Summary ……………………………………………………………………………………………… 367
Ch 15: Review Exercises ……………………………………………………………………………… 367
Ch 16: Diesel Engine Run-In and Performance Testing ………………………………………………………………………………….. 368
Ch 16: Objectives ………………………………………………………………………………………… 368
Ch 16: Key Terms ………………………………………………………………………………………….. 368
Ch 16: Introduction …………………………………………………………………………………….. 369
Rebuilt Engine Run-In Procedure ……………………………………………………………….. 369
Chass is Dynamometer Testing …………………………………………………………………….. 373
Engine Dynamometer Testing ………………………………………………………………………… 377
Road Testing …………………………………………………………………………………………………. 380
Ch 16: Summary ……………………………………………………………………………………………… 384
Ch 16: Review Exercises ……………………………………………………………………………… 385
Ch 16: Review Questions ……………………………………………………………………………… 385
Section 2: Diesel Fuel Systems ………………………………………………………………………… 386
Ch 17: Chemistry and Combustion …………………………………………………………………… 388
Ch 17: Objectives ………………………………………………………………………………………… 388
Ch 17: Key Terms ………………………………………………………………………………………….. 388
Ch 17: Introduction …………………………………………………………………………………….. 389
Basic Chemistry ……………………………………………………………………………………………. 389
Properties of Some Common Elements ………………………………………………………….. 394
Properties of Some Mixtures and Compounds ……………………………………………… 396
Combustion …………………………………………………………………………………………………….. 397
The Actual Combustion Cycle in a Diesel Engine …………………………………….. 400
Ch 17: Summary ……………………………………………………………………………………………… 402
Ch 17: Review Questions ……………………………………………………………………………… 402
Ch 18: Diesel Fuel Characteristics ……………………………………………………………… 405
Ch 18: Objectives ………………………………………………………………………………………… 405
Ch 18: Key Terms ………………………………………………………………………………………….. 405
Ch 18: Introduction …………………………………………………………………………………….. 406
Fuel Terminology ………………………………………………………………………………………….. 406
Petroleum ………………………………………………………………………………………………………. 409
Diesel Fuel Characteristics ………………………………………………………………………. 412
Fuel Storage, Deterioration, and Performance ………………………………………… 416
Ch 18: Summary ……………………………………………………………………………………………… 419
Ch 18: Review Questions ……………………………………………………………………………… 420
Ch 19: Fuel Subsystems …………………………………………………………………………………… 422
Ch 19: Objectives ………………………………………………………………………………………… 422
Ch 19: Key Terms ………………………………………………………………………………………….. 422
Ch 19: Introduction …………………………………………………………………………………….. 423
Fuel Subsystem Objectives ………………………………………………………………………….. 423
Fuel Tanks …………………………………………………………………………………………………….. 424
Fuel Filters …………………………………………………………………………………………………. 428
Fuel Charging/Transfer Pumps …………………………………………………………………………………………………… 435
Complete Fuel Circuit …………………………………………………………………………………. 439
Ch 19: Summary ……………………………………………………………………………………………… 440
Ch 19: Review Questions ……………………………………………………………………………… 441
Ch 20: Fuel Injection Basics and Governor Principles ……………………………… 443
Ch 20: Objectives ………………………………………………………………………………………… 443
Ch 20: Key Terms ………………………………………………………………………………………….. 443
Ch 20: Overview of Diesel Fuel Injection Principles ……………………………. 444
Engine Management Objectives …………………………………………………………………….. 447
Delivery, Injection, and Combustion ………………………………………………………… 448
Governing Objectives …………………………………………………………………………………… 451
Oem Management Systems ……………………………………………………………………………….. 454
Ch 20: Summary ……………………………………………………………………………………………… 458
Ch 20: Review Questions ……………………………………………………………………………… 459
Ch 21: Injector Nozzles …………………………………………………………………………………. 461
Ch 21: Objectives ………………………………………………………………………………………… 461
Ch 21: Key Terms ………………………………………………………………………………………….. 461
Ch 21: Introduction …………………………………………………………………………………….. 462
Single Orifice Nozzles ……………………………………………………………………………….. 463
Multiple Orifice Nozzles ……………………………………………………………………………. 466
Electrohydraulic Injectors ………………………………………………………………………… 469
Nozzle Hole Geometry …………………………………………………………………………………… 472
Nozzle Testing and Reconditioning ……………………………………………………………. 473
Nozzle Trouble Shooting ……………………………………………………………………………… 477
EHI Testing and Reconditioning …………………………………………………………………………………………………. 478
Ch 21: Summary ……………………………………………………………………………………………… 482
Ch 21: Review Questions ……………………………………………………………………………… 483
Ch 22: Port-Helix Metering Injection Pumps ………………………………………………………………………………………….. 485
Ch 22: Objectives ………………………………………………………………………………………… 485
Ch 22: Key Terms ………………………………………………………………………………………….. 485
Ch 22: Introduction …………………………………………………………………………………….. 486
Technical Description …………………………………………………………………………………. 486
Injection Pump Components ………………………………………………………………………….. 492
Governor Trim Devices …………………………………………………………………………………. 497
Timing Injection Pumps to an Engine ………………………………………………………… 498
Phasing and Calibration ……………………………………………………………………………… 503
Critical System Pressure Values ……………………………………………………………….. 504
Electronic Port-Helix Metering …………………………………………………………………………………………………. 504
Electronic Pump To-Engine Timing ……………………………………………………………………………………………….. 510
Future of Port-Helix Metering Pumps …………………………………………………………………………………………….. 511
Ch 22: Summary ……………………………………………………………………………………………… 511
Ch 22: Review Questions ……………………………………………………………………………… 512
Ch 23: Inlet-Metering Rotary Distributor Pumps ………………………………………………………………………………………. 514
Ch 23: Objectives ………………………………………………………………………………………… 514
Ch 23: Key Terms ………………………………………………………………………………………….. 514
Ch 23: Introduction …………………………………………………………………………………….. 515
Roosa Master …………………………………………………………………………………………………. 515
Opposed-Plunger, Inlet-Metering Injection Pumps ………………………………………………………………………………….. 515
Opposed-Plunger, Inlet-Metering Pump Summary …………………………………………………………………………………….. 523
Ch 23: Summary ……………………………………………………………………………………………… 524
Ch 23: Review Questions ……………………………………………………………………………… 524
Ch 24: Sleeve-Metering Rotary Distributor Pumps ……………………………………………………………………………………… 526
Ch 24: Objectives …………………………………………………………………………………………………………….. 526
Ch 24: Key Terms ………………………………………………………………………………………….. 526
Ch 24: Introduction …………………………………………………………………………………….. 527
Sleeve-Metering, Single Plunger Distributor Pumps ……………………………….. 527
VE Pump Electronic Controls ……………………………………………………………………………………………………. 538
Ch 24: Summary ……………………………………………………………………………………………… 542
Ch 24: Review Questions ……………………………………………………………………………… 542
Ch 25: Single-Actuat or EUI Systems ………………………………………………………………………………………………… 544
Ch 25: Objectives ………………………………………………………………………………………… 544
Ch 25: Key Terms ………………………………………………………………………………………….. 544
Ch 25: Introduction …………………………………………………………………………………….. 545
System Overview ……………………………………………………………………………………………. 546
ECM …………………………………………………………………………………………………………………………. 548
EUI Operation ………………………………………………………………………………………………………………… 549
Calibration Codes ………………………………………………………………………………………… 554
Understanding IRT …………………………………………………………………………………………………………….. 555
Multiple Injection Events ………………………………………………………………………….. 555
Servicing and Diagnostics ………………………………………………………………………….. 557
Celect Plus Euis ………………………………………………………………………………………….. 563
Bench Testing Euis ………………………………………………………………………………………. 567
Ch 25: Summary ……………………………………………………………………………………………… 568
Ch 25: Review Questions ……………………………………………………………………………… 569
Ch 26: Dual-Actuator EUI Systems …………………………………………………………………………………………………… 571
Ch 26: Objectives ………………………………………………………………………………………… 571
Ch 26: Key Terms ………………………………………………………………………………………….. 571
Ch 26: Introduction …………………………………………………………………………………….. 572
System Overview ……………………………………………………………………………………………. 574
Input Circuit ……………………………………………………………………………………………….. 576
Management Electronics ……………………………………………………………………………….. 576
Output Circuit ……………………………………………………………………………………………… 582
Bench-Testing E3 Injectors …………………………………………………………………………………………………….. 588
Ch 26: Summary ……………………………………………………………………………………………… 588
Ch 26: Review Questions ……………………………………………………………………………… 589
Ch 27: Cater Pillar and Navistar HEUI ………………………………………………………………………………………………. 591
Ch 27: Objectives ………………………………………………………………………………………… 591
Ch 27: Key Terms ………………………………………………………………………………………….. 591
Ch 27: Introduction …………………………………………………………………………………….. 592
Principles of Operation ……………………………………………………………………………… 594
Fuel Supply System ………………………………………………………………………………………. 594
Injection Actuation System……………………………………………………………………………………………………… 595
HEUI Injector ………………………………………………………………………………………………………………… 596
Heui Electronicmanagement and Switching …………………………………………………………………………………………. 602
HEUI Diagnostics ……………………………………………………………………………………………………………… 605
Ch 27: Summary ……………………………………………………………………………………………… 609
Ch 27: Review Questions ……………………………………………………………………………… 610
Ch 28: Electronic Unit Pump (EUP) Systems …………………………………………………………………………………………… 612
Ch 28: Objectives ………………………………………………………………………………………… 612
Ch 28: Key Terms ……………………………………………………………………………………………………………… 612
Ch 28: Introduction …………………………………………………………………………………….. 613
System Overview ……………………………………………………………………………………………. 613
Fuel Subsystem ……………………………………………………………………………………………… 615
Input Circuit ……………………………………………………………………………………………….. 616
Engine Controllers and Management Electronics ………………………………………. 617
Electronic Unit Pumps …………………………………………………………………………………. 618
Ch 28: Summary ……………………………………………………………………………………………… 625
Ch 28: Review Questions ……………………………………………………………………………… 626
Ch 29: Cummins HPI-TP …………………………………………………………………………………………………………….. 628
Ch 29: Objectives ………………………………………………………………………………………… 628
Ch 29: Key Terms ………………………………………………………………………………………….. 628
Ch 29: Introduction …………………………………………………………………………………….. 629
TP Hydraulic Equation …………………………………………………………………………………………………………. 629
Engine Management Electronics …………………………………………………………………… 630
Fuel System Components ……………………………………………………………………………….. 630
Overhead Adjustments …………………………………………………………………………………… 637
Troubleshooting Isx …………………………………………………………………………………….. 639
Ch 29: Summary ……………………………………………………………………………………………… 640
Ch 29: Review Questions ……………………………………………………………………………… 641
Ch 30: Common Rail Systems ……………………………………………………………………………. 643
Ch 30: Objectives ………………………………………………………………………………………… 643
Ch 30: Key Terms ………………………………………………………………………………………….. 643
Ch 30: Introduction …………………………………………………………………………………….. 644
Cr Subsystems and Components …………………………………………………………………….. 646
Cr Management Electronics ………………………………………………………………………….. 647
CR Fuel Routing Circuit ……………………………………………………………………………………………………….. 648
Delphi CR ……………………………………………………………………………………………………………………. 662
Diagnosing CR System Problems ………………………………………………………………………………………………….. 664
Ch 30: Summary ……………………………………………………………………………………………… 666
Ch 30: Review Questions ……………………………………………………………………………… 667
Ch 31: Amplified Common Rail Systems ………………………………………………………….. 669
Ch 31: Objectives ………………………………………………………………………………………… 669
Ch 31: Key Terms ………………………………………………………………………………………….. 669
Ch 31: Introduction …………………………………………………………………………………….. 670
ACRS Applications and Generations ………………………………………………………………………………………………. 670
ACRS Circuit Layout …………………………………………………………………………………………………………… 671
ACRS HADI …………………………………………………………………………………………………………………… 677
Ch 31: Summary ……………………………………………………………………………………………… 685
Ch 31: Review Questions ……………………………………………………………………………… 686
Section 3: Engine Management, Alternate Power, and Emissions …………………… 688
Ch 32: Review of Electrical and Electronics Fundamentals ………………………. 690
Ch 32: Objectives ………………………………………………………………………………………… 690
Ch 32: Key Terms ………………………………………………………………………………………….. 691
Ch 32: Introduction …………………………………………………………………………………….. 691
Atomic Structure and Electron Movement …………………………………………………… 692
Conductors and Insulators ………………………………………………………………………….. 694
Current Flow …………………………………………………………………………………………………. 694
Magnetism ………………………………………………………………………………………………………. 696
Electromagnetism ………………………………………………………………………………………….. 697
Electrical Current Characteristics and Sources of Electricity ………….. 699
Electrical Circuits and OHM’s Law……………………………………………………………………………………………….. 701
Capacitance …………………………………………………………………………………………………… 705
Coils and Transformers ……………………………………………………………………………….. 707
Semiconductors ……………………………………………………………………………………………… 707
Testing Semiconductors ……………………………………………………………………………….. 712
Photonic Devices ………………………………………………………………………………………….. 712
Using Electronic Signals ……………………………………………………………………………. 713
Conclusion …………………………………………………………………………………………………….. 718
Ch 32: Summary ……………………………………………………………………………………………… 718
Ch 32: Review Questions ……………………………………………………………………………… 720
Ch 33: Networking, Communications, and Telematics …………………………………… 722
Ch 33: Objectives ………………………………………………………………………………………… 722
Ch 33: Key Terms ………………………………………………………………………………………….. 722
Ch 33: Introduction …………………………………………………………………………………….. 723
Networking …………………………………………………………………………………………………….. 723
The Internet …………………………………………………………………………………………………. 724
Lans and Intranet Systems ………………………………………………………………………….. 725
The Telecommunications System …………………………………………………………………… 725
Electronic on Board Recorders …………………………………………………………………… 734
Data Mining Using Telematics …………………………………………………………………….. 735
Geofences ………………………………………………………………………………………………………. 736
Ch 33: Summary ……………………………………………………………………………………………… 737
Ch 33: Review Questions ……………………………………………………………………………… 738
Ch 34: Vehicle Computer Systems …………………………………………………………………… 740
Ch 34: Objectives ………………………………………………………………………………………… 740
Ch 34: Key Terms ……………………………………………………………………………………………………………… 740
Ch 34: Introduction …………………………………………………………………………………….. 741
Ch 34: Input Circuit …………………………………………………………………………………… 746
ECMS and the Processing Cycle ………………………………………………………………………………………………….. 755
Output Circuit ……………………………………………………………………………………………… 761
Ecm Programming ……………………………………………………………………………………………. 763
Engine Management Systems ………………………………………………………………………….. 765
Body Controllers ………………………………………………………………………………………….. 766
Ch 34: Summary ……………………………………………………………………………………………… 767
Ch 34: Review Questions ……………………………………………………………………………… 768
Ch 35: ESTs and SISs ……………………………………………………………………………………………………………… 770
Ch 35: Objectives ………………………………………………………………………………………… 770
Ch 35: Key Terms ………………………………………………………………………………………….. 771
Ch 35: Introduction …………………………………………………………………………………….. 771
Development of ESTs …………………………………………………………………………………………………………… 772
Digital Multimeters …………………………………………………………………………………….. 774
Generic EST ………………………………………………………………………………………………………………….. 783
Connecting OEM ESTs to the Data Bus …………………………………………………………………………………………….. 787
Electronic Troubleshooting ………………………………………………………………………… 789
Data Bus Codes and Protocols …………………………………………………………………….. 793
HD-OBD ………………………………………………………………………………………………………………………. 794
Generic SISs, ESTs, and Diagnostic Software ……………………………………………………………………………………… 795
Interpreting Dashwarning Lights ……………………………………………………………….. 796
Ch 35: Summary ……………………………………………………………………………………………… 798
Ch 35: Review Questions ……………………………………………………………………………… 799
Ch 36: Electrical Wiring, Connector, and Terminal Repair ……………………………………………………………………………… 802
Ch 36: Objectives ………………………………………………………………………………………… 802
Ch 36: Key Terms ……………………………………………………………………………………………………………… 802
Ch 36: Introduction …………………………………………………………………………………….. 803
Sae Wiring Standards …………………………………………………………………………………… 803
Connector Assembly and Repair …………………………………………………………………… 805
Splicing Guidelines …………………………………………………………………………………….. 812
Circuit Protection Devices ………………………………………………………………………… 814
Relays ……………………………………………………………………………………………………………. 816
Troubleshooting Techniques ………………………………………………………………………… 817
Ch 36: Summary ……………………………………………………………………………………………… 824
Ch 36: Review Questions ……………………………………………………………………………… 824
Ch 37: Multiplexing ………………………………………………………………………………………… 826
Ch 37: Objectives ………………………………………………………………………………………… 826
Ch 37: Key Terms ………………………………………………………………………………………….. 826
Ch 37: Introduction …………………………………………………………………………………….. 827
Multiplexing, Clients, and Servers ……………………………………………………………………………………………… 828
Multiplexing Basics …………………………………………………………………………………….. 829
Accessing the Data Bus ……………………………………………………………………………….. 845
Diagnosing Bus Faults …………………………………………………………………………………. 851
Ch 37: Summary ……………………………………………………………………………………………… 854
Ch 37: Review Questions ……………………………………………………………………………… 855
Ch 38: Natural Gas, Propane, and Biodiesel Fuels …………………………………….. 857
Ch 38: Objectives ………………………………………………………………………………………… 857
Ch 38: Key Terms ………………………………………………………………………………………….. 857
Ch 38: Introduction …………………………………………………………………………………….. 858
Biodiesel ………………………………………………………………………………………………………. 859
Methane Fuels…………………………………………………………………………………………………………………. 862
Compressed and Liquid …………………………………………………………………………………. 862
Spark Ignition Theory …………………………………………………………………………………. 865
FMVSS 304 Precautions………………………………………………………………………………………………………….. 872
Liquefied Petroleum Gas………………………………………………………………………………………………………… 875
Alcohol-Based Fuels (Methanol/Ethanol) ………………………………………………………………………………………….. 876
Fuel Alternatives for Engines …………………………………………………………………… 877
Ch 38: Summary ……………………………………………………………………………………………… 879
Ch 38: Review Questions ……………………………………………………………………………… 879
Ch 39: Electric, Electric Hybrid, and Hydraulic Hybrid Drives ……………… 882
Ch 39: Objectives ………………………………………………………………………………………… 882
Ch 39: Key Terms ………………………………………………………………………………………….. 882
Ch 39: Introduction …………………………………………………………………………………….. 883
Batteries and Ultracapacitors…………………………………………………………………………………………………… 884
Electricity…………………………………………………………………………………………………………………… 886
Hybrid Electric Vehicles ……………………………………………………………………………. 887
Hydraulic Hybrids ………………………………………………………………………………………… 892
Fuel Cells …………………………………………………………………………………………………….. 893
Ch 39: Summary ……………………………………………………………………………………………… 897
Ch 39: Review Questions ……………………………………………………………………………… 898
Ch 40: Bosch EDC Systems…………………………………………………………………………………………………………… 900
Ch 40: Objectives ………………………………………………………………………………………… 900
Ch 40: Key Terms ………………………………………………………………………………………….. 900
Ch 40: Introduction …………………………………………………………………………………….. 901
Bosch Diesel Systems …………………………………………………………………………………… 901
EDC Management Logic…………………………………………………………………………………………………………… 903
Block Diagrams ……………………………………………………………………………………………… 905
Making the Connection …………………………………………………………………………………. 905
Ch 40: Summary ……………………………………………………………………………………………… 908
Ch 40: Review Questions ……………………………………………………………………………… 908
Ch 41: Caterpillar Engine Management Systems ……………………………………………. 909
Ch 41: Objectives ………………………………………………………………………………………… 909
Ch 41: Key Terms ………………………………………………………………………………………….. 909
Ch 41: Introduction …………………………………………………………………………………….. 910
ACERT ……………………………………………………………………………………………………………………….. 911
Adem Electronics ………………………………………………………………………………………….. 913
Input Circuit ……………………………………………………………………………………………….. 913
System Diagnostics and Communications …………………………………………………….. 919
Ch 41: Summary ……………………………………………………………………………………………… 922
Ch 41: Review Questions ……………………………………………………………………………… 922
Ch 42: Cummins Management Systems ……………………………………………………………….. 924
Ch 42: Objectives ………………………………………………………………………………………… 924
Ch 42: Key Terms ………………………………………………………………………………………….. 924
Ch 42: Introduction …………………………………………………………………………………….. 925
Ch 42: System Overview ……………………………………………………………………………….. 926
Input Circuit ……………………………………………………………………………………………….. 927
Electronic Control Module (ECM)…………………………………………………………………………………………………. 928
System Trouble Shooting and Engine Testing ……………………………………………. 931
Ch 42: Summary ……………………………………………………………………………………………… 932
Ch 42: Review Questions ……………………………………………………………………………… 933
Ch 43: Detroit Diesel Electronic Controls (DDEC)……………………………………………………………………………………… 935
Ch 43: Objectives ………………………………………………………………………………………… 935
Ch 43: Key Terms ………………………………………………………………………………………….. 935
Ch 43: Introduction …………………………………………………………………………………….. 936
Emissions Management…………………………………………………………………………………………………………… 940
Input Circuit ……………………………………………………………………………………………….. 942
Governor Options ………………………………………………………………………………………….. 947
Diagnostic Tools ………………………………………………………………………………………….. 948
DDEC Features…………………………………………………………………………………………………………………. 950
Ch 43: Summary ……………………………………………………………………………………………… 953
Ch 43: Review Questions ……………………………………………………………………………… 953
Ch 44: Navistar Diamond Logic …………………………………………………………………… 955
Ch 44: Objectives ………………………………………………………………………………………… 955
Ch 44: Key Terms ………………………………………………………………………………………….. 955
Ch 44: Introduction …………………………………………………………………………………….. 956
Diamond Logic Controls…………………………………………………………………………………………………………. 958
ECM Diagnostics ………………………………………………………………………………………………………………. 961
Ch 44: Summary ……………………………………………………………………………………………… 963
Ch 44: Review Questions ……………………………………………………………………………… 963
Ch 45: PAACCAR Engine Management Systems…………………………………………………………………………………………….. 965
Ch 45: Objectives ………………………………………………………………………………………… 965
Ch 45: Key Terms ………………………………………………………………………………………….. 965
Ch 45: Introduction …………………………………………………………………………………….. 966
PX-Series…………………………………………………………………………………………………………………….. 966
PRE-2013 MX-13 Series………………………………………………………………………………………………………….. 966
Post-2013 MX-Series……………………………………………………………………………………………………………. 966
System Diagnostics and Communications …………………………………………………….. 972
PACCAR Exhaust After Treatment………………………………………………………………………………………………….. 973
Ch 45: Summary ……………………………………………………………………………………………… 975
Ch 45: Review Questions ……………………………………………………………………………… 975
Ch 46: Volvo and Mack Engine Management …………………………………………………….. 977
Ch 46: Objectives ………………………………………………………………………………………… 977
Ch 46: Key Terms ………………………………………………………………………………………….. 977
Ch 46: Introduction …………………………………………………………………………………….. 978
V-MAC and Vectro Electronics……………………………………………………………………………………………………. 980
Ch 46: Summary ……………………………………………………………………………………………… 988
Ch 46: Review Questions ……………………………………………………………………………… 988
Ch 47: Emissions Management ………………………………………………………………………. 990
Ch 47: Objectives ………………………………………………………………………………………… 990
Ch 47: Key Terms ………………………………………………………………………………………….. 990
Ch 47: Introduction …………………………………………………………………………………….. 991
Pollutants …………………………………………………………………………………………………….. 992
EPA Certification Testing………………………………………………………………………………………………………. 995
Diesel Engine Emissions Controls ……………………………………………………………… 997
Diesel Particulate Filters (DPFs)………………………………………………………………………………………………..1002
Selective Catalytic Reduction (SCR)………………………………………………………………………………………………1009
Meeting Chassis GHG Reduction Standards…………………………………………………………………………………………..1015
Ch 47: Summary ………………………………………………………………………………………………1015
Ch 47: Review Questions ………………………………………………………………………………1016
Ch 48: Servicing and Maintenance of Exhaust After Treatment Systems ……1018
Ch 48: Objectives………………………………………………………………………………………………………………1018
Ch 48: Key Terms …………………………………………………………………………………………..1018
Ch 48: Introduction ……………………………………………………………………………………..1019
Visible Smoke Emission: Legacy Engines ……………………………………………………1020
Exhaust Gas Recirculation (EGR) Systems…………………………………………………………………………………………..1021
Diesel Particulate Filters (DPFs)………………………………………………………………………………………………..1024
DPF Failures…………………………………………………………………………………………………………………..1030
Selective Catalytic Reduction (SCR)………………………………………………………………………………………………1031
Emissions Tampering ……………………………………………………………………………………..1034
Field Testing of Smoke Density ………………………………………………………………….1036
After Treatment Device Removal and Replacement ……………………………………..1041
Aftertreatment System Electronics …………………………………………………………….1043
Ch 48: Summary ………………………………………………………………………………………………1045
Ch 48: Review Questions ………………………………………………………………………………1045
Ch 49: Failure Analysis ………………………………………………………………………………….1048
Ch 49: Objectives …………………………………………………………………………………………1048
Ch 49: Key Terms …………………………………………………………………………………………..1048
Ch 49: Introduction ……………………………………………………………………………………..1049
Structured Failure Analysis ……………………………………………………………………….1049
Principles of Failure Analysis ………………………………………………………………….1050
Component Failures ……………………………………………………………………………………….1057
Common Abuses of Engines and Fuel Systems ………………………………………………1080
Ch 49: Summary ………………………………………………………………………………………………1080
Ch 49: Review Questions ………………………………………………………………………………1081
Ch 50: Troubles Hooting and Diagnosis …………………………………………………………1083
Ch 50: Objectives …………………………………………………………………………………………1083
Ch 50: Key Terms …………………………………………………………………………………………..1083
Ch 50: Introduction ……………………………………………………………………………………..1084
Troubleshooting Tools ………………………………………………………………………………….1084
Smoke Analysis ………………………………………………………………………………………………1085
Troubleshooting Guidelines …………………………………………………………………………1088
Quick Reference Diagnostic Charts …………………………………………………………….1100
Technical Support …………………………………………………………………………………………1107
HD-OBD ……………………………………………………………………………………………………………………….1108
Ch 50: Summary ………………………………………………………………………………………………1109
Ch 50: Review Questions ………………………………………………………………………………1110
Glossary ………………………………………………………………………………………………………………..1113
List of Acronyms ………………………………………………………………………………………………….1157
Index ……………………………………………………………………………………………………………………..1165
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