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

ISBN 13:
9781401814991
ISBN 10:
1401814999
Edition: 2nd
Format: Hardcover
Copyright: 12/19/2003
Publisher: Cengage Learning
Newer Edition

Note: Not guaranteed to come with supplemental materials (access cards, study guides, lab manuals, CDs, etc.)

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Summary

Written by an experienced truck technician in easy-to-understand language, this book provides a comprehensive introduction to highway diesel engines and their management systems. Coverage of the full range of truck diesels from light duty to heavy duty is provided, as well as the most current diesel engine management electronics used today. New topics include rotary distributor pumps, alternate fuel technologies, multiplexing, Bosch electronic common rail systems, and Cummins CAPS and HPI-TP. Recent innovations in engine technology and greatly expanded coverage of SAE J1667 emissions testing round out the enhancements, making this edition a superior learner's guide and an invaluable reference to the practicing technician

Preface

xiii

Acknowledgments

xvii

Section 1 Diesel Engine Fundamentals

(252)

Introduction

(10)

Introduction

(1)

Role of the Trucking Industry and the Truck Technician

(1)

The Truck Technician of the Twenty-First Century

(2)

Training and the Truck Technician

(1)

Customer Service and Professionalism

(1)

Qualifications and Careers for the Truck Technician

(1)

Professional Associations

(3)

Hand and Shop Tools, Precision Tools, and Units of Measurement

(22)

Introduction

(1)

Hand Tools

(5)

Precision Measuring Tools

(4)

Truck Technician's Toolbox

(2)

Shop Tools

(3)

SAE Fastener Grades and Torques

(2)

The Metric System and English/Metric Conversion

(5)

Personal and Safety Awareness

(10)

Personal Safety Equipment

(2)

Workplace Hazards and Safety Regulations

(3)

Oxy-Acetylene Safety

(2)

Safety Hotlines

(2)

Engine Basics

(12)

Introduction

(1)

Engine Terminology

(4)

The Diesel Cycle

(2)

The Two-Stroke Cycle Diesel Engine

(1)

The Otto Cycle

(1)

Engine Systems and Circuits

(3)

History of the Heat Engine

(12)

Introduction

(1)

A Biographical Chronology of the Modern Diesel Engine

(11)

Power

(12)

Introduction

(1)

Definitions and Formulae

(1)

Power Calculations

(6)

How Much Power Do You Need?

(4)

Engine Powertrain Components

(32)

Introduction

(1)

Piston Assemblies

(6)

Piston Rings

(8)

Connecting Rods

(3)

Crankshafts and Bearings

(6)

Vibration Dampers/Harmonic Balancers

105

(2)

Flywheels

107

(6)

Engine Feedback Assembly

113

(20)

Introduction

114

(1)

Timing Gears

114

(3)

Camshafts

117

(4)

Valve/Injector Trains and Rocker Assemblies

121

(2)

Cylinder Head Valves

123

(3)

Valve Lash Adjustment

126

(3)

Other Feedback Assembly Functions

129

(4)

Engine Housing Components

133

(14)

Introduction

134

(1)

Engine Cylinder Block

134

(5)

Cylinder Heads

139

(3)

Intake and Exhaust Manifolds

142

(1)

Exhaust Manifold

142

(1)

Oil Pans or Sumps

143

(4)

Engine Lubrication Systems

147

(24)

Introduction

148

(1)

Engine Lubricating Oil

148

(7)

Lubrication System Components

155

(9)

Interpreting Oil Analyses

164

(2)

API Oil Category Comparisons

166

(1)

Extended Oil Changes

166

(5)

Engine Cooling Systems

171

(22)

Introduction

172

(2)

Engine Coolant

174

(4)

Cooling System Components

178

(11)

Cooling System Management

189

(4)

Engine Breathing

193

(20)

Introduction

194

(1)

Air Intake System Components

195

(2)

Roots Blowers

197

(1)

Turbochargers

198

(5)

Charge Air Heat Exchangers

203

(3)

Intake Manifold Design

206

(1)

Exhaust System Components

207

(6)

Engine Retarders

213

(12)

Introduction

214

(1)

Principles of Operation

215

(1)

Engine Brake Operation and Control Circuits

215

(10)

Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines

225

(14)

Introduction

226

(1)

Removal of an Engine from a Vehicle

226

(1)

Engine Disassembly

227

(3)

Cleaning and Inspecting Components

230

(1)

Engine Reassembly Guidelines

230

(9)

Engine Run-In and Performance Testing

239

(14)

Introduction

240

(1)

Rebulilt Engine Run-In Procedure

240

(2)

Engine Run-In Procedure

242

(1)

Dynamometer Testing Objectives

242

(1)

Chassis Dynamometer Testing

243

(4)

Engine Dynamometer Testing

247

(3)

Road Testing

250

(3)

Section 2 Hydromechanical Diesel Fuel Injection Systems

253

(202)

Chemistry and Combustion

255

(14)

Introduction

256

(1)

Basic Chemistry

256

(2)

Atomic Structure

258

(1)

States of Matter

259

(1)

Properties of Some Common Elements

260

(1)

Properties of Some Mixtures and Compounds

261

(2)

Combustion

263

(1)

Cylinder Gas Dynamics

263

(1)

Calculating Air/Fuel Ratio

264

(1)

The Actual Combustion Cycle in a Diesel Engine

265

(1)

Detonation

266

(3)

Diesel Fuel

269

(14)

Fuel Terminology

270

(2)

Petroleum

272

(3)

Diesel Fuel Characteristics

275

(2)

Fuel Storage, Fuel Deterioration, and Performance

277

(1)

Fuel Conditioners

278

(1)

Cerium Dioxide (CeO2)

278

(2)

EPA Requirements of Diesel Fuels

280

(3)

Fuel Subsystems

283

(16)

Introduction

284

(1)

Fuel Subsystem Objectives

284

(1)

Fuel Tanks

284

(3)

Fuel Tank Repair

287

Fuel Filters

285

(5)

Water Separators

290

(1)

Fuel Heaters

291

(1)

Fuel Charging/Transfer Pumps

292

(1)

Plunger-Type Pumps

292

(1)

Priming a Fuel System

293

(6)

Hydromechanical Injection Principles

299

(8)

Overview of Diesel Fuel Injection Principles

300

(1)

Units of Pressure and Linear Measurement

301

(1)

Engine Management Objectives

302

(5)

Hydraulic Injector Nozzles

307

(14)

Introduction

308

(1)

Poppet Nozzles

308

(1)

Pintle Nozzles

308

(1)

Orifice Nozzles

309

(2)

Electrohydraulic Injectors

311

(2)

Nozzle Differential Ratio

313

(1)

Nozzle Holders/Injectors

314

(1)

VCO Nozzles

314

(1)

Nozzle Testing and Reconditioning

314

(4)

High-Pressure Pipes

318

(3)

Port-Helix Metering Injection Pumps

321

(22)

Introduction

322

(1)

Technical Description

322

(5)

Injection Pump Components

327

(2)

Charging Pumps

329

(1)

Governor or Rack Actuator Housing

329

(1)

Lubrication

330

(1)

Injection Rate and Fuel Rate

330

(1)

Timing Advance and Variable Timing Mechanisms

331

(1)

Timing Injection Pumps to an Engine

332

(4)

Phasing and Calibration

336

(2)

Delivery, Injection, and Combustion

338

(5)

Detroit Diesel Mechanical Unit Injection

343

(16)

Introduction

344

(1)

Engine Identification

344

(1)

Fuel System Components

344

(1)

DDC Mechanical Unit Injectors

345

(4)

Governor

349

(1)

Detroit Diesel Tune-Up

349

(10)

Caterpillar---Mechanical Unit Injection

359

(10)

Introduction

360

(1)

Fuel Subsystem Components

361

(1)

Principles of Operation of Caterpillar Mechanical Unit Injectors

361

(3)

Governors

364

(1)

3114, 3116, and 3126 Engine Testing and Adjustments

365

(1)

Fuel Timing, Valve Setting, and Injector Synchronization

366

(3)

Cummins PT

369

(22)

Introduction

370

(1)

PT System Theory

370

(2)

The PT Injector

372

(1)

The PTG-AFC Pump

373

(4)

PT Pump Circuit Schematics

377

(3)

PT Pump Testing and Adjustments

380

(3)

PT Injector Installation and Adjustment

383

(1)

Cam Follower Housing Timing/Offset Camshaft Key Timing

384

(1)

Step Timing Control

385

(1)

PACE and PACER

386

(5)

Rotary Distributor Pumps

391

(24)

Introduction

392

(1)

Opposed-plunger, Inlet-metering Injection Pumps

392

(8)

Sleeve-Metering, Single Plunger Distributor Pumps

400

(15)

Governors

415

(8)

Introduction

416

(1)

Governor Types

416

(3)

Governor Classification

419

(1)

Governor Terminology

420

(3)

Alternate Fuels

423

(10)

Introduction

424

(1)

Biodiesel

424

(1)

Electricity

425

(1)

Fuel Cells

426

(3)

Fuel Alternatives for Engines

429

(4)

Failure Analysis, Troubleshooting, and Diagnoses Strategies

433

(22)

Introduction

434

(1)

Smoke Analysis

434

(2)

Troubleshooting

436

(8)

Failure Analysis

444

(7)

Common Abuses of Engines and Fuel Systems

451

(4)

Section 3 Computerized Truck Management Systems

455

(278)

Electricity and Electronics

457

(30)

Introduction

458

(1)

Atomic Structure and Electron Movement

459

(2)

Conductors and Insulators

461

(1)

Current Flow

461

(1)

Magnetism

462

(2)

Electromagnetism

464

(1)

Electrical Current Characteristics and Sources of Electricity

465

(1)

Electrical Circuits and Ohm's Law

466

(4)

Capacitance

470

(1)

Coils and Transformers

471

(1)

Semiconductors

472

(1)

Diodes

473

(2)

Transistors

475

(2)

Testing Semiconductors

477

(1)

Photonic Devices

478

(1)

Using Electronic Signals

479

(8)

Digital Computers

487

(16)

Introduction

488

(1)

Computer Terminology

488

(6)

A Brief History of Computers

494

(1)

Computer Hardware

494

(4)

Electronically Represented Data

498

(1)

Summary of Computer Operation and the Processing Cycle

498

(5)

Networking and Communications in the Trucking Industry

503

(10)

Introduction

504

(1)

Networking

504

(1)

The Internet

504

(1)

The Telecommunications System

505

(3)

Security Issues

508

(1)

Satellite Communications Technology

508

(2)

Vehicle Navigation

510

(3)

Vehicle Computer Systems

513

(18)

Introduction

514

(2)

Data Retention in Vehicle ECMs

516

(2)

Input Circuit

518

(5)

ECMs and the Processing Cycle

523

(1)

ECM Self-Diagnostic Capability

524

(1)

Output Circuit

525

(1)

ECM Programming

526

(2)

Engine Management Systems

528

(3)

Electronic Service Tools

531

(20)

Introduction

532

(1)

Understanding and Using DMMs on Heavy-Duty Truck and Bus Systems

533

(7)

DMM Circuit Testing

540

(5)

Generic Reader-Programmer

545

(2)

Electronic Troubleshooting

547

(1)

SAE/ATA J1587, J1708, J1939 Codes and Protocols

547

(4)

Electrical Wiring, Connector, and Terminal Repair

551

(14)

Introduction

552

(1)

Connector Assembly and Repair

552

(4)

Splicing Guidelines

556

(1)

Relays

557

(1)

Troubleshooting Techniques

558

(7)

Multiplexing

565

(12)

Introduction

566

(1)

A Multiplexing Analogy

566

(2)

Multilexing Basics

568

(4)

Second Generation Multiplexing

572

(5)

Bosch Electronic Distributor and Common Rail Systems

577

(34)

Introduction

578

(1)

Electronic Diesel Control

578

(2)

Electronic Control of Sleeve-Metering, Single Plunger Distributor Pumps

580

(2)

Common Rail Accumulator Fuel-Injection System

582

(29)

Mack Trucks and V-MAC I and II

611

(1)

Introduction

596

(1)

System Overview

596

(1)

Bosch PE7100/PE8500 Injection Pumps

596

(5)

Econovance

601

(1)

Injection Pump-to-Engine Timing

601

(1)

V-MAC Electronic

602

(9)

Detroit Diesel Electronic Controls (DDEC)

611

(18)

Introduction

612

(1)

System Overview

612

(1)

Fuel Subsystem

612

(1)

Electronic Control Module (ECM)

613

(1)

Input Circuit Sensors

614

(3)

Output Circuit

617

(4)

Governing

621

(1)

Engine Diagnostics

621

(2)

Calibration Reprogramming

623

(1)

Series 60 and 50 Tune Up

624

(2)

DDEC IV Features

626

(3)

Caterpillar ADEM and Volvo VECTRO EUI Systems

629

(20)

Introduction

630

(2)

System Overview

632

(1)

Fuel Subsystem

632

(1)

Management Electronics

632

(2)

Input Circuit

634

(2)

ECM

636

(2)

Output Circuit

638

(5)

System Diagnostics and Communications

643

(2)

Programming Options

645

(4)

Cummins CELECT Plus

649

(16)

Introduction

650

(1)

System Overview

650

(1)

Fuel Subsystem

651

(1)

Input Circuit

652

(1)

Electronic Control Module (ECM)

652

(1)

Output Circuit

653

(1)

The CELECT Plus Injector

653

(7)

CELECT Plus Engine Protection System

660

(1)

CELECT Plus Programmable Features

660

(1)

System Troubleshooting and Engine Testing

661

(4)

Bosch EUP on V-MAC III-E-Tech and Mercedes-Benz

665

(14)

Introduction

666

(1)

System Overview

667

(1)

Fuel Subsystem

667

(2)

Input Circuit

669

(2)

Engine Controllers and Management Electronics

671

(2)

Electronic Unit Pumps

673

(1)

Removal and Installation of EUPs

674

(1)

Information Management Systems

675

(1)

Conclusion

676

(3)

Caterpillar and International Trucks HEUI

679

(20)

Introduction

680

(1)

Principles of Operation

680

(1)

Fuel Supply System

681

(1)

Injection Actuation System

681

(2)

Hydraulically Actuated Electronically Controlled Unit Injector

683

(5)

HEUI Electronic Management and Switching

688

(4)

HEUI Diagnostics

692

(4)

HEUI Conclusions

696

(3)

Cummins HPI-TP

699

(12)

Introduction

700

(1)

Fuel System Components

700

(2)

Fuel Flow

702

(1)

HPI-TP Injectors

703

(2)

Injection Cycle

705

(1)

Overhead Adjustments

706

(1)

ISX Electronics and Engine Features

707

(1)

Troubleshooting ISX

707

(4)

Cummins Accumulator Pump System

711

(8)

Introduction

712

(1)

Fuel System Components

712

(1)

CAPS Pump

713

(3)

CAPS Troubleshooting

716

(3)

Emissions

719

(14)

Introduction

720

(1)

Photochemical Smog

720

(4)

EPA Certification Testing

724

(1)

Truck Engine Emission Controls

724

(3)

Field Testing of Smoke Density

727

(6)

Appendix

Acronyms

733

(4)

Glossary

737

(30)

Index

767

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

9781401814991

1401814999

Summary

Table of Contents

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