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Medium/Heavy Duty Truck Engines, Fuel and Computerized Management Systems,9781401814991
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Medium/Heavy Duty Truck Engines, Fuel and Computerized Management Systems

by
Edition:
2nd
ISBN13:

9781401814991

ISBN10:
1401814999
Format:
Hardcover
Pub. Date:
12/19/2003
Publisher(s):
Cengage Learning
List Price: $179.95
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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

Table of Contents

Preface xiii
Acknowledgments xvii
Section 1 Diesel Engine Fundamentals
1(252)
Introduction
3(10)
Introduction
4(1)
Role of the Trucking Industry and the Truck Technician
4(1)
The Truck Technician of the Twenty-First Century
5(2)
Training and the Truck Technician
7(1)
Customer Service and Professionalism
8(1)
Qualifications and Careers for the Truck Technician
9(1)
Professional Associations
10(3)
Hand and Shop Tools, Precision Tools, and Units of Measurement
13(22)
Introduction
14(1)
Hand Tools
14(5)
Precision Measuring Tools
19(4)
Truck Technician's Toolbox
23(2)
Shop Tools
25(3)
SAE Fastener Grades and Torques
28(2)
The Metric System and English/Metric Conversion
30(5)
Personal and Safety Awareness
35(10)
Personal Safety Equipment
36(2)
Workplace Hazards and Safety Regulations
38(3)
Oxy-Acetylene Safety
41(2)
Safety Hotlines
43(2)
Engine Basics
45(12)
Introduction
46(1)
Engine Terminology
46(4)
The Diesel Cycle
50(2)
The Two-Stroke Cycle Diesel Engine
52(1)
The Otto Cycle
53(1)
Engine Systems and Circuits
54(3)
History of the Heat Engine
57(12)
Introduction
58(1)
A Biographical Chronology of the Modern Diesel Engine
58(11)
Power
69(12)
Introduction
70(1)
Definitions and Formulae
70(1)
Power Calculations
71(6)
How Much Power Do You Need?
77(4)
Engine Powertrain Components
81(32)
Introduction
82(1)
Piston Assemblies
82(6)
Piston Rings
88(8)
Connecting Rods
96(3)
Crankshafts and Bearings
99(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


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