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Modern Diesel Technology Electronic Diesel Engine Diagnosis

ISBN-10: 1401870791
ISBN-13: 9781401870799
Edition: 2007
Authors: Sean Bennett
List price: $194.95 Buy it from $160.19
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Description: Gain a sound understanding of electronically controlled diesel engines as well as maintenance and diagnostic procedures. This book uses the ASE L2 ?composite? diesel engine as a platform for fostering a detailed understanding of current truck engine  More...

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Book details

List price: $194.95
Copyright year: 2007
Publisher: Delmar Cengage Learning
Publication date: 11/3/2006
Binding: Paperback
Pages: 384
Size: 8.50" wide x 10.80" long x 0.70" tall
Weight: 2.046
Language: English

Gain a sound understanding of electronically controlled diesel engines as well as maintenance and diagnostic procedures. This book uses the ASE L2 ?composite? diesel engine as a platform for fostering a detailed understanding of current truck engine management systems including electronic unit injector (EUI), hydraulically actuated electronic unit injector (HEUI), electronic unit pump (EUP), time-pressure injection (HPI-TP), computer-controlled pump-line-nozzle (PLN), and diesel common rail (CR) fuel management systems. Coverage is comprehensive in scope, addressing vehicle management computers, electronic service tools (ESTs), connector and wiring repair, and the principles of multiplexing, as well as each major system of the various fuel management systems used on today?s diesel powered trucks.

Sean Bennett is a former program coordinator for the Truck and Diesel Department at Centennial College as well as a former corporate trainer for Mack Trucks. During his 20-year tenure at the college, he authored new curricula, helped overhaul existing course offerings, and chaired a wide range of curriculum development committees for the Province of Ontario. Mr. Bennett has written more than 30 books dealing with diesel, truck, heavy equipment, and automotive technology and currently devotes his career to technical writing and speaking engagements. He is an active member of the American Trucking Association's Technology and Maintenance Council, the Association of Diesel Specialists, the Society of Automotive Engineers, and the North American Council of Automotive Teachers. He is widely regarded as the foremost author in medium/heavy-duty truck technology.

Preface
Series Preface
Introduction and Safety
Introduction
Assumed Knowledge
Scope of Coverage
Personal Safety Equipment
Safety Boots
Safety Glasses
Hearing Protection
Gloves
Back Care
Coveralls
Butane Lighters
Hair and Jewelry
Fire Safety
Fire Extinguishers
Shop Equipment
Lifting Devices
General Shop Precautions
Exhaust Extraction
Workplace Housekeeping
Components Under Tension
Compressed Fluids
Pneumatics Safety
Chassis and Shop Electrical Safety
Static Discharge
Chassis Wiring and Connectors
Mains Electrical Equipment
Summary
Review Questions
Vehicle Computer Systems
Introduction
The Computer-Controlled Chassis
Data Input
Data Processing
Outputs
Data Bus Hardware and Software Protocols
Multiplexing
Data Retention in Vehicle ECMs
Random Access Memory
Read-Only Memory
Programmable ROM
Electronically Erasable PROM
Input Circuit
Sensor Circuits
ECMs and the Processing Cycle
ECM Self-Diagnostic Capability
Time and Electronically Managed Engines
Output Circuit
ECM Programming
Customer Data Programming
Proprietary Data Programming
Engine Management Systems
Full Authority Systems
Partial Authority Systems
Summary
Review Questions
Electronic Service Tools
Introduction
Onboard Diagnostic Lights
Digital Multimeters
Scanners
Generic Reader/Programmers
Proprietary Reader/Programmers
Personal Computer (PC)
Personal Digital Assitant (PDA)
Accessing the Data Bus
Understanding and Using DMMs on Heavy-Duty Truck and Bus Systems
DMM Subcomponents
Input Terminals
Rotary Switch
Pushbuttons
Data Display
Resolution
Accuracy
Operating Principles
Measuring Voltage
Measuring Resistance
Diode Testing
Measuring Current
Current Probe Accessories
Current Transformers
Hall Effect Probe
Some Typical DMM Tests
Engine Position (Fuel Injection Pump Camshaft), Cam, and Crank Position Sensors
Potentiometer-Type TPS
Magnetic Sensors
Min/Max Average Test for Lambda ([lambda]) (O[subscript 2]) Sensors
Thermistors
Breakout Boxes and Breakout Tees
Diagnostic Connector Dummies
DMM Circuit Testing
Testing Resistors
Testing Semiconductors
Generic Reader/Programmer
RS-232 Serial Port
Updating a Prolink Cartridge
Electronic Troubleshooting
Snapshot Tests
SAE/ATA J1587, J1708, and J1939 Codes and Protocols
Failure Mode Identifiers
Summary
Review Questions
Electrical Wiring, Connector, and Terminal Repair
Introduction
Connector Assembly and Repair
Weatherproof Connectors
Removal and Repair
Removal and Repair
Deutsch Connectors
Installation of Deutsch Connectors
Removal
Splicing Guidelines
Tools Required
Straight Leads
Solder
Shrink Wrap
Multiple Broken Wires
Three-Wire Splice
Relays
Coil Circuit
Switched Circuit
Terminal Assignments
Troubleshooting Techniques
Wire Gauge Factors
Circuit Voltage Behavior
Voltage Drop versus Resistance
Teslite Circuit Testing
Teslite Test Procedure
Circuit Analysis
Circuit Symbols
Circuit Schematics
Summary
Review Questions
Multiplexing
Introduction
Multiplexing, Clients, and Servers
Multiplexing Basics
Power Line Carrier
Types of Logic
Serial Data Transmission
The J1939 Backbone
Proprietary Data Bus
Summary of Multiplexing Basics
Diamond Logic
Virtual Fusing
Benefits of Networking
Accessing the Data Bus
J1587/1708 Connector
J1939 Connectors
Making the Connection
Connect to Chassis Data Bus
Summary
Review Questions
Medium-/Heavy-Duty Composite Engine
Introduction
Composite Engine Examples
System Overview
Fuel Subsystem
Check and Relief Valves
Filters and Separators
Transfer and Priming Pumps
Fuel Routing to the EUIs
Fuel Subsystem Sensors
Electronic Input Circuit
Command and Monitoring Sensors
Position-Sensing Inputs
Shaft Speed Sensors
Pressure Sensors
Temperature Sensors
Switches
Management Electronics
ECM
V-Ref
Output Circuit
Electronic Unit Injectors (EUIs)
Engine Cooling Fan
Warning/Diagnostic Indicator Lights
Engine Brake
System Diagnostics and Communications
ESTs and Software
Data Link
Injector Cutout Tests
Engine Programming Options
Smart Options
Summary
Review Questions
Electronic Unit Injector-Fueled Engines
Introduction
System Overview
Fuel Subsystem
Transfer Pumps
Fuel Filters
Water Separators
Electronic Control Module (ECM)
Input Circuit-Sensors
Engine RPM and Timing Sensors
Output Circuit
Electronic Unit Injector
Types of EUI
Fuel Trim Programming
Control Cartridge Switching
Injector Response Time
Multipulse Injection
EUI Control Cartridge
Control Cartridge Operation
Governing
Cruise Control
Progressive Shifting
Engine Protection Features
Stop Engine Override Options
Engine Diagnostics
Blink Codes
Diagnostic Data Readers
Personal Computer
Personal Digital Assistant
Fault Codes
Categorizing Fault Codes
Injector Cutout Test
EUI System Tune-Up
EUI Timing
EUI Removal
EUI Installation
EUI Solenoid Replacement
Identify EUI Failures
Summary
Review Questions
Bosch Electronic Distributor and Common Rail Systems
Introduction
Electronic Diesel Control
Input Circuit
Signal Conditioning
Processing Cycle
Output Circuit
Multiplexing
Electronic Control of Sleeve-Metering, Single-Plunger Distributor Pumps
Difference Between Electronic and Hydromechanical Versions
Output Circuit Components
Common Rail Accumulator Fuel Injection System
Fuel Subsystem
High-Pressure Stage Components
Electrohydraulic Injectors
Phases of Injection
Multiplexing
Summary
Review Questions
Pump-Line-Nozzle, Integral Pump Systems
Introduction
System Overview
Bosch PE7100/PE8500 Injection Pumps
RE24/30 Rack Actuator Housings
Econovance
Proportional Solenoid
Hydraulic Spool Valve
Econovance Operation
Injection Pump to Engine Timing
Static Timing Setting on an E-7 Engine with V-MAC Electronics
V-MAC Electronics
Customer Data Programming
Mack Trucks Data Programming
Caterpillar PEEC
PEEC Layout on 3406
PEEC Rack Actuator Housing
Timing Advance Unit
Sensoring/Monitoring Circuit
Command Circuit
CAT PEEC-ECM
Transducer Module
PEEC Circuit
Sequential Electronic Troubleshooting
PEEC Diagnostics
Inspecting Electrical Connectors
Summary
Review Questions
Bosch EUP on V-MAC III-E-Tech and Mercedes-Benz
Introduction
System Overview
Fuel Subsystem
Mack E-Tech Fuel Routing
Priming the Fuel Subsystem
Mercedes-Benz EUP Fuel Routing
Input Circuit
V-MAC III Inputs
Mercedes-Benz Inputs
Engine Controllers and Management Electronics
V-MAC III Electronics
Mercedes-Benz Electronics
Electronic Unit Pumps
Removal and Installation of EUPs
Removal
Tappet and EUP Installation
Testing Injectors
Information Management Systems
DataMax
InfoMax
Conclusion
Summary
Review Questions
Caterpillar and International Trucks HEUI
Introduction
Principles of Operation
Fuel Supply System
Injection Actuation System
Injection Pressure Regulator (IPR)
HEUI Assembly
HEUI Oil and Fuel Manifold
HEUI Assembly
Solenoid
Poppet Valve
Intensifier or Amplifier Piston
Plunger and Barrel
Injector Nozzle
Stages of Injection
Preinjection
Pilot Injection
Delay
Main Injection
End of Injection
HEUI Electronic Management and Switching
ECM Functions
Reference Voltage
Input Conditioning
Microcomputer
Outputs
Injection Driver Module (IDM)
Electronic Distributor for the HEUIs
Powers the HEUIs
Output Driver for the HEUIs
IDM and HEUI Diagnostics
Injection Actuation Pressure
HEUI Diagnostics
Caterpillar ET
Injector Cutout Test
Injection Actuation Pressure Test
International HEUI Diagnostics
International Trucks' Self-Test
International Trucks' HEUI Circuit Schematic
Conclusion
Summary
Review Questions
Cummins ISX Engines with HPI-TP Management
Introduction
Fuel System Components
IFSM (Integrated Fuel System Module)
Fuel Flow
HPI-TP Injectors
Upper Plunger/Tappet
Injector Retraction Spring
Inlet Screen
Timing Check Valve
Timing Plunger
Timing Plunger Spring
Timing Chamber
Spill Regulator
Lower Plunger/Annular Groove
Lower Plunger Spring
Metering Chamber
Rail Metering Check Valve
Trapped Volume Spill (TVS) Port
Cup Orifices
Injection Cycle
Overhead Adjustments
Setting Valves and Injectors
ISX Electronics and Engine Features
Troubleshooting ISX
Intebrake
Summary
Review Questions
Emissions
Introduction
Photochemical Smog
Ingredients of Smog
EPA Certification Testing
Actual EPA Emissions Requirements by Year
ULS Fuel
Importance of Using the Correct Fuel
Biodiesel
What Is Biodiesel?
Biodiesel and Engine Warranty
Lube Oil
Truck Engine Emission Controls
Engine Control Module
Engine Manufacturer Diagnostics (EMD)
Diesel Particulate Filters (DPFs)
DPF Operating Principles
Catalytic Converters
NOx Adsorber Catalysts
Cooled EGR
Selective Catalytic Reduction
Clean Gas Induction (CGI)
CGI Sensors
Auxiliary Devices
Field Testing of Smoke Density
Opacity Meters
Performing J1667 Testing
Evaluating J1667 Test Results
Opacity Readings
Smoke Analysis
Black Smoke
White Smoke
Blue Smoke
Summary
Review Questions
Electronic Diesel Engine Controls Diagnosis
Introduction
Composite Engine Description
Composite Engine Electronic Control Module
ECM Memory
ECM Processing Cycle
Injector Drivers
Fuel System
Programmable Parameters
Engine Protection System
Protection Levels
Composite Engine Operating Specifications
Sensors
Throttle Position Sensor
Engine Oil Pressure Sensor (EOP)
Boost Pressure Sensor (BP)
Intake Manifold Temperature Sensor (IMT)
Barometric Pressure Sensor (BARO)
Engine Coolant Temperature Sensor (ECT)
Coolant Level Sensor (CL)
Fuel Temperature Sensor (FT)
Engine Oil Temperature Sensor (EOT)
Engine Position Sensor (EPS)
Engine Speed Sensor (ESS)
Vehicle Speed Sensor (VSS)
Inlet Air Temperature Sensor (IAT)
Switches
Engine Cooling Fan Manual Switch
Diagnostic On/Off Switch
Air Conditioning (A/C) High-Pressure Switch
Idle Validation Switch (IVS)
Cruise Control On/Off Switch
Cruise Set/Resume Switch
Clutch Switch
Service Brake Switch
Engine Brake On/Off Switch
Engine Brake Selector Switch
Power Takeoff (PTO) On/Off Switch
Power Takeoff (PTO) Remote Switch
Engine Protection Override Switch
Actuators
Electronic Unit Injectors (EUIs)
Engine Cooling Fan Solenoid
Warning/Diagnostic Indicator Lights
Engine Brake Solenoids
Wastegate Controller Solenoids
Data Link Connectors
Diagnostic Equipment
Identifiers
Diagnostic Trouble Codes (DTCs)
J1939 and J1587 Codes
Composite Vehicle Schematics
Engine Electronic Controls Schematic
Vehicle OEM Electronic Controls
Electrical and Sensor Specifications
Summary
Review Questions
Engine Intake and Exhaust Diagnosis
Introduction
Breathing System Components
Engine Breathing Components on a Typical Four-Stroke Cycle Truck Diesel Engine
Air Intake System Components
Air Cleaners
Turbochargers
Principles of Operation
Construction
Turbocharger Gas Flow
Turbocharger Geometry and Performance
Diffuser
Charge Air Heat Exchangers
Air-to-Air
Aftercoolers and Intercoolers
Tip Turbines
Testing for Boost Circuit Leakage
Intake Manifold Design
Valve Design, Configuration, and Breathing
Exhaust System Components
Exhaust Manifold
Pyrometer
Exhaust Piping
Diesel Particulate Filters
Engine Silencers
Catalytic Converters
Exhaust Gas Recirculation (EGR)
ACERT Technology
ACERT EUI Engine Family
ACERT Management
ACERT Components
Intake Valve Actuation
Clean gas induction (CGI)
CGI Sensors
Compression Brake Operation
ACERT Adjustment Precautions
Troubleshooting
Summary
Review Questions
Fuel Subsystems
Introduction
Fuel Subsystem Objectives
Diesel Fuels
Fuel Tanks
Fuel Tank Caps and Vents
Fuel tank Sending Units
Dual Tanks
Pickup Tubes
Venting
Fuel Filters
Primary Filters
Secondary Filters
Servicing Filters
Procedure for Servicing Spin-On Filter Cartridges
Replacement Procedure
Water Separators
Fuel Heaters
Electric Element
Engine Coolant Heat Exchanger
Fuel Charging/Transfer Pumps
Pumping Principle
Plunger Pumps
Gear Pumps
Hand Primer Pumps
Priming a Fuel System
Recommended Procedure
Service Intervals
Fuel Subsystem Sensors
Fuel Temperature Sensors
Fuel Pressure Sensors
Water-in-Fuel Sensors
Summary
Review Questions
Glossary
Index

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