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