Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems, Sixth Edition
By Sean Bennett
Contents:
Contents for Photo Sequences . vii
Preface viii
Structure of the 6th Edition . viii
New to This Edition . viii
Some Transportation History viii
Electric Drivetrains viii
The Future . ix
Diesel Power . ix
Hands-on Learning ix
Acknowledgments . ix
Acknowledgments xiv
Section 1
Diesel Engine
Fundamentals 2
CHAPTER 1
Introduction 4
Why Read This? • 5 Commercial Vehicle
Powertrains • 5 The Connected Truck • 8
Qualifications, Training, and Employment • 10
Customer Service and Professionalism • 18
Engine ID and OEM Market Share • 20
CHAPTER 2
Hand and Shop Tools, Precision
Tools, and Units of Measurement 25
Why Read This? • 26 Hand Tools • 26
Precision Measuring Tools • 32 Shop Tools • 43
Fasteners • 48 Fastener Grades and Classes • 48
Adhesives and Chemical Sealing Materials • 55
The Metric System and English/
Metric
Conversion • 56 Workplace Organization • 58
CHAPTER 3
Personal and Safety Awareness 62
Personal Protective Equipment • 63 Lockout,
Tagout • 65 Workplace Hazards and Safety
Regulations • 68 Emergencies • 70 OSHA • 71
Safety Hotlines • 74
CHAPTER 4
Engine Basics 78
Why Read This? • 79 Key Engine Terms • 79
The Diesel Cycle • 81 The Two-Stroke Cycle Diesel
Engine • 84 The Otto Cycle • 85 Engine Systems
and Circuits • 86 Advanced Engine Terms • 87
CHAPTER 5
History of the Heat Engine 92
Why Read This? • 93 History of Motive Power
Technology • 93
CHAPTER 6
Power 105
Why Read This? • 106 Definitions and
Formulae • 106 Engine Configuration, Engine
Speed, and Torsional Forces • 113 How Much
Power Do You Need? • 114
CHAPTER 7
Engine Powertrain Components 117
Why Read This? • 118 Piston Assemblies • 118
Piston Rings • 127 Connecting Rods • 133
Crankshafts and Bearings • 137 Rod and Main
Bearings • 141 Vibration Dampers • 145
Flywheels • 147
CHAPTER 8
Engine Feedback Assembly 153
Why Read This? • 154 Timing Gears • 154
Camshafts • 158 Valve and Injector Trains • 162
Cylinder Head Valves • 166
CHAPTER 9
Engine Housing Components 178
Why Read This? • 179 Engine Cylinder
Block • 179 Cylinder Heads • 186 Intake and
Exhaust Manifolds • 190
CHAPTER 10
Engine Lubrication Systems 195
Why Read This? • 196 Engine Lubricating
Oil • 197 Lubrication System Components • 205
Interpreting Oil Analyses • 217 Lubricating Circuit
Problems • 219
CHAPTER 11
Engine Cooling Systems 224
Why Read This? • 225 Engine Coolant • 226
Cooling System Components • 234 Repairing
Leaks • 236 Filters • 240 Coolant Monitoring
Circuit • 241 Thermostats • 242 Cooling
Fans • 244 Cooling System Problems • 251
Cooling System Management • 252 Coolant
Heaters • 253
CHAPTER 12
Engine Breathing 258
Why Read This? • 259 Gas Flow in Breathing
Circuit • 259 Breathing Components • 259
Air Intake System Components • 262
Turbochargers • 264 Charge Air Heat
Exchangers • 273 Air-to-Air Heat Exchangers • 274
Exhaust Gas Recirculation • 276 Valve
Design and Breathing • 278 Exhaust System
Components • 280 Breathing Circuit Sensors • 282
CHAPTER 13
Engine Retarders 286
Why Read This? • 287 Energy Conversion in Air
Brakes • 287 Principles of Operation • 288
Exhaust Brakes • 290 Internal Compression
Brakes • 291 Bus Requests to Engine
Brakes • 297
CHAPTER 14
Servicing and Maintenance 301
Why Read This? • 302 Startup and
Engine Break-in • 303 Air Intake System
Maintenance • 304 Engine Lube Service • 306
Cooling System Service • 310 Fuel System
Maintenance • 313 Selective Catalytic
Reduction • 319 Diesel Particulate Filter
Service • 321
CHAPTER 15
Engine Removal, Disassembly,
Cleaning, Inspection, and
Reassembly Guidelines 325
Why Read This? • 326 Service Literature • 326
Removal of an Engine from a Vehicle • 326
Engine Disassembly • 328 Cleaning and
Inspecting Components • 332 Engine Reassembly
Guidelines • 333
CHAPTER 16
Diesel Engine Run-in and
Performance
Testing 349
Why Read This? • 350 Dynamometers • 350
Rebuilt Engine Run-in Procedure • 351 Chassis
Dynamometer Testing • 355 Engine Dynamometer
Testing • 361 Over the Road Break-in • 364
Section 2
Diesel Fuel Systems 368
CHAPTER 17
Chemistry and Combustion 370
Why Read This? • 371 Basic Chemistry • 371
Properties of Some Common Elements • 375
Properties of Some Mixtures and Compounds • 377
Combustion • 378 The Actual Combustion Cycle in
a Diesel Engine • 381
CHAPTER 18
Diesel Fuel Characteristics 385
Why Read This? • 386 Fuel Terminology • 386
Petroleum • 389 Diesel Fuel
Characteristics • 391 Fuel Storage, Deterioration,
and Performance • 396
CHAPTER 19
Fuel Subsystems 401
Why Read This? • 402 Fuel Subsystem
Objectives • 402 Fuel Tanks • 403 Fuel
Filters • 407 Fuel Charging/Transfer Pumps • 414
Complete Fuel Circuit • 417
CHAPTER 20
Fuel Injection Basics and Governor
Principles 423
Overview of Diesel Fuel Injection Principles • 424
Engine Management Objectives • 427 Delivery,
Injection, and Combustion • 428 Governing
Objectives • 431 OEM Management
Systems • 434
CHAPTER 21
Injector Nozzles 440
Why Read This? • 441 Single Orifice
Nozzles • 442 Multiple Orifice Nozzles • 444
Electrohydraulic Injectors • 447
Nozzle Testing and Reconditioning • 451
Nozzle Troubleshooting • 454 EHI Testing and
Reconditioning • 456
CHAPTER 22
Port-Helix Metering Injection
Pumps 463
Why Read This? • 464 Technical
Description • 464 Injection Pump
Components • 470 Governor Trim Devices • 474
Timing Injection Pumps to an Engine • 475
Phasing and Calibration • 479 Critical System
Pressure Values • 480 Electronic Port-Helix
Metering • 481 Electronic Pump-to-Engine
Timing • 486 Future of Port-Helix Metering
Pumps • 487
CHAPTER 23
Inlet-Metering Rotary Distributor
Pumps 490
Why Read This? • 491 Roosa Master • 491
Opposed-Plunger, Inlet-Metering Injection
Pumps • 491 Opposed-Plunger, Inlet-Metering
Pump Summary • 499
CHAPTER 24
Sleeve-Metering Rotary Distributor
Pumps 501
Why Read This? • 502 Sleeve-Metering, Single
Plunger Distributor Pumps • 502 VE Pump
Electronic Controls • 513
CHAPTER 25
Single-Actuator EUI Systems 518
Why Read This? • 519 System Overview • 520
ECM • 521 EUI Operation • 523 Calibration
Codes • 527 Understanding IRT • 528
Multiple Injection Events • 529 Servicing and
Diagnostics • 531 Celect Plus EUIs • 536 Bench
Testing EUIs • 540
CHAPTER 26
Dual-Actuator EUI Systems 544
Why Read This? • 545 System Overview • 547
Input Circuit • 549 Management
Electronics • 549 Output Circuit • 553
Bench-Testing E3 Injectors • 560
CHAPTER 27
HEUI Fuel Systems 563
Why Read This? • 564 Principles of
Operation • 565 Fuel Supply System • 566
Injection Actuation System • 566 HEUI
Injector • 567 HEUI Electronic Management and
Switching • 573 HEUI Diagnostics • 576
CHAPTER 28
Electronic Unit Pump (EUP)
Systems 583
Why Read This? • 584 System Overview • 584
Fuel Subsystem • 586 Input Circuit • 587
Engine Controllers and Management
Electronics • 588 Electronic Unit Pumps • 590
CHAPTER 29
Cummins HPI-TP 599
Why Read This? • 600 TP Hydraulic
Equation • 600 Engine Management
Electronics • 601 Fuel System Components • 601
Overhead Adjustments • 607 Troubleshooting
ISX • 610
CHAPTER 30
Common Rail Systems 613
Why Read This? • 614 What is CR? • 614
CR Subsystems and Components • 616 CR
Management Electronics • 617 CR Fuel Routing
Circuit • 618 Delphi CR • 631 Diagnosing CR
System Problems • 633
CHAPTER 31
Amplified Common
Rail Systems 639
Why Read This? • 640 ACRS Applications and
Generations • 640 ACRS Circuit Layout • 641
ACRS HADI • 648 ACRS Service Procedures • 651
Section 3
Engine Management,
Alternate
Power,
Emissions, and
Diagnostics 658
CHAPTER 32
Review of Electrical and Electronics
Fundamentals 660
Why Read This? • 661 Atomic Structure
and Electron Movement • 662 Conductors
and Insulators • 664 Current Flow • 664
Magnetism • 665 Electromagnetism • 666
Electrical Current Characteristics and Sources of
Electricity • 668 Electrical Circuits and
Ohm’s Law • 670 Capacitance • 674
Coils and Transformers • 676
Semiconductors • 676 Testing
Semiconductors • 681 Photonic Devices • 681
Using Electronic Signals • 682 Conclusion • 686
CHAPTER 33
Vehicle Computer Systems 691
Why Read This? • 692 Engine Controllers • 692
Input Circuit • 697 ECMS and the Processing
Cycle • 708 Output Circuit • 712 ECM
Programming • 714 Engine Management
Systems • 716 Body Controllers • 717
CHAPTER 34
ESTs and SISs 721
Why Read This? • 722 Development of
ESTs • 722 Digital Multimeters • 725 Generic
EST • 733 Connecting OEM ESTs to the Data
Bus • 737 Electronic Troubleshooting • 739 Data
Bus Codes and Protocols • 742 HD-OBD • 744
Generic SISs, ESTs, and Diagnostic Software • 744
Interpreting Dash Warning Lights • 745
CHAPTER 35
Electrical Wiring, Connector, and
Terminal Repair 752
Why Read This? • 753 SAE Wiring
Standards • 753 Connector Assembly and
Repair • 756 Splicing Guidelines • 762
Circuit Protection Devices • 763 Relays • 765
Troubleshooting Techniques • 767
CHAPTER 36
Multiplexing 776
Why Read This? • 777 Multiplexing, Clients,
and Servers • 778 Multiplexing Basics • 778
Accessing the Data Bus • 796 Diagnosing Bus
Faults • 802
CHAPTER 37
The Connected Vehicle 808
Why Read This? • 809 Communications
Media • 809 Vehicle Navigation • 813
Video • 814 Telematics • 817 Electronic Logging
Devices • 820 Cybersecurity • 822
CHAPTER 38
Natural Gas, Propane, and
Biodiesel Fuels 828
Why Read This? • 829 Biodiesel • 830 Methane
Fuels • 833 Compressed and Liquid NG • 833
Igniting NG • 837 FMVSS 304 Precautions • 844
Liquefied Petroleum Gas • 847 Alcohol-Based
Fuels (Methanol/Ethanol) • 848 Fuel Alternatives
for Engines • 849
CHAPTER 39
High Voltage Electricity 853
Definitions • 854 Understanding Electrical
Energy • 854 General HV Safety • 856
High Voltage Testing • 860 Welding on HV
Vehicles • 861 Battery Safety • 862
CHAPTER 40
Hybrid and Hydrogen Fuel Cell
Drivetrains 867
Why Read This? • 868 Hybrid Electric
Vehicles • 868 Hydraulic Hybrids • 873
Fuel Cells • 875
CHAPTER 41
Electric Powertrains 883
Emergence of CEVs • 884 Sources
of Electricity • 885 Overview of CEV
Components • 887 Rechargeable Electricity Storage
Systems • 887 Traction Motors • 893 Electric
Power Management System • 897 Charging
CEVs • 899 CEV Preventative Maintenance • 901
CHAPTER 42
Bosch EDC Systems 907
Why Read This? • 908 Bosch Diesel
Systems • 908 EDC Management Logic • 910
Block Diagrams • 912 Making the
Connection • 912
CHAPTER 43
Caterpillar Engine M
anagement
Systems 917
Why Read This? • 918 ACERT • 919 ADEM
Electronics • 921 Input Circuit • 921 ECM • 923
System Diagnostics and Communications • 926
CHAPTER 44
Cummins Management
Systems 932
Why Read This? • 933 Management
Systems • 933 Electronic
Engines • 935 Input Circuit • 935
Electronic Control Module (ECM) • 937
Programmable Features • 939 System
Troubleshooting and Engine Testing • 940
CHAPTER 45
Detroit Diesel Electronic Controls
(DDEC) 944
Why Read This? • 945 Management
Systems • 948 Software Tools • 949 DD
Electronic Service Tools • 950 Input
Circuit • 955 Programming Options • 958
Diagnostic Tools • 960 DDEC Features • 962
CHAPTER 46
Navistar Diamond Logic 967
Why Read This? • 968 Navistar Engine
Lineup • 968 Diamond Logic Controls • 970
ECM Diagnostics • 973
CHAPTER 47
Paccar Engine M
anagement
Systems 979
Why Read This? • 980 Paccar Engine Lineup • 980
Paccar Electronics • 984 System Diagnostics
and Communications • 986 Paccar Exhaust
Aftertreatment • 987
CHAPTER 48
Volvo and Mack Engine
Management 991
Why Read This? • 992 Electronic Engine
Families • 992 V-MAC and Vectro Electronics • 993
Programming and Diagnostics • 997
CHAPTER 49
Emissions Management 1005
Why Read This? • 1006 Pollutants • 1006
EPA Certification Testing • 1010 Diesel Engine
Emissions Controls • 1012 Diesel Particulate
Filters (DPFs) • 1018 Selective Catalytic
Reduction (SCR) • 1025 Meeting Chassis GHG
Reduction
Standards • 1030
CHAPTER 50
Servicing and Maintenance
of Exhaust Aftertreatment
Systems 1034
Why Read This? • 1035 Visible Smoke Emission:
Legacy Engines • 1036 Exhaust Gas Recirculation
(EGR) Systems • 1037 Diesel Particulate Filters
(DPFs) • 1040 Selective Catalytic Reduction
(SCR) • 1049 Emissions Tampering • 1053
Field Testing of Smoke Density • 1054
Aftertreatment Device Removal and
Replacement • 1059 Aftertreatment System
Electronics • 1061
CHAPTER 51
Failure Analysis 1066
Why Read This? • 1067 Structured Failure
Analysis • 1067 Principles of Failure
Analysis • 1068 Component Failures • 1074
Common Abuses of Engines and Fuel
Systems • 1096
CHAPTER 52
Troubleshooting
and Diagnostics 1099
Why Read This? • 1100 Troubleshooting
Tools • 1100 Exhaust Analysis • 1101
Troubleshooting Guidelines • 1104
Quick Reference Diagnostic Charts • 1114
Technical Support • 1121 HD-OBD • 1122
List of Acronyms ………………………………………1126
Glossary ………………………………………1134
Appendix A ………………………………………1184
Appendix B ………………………………………1186
Appendix C ………………………………………1187
Appendix D ………………………………………1188
Index ………………………………………1189
Photo Sequences
1 Chassis Dyno Test Preparation……………………..358
2 Engine Dyno Test Preparation………………………362
3 Bench Testing a Common Rail (CR)
Electrohydraulic Injector (EHI)…………………….458
4 Spill Timing for an Inline,
Port-Helix Metering Injection Pump………………476
5 Accessing a Truck Data Bus with an EST…………………………………………….800