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Volvo Mack Paccar Caterpillar Cat Cummins Detroit Diesel Engine Fuel System Manual pdf Download

Volvo Mack Paccar Caterpillar Cat Cummins Detroit Diesel Engine Fuel System Manual pdf Download

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




Section 1 Diesel Engine Fundamentals . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction 3 n Role of the Trucking Industry and the Truck Technician 4
n The Truck Technician of the Twenty-First Century 5 n Training and the Truck
Technician 7 n Customer Service and Professionalism 9 n Qualifications
and Careers for the Truck Technician 12 n Professional Associations 13
n Proprietary Associations 13 n Defining Engines by Displacement 13
n Engine Oems and Market Share 14 n Health, Safety, and a Green
Environment 14 n VIN 15
Hand and Shop Tools, Precision Tools, and Units of Measurement . . . . . . . . 17
Introduction 18 n Hand Tools 18 n Precision Measuring Tools 23
n Shop Tools 31 n Fastener Grades and Torques 35 n The Metric System
and English/Metric Conversion 37 n Workplace Organization 39
Personal and Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Personal Safety Equipment 44 n Workplace Hazards and Safety
Regulations 46 n Emergencies 47 n Osha 48 n Safety Hotlines 51
Engine Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Introduction 55 n Key Engine Terms 55 n The Diesel Cycle 57
n The Two-Stroke Cycle Diesel Engine 59 n The Otto Cycle 61 n Engine Systems
and Circuits 62 n Advanced Engine Terms 63
History of the Heat Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Introduction 68 n History of the Modern Diesel Engine 68
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Introduction 80 n Definitions and Formulae 80 n Engine Configuration,
Engine Speed, and Torsional Forces 87 n How Much Power Do You Need? 88
Engine Powertrain Components . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Introduction 91 n Piston Assemblies 91 n Piston Rings 99 n Connecting
Rods 105 n Crankshafts and Bearings 109 n Rod and Main Bearings 113
n Vibration Dampers 116 n Flywheels 118
Engine Feedback Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Introduction 125 n Timing Gears 125 n Camshafts 129 n Valve and
Injector Trains 132 n Cylinder Head Valves 136
Engine Housing Components . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Introduction 148 n Engine Cylinder Block 148 n Cylinder Heads 155
n Intake and Exhaust Manifolds 158
Engine Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Introduction 164 n Engine Lubricating Oil 165 n Lubrication System Components
172 n Interpreting Oil Analyses 181 n Lubricating Circuit Problems 184
Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Introduction 189 n Engine Coolant 191 n Cooling System Components 197
n Filters 201 n Coolant Monitoring Circuit 202 n Thermostats 203
n Cooling Fans 205 n Cooling System Problems 210 n Cooling System
Management 211 n Coolant Heaters 211
Engine Breathing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Introduction 216 n Breathing Components 218 n Air Intake System
Components 219 n Turbochargers 221 n Charge Air Heat Exchangers 228
n Exhaust Gas Recirculation 230 n Valve Design and Breathing 232
n Exhaust System Components 234 n Breathing Circuit Sensors 236
Engine Retarders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Introduction 240 n Principles of Operation 241 n Exhaust Brakes 242
n Internal Compression Brakes 243 n Caterpillar Brakesaver 249
Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Introduction 254 n Start-Up and Engine Break-In 254 n Air Intake System
Maintenance 256 n Engine Lube Service 258 n Cooling System Service 261
n Fuel System Maintenance 263 n Selective Catalytic Reduction 268
n Diesel Particulate Filter Service 270
Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines . . . . 273
Introduction 274 n Service Literature 274 n Removal of an Engine
from a Vehicle 274 n Engine Disassembly 276 n Cleaning And
Inspecting Components 279 n Engine Reassembly Guidelines 279
Diesel Engine Run-In and Performance Testing . . . . . . . . . . . . . . . . . 294
Introduction 295 n Rebuilt Engine Run-In Procedure 295 n Chassis
Dynamometer Testing 298 n Engine Dynamome
Chemistry and Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Introduction 311 n Basic Chemistry 311 n Properties of Some Common
Elements 315 n Properties of Some Mixtures and Compounds 317
n Combustion 318 n The Actual Combustion Cycle in a Diesel Engine 321
Diesel Fuel Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Introduction 326 n Fuel Terminology 326 n Petroleum 329 n Diesel Fuel
Characteristics 331 n Fuel Storage, Fuel Deterioration, and Performance 335
Fuel Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Introduction 341 n Fuel Subsystem Objectives 341 n Fuel Tanks 342
n Fuel Filters 345 n Fuel Charging/Transfer Pumps 352 n Complete
Fuel Circuit 356
Fuel Injection Basics and Governor Principles . . . . . . . . . . . . . . . . . . 359
Overview of Diesel Fuel Injection Principles 360 n Engine Management
Objectives 363 n Delivery, Injection, and Combustion 364 n Governing
Objectives 366 n Oem Management Systems 369
Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Introduction 376 n Single Orifice Nozzles 377 n Multiple Orifice Nozzles 379
n Electrohydraulic Injectors 382 n Nozzle Testing and Reconditioning 385
n Nozzle Troubleshooting 389 n Ehi Testing and Reconditioning 390
Port-Helix Metering Injection Pumps . . . . . . . . . . . . . . . . . . . . . . 397
Introduction 398 n Technical Description 399 n Injection Pump Components
404 n Governor Trim Devices 408 n Timing Injection Pumps to an
Engine 409 n Phasing and Calibration 413 n Critical System Pressure Values 414
n Electronic Port-Helix Metering 414 n Electronic Pump-to-Engine Timing 419
Inlet-Metering Rotary Distributor Pumps . . . . . . . . . . . . . . . . . . . . 423
Introduction 424 n Roosa Master 424 n Opposed-Plunger, Inlet-Metering
Injection Pumps 424 n Opposed-Plunger, Inlet-Metering Pump Summary 432
Sleeve-Metering Rotary Distributor Pumps . . . . . . . . . . . . . . . . . . . 434
Introduction 435 n Sleeve-Metering, Single Plunger Distributor Pumps 435
n Ve Pump Electronic Controls 445
Single-Actuator Eui Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Introduction 451 n System Overview 452 n Ecm 453 n Eui Operation 455
n Calibration Codes 459 n Understanding Irt 460 n Multiple Injection
Events 460 n Servicing and Diagnostics 462 n Celect Plus Euis 467
n Bench Testing Euis 471
Dual Actuator Eui Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Introduction 475 n System Overview 477 n Input Circuit 479
n Management Electronics 479 n Output Circuit 484 n Installation
of a Delphi E3 Eui 487 n Bench Testing E3 Injectors 489
Caterpillar and Navistar Heui . . . . . . . . . . . . . . . . . . . . . . . . . . 492
Introduction 493 n Principles of Operation 494 n Fuel Supply System 495
n Injection Actuation System 495 n Heui Injector 497 n Heui Electronic
Management and Switching 502 n Heui Diagnostics 506
Electronic Unit Pump (Eup ) Systems . . . . . . . . . . . . . . . . . . . . . . . 511
Introduction 512 n System Overview 513 n Fuel Subsystem 513
n Input Circuit 515 n Engine Controllers and Management Electronics 516
n Electronic Unit Pumps 517
Cummins Hpi -Tp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Introduction 526 n Tp Hydraulic Equation 526 n Engine Management
Electronics 527 n Fuel System Components 527 n Overhead
Adjustments 533 n Troubleshooting Isx 535
Common Rail Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
Introduction 539 n Cr Subsystems and Components 541 n Cr Management
Electronics 541 n Cr Fuel Routing Circuit 543 n Diagnosing Cr System Problems 557
Amplified Common Rail Systems . . . . . . . . . . . . . . . . . . . . . . . . . 561
Introduction 562 n ACRS Applications and Generations 562 n Acrs Circuit
Layout 563 n Acrs Hadi 568 n Acrs Service Procedures 572
Section 3 Engine Management, Alternate Power,
and Emissions . . . . . . . . . . . . . . . . . 579
Review of Electrical and Electronics Fundamentals . . . . . . . . . . . . . . . 580
Introduction 581 n Atomic Structure and Electron Movement 582
n Conductors and Insulators 584 n Current Flow 585 n Magnetism 586
n Electromagnetism 587 n Electrical Current Characteristics and Sources of
Electricity 589 n Electrical Circuits and Ohms Law 591 n Capacitance 595
n Coils and Transformers 596 n Semiconductors 597 n Diodes 597
n Transistors 600 n Testing Semiconductors 602 n Photonic Devices 602
n Using Electronic Signals 603
Networking, Communications, and Telematics . . . . . . . . . . . . . . . . . 611
Introduction 612 n Networking 612 n The Internet 612 n Lans and Intranet
Systems 613 n The Telecommunications System 613 n Electronic Onboard
Recorders 621 n Data Mining Using Telematics 622
Vehicle Computer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
Introduction 627 n Input Circuit 632 n Ecms and the Processing Cycle 639
n Output Circuit 643 n Ecm Programming 645 n Engine Management Systems
Est s and Sis s ������������������������������������������������������������������������������������������������������ 650
Introduction 651 n Digital Multimeters 653 n Generic Est 664 n Connecting Oem
Est s to the Data Bus 667 n Electronic Troubleshooting 669 n Data Bus Codes and
Protocols 671 n Hd-Obd 674 n Generic Siss, Est s, and Diagnostic Software 675
Electrical Wiring, Connector, and Terminal Repair . . . . . . . . . . . . . . . 678
Introduction 679 n Sae Wiring Standards 679 n Connector Assembly and
Repair 682 n Splicing Guidelines 687 n Circuit Protection Devices 689
n Relays 690 n Troubleshooting Techniques 692
Multiplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
Introduction 700 n Multiplexing, Clients, and Servers 701 n Multiplexing
Basics 701 n Accessing the Data Bus 711 n Diagnosing Bus Faults 714
Biodiesel and Alternate Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . 718
Introduction 719 n Biodiesel 720 n Fuel Alternatives for Engines 723
n Natural Gases 724 n Liquefied Petroleum Gas 729 n Alcohol-Based
Fuels (Methanol/Ethanol) 730
Electric, Electric Hybrid, and Hydraulic Hybrid Drives . . . . . . . . . . . . . . 734
Introduction 735 n Batteries and Ultracapacitors 736 n Electricity 738
n Hybrid Electric Vehicles 739 n Hydraulic Hybrids 742 n Fuel Cells 744
Bosch Edc Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Introduction 751 n Bosch Diesel Systems 751 n Edc Management
Logic 752 n Block Diagrams 754 n Making the Connection 757
Caterpillar Engine Management Systems . . . . . . . . . . . . . . . . . . . . 759
Introduction 760 n Acert 761 n Adem Electronics 761 n Input
Circuit 763 n Ecm 763 n System Diagnostics and Communications 767
Cummins Management Systems . . . . . . . . . . . . . . . . . . . . . . . . . 772
Introduction 773 n System Overview 774 n Input Circuit 774
n Electronic Control Module (Ecm) 775 n System Troubleshooting and
Engine Testing 778
Detroit Diesel Electronic Controls (Ddec ) . . . . . . . . . . . . . . . . . . . . 782
Introduction 783 n Emissions Management 785 n Input Circuit 787
n Governor Options 790 n Diagnostic Tools 791 n Ddec Features 794
Navistar Diamond Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
Introduction 799 n Diamond Logic Controls 800 n Ecm Diagnostics 803
Paccar Engine Management Systems . . . . . . . . . . . . . . . . . . . . . . 807
Introduction 808 n Paccar Electronics 809 n System Diagnostics and
Communications 811
Volvo and Mack Engine Management . . . . . . . . . . . . . . . . . . . . . . 813
Introduction 814 n V-Mac and Vectro Electronics 816
Emissions Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
Introduction 825 n Pollutants 826 n Epa Certification Testing 828
n Diesel Engine Emissions Controls 830 n Diesel Particulate Filters (Dpfs) 834
n Selective Catalytic Reduction (Scr) 840
Servicing and Maintenance of Exhaust Aftertreatment Systems . . . . . . . . . 847
Introduction 848 n Visible Smoke Emission: Legacy Engines 848
n Exhaust Gas Recirculation (Egr) Systems 849 n Diesel Particulate Filters
(Dpfs) 853 n Selective Catalytic Reduction (Scr) 856
n Field Testing of Smoke Density 858
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865
Introduction 866 n Structured Failure Analysis 866 n Principles of Failure
Analysis 867 n Component Failures 873 n Common Abuses of Engines
and Fuel Systems 893
Troubleshooting and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 896
Introduction 897 n Troubleshooting Tools 897 n Smoke Analysis 898
n Troubleshooting Guidelines 901 n Quick Reference Diagnostic Charts 911
Technical Support 918 n Hd-Obd 920 Please email at ireneroberson9@gmail.com and we will provide you with the any manual you need right away. We are constantly updating the site with new stock but we have much more than available in the website.
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