These digital manuals cover a wide range of topics related to medium and heavy-duty truck engines, fuel systems, and computerized management systems. The manuals are designed to provide comprehensive information for professional mechanics as well as DIY enthusiasts.
Section 1: Diesel Engine Fundamentals
Introduction
Role of the Trucking Industry and the Truck Technician
Training and the Truck Technician
Customer Service and Professionalism
Qualifications and Careers for the Truck Technician
Defining Engines by Displacement
Engine OEMs and Market Share
Health, Safety, and a Green Environment
VIN
Hand and Shop Tools, Precision Tools, and Units of Measurement
Introduction
Hand Tools
Precision Measuring Tools
Shop Tools
Fastener Grades and Torques
The Metric System and English/Metric Conversion
Workplace Organization
Personal and Safety Awareness
Personal Safety Equipment
Workplace Hazards and Safety Regulations
Emergencies
OSHA
Safety Hotlines
Engine Basics
Introduction
Key Engine Terms
The Diesel Cycle
The Otto Cycle
Engine Systems and Circuits
Advanced Engine Terms
History of the Heat Engine
Introduction
History of the Modern Diesel Engine
Power
Introduction
Definitions and Formulae
Engine Configuration, Engine Speed, and Torsional Forces
How Much Power Do You Need?
Engine Powertrain Components
Introduction
Piston Assemblies
Piston Rings
Connecting Rods
Crankshafts and Bearings
Rod and Main Bearings
Vibration Dampers
Flywheels
Engine Feedback Assembly
Introduction
Timing Gears
Camshafts
Valve and Injector Trains
Cylinder Head Valves
Engine Housing Components
Introduction
Engine Cylinder Block
Cylinder Heads
Intake and Exhaust Manifolds
Engine Lubrication Systems
Introduction
Engine Lubricating Oil
Lubrication System Components
Interpreting Oil Analyses
Lubricating Circuit Problems
Engine Cooling Systems
Introduction
Engine Coolant
Cooling System Components
Filters
Coolant Monitoring Circuit
Thermostats
Cooling Fans
Cooling System Problems
Coolant Heaters
Engine Breathing
Introduction
Breathing Components
Air Intake System Components
Turbochargers
Charge Air Heat Exchangers
Exhaust Gas Recirculation
Valve Design and Breathing
Exhaust System Components
Breathing Circuit Sensors
Engine Retarders
Introduction
Principles of Operation
Exhaust Brakes
Internal Compression Brakes
Caterpillar Brakesaver
Servicing and Maintenance
Introduction
Start-Up and Engine Break-In
Air Intake System Maintenance
Engine Lube Service
Cooling System Service
Fuel System Maintenance
Selective Catalytic Reduction
Diesel Particulate Filter Service
Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines
