Copyright Goodheart-Willcox Co., Inc. 13 Output Devices 475 Fuel Injection Control / Engine Cooling Fan Solenoid / EGR Valve Motor / Variable Geometry Turbocharger Actuator / Engine Brake Solenoids / Stop Engine Lamp (SEL) / Check Engine Lamp (CEL) / Multifunction Indicator Lamp (MIL) / Idle Shutdown Timer (IST) / Instrument Panel Control Module Electronically Controlled Fuel Injection Systems 476 High-Pressure Common Rail (HPCR) / Low-Pressure System / High-Pressure System / Fuel Injector / Return System / Common Concerns Engine Control System Operation 478 Limp Home (Reduced Power) Mode /Misfire Monitoring / Engine Diagnostics / Warning Lamps / Engine Protection (Shutdown) System / Viewing Diagnostic Code Information / Self-Diagnostics / Software Programs Factory and Customer Programmed Parameters 481 Lifetime Totals and Maintenance Indicator Data / Security Electronic Fuel Injection System Overviews 482 Detroit Diesel Electronic Controls (DDEC) / Cummins Electronic Management Systems / Caterpillar Electronic Engine Control Systems / Mack V-MAC Control System Troubleshooting Electronic Controls 488 Troubleshooting Procedures / Multimeter Checks / Oscilloscopes / Substitution / Service Precautions Chapter 24 Diesel Engine Charging Systems . . . . . 495 Charging System 496 Principles of Magnetism Alternators 498 Alternator Design and Components / Brushless Alternators / Ac Rectification Voltage Regulators 502 Reverse Polarity Protection / A and B Field Circuits Service Precautions 503 Charging System Problems 504 Alternator Problems / Voltage Regulator Adjustment / Alternator Output Test / Full Field Testing / Stator Winding Test / Testing Diodes and Brushes / Regulator Circuit Test / AC Voltage Test / Oscilloscope Test /Charging Circuit Resistance Test Alternator Removal and Installation 508 Drive Belt Service 509 Chapter 25 Diesel Starting Systems . . . . . . . . . . 513 Starting System 514 Electric Starter System Components 514 Starter Motor Design and Operation / Starter Motor Components / Starter /Solenoid / Starter Motor Drives / Series-Parallel Starter Motor Switch Electric Starting System Tests 519 Cranking Current Test / Available Voltage Check / Relay Bypass Test / Control Circuit Tests / Starter Circuit Resistance Tests / Removing and Installing the Starter Motor Air Powered Starting Systems 523 System Components / Troubleshooting Air Starting Systems Hydraulic Starting Systems 524 Troubleshooting Hydraulic Starting Systems Cold Starting Aids 525 Coolant Heaters / Lubricating Oil Heaters / Glow Plugs / Intake Air Heaters / Fluid Starting Aids / Battery Warmers Chapter 26 Engine Reassembly and Installation . . . 531 Establish Good Work Habits 532 Cylinder Block, Sleeves and Crankshaft Assembly 532 Installing Bearings and Crankshaft / Gear Housing / Installing Pistons and Connecting Rods / Oil Pump and Oil Pan / Flywheel and Crankshaft Rear Seal / Camshaft Installation / Inline or Distributor Injection Pumps / Timing Gear Cover / Lifter Assemblies (Cam Roller Followers) / Cylinder Head Reassembly and Installation / Unit Fuel Injectors / Air Inlet Manifold / Push Rods and Rocker Arms / Fuel Injectors / Valve Cover / Vibration Damper, Crankshaft Pulley and Crankshaft Front Seal / Exhaust Manifold / Fuel Transfer Pump / Fuel and Oil Filters / Power Steering Pump and Water Pump / Air Compressor / Final Assembly