Heavy Duty Truck Systems, 7th Edition PDF by Sean Bennett

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Heavy Duty Truck Systems, Seventh Edition

By Sean Bennett

Heavy Duty Truck Systems 7th Edition

Contents:

Contents for Photo Sequences . vii

Preface ix

Features of the Text xi

Supplements xiii

Acknowledgments xv

Chapter 1

Introduction to Servicing

Heavy-Duty Trucks 1

1.1 Truck Classifications • 2 1.2 Heavy-

Duty Trucks • 5 1.3 Career Opportunities

for

Heavy-Duty Truck Technicians • 12 1.4 Job

Classifications • 15 1.5 Advancement in

the Profession • 20 1.6 Electronic Logging

Devices • 22 1.7 Autonomous and Electric Trucks • 23

Chapter 2

Shop Safety and Operations 27

2.1 Personal Protective Equipment • 28

2.2 Work Area Safety • 32 2.3 Oxyacetylene

Equipment • 37 2.4 Electric Arc Welding • 40

2.5 Shop Tool Safety • 40 2.6 Hazardous

Materials and WHMIS • 40 2.7 Handling and

Disposal of Hazardous Waste • 41 2.8 Shop

Records • 45 2.9 Lockout/Tagout • 48

Chapter 3

Tools and Fasteners 52

3.1 Hand Tools • 53 3.2 Power Tools • 64

3.3 Measuring Tools • 69 3.4 Manufacturers’

Service Literature • 78 3.5 Fasteners • 84

Chapter 4

Maintenance Programs 96

4.1 VMRS • 100 4.2 Setting Up a Maintenance

Program • 102 4.3 Out-of-Service or Deadlining

a Vehicle • 110 4.4 PM Scheduling • 116

4.5 Lubricants • 120 4.6 Winterizing • 127

4.7 Performing a Lube Job • 135 4.8 Fleet

Management Software • 137 4.9 Maintaining

Emissions Control Equipment • 138

Chapter 5

Fundamentals of Electricity 141

5.1 Atomic Structure and Electron

Movement • 142 5.2 Conductors

and Insulators • 147 5.3 Current

Flow • 148 5.4 Magnetism • 149

5.5 Electromagnetism • 150 5.6 Electrical

Current Characteristics • 152 5.7 Sources of Electricity • 153 5.8 Electrical Circuits and Ohm’s Law • 155 5.9 Electric Motor and Generator Principle • 162 5.10 Coils, Transformers, and Solenoids • 165

Chapter 6

Fundamentals of Electronics and Computers 170

6.1 Using Electronic Signals • 171

6.2 Semiconductors • 173 6.3 Diodes • 175

6.4 Transistors • 177 6.5 Photonic

Semiconductors • 180 6.6 Testing

Semiconductors • 181 6.7 Integrated

Circuits (I/Cs) • 183 6.8 Gates and Truth

Tables • 184 6.9 Binary System Basics • 185

6.10 Microprocessors • 187 6.11 Data Retention

in a Vehicle ECU • 196 6.12 Auxiliary Electronic

Systems • 197 6.13 Accident Avoidance

Systems • 198

Chapter 7

Batteries 206

7.1 Battery-Operating Principles • 207

7.2 Battery Ratings • 214 7.3 Battery

Classifications • 215 7.4 Battery

Maintenance • 216 7.5 Battery Testing • 219

7.6 Charging the Battery • 225 7.7 Conductance

Testing • 231 7.8 Alternative Battery

Technology • 236 7.9 Ultracapacitors and

Supercapacitors • 237 7.10 Battery Management

Systems • 238

Chapter 8

Charging Systems 242

8.1 Alternator Construction • 243 8.2 Alternator

Operation • 246 8.3 Charging System Failures

and Testing • 250 8.4 Alternator

Rebuild • 255

Chapter 9

Cranking Systems 264

9.1 Cranking Circuit Components • 265

9.2 Starter Motors • 268 9.3 Cranking Circuit

Testing • 275 9.4 Starter Rebuild • 281

Chapter 10

Chassis Electrical Circuits 286

10.1 Lighting Systems • 287 10.2 Auxiliary

Electrical Equipment • 296 10.3 Rapid Checking

of a Truck Electrical Circuit • 307

Chapter 11

Diagnosis and Repair of Electronic Circuits 315

11.1 Types of EST • 317 11.2 Using Digital

Multimeters • 320 11.3 Multifunctional

Handheld Diagnostic Tools • 331 11.4 Handheld

Diagnostic Instruments • 331 11.5 PCs and

OEM Software • 336 11.6 Oscilloscopes • 341

11.7 Electronic Troubleshooting • 343

11.8 Bus Codes and Protocols • 346

11.9 Troubleshooting CWS and CMS • 347

11.10 Electrical Wiring, Connector, and Terminal

Repair • 349 11.11 Wiring Schematics • 354

11.12 Supplemental Restraint System • 359

Chapter 12

Multiplexing 367

12.1 Multiplexing, Clients, and Servers • 369

12.2 Multiplexing Basics • 369 12.3 Multiplex

Switching • 377 12.4 Multiplex Transactions • 379

12.5 Accessing the Data Bus • 381

Chapter 13

Hydraulics 390

13.1 Fundamentals • 391 13.2 Hydraulic

Components • 397 13.3 Pumps • 398

13.4 Actuators • 407 13.5 Hydraulic

Motors • 409 13.6 Conductors and

Connectors • 411 13.7 Hydraulic Fluids • 418

13.8 Symbols and Schematics • 419

13.9 Maintenance • 420

Chapter 14

Clutches 428

14.1 Clutch Function • 428 14.2 Clutch

Components • 429 14.3 Troubleshooting • 441

14.4 Maintenance • 443 14.5 Clutch

Servicing • 453

Chapter 15

Standard Transmissions 476

15.1 Main and Auxiliary Gearing • 477

15.2 Geartrain Configurations • 484

15.3 Mechanical Shift Mechanisms • 484

15.4 Shift Housing Assembly • 494

15.5 Twin-Countershaft Transmissions • 498

15.6 Auxiliary Gear Sections • 498

15.7 Transfer Cases • 514

Chapter 16

Standard Transmission

Servicing 522

16.1 Lubrication • 522 16.2 Preventive

Maintenance Inspections • 525

16.3 Troubleshooting • 529

16.4 Transmission Overhaul • 535

16.5 General Overhaul Guidelines • 539

16.6 Step-By-Step Overhaul • 539

16.7 Troubleshooting Air Shift

Systems • 555

Chapter 17

Torque Converters 563

17.1 Torque Converter Construction • 564

17.2 Principles of Operation • 568

17.3 Maintenance and Service • 575

Chapter 18

Automatic Transmissions 585

18.1 Planetary Gearset Components • 586

18.2 Compound Planetary Gearsets • 593

18.3 Transmission Hydraulic Systems • 602

18.4 Hydraulic Retarders • 610

Chapter 19

Automatic Transmission

Maintenance 613

19.1 Inspection and Maintenance • 614

19.2 Shift Point Adjustments • 623

19.3 Power Take-Offs (PTOs) • 629

Chapter 20

Automated Manual and Hybrid

Transmissions 631

20.1 Transmission Identification • 633

20.2 Ultrashift Components • 635

20.3 Transmission ECU • 642 20.4 Fault

Detection and Data Links • 646 20.5 AMT

Clutch Actuators • 649 20.6 Hybrid

Transmissions • 650

Chapter 21

Electronically Controlled

Automatic Transmissions

(ECAT s) 657

21.1 ECAT Management • 659 21.2 Allison

DOC • 663 21.3 WT Transmissions • 664

21.4 Allison TC10 • 695 21.5 Caterpillar CX

Truck Transmissions • 714 21.6 Voith Diwa

Transmission • 723 21.7 N avigating ECU

Schematics • 723

Chapter 2 2

Driveshaft Assemblies 728

22.1 Driveshaft Construction • 729

22.2 Driveshaft Inspection • 736

22.3 Lubrication • 737 22.4 U-Joint

Replacement • 739 22.5 Chassis Vibration

Diagnosis • 745

Chapter 23

Heavy-Duty Truck Axles 754

23.1 Drive Axles • 756 23.2 Power

Dividers • 765 23.3 Two-Speed Drive

Axles • 772 23.4 Drive Axle Shaft

Configurations • 778 23.5 N ondriving

Axles • 778

Chapter 24

Heavy-Duty Truck Axle Service

and Repair 784

24.1 Drive Axle Lubrication • 785 24.2 Truck

Axle Cleaning and Inspection • 788 24.3 Carrier,

Axle, and Gearing Identification • 789

24.4 Failure Analysis • 789 24.5 Axle

Adjustments and Checks • 806

Chapter 25

Steering and Alignment 817

25.1 Steering System Components • 818

25.2 Front-End Alignment • 823 25.3 Electronic

Alignment Systems • 834 25.4 Steering

Axle Inspection • 838 25.5 Manual Steering

Gears • 849 25.6 Power-Assist Steering

Systems • 855 25.7 Troubleshooting Power

Steering Systems • 859 25.8 Rack and Pinion

Steering • 863 25.9 Electronic and Load-Sensing

Steering • 864 25.10 Commercial Vehicle Safety

Alliance (CVSA) OOS Steering Criteria • 868

Chapter 26

Suspension Systems 871

26.1 Leaf Spring Suspensions • 872

26.2 Cushion and Torsion Suspensions • 879

26.3 Air Spring Suspensions • 882

26.4 Servicing Mechanical Suspensions • 885

26.5 Servicing Equalizing Beams • 892

26.6 Servicing Air Suspensions • 896

26.7 Suspension Alignment • 902

26.8 Roll Stability Control • 905 26.9 Cab Air

Suspensions and Driver Seats • 906 26.10 Ride

Analysis • 908

Chapter 27

Wheels and Tires 912

27.1 Wheels and Rims • 913 27.2 Tires • 918

27.3 Tire Maintenance • 923 27.4 Tire,

Rim, and Wheel Service • 928 27.5 Wheel

Balancing • 942 27.6 Chassis Tire Pressure

Management • 946 27.7 Wheel Hubs,

Bearings, and Seals • 949 27.8 Wheel

Bearing Adjustment • 955 27.9 Wheel

Seal Service • 958 27.10 Wheel End

Conclusion • 962

Chapter 28

Truck Brake Systems 966

28.1 Air Brakes: A Driver’s Point of View • 968

28.2 Air Brake Subsystems • 970 28.3 The Air

Supply Circuit • 972 28.4 Primary Circuit • 982

28.5 Secondary Circuit • 984 28.6 Trailer

Circuit • 989 28.7 Foundation Brakes • 992

28.8 Air Brake System Components • 998

28.9 Brake System Balance • 1017 28.10 Air

Start Systems • 1020

Chapter 29

Hydraulic Brakes and Air-Over-

Hydraulic Brake Systems 1024

29.1 Hydraulic Brake System Components • 1025

29.2 Air-Over-Hydraulic Brake Systems • 1037

29.3 Hydraulic Brake Service Procedures • 1038

29.4 Hydraulic ABS • 1050 29.5 CVSA

OOS • 1053

Chapter 30

ABS and EBS 1058

30.1 Basics of ABS Operation • 1059

30.2 ABS Components • 1061 30.3 ABS

Configurations • 1068 30.4 Automatic Traction

Control (ATC) Systems • 1070 30.5 Trailer

ABS • 1070 30.6 ABS Diagnostics • 1072

30.7 ABS Service Procedure • 1075 30.8 ABS

Add-Ons • 1079 30.9 Electronic Braking Systems

(EBS) • 1082

Chapter 31

Air Brake Servicing 1087

31.1 Maintenance and Safety • 1088 31.2 Test

Equipment • 1091 31.3 Assessing Brake

System Performance • 1093 31.4 Supply

Circuit Service • 1098 31.5 Service

Application Circuit • 1104 31.6 Parking/

Emergency Circuit • 1110 31.7 Slack

Adjusters • 1115 31.8 Trailer Brake

System • 1118 31.9 Foundation Brake

Service • 1119 31.10 Brake Adjustment • 1126

31.11 General Brake Valve Troubleshooting • 1132

31.12 Service Procedures on Air Disc

Brakes • 1134 31.13 Servicing Wedge

Brakes • 1137 31.14 Brake Certification,

Inspection, and Testing • 1137 31.15 Commercial

Vehicle Stopping Distances • 1139

Chapter 32

Vehicle Chassis Frame 1143

32.1 Basic Frame Terms • 1144 32.2 Frame

Theory • 1145 32.3 Frame Construction • 1149

32.4 Frame Damage • 1152 32.5 Frame

Alignment • 1154 32.6 Repair of Frame, Side

Rails, and Cross-Members • 1157

Chapter 33

Heavy-Duty Truck Trailers 1167

33.1 Tractor/Trailer Combinations • 1168

33.2 Freight Van Trailers • 1172

33.3 Refrigerated and Insulated Vans • 1176

33.4 Specialty Trailer Designs • 1180

33.5 Trailer Undersides • 1183 33.6 Trailer

Maintenance • 1190 33.7 Testing Trailer Air

and Electrical Circuits • 1194

Chapter 3 4

Fifth Wheels and Coupling

Systems 1198

34.1 Types of Fifth Wheels • 1199

34.2 Fifth Wheel Height and Location • 1203

34.3 Principles of Fifth Wheel Operation • 1203

34.4 Fifth Wheel Maintenance • 1210

34.5 Coupling • 1215 34.6 Mounting Fifth

Wheels • 1216 34.7 Sliding Fifth Wheels • 1218

34.8 Kingpins and Upper Couplers • 1220

34.9 Pintle Hooks/Ball Hitches • 1222

34.10 Coupling Device CVSA OOS • 1224

Chapter 35

Heavy-Duty Heating, Ventilation,

and Air Conditioning Systems 1228

35.1 Principles of Refrigeration • 1229

35.2 Refrigerant • 1231 35.3 The Refrigeration

Cycle • 1235 35.4 Air Conditioning

System Components • 1236 35.5 Safety

Precautions • 1251 35.6 Performance Testing

an Air Conditioning System • 1252 35.7 Air

Conditioning Service Equipment • 1255 35.8 Air

Conditioning Service Procedures • 1259

35.9 Common Air Conditioning Problems • 1267

35.10 Converting an R-12 System to an R-134A

System • 1269 35.11 Cab Ventilating and

Heating Systems • 1270 35.12 Liquid-Cooled

Heating System • 1271 35.13 Electronically

Managed Climate Control • 1275 35.14 Bluecool

Truck Thermal Storage System • 1280

Appendix A Acronyms………………………………..1283

Appendix B Truck Nominal Class Designations ..1288

Appendix C Brake Shoe Identification Chart…….1289

Appendix D Vibration Diagnosis …………………..1290

Appendix E Hard Steering Troubleshooting

Flow Chart ………………………………1292

Appendix F Dual Circuit Brake

System Troubleshooting ……………..1293

Appendix G Driveline Configurations ……………..1297

Appendix H Measuring Driveline Angles………….1298

Appendix I Vehicle Configurations………………..1299

Appendix J Quick Conversion Formula…………..1300

Appendix K J1939 Message Decoder…………….1301

Appendix L Tire Code Interpretation and

Tread Pattern Designations…………..1302

Glossary …………………………………………….1303

Index …………………………………………….1345

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