Heavy Duty Truck Systems

by Bennett, Sean

• ISBN13: 9781401870645
• ISBN10: 1401870643
• Edition: 4th
• Format: Hardcover
• Copyright: 2005-11-03
• Publisher: Delmar Cengage Learning

Summary

This best-selling introduction to servicing medium-and heavy-duty trucks continues to provide a strong foundation of content on Electricity and Electronics, Power Train, Steering and Suspension, Brakes, and Accessories Systems. The Fourth Edition has been technically updated and restructured to address 2004 compliance issues and Out Of Service (OOS) criteria. Heavy Duty Truck Systems, Fourth Edition also features a dedicated chapter on multiplexing with special focus on the Freightliner M2 and Navistar Diamond Plus systems, as well as new material introducing simple truck hydraulic circuits in a user-friendly manner. Other enhancements include improved coverage of transmissions to address changing technologies, and an expanded chapter on electronically automated transmissions that includes emerging Meritor and Mercedes-Benz transmissions, and also explores the currently popular anti-rollover protection electronics.

Table of Contents

Contents for Photo Sequences	ix
Preface	xiii
About the 4th Edition	xiii
Changes in Technology	xiii
New to This Edition	xiii
The Trucking Industry	xiv
Features of the Text	xv
Acknowledgments	xviii
Introduction to Servicing Heavy-Duty Trucks	1	(18)
Truck Classifications	2	(1)
Heavy-Duty Trucks	3	(5)
Career Opportunities for Heavy-Duty Truck Technicians	8	(2)
Job Classifications	10	(5)
Advancement in the Profession	15	(4)
Shop Safety and Operations	19	(18)
Personal Safety	20	(2)
Work Area Safety	22	(3)
Shop Tool Safety	25	(1)
Hazardous Materials	25	(5)
Handling and Disposal of Hazardous Waste	30	(1)
Shop Records	31	(6)
Tools and Fasteners	37	(42)
Hand Tools	38	(11)
Power Tools	49	(5)
Measuring Tools	54	(5)
Manufacturers' Service Publications	59	(7)
Fasteners	66	(13)
Preventive Maintenance Program	79	(36)
Setting Up a PM Program	80	(7)
Out-of-Service or Deadlining a Vehicle	87	(7)
PM Scheduling	94	(3)
Lubricants	97	(7)
Winterizing	104	(6)
Performing a Lube Job	110	(5)
Fundamentals of Electricity	115	(30)
Atomic Structure and Electron Movement	116	(5)
Conductors and Insulators	121	(1)
Current Flow	122	(1)
Magnetism	123	(1)
Electromagnetism	124	(2)
Electrical Current Characteristics	126	(1)
Sources of Electricity	127	(2)
Electrical Circuits and Ohm's Law	129	(6)
Electric Motor and Generator Principle	135	(3)
Coils, Transformers, and Solenoids	138	(7)
Fundamentals of Electronics and Computers	145	(34)
Using Electronic Signals	146	(2)
Semiconductors	148	(2)
Diodes	150	(2)
Transistors	152	(3)
Photonic Semiconductors	155	(1)
Testing Semiconductors	156	(1)
Integrated Circuits (I/Cs)	156	(2)
Gates and Truth Tables	158	(1)
Binary System Basics	159	(2)
Microprocessors	161	(8)
Data Retention in Vehicle ECMS	169	(2)
Collision Warning Systems (CWS)	171	(8)
Batteries	179	(30)
Battery-operating principles	179	(8)
Battery Ratings	187	(1)
Battery Maintenance	187	(4)
Battery Testing	191	(6)
Charging the Battery	197	(6)
Conductance Testing	203	(6)
Charging Systems	209	(18)
Alternator Construction	210	(3)
Alternator Operation	213	(4)
Charging System Failures and Testing	217	(4)
Alternator Rebuild	221	(6)
Cranking Systems	227	(22)
Cranking Circuit Components	228	(2)
Starter Motors	230	(8)
Cranking Circuit Testing	238	(7)
Starter Rebuild	245	(4)
Chassis Electrical Circuits	249	(28)
Lighting Systems	250	(9)
Auxiliary Electrical Equipment	259	(11)
Rapid Checking of a Truck Electrical Circuit	270	(7)
Diagnosis and Repair of Electronic Circuits	277	(42)
Types of EST	279	(1)
Flash or Blink Codes	279	(1)
Using Digital Multimeters	280	(12)
ProLink 9000	292	(4)
ProLink Tasks	296	(3)
PCs and OEM Software	299	(7)
Electronic Troubleshooting	306	(1)
SAE/ATA J1587/J1708/J1939 Codes and Protocols	307	(1)
Troubleshooting VORAD	308	(1)
Electrical Wiring, Connector, and Terminal Repair	309	(5)
Splicing Guidelines	314	(5)
Multiplexing	319	(18)
Multiplexing, Clients, and Servers	320	(1)
Multiplexing Basics	321	(7)
Multiplex Switching	328	(1)
Multiplex Transactions	329	(2)
Accessing the Data Bus	331	(6)
Hydraulics	337	(38)
Fundamentals	338	(6)
Hydraulic Components	344	(1)
Pumps	345	(9)
Actuators	354	(1)
Hydraulic Motors	355	(3)
Conductors and Connectors	358	(6)
Hydraulic Fluids	364	(1)
Symbols and Schematics	365	(1)
Maintenance	365	(10)
Clutches	375	(46)
Clutch Function	375	(1)
Clutch Components	376	(12)
Troubleshooting	388	(2)
Periodic Maintenance	390	(10)
Clutch Servicing	400	(21)
Standard Transmissions	421	(44)
Main and Auxiliary Gearing	422	(7)
Gear Train Configurations	429	(1)
Mechanical Shift Mechanisms	429	(10)
Shift Housing Assembly	439	(1)
Twin Countershaft Transmissions	440	(2)
Auxiliary Gear Sections	442	(15)
Transfer Cases	457	(8)
Standard Transmission Servicing	465	(44)
Lubrication	465	(2)
Preventive Maintenance Inspections	467	(4)
Troubleshooting	471	(4)
Transmission Disassembly	475	(6)
General Reassembly Guidelines	481	(1)
Sub-Assembly Overhaul	482	(15)
Main Box Reassembly	497	(4)
Troubleshooting Air Shift Systems	501	(8)
Torque Converters	509	(20)
Torque Converter Construction	510	(3)
Principles of Operation	513	(7)
Maintenance and Service	520	(9)
Automatic Transmissions	529	(28)
Planetary Gearset Components	530	(6)
Compound Planetary Gearsets	536	(10)
Transmission Hydraulic Systems	546	(7)
Hydraulic Retarders	553	(4)
Automatic Transmission Maintenance	557	(20)
Inspection and Maintenance	558	(9)
Shift Point Adjustments	567	(5)
Power Takeoffs	572	(5)
Electronically Automated Standard Transmissions	577	(20)
Transmission Identification	578	(1)
AutoShift Components	579	(9)
Transmission Controller	588	(4)
Fault Detection and Data Links	592	(1)
Alternative Automated Transmissions	593	(4)
Allison Electronic Transmissions	597	(44)
CEC Transmissions	599	(7)
WT Modular Construction	606	(2)
WT Input Modules	608	(2)
Gearbox Modules	610	(1)
Output Modules	611	(3)
WTEC Electronics	614	(3)
WT Output Circuit	617	(3)
The WT Hydraulic Circuit	620	(2)
Allison WT Torque Paths and Range Management	622	(11)
Troubleshooting WT Transmissions	633	(8)
Driveshaft Assemblies	641	(32)
Driveshaft Construction	642	(6)
Driveshaft Inspection	648	(1)
Lubrication	649	(2)
U-Joint Replacement	651	(7)
Chassis Vibration Diagnosis	658	(7)
Driveline Retarders	665	(8)
Heavy-Duty Truck Axles	673	(32)
Drive Axles	675	(10)
Power Dividers	685	(6)
Two-Speed Drive Axles	691	(8)
Drive Axle Shaft Configurations	699	(1)
Non-driving Axles	700	(5)
Heavy-Duty Truck Axle Service and Repair	705	(36)
Drive Axle Lubrication	705	(4)
Truck Axle Cleaning and Inspection	709	(1)
Carrier, Axle, and Gearing Identification	710	(1)
Failure Analysis	710	(18)
Axle Adjustments and Checks	728	(13)
Steering and Alignment	741	(54)
Steering System Components	742	(5)
Front-End Alignment	747	(11)
Electronic Alignment Systems	758	(3)
Steering Axle Inspection	761	(11)
Manual Steering Gears	772	(6)
Power-Assist Steering Systems	778	(5)
Troubleshooting Power Steering Systems	783	(3)
Air-Assist Steering Systems	786	(3)
Electronic and Load-Sensing Steering	789	(6)
Suspension Systems	795	(42)
Leaf-Spring Suspensions	796	(8)
Air Spring Suspensions	804	(4)
Servicing Mechanical Suspensions	808	(6)
Servicing Equalizing Beams	814	(5)
Servicing Air Suspensions	819	(5)
Suspension Alignment	824	(5)
Roll Stability Control	829	(1)
Cab Air Suspensions and Driver Seats	829	(2)
Ride Analysis	831	(6)
Wheels and Tires	837	(48)
Wheels and Rims	838	(4)
Tires	842	(2)
Tire Maintenance	844	(5)
Tire, Rim, and Wheel Service	849	(16)
Chassis Tire Pressure Management	865	(1)
Wheel Hubs, Bearings, and Seals	866	(6)
Wheel Bearing Adjustment	872	(4)
Wheel Seal Service	876	(4)
Wheel-End Conclusion	880	(5)
Truck Brake Systems	885	(54)
Air Brake Sub-Systems	889	(1)
The Air Supply Circuit	889	(11)
Primary Circuit	900	(1)
Secondary Circuit	901	(5)
Trailer Circuit	906	(4)
Foundation Brakes	910	(4)
Air Brake System Components	914	(18)
Brake System Balance	932	(3)
Air Start Systems	935	(4)
Hydraulic Brakes and Air-Over-Hydraulic Brake Systems	939	(28)
Hydraulic Brake System Components	941	(7)
Air-Over-Hydraulic Brake Systems	948	(4)
Hydraulic Brake Service Procedures	952	(9)
Hydraulic ABS	961	(6)
ABS and EBS	967	(28)
Basics of ABS Operation	968	(1)
ABS Components	969	(7)
ABS Configurations	976	(3)
Automatic Traction Control (ATC) Systems	979	(1)
Trailer ABS	979	(3)
ABS Diagnostics	982	(2)
ABS Service Procedure	984	(5)
ABS Add-Ons	989	(1)
Electronic Braking Systems (EBS)	990	(5)
Air Brake Servicing	995	(56)
Maintenance and Safety	996	(3)
Test Equipment	999	(2)
Assessing Brake System Performance	1001	(6)
Supply Circuit Service	1007	(7)
Service Application Circuit	1014	(6)
Parking/Emergency Circuit	1020	(5)
Slack Adjusters	1025	(3)
Trailer Brake System	1028	(1)
Foundation Brake Service	1029	(6)
Brake Adjustment	1035	(3)
General Brake Valve Troubleshooting	1038	(4)
Service Procedures on Air Disc Brakes	1042	(1)
Servicing Wedge Brakes	1043	(2)
Brake Certification, Inspection, and Testing	1045	(6)
Vehicle Chassis Frame	1051	(24)
Basic Frame Terms	1052	(1)
Frame Theory	1053	(5)
Frame Construction	1058	(2)
Frame Damage	1060	(2)
Frame Alignment	1062	(2)
Repair of Frame, Side Rails, and Cross-Members	1064	(11)
Heavy-Duty Truck Trailers	1075	(22)
Freight Van Trailers	1079	(4)
Refrigerated and Insulated Vans	1083	(3)
Other Trailer Types and Designs	1086	(2)
Trailer Undersides	1088	(5)
Trailer Maintenance	1093	(4)
Fifth Wheels and Coupling Systems	1097	(26)
Types of Fifth Wheels	1098	(3)
Fifth Wheel Height and Location	1101	(1)
Principles of Fifth Wheel Operation	1101	(7)
Fifth Wheel Maintenance	1108	(4)
Mounting Fifth Wheels	1112	(3)
Sliding Fifth Wheels	1115	(1)
Kingpins and Upper Couplers	1116	(2)
Pintle Hooks	1118	(5)
Heavy-Duty Heating, Ventilation, and Air Conditioning Systems	1123	(50)
Principles of Refrigeration	1124	(1)
Refrigerant	1125	(2)
The Refrigeration Cycle	1127	(3)
Air Conditioning System Components	1130	(12)
Safety Precautions	1142	(1)
Performance Testing an Air Conditioning System	1143	(3)
Air Conditioning Service Equipment	1146	(4)
Air Conditioning Service Procedures	1150	(8)
Common Air Conditioning Problems	1158	(3)
Retrofitting an R-134 System to an R-12 System	1161	(1)
Cab Ventilation and Heating Systems	1162	(1)
Liquid Cooled Heating System	1162	(4)
Electronically Managed Climate Control	1166	(7)
Appendix A Acronyms	1173	(4)
Appendix B Truck Nominal Class Designations	1177	(1)
Appendix C Vibration Diagnosis	1178	(2)
Appendix D Brake Shoe Identification Chart	1180	(1)
Appendix E Hard Steering Troubleshooting Flow Chart	1181	(1)
Appendix F Dual Circuit Brake System Troubleshooting	1182	(1)
Appendix G Vehicle Configurations	1183	(2)
Appendix H Driveline Configurations	1185	(1)
Appendix I Measuring Driveline Angles	1186	(1)
Glossary	1187	(26)
Index	1213