Heavy Duty Truck Systems, Seventh Edition
By Sean Bennett
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