Heavy Duty Truck Systems Fifth Edition This page intentionally left blank Heavy Duty Truck Systems Fifth Edition Sean Bennett Ian Andrew Norman Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States Heavy Duty Truck Systems, Fifth Edition © 2011 Delmar, Cengage Learning Sean Bennett/Ian Andrew Norman ALL RIGHTS RESERVED. No part of this work covered by the copyright herein may be reproduced, transmitted, stored or used in any form or by any means Vice President, Editorial: Dave Garza graphic, electronic, or mechanical, including but not limited to photocopying, Director of Learning Solutions: Sandy Clark recording, scanning, digitizing, taping, Web distribution, information networks, Executive Editor: David Boelio or information storage and retrieval systems, except as permitted under Managing Editor: Larry Main Section 107 or 108 of the 1976 United States Copyright Act, without the prior written permission of the publisher. Senior Product Manager: Sharon Chambliss Editorial Assistant: Jillian Borden For product information and technology assistance, contact us at Vice President, Marketing: Jennifer McAvey Professional & Career Group Customer Support, 1-800-648-7450 Executive Marketing Manger: Deborah S. Yarnell For permission to use material from this text or product, Marketing Specialist: Mark Pierro submit all requests online at cengage.com/permissions Further permissions questions can be emailed to Production Director: Wendy Troeger [email protected] Production Manager: Mark Bernard Content Project Manager: Barbara LeFleur Library of Congress Control Number: 2009925099 Art Director: Benj Gleeksman ISBN-13: 978-1-435-4838-28 Technology Project Manager: Christopher Catalina ISBN-10: 1-435-48382-0 Production Technology Analyst: Thomas Stover Delmar 5 Maxwell Drive Clifton Park, NY 12065-2919 USA Cengage Learning is a leading provider of customized learning solutions with offi ce locations around the globe, including Singapore, the United Kingdom, Australia, Mexico, Brazil, and Japan. Locate your local offi ce at: international.cengage.com/region Cengage Learning products are represented in Canada by Nelson Education, Ltd. For your lifelong learning solutions, visit delmar.cengage.com Visit our corporate website at www.cengage.com Notice to the Reader Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities described herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The publisher makes no representations or warranties of any kind, including but not limited to, the warranties of fi tness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers’ use of, or reliance upon, this material. Printed in the United States of America 1 2 3 4 5 XX 12 11 10 Contents Contents for Photo Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv About the 5th Edition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv Changes in Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv New to This Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv The Collaborative Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi Features of the Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx Chapter 1 Introduction to Servicing Heavy-Duty Trucks. . . . . . . . . . . . . . . 1 1.1 Truck Classifications (cid:129) 2 1.2 Heavy-Duty Trucks (cid:129) 4 1.3 Career Opportunities for Heavy-Duty Truck Technicians (cid:129) 10 1.4 Job Classifications (cid:129) 12 1.5 Advancement in the Profession (cid:129) 18 Chapter 2 Shop Safety and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.1 Personal Safety (cid:129) 22 2.2 Work Area Safety (cid:129) 25 2.3 Shop Tool Safety (cid:129) 27 2.4 Hazardous Materials (cid:129) 28 2.5 Handling and Disposal of Hazardous Waste (cid:129) 33 2.6 Shop Records (cid:129) 33 Chapter 3 Tools and Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.1 Hand Tools (cid:129) 40 3.2 Power Tools (cid:129) 51 3.3 Measuring Tools (cid:129) 56 3.4 Manufacturers’ Service Literature (cid:129) 63 3.5 Fasteners (cid:129) 70 Chapter 4 Maintenance Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 4.1 Setting Up a Maintenance Program (cid:129) 84 4.2 Out-of-Service or Deadlining a Vehicle (cid:129) 91 4.3 PM Scheduling (cid:129) 92 4.4 Lubricants (cid:129) 101 4.5 Winterizing (cid:129) 108 4.6 Performing a Lube Job (cid:129) 115 4.7 Fleet Management Software (cid:129) 116 Chapter 5 Fundamentals of Electricity . . . . . . . . . . . . . . . . . . . . . . . . . 119 5.1 Atomic Structure and Electron Movement (cid:129) 120 5.2 Conductors and Insulators (cid:129) 125 5.3 Current Flow (cid:129) 126 5.4 Magnetism (cid:129) 127 5.5 Electromagnetism (cid:129) 129 5.6 Electrical Current Characteristics (cid:129) 130 5.7 Sources of Electricity (cid:129) 131 5.8 Electrical Circuits and Ohm’s Law (cid:129) 133 5.9 Electric Motor and Generator Principle (cid:129) 140 5.10 Coils, Transformers, and Solenoids (cid:129) 143 Chapter 6 Fundamentals of Electronics and Computers. . . . . . . . . . . . . 149 6.1 Using Electronic Signals (cid:129) 150 6.2 Semiconductors (cid:129) 153 6.3 Diodes (cid:129) 154 6.4 Transistors (cid:129) 156 6.5 Photonic Semiconductors (cid:129) 159 6.6 Testing Semiconductors (cid:129) 161 6.7 Integrated Circuits (I/Cs) (cid:129) 162 6.8 Gates and Truth Tables (cid:129) 163 6.9 Binary System Basics (cid:129) 164 6.10 Microprocessors (cid:129) 166 6.11 Data Retention in Vehicle ECMs (cid:129) 175 6.12 Auxiliary Electronic Systems (cid:129) 176 v vi Contents Chapter 7 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 7.1 Battery-Operating Principles (cid:129) 185 7.2 Battery Ratings (cid:129) 193 7.3 Battery Maintenance (cid:129) 194 7.4 Battery Testing (cid:129) 198 7.5 Charging the Battery (cid:129) 203 7.6 Conductance Testing (cid:129) 210 7.7 Alternative Battery Technology (cid:129) 214 Chapter 8 Charging Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 8.1 Alternator Construction (cid:129) 218 8.2 Alternator Operation (cid:129) 221 8.3 Charging System Failures and Testing (cid:129) 225 8.4 Alternator Rebuild (cid:129) 231 Chapter 9 Cranking Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 9.1 Cranking Circuit Components (cid:129) 237 9.2 Starter Motors (cid:129) 239 9.3 Cranking Circuit Testing (cid:129) 247 9.4 Starter Rebuild (cid:129) 253 Chapter 10 Chassis Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 10.1 Lighting Systems (cid:129) 258 10.2 Auxiliary Electrical Equipment (cid:129) 267 10.3 Rapid Checking of a Truck Electrical Circuit (cid:129) 280 Chapter 11 Diagnosis and Repair of Electronic Circuits . . . . . . . . . . . . . . 286 11.1 Types of EST (cid:129) 288 11.2 Flash or Blink Codes (cid:129) 289 11.3 Using Digital Multimeters (cid:129) 289 11.4 Multifunctional Handheld Diagnostic Tools (cid:129) 301 11.5 Handheld Diagnostic Instruments (cid:129) 301 11.6 PCs and OEM Software (cid:129) 306 11.7 Electronic Troubleshooting (cid:129) 314 11.8 SAE/ATA Codes and Protocols (cid:129) 314 11.9 Troubleshooting VORAD (cid:129) 316 11.10 Electrical Wiring, Connector, and Terminal Repair (cid:129) 317 11.11 Splicing Guidelines (cid:129) 322 11.12 Supplemental Restraint System (cid:129) 323 Chapter 12 Multiplexing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 12.1 Multiplexing, Clients, and Servers (cid:129) 332 12.2 Multiplexing Basics (cid:129) 333 12.3 Multiplex Switching (cid:129) 340 12.4 Multiplex Transactions (cid:129) 341 12.5 Accessing the Data Bus (cid:129) 343 Chapter 13 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 13.1 Fundamentals (cid:129) 350 13.2 Hydraulic Components (cid:129) 355 13.3 Pumps (cid:129) 357 13.4 Actuators (cid:129) 365 13.5 Hydraulic Motors (cid:129) 366 Piston Motors (cid:129) 368 13.6 Conductors and Connectors (cid:129) 369 13.7 Hydraulic Fluids (cid:129) 376 13.8 Symbols and Schematics (cid:129) 377 13.9 Maintenance (cid:129) 377 Chapter 14 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 14.1 Clutch Function (cid:129) 386 14.2 Clutch Components (cid:129) 387 14.3 Troubleshooting (cid:129) 399 14.4 Maintenance (cid:129) 402 14.5 Clutch Servicing (cid:129) 412 Chapter 15 Standard Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 15.1 Main and Auxiliary Gearing (cid:129) 435 15.2 Geartrain Configurations (cid:129) 442 15.3 Mechanical Shift Mechanisms (cid:129) 443 15.4 Shift Housing Assembly (cid:129) 452 15.5 Twin Countershaft TransMissions (cid:129) 453 15.6 Auxiliary Gear Sections (cid:129) 456 15.7 Transfer Cases (cid:129) 470 Chapter 16 Standard Transmission Servicing. . . . . . . . . . . . . . . . . . . . . . 478 16.1 Lubrication (cid:129) 478 16.2 Preventive Maintenance Inspections (cid:129) 480 16.3 Troubleshooting (cid:129) 484 16.4 Transmission Overhaul (cid:129) 488 16.5 General Overhaul Guidelines (cid:129) 494 16.6 Step-by-Step Overhaul (cid:129) 495 16.8 Troubleshooting Air Shift Systems (cid:129) 512 Contents vii Chapter 17 Torque Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 17.1 Torque Converter Construction (cid:129) 522 17.2 Principles of Operation (cid:129) 525 17.3 Maintenance and Service (cid:129) 531 Chapter 18 Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 18.1 Planetary Gearset Components (cid:129) 542 18.2 Compound Planetary Gearsets (cid:129) 549 18.3 Transmission Hydraulic Systems (cid:129) 559 18.4 Hydraulic Retarders (cid:129) 566 Chapter 19 Automatic Transmission Maintenance . . . . . . . . . . . . . . . . . . 569 19.1 Inspection and Maintenance (cid:129) 570 19.2 Shift Point Adjustments (cid:129) 579 19.3 Power Take-Offs (PTOs) (cid:129) 584 Chapter 20 Electronically Automated Standard Transmissions. . . . . . . . . 588 20.1 Transmission Identification (cid:129) 590 20.2 Autoshift Components (cid:129) 591 20.3 Transmission ECU (cid:129) 600 20.4 Fault Detection and Data Links (cid:129) 603 20.5 Other Automated Transmissions (cid:129) 608 Chapter 21 Electronic Automatic Transmissions . . . . . . . . . . . . . . . . . . . 612 21.1 CEC Transmissions (cid:129) 614 21.2 WT Modular Construction (cid:129) 621 21.3 WT Input Modules (cid:129) 623 21.4 Gearbox Modules (cid:129) 623 21.5 Output Modules (cid:129) 626 21.6 WTEC Electronics (cid:129) 629 21.7 WT Output Circuit (cid:129) 633 21.8 The WT Hydraulic Circuit (cid:129) 635 21.9 Allison WT Torque Paths and Range Management (cid:129) 637 21.10 Troubleshooting WTs (cid:129) 650 21.11 Caterpillar CX Truck Transmissions (cid:129) 652 21.12 Voith DIWA Transmission (cid:129) 663 Chapter 22 Drive Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667 22.1 Drive Shaft Construction (cid:129) 668 22.2 Drive Shaft Inspection (cid:129) 675 22.3 Lubrication (cid:129) 676 22.4 U-Joint Replacement (cid:129) 678 22.5 Chassis Vibration Diagnosis (cid:129) 684 Chapter 23 Heavy-Duty Truck Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 23.1 Drive Axles (cid:129) 696 23.2 Power Dividers (cid:129) 706 23.3 Two-Speed Drive Axles (cid:129) 712 23.4 Drive Axle Shaft Configurations (cid:129) 719 23.5 Nondriving Axles (cid:129) 719 Chapter 24 Heavy-Duty Truck Axle Service and Repair . . . . . . . . . . . . . . 724 24.1 Drive Axle Lubrication (cid:129) 725 24.2 Truck Axle Cleaning and Inspection (cid:129) 728 24.3 Carrier, Axle, and Gearing Identification (cid:129) 729 24.4 Failure Analysis (cid:129) 729 24.5 Axle Adjustments and Checks (cid:129) 747 Chapter 25 Steering and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 25.1 Steering System Components (cid:129) 760 25.2 Front-End Alignment (cid:129) 765 25.3 Electronic Alignment Systems (cid:129) 776 25.4 Steering Axle Inspection (cid:129) 780 25.5 Manual Steering Gears (cid:129) 791 25.6 Power-Assist Steering Systems (cid:129) 797 25.7 Troubleshooting Power Steering Systems (cid:129) 801 25.8 Rack and Pinion Steering (cid:129) 805 25.9 Electronic and Load-Sensing Steering (cid:129) 806 25.10 Commercial Vehicle Safety Alliance (CVSA) OOS Steering Criteria (cid:129) 809 Chapter 26 Suspension Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813 26.1 Leaf Spring Suspensions (cid:129) 814 26.2 Cushion and Torsion Suspensions (cid:129) 821 26.3 Air Spring Suspensions (cid:129) 823 26.4 Servicing Mechanical Suspensions (cid:129) 828 26.5 Servicing Equalizing Beams (cid:129) 834 26.6 Servicing Air Suspensions (cid:129) 838 viii Contents 26.7 Suspension Alignment (cid:129) 844 26.8 Roll Stability Control (cid:129) 848 26.9 Cab Air Suspensions and Driver Seats (cid:129) 849 26.10 Ride Analysis (cid:129) 850 Chapter 27 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855 27.1 Wheels and Rims (cid:129) 856 27.2 Tires (cid:129) 860 27.3 Tire Maintenance (cid:129) 865 27.4 Tire, Rim, and Wheel Service (cid:129) 869 27.5 Chassis Tire Pressure Management (cid:129) 885 27.6 Wheel Hubs, Bearings, and Seals (cid:129) 887 27.7 Wheel Bearing Adjustment (cid:129) 894 27.8 Wheel Seal Service (cid:129) 897 27.9 Wheel End Conclusion (cid:129) 901 Chapter 28 Truck Brake Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906 28.1 Air Brakes—A Driver’s Point of View (cid:129) 909 28.2 Air Brake Subsystems (cid:129) 910 28.3 The Air Supply Circuit (cid:129) 912 28.4 Primary Circuit (cid:129) 921 28.5 Secondary Circuit (cid:129) 923 28.6 Trailer Circuit (cid:129) 928 28.7 Foundation Brakes (cid:129) 931 28.8 Air Brake System Components (cid:129) 936 28.9 Brake System Balance (cid:129) 954 28.10 Air Start Systems (cid:129) 957 Chapter 29 Hydraulic Brakes and Air-over-Hydraulic Brake Systems. . . . . 962 29.1 Hydraulic Brake System Components (cid:129) 963 29.2 Air-over-Hydraulic Brake Systems (cid:129) 971 29.3 Hydraulic Brake Service Procedures (cid:129) 974 29.4 Hydraulic ABS (cid:129) 984 29.5 CVSA OOS (cid:129) 987 Chapter 30 ABS and EBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 991 30.1 Basics of ABS Operation (cid:129) 993 30.2 ABS Components (cid:129) 994 30.3 ABS Configurations (cid:129) 1001 30.4 Automatic Traction Control (ATC) Systems (cid:129) 1003 30.5 Trailer ABS (cid:129) 1004 30.6 ABS Diagnostics (cid:129) 1006 30.7 ABS Service Procedure (cid:129) 1008 30.8 ABS Add-Ons (cid:129) 1013 30.9 Electronic Braking Systems (EBS) (cid:129) 1015 Chapter 31 Air Brake Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021 31.1 Maintenance and Safety (cid:129) 1022 31.2 Test Equipment (cid:129) 1026 31.3 Assessing Brake System Performance (cid:129) 1028 31.4 Supply Circuit Service (cid:129) 1033 31.5 Service Application Circuit (cid:129) 1039 31.6 Parking/Emergency Circuit (cid:129) 1046 31.7 Slack Adjusters (cid:129) 1052 31.8 Trailer Brake System (cid:129) 1054 31.9 Foundation Brake Service (cid:129) 1055 31.10 Brake Adjustment (cid:129) 1063 31.11 General Brake Valve Troubleshooting (cid:129) 1068 31.12 Service Procedures on Air Disc Brakes (cid:129) 1070 31.13 Servicing Wedge Brakes (cid:129) 1071 31.14 Brake Certification, Inspection, and Testing (cid:129) 1073 31.15 Commercial Vehicle Stopping Distances (cid:129) 1075 Chapter 32 Vehicle Chassis Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079 32.1 Basic Frame Terms (cid:129) 1080 32.2 Frame Theory (cid:129) 1081 32.3 Frame Construction (cid:129) 1085 32.4 Frame Damage (cid:129) 1088 32.5 Frame Alignment (cid:129) 1090 32.6 Repair of Frame, Side Rails, and Cross-Members (cid:129) 1092 Chapter 33 Heavy-Duty Truck Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . 1102 33.1 Tractor/Trailer Combinations (cid:129) 1103 33.2 Freight Van Trailers (cid:129) 1107 33.3 Refrigerated and Insulated Vans (cid:129) 1111 33.4 Specialty Trailer Designs (cid:129) 1115 33.5 Trailer Undersides (cid:129) 1117 33.6 Trailer Maintenance (cid:129) 1122 33.7 Mobile Universal Trailer Tester (cid:129) 1126 Contents ix Chapter 34 Fifth Wheels and Coupling Systems . . . . . . . . . . . . . . . . . . 1130 34.1 Types of Fifth Wheels (cid:129) 1131 34.2 Fifth Wheel Height and Location (cid:129) 1134 34.3 Principles of Fifth Wheel Operation (cid:129) 1134 34.4 Fifth Wheel Maintenance (cid:129) 1141 34.5 Mounting Fifth Wheels (cid:129) 1147 34.6 Sliding Fifth Wheels (cid:129) 1150 34.7 Kingpins and Upper Couplers (cid:129) 1151 34.8 Pintle Hooks (cid:129) 1154 34.9 Coupling Device CVSA OOS (cid:129) 1155 Chapter 35 H eavy-Duty Heating, Ventilation, and Air Conditioning Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1158 35.1 Principles of Refrigeration (cid:129) 1159 35.2 Refrigerant (cid:129) 1160 35.3 The Refrigeration Cycle (cid:129) 1164 35.4 Air-Conditioning System Components (cid:129) 1165 35.5 Safety Precautions (cid:129) 1178 35.6 Performance Testing an Air Conditioning System (cid:129) 1179 35.7 Air-Conditioning Service Equipment (cid:129) 1182 35.8 Air Conditioning Service Procedures (cid:129) 1186 35.9 Common Air Conditioning Problems (cid:129) 1194 35.10 Converting an R-12 System to an R-134a System (cid:129) 1198 35.11 Cab Ventilating and Heating Systems (cid:129) 1198 35.12 Liquid-Cooled Heating System (cid:129) 1199 35.13 Electronically Managed Climate Control (cid:129) 1202 35.14 Bluecool Heat Exchanger (cid:129) 1206 Appendix A Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1210 Appendix B Truck Nominal Class Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1214 Appendix C Brake Shoe Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1215 Appendix D Vibration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1216 Appendix E Hard Steering Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . .1218 Appendix F Dual Circuit Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .1219 Appendix G Driveline Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1220 Appendix H Measuring Driveline Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1221 Appendix I Vehicle Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1222 Appendix J Quick Conversion Formula. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223 Glossary 1224 Index 1253