2015 Heavy Duty Truck Systems 6th ed – Sean Bennett – PDF DOWNLOAD

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2015 Heavy Duty Truck Systems 6th ed – Sean Bennett – PDF DOWNLOAD

TABLE OF CONTENTS:

2015 Heavy Duty Truck Systems 6th ed – Sean Bennett – PDF DOWNLOAD

Contents for Photo Sequences . xi
Preface . xv
About the 6th Edition . xv
Changes in Technology xv
New to This Edition xv
Feedback from Educators . xvi
Features of the Text . xvii
Supplements xix
Acknowledgments . xxi
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 • 11
1.4 Job Classifications • 14 1.5 Advancement in the Profession • 19
Chapter 2 Shop Safety and Operations 23
2.1 Personal Protective Equipment • 24 2.2 Work Area Safety • 28
2.3 Oxyacetylene Equipment • 33 2.4 Electric Arc Welding • 35
2.5 Shop Tool Safety • 35 2.6 Hazardous Materials and WHMIS • 35
2.7 Handling and Disposal of Hazardous Waste • 36 2.8 Shop Records • 40
Chapter 3 Tools and Fasteners 45
3.1 Hand Tools • 46 3.2 Power Tools • 56 3.3 Measuring Tools • 62
3.4 Manufacturers’ Service Literature • 70 3.5 Fasteners • 76
Chapter 4 Maintenance Programs . 88
4.1 Setting up a Maintenance Program • 92
4.2 Out-of-Service or Deadlining a Vehicle • 99 4.3 PM Scheduling • 100
4.4 Lubricants • 108 4.5 Winterizing • 115 4.6 Performing a Lube Job • 121
4.7 Fleet Management Software • 123
4.8 Maintaining Emissions Control Equipment • 124
Chapter 5 Fundamentals of Electricity . 127
5.1 Atomic Structure and Electron Movement • 128
5.2 Conductors and Insulators • 133 5.3 Current Flow • 134
5.4 Magnetism • 135 5.5 Electromagnetism • 136
5.6 Electrical Current Characteristics • 138 5.7 Sources of Electricity • 139
5.8 Electrical Circuits and Ohm’s Law • 141
5.9 Electric Motor and Generator Principle • 148
5.10 Coils, Transformers, and Solenoids • 151
Copyright 2016 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
vi Contents
Chapter 6 Fundamentals of Electronics and Computers 156
6.1 Using Electronic Signals • 157 6.2 Semiconductors • 159
6.3 Diodes • 161 6.4 Transistors • 163
6.5 Photonic Semiconductors • 166 6.6 Testing Semiconductors • 167
6.7 Integrated Circuits (I/Cs) • 169 6.8 Gates and Truth Tables • 170
6.9 Binary System Basics • 171 6.10 Microprocessors • 173
6.11 Data Retention in a Vehicle ECU • 182
6.12 Auxiliary Electronic Systems • 183
6.13 Accident Avoidance Systems • 184
Chapter 7 Batteries 192
7.1 Battery-Operating Principles • 193 7.2 Battery Ratings • 200
7.3 Battery Maintenance • 201 7.4 Battery Testing • 205
7.5 Charging the Battery • 210 7.6 Conductance Testing • 216
7.7 Alternative Battery Technology • 219
7.8 Ultracapacitors and Supercapacitors • 222
7.9 Battery Management Systems • 223
Chapter 8 Charging Systems 227
8.1 Alternator Construction • 228 8.2 Alternator Operation • 231
8.3 Charging System Failures and Testing • 235
8.4 Alternator Rebuild • 240
Chapter 9 Cranking Systems . 249
9.1 Cranking Circuit Components • 250 9.2 Starter Motors • 252
9.3 Cranking Circuit Testing • 260 9.4 Starter Rebuild • 266
Chapter 10 Chassis Electrical Circuits 270
10.1 Lighting Systems • 271 10.2 Auxiliary Electrical Equipment • 279
10.3 Rapid Checking of a Truck Electrical Circuit • 290
Chapter 11 Diagnosis and Repair of Electronic Circuits 297
11.1 Types of EST • 299 11.2 Using Digital Multimeters • 302
11.3 Multifunctional Handheld Diagnostic Tools • 313
11.4 Handheld Diagnostic Instruments • 313
11.5 PCs and OEM Software • 318 11.6 Bus Codes and Protocols • 326
11.7 Troubleshooting CWS and CMS • 328
11.8 Electrical Wiring, Connector, and Terminal Repair • 329
11.9 Splicing Guidelines • 334 11.10 Supplemental Restraint System • 335
Chapter 12 Multiplexing 343
12.1 Multiplexing, Clients, and Servers • 345 12.2 Multiplexing Basics • 345
12.3 Multiplex Switching • 353
12.4 Multiplex Transactions • 354 12.5 Accessing the Data Bus • 356
Chapter 13 Hydraulics . 365
13.1 Fundamentals • 366 13.2 Hydraulic Components • 371
13.3 Pumps • 372 13.4 Actuators • 380 13.5 Hydraulic Motors • 382
13.6 Conductors and Connectors • 384 13.7 Hydraulic Fluids • 391
13.8 Symbols and Schematics • 392 13.9 Maintenance • 392
Copyright 2016 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
contents vii
Chapter 14 Clutches 400
14.1 Clutch Function • 401 14.2 Clutch Components • 401
14.3 Troubleshooting • 413 14.4 Maintenance • 415
14.5 Clutch Servicing • 425
Chapter 15 Standard Transmissions . 448
15.1 Main and Auxiliary Gearing • 449 15.2 Geartrain Configurations • 456
15.3 Mechanical Shift Mechanisms • 456 15.4 Shift Housing Assembly • 466
15.5 Twin-Countershaft Transmissions • 469 15.6 Auxiliary Gear Sections • 470
15.7 Transfer Cases • 486
Chapter 16 Standard Transmission Servicing . 494
16.1 Lubrication • 494 16.2 Preventive Maintenance Inspections • 497
16.3 Troubleshooting • 501 16.4 Transmission Overhaul • 507
16.5 General Overhaul Guidelines • 511 16.6 Step-By-Step Overhaul • 511
16.7 Troubleshooting Air Shift Systems • 527
Chapter 17 Torque Converters 535
17.1 Torque Converter Construction • 536 17.2 Principles of Operation • 540
17.3 Maintenance and Service • 546
Chapter 18 Automatic Transmissions . 556
18.1 Planetary Gearset Components • 557 18.2 Compound Planetary Gearsets • 564
18.3 Transmission Hydraulic Systems • 573 18.4 Hydraulic Retarders • 581
Chapter 19 Automatic Transmission Maintenance . 584
19.1 Inspection and Maintenance • 585 19.2 Shift Point Adjustments • 594
19.3 Power Take-Offs (PTOs) • 600
Chapter 20 Automated Manual and Hybrid Transmissions 602
20.1 Transmission Identification • 604 20.2 Ultrashift Components • 604
20.3 Transmission ECU • 613 20.4 Fault Detection and Data Links • 617
20.5 AMT clutch actuators • 619 20.6 Hybrid transmissions • 621
Chapter 21 Electronically Controlled Automatic Transmissions (ECATs) 628
21.1 ECAT Management • 630 21.2 Allison DOC • 633
21.3 WT Transmissions • 635 21.4 Allison TC10 • 665
21.5 Caterpillar CX Truck Transmissions • 683
21.6 Voith Diwa Transmission • 692
Chapter 22 Driveshaft Assemblies 696
22.1 Driveshaft Construction • 697 22.2 Driveshaft Inspection • 704
22.3 Lubrication • 705 22.4 U-Joint Replacement • 707
22.5 Chassis Vibration Diagnosis • 713
Chapter 23 Heavy-Duty Truck Axles 722
23.1 Drive Axles • 724 23.2 Power Dividers • 734
23.3 Two-Speed Drive Axles • 740 23.4 Drive Axle Shaft Configurations • 747
23.5 Nondriving Axles • 747
Copyright 2016 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
viii Contents
Chapter 24 Heavy-Duty Truck Axle Service and Repair 752
24.1 Drive Axle Lubrication • 753 24.2 Truck Axle Cleaning and Inspection • 756
24.3 Carrier, Axle, and Gearing Identification • 757 24.4 Failure Analysis • 757
24.5 Axle Adjustments and Checks • 774
Chapter 25 Steering and Alignment 785
25.1 Steering System Components • 786 25.2 Front-End Alignment • 791
25.3 Electronic Alignment Systems • 802 25.4 Steering Axle Inspection • 805
25.5 Manual Steering Gears • 816 25.6 Power-Assist Steering Systems • 822
25.7 Troubleshooting Power Steering Systems • 826
25.8 Rack and Pinion Steering • 829
25.9 Electronic and Load-Sensing Steering • 831
25.10 Commercial Vehicle Safety Alliance (CVSA) OOS Steering Criteria • 833
Chapter 26 Suspension Systems 837
26.1 Leaf Spring Suspensions • 838 26.2 Cushion and Torsion Suspensions • 845
26.3 Air Spring Suspensions • 847 26.4 Servicing Mechanical Suspensions • 852
26.5 Servicing Equalizing Beams • 858 26.6 Servicing Air Suspensions • 862
26.7 Suspension Alignment • 867 26.8 Roll Stability Control • 872
26.9 Cab Air Suspensions and Driver Seats • 872 26.10 Ride Analysis • 874
Chapter 27 Wheels and Tires 878
27.1 Wheels and Rims • 879 27.2 Tires • 884 27.3 Tire Maintenance • 889
27.4 Tire, Rim, and Wheel Service • 894 27.5 Wheel Balancing • 908
27.6 Chassis Tire Pressure Management • 912
27.7 Wheel Hubs, Bearings, and Seals • 914 27.8 Wheel Bearing Adjustment • 921
27.9 Wheel Seal Service • 925 27.10 Wheel End Conclusion • 928
Chapter 28 Truck Brake Systems 931
28.1 Air Brakes: a Driver’s Point of View • 933 28.2 Air Brake Subsystems • 935
28.3 The Air Supply Circuit • 937 28.4 Primary Circuit • 947
28.5 Secondary Circuit • 950 28.6 Trailer Circuit • 954
28.7 Foundation Brakes • 958 28.8 Air Brake System Components • 964
28.9 Brake System Balance • 981 28.10 Air Start Systems • 985
Chapter 29 Hydraulic Brakes and Air-over-Hydraulic Brake Systems 989
29.1 Hydraulic Brake System Components • 990
29.2 Air-over-Hydraulic Brake Systems • 1002
29.3 Hydraulic Brake Service Procedures • 1005
29.4 Hydraulic ABS • 1015 29.5 CVSA OOS • 1018
Chapter 30 ABS and EBS . 1023
30.1 Basics of ABS Operation • 1024 30.2 ABS Components • 1026
30.3 ABS Configurations • 1033
30.4 Automatic Traction Control (ATC) Systems • 1035 30.5 Trailer ABS • 1035
30.6 ABS Diagnostics • 1037 30.7 ABS Service Procedure • 1040
30.8 ABS Add-Ons • 1044 30.9 Electronic Braking Systems (EBS) • 1047
Chapter 31 Air Brake Servicing . 1052
31.1 Maintenance and Safety • 1053 31.2 Test Equipment • 1056
31.3 Assessing Brake System Performance • 1057
Copyright 2016 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
contents ix
31.4 Supply Circuit Service • 1063 31.5 Service Application Circuit • 1069
31.6 Parking/Emergency Circuit • 1075 31.7 Slack Adjusters • 1080
31.8 Trailer Brake System • 1083 31.9 Foundation Brake Service • 1084
31.10 Brake Adjustment • 1091 31.11 General Brake Valve Troubleshooting • 1097
31.12 Service Procedures on Air Disc Brakes • 1099
31.13 Servicing Wedge Brakes • 1102
31.14 Brake Certification, Inspection, and Testing • 1102
31.15 Commercial Vehicle Stopping Distances • 1104
Chapter 32 Vehicle Chassis Frame 1107
32.1 Basic Frame Terms • 1108 32.2 Frame Theory • 1109
32.3 Frame Construction • 1113 32.4 Frame Damage • 1116
32.5 Frame Alignment • 1118
32.6 Repair of Frame, Side Rails, and Cross-Members • 1121
Chapter 33 Heavy-Duty Truck Trailers . 1131
33.1 Tractor/Trailer Combinations • 1132 33.2 Freight Van Trailers • 1136
33.3 Refrigerated and Insulated Vans • 1140
33.4 Specialty Trailer Designs • 1144
33.5 Trailer Undersides • 1146 33.6 Trailer Maintenance • 1153
33.7 Mobile Universal Trailer Tester • 1157
Chapter 34 Fifth Wheels and Coupling Systems . 1160
34.1 Types of Fifth Wheels • 1161 34.2 Fifth Wheel Height and Location • 1164
34.3 Principles of Fifth Wheel Operation • 1165
34.4 Fifth Wheel Maintenance • 1171 34.5 Coupling • 1174
34.6 Mounting Fifth Wheels • 1179 34.7 Sliding Fifth Wheels • 1180
34.8 Kingpins and Upper Couplers • 1181
34.9 Pintle Hooks/Ball Hitches • 1184
34.10 Coupling Device CVSA OOS • 1186
Chapter 35 Heavy-Duty Heating, Ventilation, and Air Conditioning Systems 1190
35.1 Principles of Refrigeration • 1191 35.2 Refrigerant • 1193
35.3 The Refrigeration Cycle • 1197
35.4 Air Conditioning System Components • 1199
35.5 Safety Precautions • 1212
35.6 Performance Testing an Air Conditioning System • 1213
35.7 Air Conditioning Service Equipment • 1216
35.8 Air Conditioning Service Procedures • 1220
35.9 Common Air Conditioning Problems • 1227
35.10 Converting an R-12 System to an R-134a System • 1229
35.11 Cab Ventilating and Heating Systems • 1230
35.12 Liquid-Cooled Heating System • 1231
35.13 Electronically Managed Climate Control • 1234
35.14 Bluecool Truck Thermal Storage System • 1239
Appendix A Acronyms . 1243
Appendix B Truck Nominal Class Designations . 1248
Appendix C Brake Shoe Identification Chart . 1249
Appendix D Vibration Diagnosis . 1250
Appendix E Hard Steering Troubleshooting Flow Chart . 1252
Appendix F Dual Circuit Brake System Troubleshooting . 1253
Copyright 2016 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
x Contents
Appendix G Driveline Configurations . 1257
Appendix H Measuring Driveline Angles . 1258
Appendix I Vehicle Configurations . 1259
Appendix J Quick Conversion Formula . 1260
Appendix K J1939 Message Decoder . 1261
Appendix L Tire Code Interpretation and Tread Pattern Designations . 1262
Glossary 1263
Index 1303
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2015 HEAVY DUTY TRUCK SYSTEMS 6TH ED – SEAN BENNETT – PDF DOWNLOAD:

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