Heavy Duty Truck Systems

CONTENTS
CHAPTER 1: INTRODUCTION TO SERVICING HEAVY-DUTY TRUCKS
1.1 Truck Classifications
1.2 Heavy-Duty Trucks
1.3 Career Opportunities for Heavy-Duty Truck Technicians
1.4 Job Classifications
1.5 Advancement in the Profession
1.6 Electronic Logging Devices
1.7 Autonomous and Electric Trucks
CHAPTER 2: SHOP SAFETY AND OPERATIONS
2.1 Personal Protective Equipment
2.2 Work Area Safety
2.3 Oxyacetylene Equipment
2.4 Electric Arc Welding
2.5 Shop Tool Safety
2.6 Hazardous Materials and WHMIS
2.7 Handling and Disposal of Hazardous Waste
2.8 Shop Records
2.9 Lockout/Tagout
CHAPTER 3: TOOLS AND FASTENERS
3.1 Hand Tools
3.2 Power Tools
3.3 Measuring Tools
3.4 Manufacturers’ Service Literature
3.5 Fasteners
CHAPTER 4: MAINTENANCE PROGRAMS
4.1 VMRS
4.2 Setting Up a Maintenance Program
4.3 Out-of-Service or Deadlining a Vehicle
4.4 PM Scheduling
4.5 Lubricants
4.6 Winterizing
4.7 Performing a Lube Job
4.8 Fleet Management Software
4.9 Maintaining Emissions Control Equipment
CHAPTER 5: FUNDAMENTALS OF ELECTRICITY
5.1 Atomic Structure and Electron Movement
5.2 Conductors and Insulators
5.3 Current Flow
5.4 Magnetism
5.5 Electromagnetism
5.6 Electrical Current Characteristics
5.7 Sources of Electricity
5.8 Electrical Circuits and Ohm’s Law
5.9 Electric Motor and Generator Principle
5.10 Coils, Transformers, and Solenoids
CHAPTER 6: FUNDAMENTALS OF ELECTRONICS AND COMPUTERS
6.1 Using Electronic Signals
6.2 Semiconductors
6.3 Diodes
6.4 Transistors
6.5 Photonic Semiconductors
6.6 Testing Semiconductors
6.7 Integrated Circuits (I/Cs)
6.8 Gates and Truth Tables
6.9 Binary System Basics
6.10 Microprocessors
6.11 Data Retention in a Vehicle ECU
6.12 Auxiliary Electronic Systems
6.13 Accident Avoidance Systems
CHAPTER 7: BATTERIES
7.1 Battery-Operating Principles
7.2 Battery Ratings
7.3 Battery Classifications
7.4 Battery Maintenance
7.5 Battery Testing
7.6 Charging the Battery
7.7 Conductance Testing
7.8 Alternative Battery Technology
7.9 Ultracapacitors and Supercapacitors
7.10 Battery Management Systems
CHAPTER 8: CHARGING SYSTEMS
8.1 Alternator Construction
8.2 Alternator Operation
8.3 Charging System Failures and Testing
8.4 Alternator Rebuild
CHAPTER 9: CRANKING SYSTEMS
9.1 Cranking Circuit Components
9.2 Starter Motors
9.3 Cranking Circuit Testing
9.4 Starter Rebuild
CHAPTER 10: CHASSIS ELECTRICAL CIRCUITS
10.1 Lighting Systems
10.2 Auxiliary Electrical Equipment
10.3 Rapid Checking of a Truck Electrical Circuit
CHAPTER 11: DIAGNOSIS AND REPAIR OF ELECTRONIC CIRCUITS
11.1 Types of EST
11.2 Using Digital Multimeters
11.3 Multifunctional Handheld Diagnostic Tools
11.4 Handheld Diagnostic Instruments
11.5 PCs and OEM Software
11.6 Oscilloscopes
11.7 Electronic Troubleshooting
11.8 Bus Codes and Protocols
11.9 Troubleshooting CWS and CMS
11.10 Electrical Wiring, Connector, and Terminal Repair
11.11 Wiring Schematics
11.12 Supplemental Restraint System
CHAPTER 12: MULTIPLEXING
12.1 Multiplexing, Clients, and Servers
12.2 Multiplexing Basics
12.3 Multiplex Switching
12.4 Multiplex Transactions
12.5 Accessing the Data Bus
CHAPTER 13: HYDRAULICS
13.1 Fundamentals
13.2 Hydraulic Components
13.3 Pumps
13.4 Actuators
13.5 Hydraulic Motors
13.6 Conductors and Connectors
13.7 Hydraulic Fluids
13.8 Symbols and Schematics
13.9 Maintenance
CHAPTER 14: CLUTCHES
14.1 Clutch Function
14.2 Clutch Components
14.3 Troubleshooting
14.4 Maintenance
14.5 Clutch Servicing
CHAPTER 15: STANDARD TRANSMISSIONS
15.1 Main and Auxiliary Gearing
15.2 Geartrain Configurations
15.3 Mechanical Shift Mechanisms
15.4 Shift Housing Assembly
15.5 Twin-Countershaft Transmissions
15.6 Auxiliary Gear Sections
15.7 Transfer Cases
CHAPTER 16: STANDARD TRANSMISSION SERVICING
16.1 Lubrication
16.2 Preventive Maintenance Inspections
16.3 Troubleshooting
16.4 Transmission Overhaul
16.5 General Overhaul Guidelines
16.6 Step-By-Step Overhaul
16.7 Troubleshooting Air Shift Systems
CHAPTER 17: TORQUE CONVERTERS
17.1 Torque Converter Construction
17.2 Principles of Operation
17.3 Maintenance and Service
CHAPTER 18: AUTOMATIC TRANSMISSIONS
18.1 Planetary Gearset Components
18.2 Compound Planetary Gearsets
18.3 Transmission Hydraulic Systems
18.4 Hydraulic Retarders
CHAPTER 19: AUTOMATIC TRANSMISSION MAINTENANCE
19.1 Inspection and Maintenance
19.2 Shift Point Adjustments
19.3 Power Take-Offs (PTOs)
CHAPTER 20: AUTOMATED MANUAL AND HYBRID TRANSMISSIONS
20.1 Transmission Identification
20.2 Ultrashift Components
20.3 Transmission ECU
20.4 Fault Detection and Data Links
20.5 AMT Clutch Actuators
20.6 Hybrid Transmissions
CHAPTER 21: ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMISSIONS (ECATS)
21.1 ECAT Management
21.2 Allison DOC
21.3 WT Transmissions
21.4 Allison TC10
21.5 Caterpillar CX Truck Transmissions
21.6 Voith DIWA Transmission
21.7 Navigating ECU Schematics
CHAPTER 22: DRIVESHAFT ASSEMBLIES
22.1 Driveshaft Construction
22.2 Driveshaft Inspection
22.3 Lubrication
22.4 U-Joint Replacement
22.5 Chassis Vibration Diagnosis
CHAPTER 23: HEAVY-DUTY TRUCK AXLES
23.1 Drive Axles
23.2 Power Dividers
23.3 Two-Speed Drive Axles
23.4 Drive Axle Shaft Configurations
23.5 Nondriving Axles
CHAPTER 24: HEAVY-DUTY TRUCK AXLE SERVICE AND REPAIR
24.1 Drive Axle Lubrication
24.2 Truck Axle Cleaning and Inspection
24.3 Carrier, Axle, and Gearing Identification
24.4 Failure Analysis
24.5 Axle Adjustments and Checks
CHAPTER 25: STEERING AND ALIGNMENT
25.1 Steering System Components
25.2 Front-End Alignment
25.3 Electronic Alignment Systems
25.4 Steering Axle Inspection
25.5 Manual Steering Gears
25.6 Power-Assist Steering Systems
25.7 Troubleshooting Power Steering Systems
25.8 Rack and Pinion Steering
25.9 Electronic and Load-Sensing Steering
25.10 Commercial Vehicle Safety Alliance (CVSA) OOS Steering Criteria
CHAPTER 26: SUSPENSION SYSTEMS
26.1 Leaf Spring Suspensions
26.2 Cushion and Torsion Suspensions
26.3 Air Spring Suspensions
26.4 Servicing Mechanical Suspensions
26.5 Servicing Equalizing Beams
26.6 Servicing Air Suspensions
26.7 Suspension Alignment
26.8 Roll Stability Control
26.9 Cab Air Suspensions and Driver Seats
26.10 Ride Analysis
CHAPTER 27: WHEELS AND TIRES
27.1 Wheels and Rims
27.2 Tires
27.3 Tire Maintenance
27.4 Tire, Rim, and Wheel Service
27.5 Wheel Balancing
27.6 Chassis Tire Pressure Management
27.7 Wheel Hubs, Bearings, and Seals
27.8 Wheel Bearing Adjustment
27.9 Wheel Seal Service
27.10 Wheel End Conclusion
CHAPTER 28: TRUCK BRAKE SYSTEMS
28.1 Air Brakes: A Driver’s Point of View
28.2 Air Brake Subsystems
28.3 The Air Supply Circuit
28.4 Primary Circuit
28.5 Secondary Circuit
28.6 Trailer Circuit
28.7 Foundation Brakes
28.8 Air Brake System Components
28.9 Brake System Balance
28.10 Air Start Systems
CHAPTER 29: HYDRAULIC BRAKES AND AIR-OVER-HYDRAULIC BRAKE SYSTEMS
29.1 Hydraulic Brake System Components
29.2 Air-Over-Hydraulic Brake Systems
29.3 Hydraulic Brake Service Procedures
29.4 Hydraulic ABS
29.5 CVSA OOS
CHAPTER 30: ABS AND EBS
30.1 Basics of ABS Operation
30.2 ABS Components
30.3 ABS Configurations
30.4 Automatic Traction Control (ATC) Systems
30.5 Trailer ABS
30.6 ABS Diagnostics
30.7 ABS Service Procedure
30.8 ABS Add-Ons
30.9 Electronic Braking Systems (EBS)
CHAPTER 31: AIR BRAKE SERVICING
31.1 Maintenance and Safety
31.2 Test Equipment
31.3 Assessing Brake System Performance
31.4 Supply Circuit Service
31.5 Service Application Circuit
31.6 Parking/Emergency Circuit
31.7 Slack Adjusters
31.8 Trailer Brake System
31.9 Foundation Brake Service
31.10 Brake Adjustment
31.11 General Brake Valve Troubleshooting
31.12 Service Procedures on Air Disc Brakes
31.13 Servicing Wedge Brakes
31.14 Brake Certification, Inspection, and Testing
31.15 Commercial Vehicle Stopping Distances
CHAPTER 32: VEHICLE CHASSIS FRAME
32.1 Basic Frame Terms
32.2 Frame Theory
32.3 Frame Construction
32.4 Frame Damage
32.5 Frame Alignment
32.6 Repair of Frame, Side Rails, and Cross-Members
CHAPTER 33: HEAVY-DUTY TRUCK TRAILERS
33.1 Tractor/Trailer Combinations
33.2 Freight Van Trailers
33.3 Refrigerated and Insulated Vans
33.4 Specialty Trailer Designs
33.5 Trailer Undersides
33.6 Trailer Maintenance
33.7 Testing Trailer Air and Electrical Circuits
CHAPTER 34: FIFTH WHEELS AND COUPLING SYSTEMS
34.1 Types of Fifth Wheels
34.2 Fifth Wheel Height and Location
34.3 Principles of Fifth Wheel Operation
34.4 Fifth Wheel Maintenance
34.5 Coupling
34.6 Mounting Fifth Wheels
34.7 Sliding Fifth Wheels
34.8 Kingpins and Upper Couplers
34.9 Pintle Hooks/Ball Hitches
34.10 Coupling Device CVSA OOS
CHAPTER 35: HEAVY-DUTY HEATING, VENTILATION, AND AIR CONDITIONING SYSTEMS
35.1 Principles of Refrigeration
35.2 Refrigerant
35.3 The Refrigeration Cycle
35.4 Air Conditioning System Components
35.5 Safety Precautions
35.6 Performance Testing an Air Conditioning System
35.7 Air Conditioning Service Equipment
35.8 Air Conditioning Service Procedures
35.9 Common Air Conditioning Problems
35.10 Converting an R-12 System to an R-134A System
35.11 Cab Ventilating and Heating Systems
35.12 Liquid-Cooled Heating System
35.13 Electronically Managed Climate Control
35.14 Bluecool Truck Thermal Storage System
Appendix A: Acronyms
Appendix B: Truck Nominal Class Designations
Appendix C: Brake Shoe Identification Chart
Appendix D: Vibration Diagnosis
Appendix E: Hard Steering Troubleshooting Flow Chart
Appendix F: Dual Circuit Brake System Troubleshooting
Appendix G: Driveline Configurations
Appendix H: Measuring Driveline Angles
Appendix I: Vehicle Configurations
Appendix J: Quick Conversion Formula
Appendix K: J1939 Message Decoder
Appendix L: Tire Code Interpretation and Tread Pattern Designations
Glossary
Index