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FUNDAMENTALS OF Mobile Heavy Equipment Owen C. Duffy Scott A. Heard Gus Wright World Headquarters Jones & Bartlett Learning 5 Wall Street Burlington, MA 01803 978-443-5000 [email protected] www.jblearning.com Jones & Bartlett Learning books and products are available through most bookstores and online booksellers. To contact Jones & Bartlett Learning directly, call 800-832-0034, fax 978-443-8000, or visit our website, www.jblearning.com. Substantial discounts on bulk quantities of Jones & Bartlett Learning publications are available to corporations, professional associations, and other qualified organizations. For details and specific discount information, contact the special sales department at Jones & Bartlett Learning via the above contact information or send an email to [email protected]. Copyright © 2019 by Jones & Bartlett Learning, LLC, an Ascend Learning Company All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission from the copyright owner. The content, statements, views, and opinions herein are the sole expression of the respective authors and not that of Jones & Bartlett Learning, LLC. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement or recommendation by Jones & Bartlett Learning, LLC and such reference shall not be used for advertising or product endorsement purposes. All trademarks displayed are the trademarks of the parties noted herein. Fundamentals of Mobile Heavy Equipment is an independent publication and has not been authorized, sponsored, or otherwise approved by the owners of the trademarks or service marks referenced in this product. There may be images in this book that feature models; these models do not necessarily endorse, represent, or participate in the activities represented in the images. Any screenshots in this product are for educational and instructive purposes only. Any individuals and scenarios featured in the case studies throughout this product may be real or fictitious, but are used for instructional purposes only. Production Credits General Manager: Douglas Kaplan Cover Design: Scott Moden Content Services Manager: Kevin Murphy Rights & Media Specialist: Robert Boder Senior Vendor Manager: Sara Kelly Media Development Editor: Shannon Sheehan Marketing Manager: Amanda Banner Cover Image (Title Page): © Chris Henderson/Getty Images VP, Manufacturing and Inventory Control: Therese Connell Printing and Binding: LSC Communications Composition and Project Management: Integra Software Cover Printing: LSC Communications Services Pvt. Ltd. Library of Congress Cataloging-in-Publication Data unavailable at time of printing. 6048 Printed in the United States of America 21 20 19 18 17 10 9 8 7 6 5 4 3 2 1 BRIEF CONTENTS SECTION 1 Foundations & Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2 CHAPTER 1 Introduction to MORE Applications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4 CHAPTER 2 Identification & Classifications of MORE � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26 CHAPTER 3 Shop and Machine Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 49 CHAPTER 4 Bearings, Seals, Lubricants, Gaskets, and Sealants � � � � � � � � � � � � � � � � � � � � � 87 CHAPTER 5 Tools and Fasteners � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 120 CHAPTER 6 Oxyacetylene-Heating and Cutting Equipment � � � � � � � � � � � � � � � � � � � � � � 158 CHAPTER 7 Shielded Metal Arc, MIG, and TIG Welding � � � � � � � � � � � � � � � � � � � � � � � � � � 178 CHAPTER 8 Principles of Hoisting, Rigging, and Slings � � � � � � � � � � � � � � � � � � � � � � � � � � � 197 SECTION II Electrical & Electronic Systems � � � � � � � � � � � � � � � � � � � � � � � � �220 CHAPTER 9 Principles of Electricity and Electrical Circuits � � � � � � � � � � � � � � � � � � � � � � � 222 CHAPTER 10 Electrical Circuits and Circuit Protection � � � � � � � � � � � � � � � � � � � � � � � � � � � 238 CHAPTER 11 Electrical Test Instruments � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 261 CHAPTER 12 Batteries and Battery Services � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 278 CHAPTER 13 Electric Motors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 319 CHAPTER 14 Starting Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 343 CHAPTER 15 Charging Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 371 CHAPTER 16 Electrical Sensors, Sending Units, and Alarm Systems � � � � � � � � � � � � � � � � � 395 CHAPTER 17 Electrical Instrumentation and Alarm Systems � � � � � � � � � � � � � � � � � � � � � � 427 CHAPTER 18 Principles of Machine Electronic Control Systems and Signal Processing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 443 CHAPTER 19 Onboard Networks Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 462 CHAPTER 20 Onboard Diagnostic Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 481 CHAPTER 21 Automated Machines, Telematics, and Autonomous Machine Operation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 495 SECTION III Fluid Power � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �528 CHAPTER 22 Fundamentals of Hydraulics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 530 CHAPTER 23 Hydraulic Components—Principles of Operations � � � � � � � � � � � � � � � � � � � 548 CHAPTER 24 Hydraulic Reservoirs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 573 CHAPTER 25 Hydraulic Pumps � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 586 CHAPTER 26 Hydraulic Valves � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 612 CHAPTER 27 Hydraulic Actuators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 644 CHAPTER 28 Hydraulic Fluids and Conditioners� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 664 CHAPTER 29 Hydraulic Conductors and Connectors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 689 CHAPTER 30 Hydraulic Accumulators and Accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � 710 CHAPTER 31 Hydrostatic Drives � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 722 iv Brief Contents CHAPTER 32 Advanced Hydraulics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 756 CHAPTER 33 Graphic Symbols and Schematics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 794 CHAPTER 34 Preventive Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 813 CHAPTER 35 Troubleshooting and Diagnostics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 825 SECTION IV Wheeled Equipment and Attachments � � � � � � � � � � � � � � � � � � �842 CHAPTER 36 Wheels, Tires, and Hubs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 844 CHAPTER 37 Operators Station � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 859 CHAPTER 38 Machine Frames and Suspension Systems � � � � � � � � � � � � � � � � � � � � � � � � � � 890 CHAPTER 39 Conventional Steering Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 911 CHAPTER 40 Wheeled and Tracked Drive Working Attachments � � � � � � � � � � � � � � � � � � � 933 SECTION V Track Drive Undercarriage & Working Attachments � � � � � � � �950 CHAPTER 41 Track Drive Undercarriage Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 952 CHAPTER 42 Undercarriage Inspection and Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � 991 SECTION VI Power Transfer Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1030 CHAPTER 43 Friction Clutches � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1032 CHAPTER 44 Gearing Basics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1057 CHAPTER 45 Manual Transmissions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1076 CHAPTER 46 Automated Transmissions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1100 CHAPTER 47 Torque Converters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1125 CHAPTER 48 Power-Shift Transmissions� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1150 CHAPTER 49 Drivelines � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1175 CHAPTER 50 Drive Axles � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1204 CHAPTER 51 Track-Type Machine Steering Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1241 CHAPTER 52 Final Drives � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1262 CHAPTER 53 Electric-Drive Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1275 SECTION VII Braking Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1292 CHAPTER 54 Off-Road Heavy-Duty Hydraulic Brakes Fundamentals � � � � � � � � � � � � � � � 1294 CHAPTER 55 Pneumatic Brake Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1317 Appendix A AED Foundation 2014 Standards for Construction Equipment Technology � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1331 Glossary � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1350 Index � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1381 CONTENTS SECTION I Foundations & Safety Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �83 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � �84 CHAPTER 1 Introduction to MORE Ase technician A/technician B style Questions � � � �85 Applications � � � � � � � � � � � � � � � � � � � � � � � � � � � �4 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5 CHAPTER 4 Bearings, Seals, Lubricants, skills and responsibilities of More technicians � � � � �5 Gaskets, and Sealants � � � � � � � � � � � � � � � � � � �87 Pre-start safety inspection � � � � � � � � � � � � � � � � � � � � � �6 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �88 What is Mobile off-road Heavy equipment? � � � � � � �7 Purpose, operation, and Construction Development Milestones of off-road Mobile of seals and Bearings � � � � � � � � � � � � � � � � � � � � � � �88 equipment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10 Bearing and seal servicing � � � � � � � � � � � � � � � � � � � � �96 off-road Machine Design � � � � � � � � � � � � � � � � � � � � �16 Adjusting Bearing Preload � � � � � � � � � � � � � � � � � � � �106 What Does a Heavy equipment repair removal, installation, and replacement technician Do? � � � � � � � � � � � � � � � � � � � � � � � � � � � �21 of seals � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �107 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � � �23 Causes of seal and Bearing failures � � � � � � � � � � � � �109 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �23 Gasket servicing � � � � � � � � � � � � � � � � � � � � � � � � � � �110 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � �24 types and Applications of sealants� � � � � � � � � � � � � �110 Ase technician A/technician B style Questions � � � �24 fluids and Lubricants � � � � � � � � � � � � � � � � � � � � � � � �111 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �116 CHAPTER 2 Identification & Classifications Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �117 of MORE � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �26 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �118 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �27 Ase technician A/technician B style Questions � � �119 Basic Categories of More � � � � � � � � � � � � � � � � � � � �27 More Construction features � � � � � � � � � � � � � � � � � �36 CHAPTER 5 Tools and Fasteners � � � � � � � � � �120 More terminology � � � � � � � � � � � � � � � � � � � � � � � � � �39 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �121 industry/Accreditation � � � � � � � � � � � � � � � � � � � � � � � �40 Purpose and Usage of tools � � � � � � � � � � � � � � � � � �121 More Attachments � � � � � � � � � � � � � � � � � � � � � � � � � �40 tools and equipment fundamentals � � � � � � � � � � � �122 More systems and Components � � � � � � � � � � � � � � �43 Purpose, Usage, and types of fasteners � � � � � � � � � �142 Attitude � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �44 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �153 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � � �45 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �153 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �46 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �156 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � �46 Ase technician A/technician B style Questions � � �156 Ase technician A/technician B style Questions � � � �47 CHAPTER 6 Oxyacetylene-Heating CHAPTER 3 Shop and Machine Safety � � � � � �49 and Cutting Equipment � � � � � � � � � � � � � � � �158 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �50 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Components � � � � � � � � � � � � � � � � � � � � � � � � �179 Circuit Classification � � � � � � � � � � � � � � � � � � � � � � � �239 safety regulations � � � � � � � � � � � � � � � � � � � � � � � � � �183 Current flow in Circuits � � � � � � � � � � � � � � � � � � � � �243 shielded Metal Arc Welding of Mild steel � � � � � � � �186 Circuit Malfunctions� � � � � � � � � � � � � � � � � � � � � � � � �246 Air-Arc Gouging � � � � � � � � � � � � � � � � � � � � � � � � � � � �190 Circuit Protection Devices � � � � � � � � � � � � � � � � � � �249 Attitude � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �191 inspecting and testing Circuit Protection sMAW terminology � � � � � � � � � � � � � � � � � � � � � � � � �192 Devices � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �253 sMAW repair techniques � � � � � � � � � � � � � � � � � � � �192 relays, Magnetic switches, and solenoids � � � � � � � �253 ready for review � � � � � � � � � � � � � � � 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equipment and Devices � � � � � � � � � � � � � � � � � � � �199 Circuit tracers � � � � � � � � � � � � � � � � � � � � � � � � � � � � �271 osHA standards for Proper Lifting techniques Graphing Meters and oscilloscopes � � � � � � � � � � � �272 and equipment � � � � � � � � � � � � � � � � � � � � � � � � � � �210 electronic service tools � � � � � � � � � � � � � � � � � � � � � �273 Wire rope Application and Use � � � � � � � � � � � � � � �212 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �275 Winch Design, operation, and troubleshooting � � �213 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �275 towing, transporting, and Coasting Precautions � � �214 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �275 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �216 Ase technician A/technician B style Questions � � �276 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �216 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �217 CHAPTER 12 Batteries and Battery Ase technician A/technician B style Questions � � �218 Services � � � � � � � � � � � � � � � � � � � � � � � � � � � � �278 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �279 SECTION II Electrical & Electronic What is a Battery? � � � � � � � � � � � � � � � � � � � � � � � � � �279 Battery Classifications � � � � � � � � � � � � � � � � � � � � � � �279 Systems types and Classifications of Batteries � � � � � � � � � � �282 CHAPTER 9 Principles of Electricity sizing and terminal Configuration � � � � � � � � � � � � � �287 and Electrical Circuits � � � � � � � � � � � � � � � � � �222 Battery ratings � � � � � � � � � � � � � � � � � � � � � � � � � � � � �288 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �223 Charging and Discharging Cycle � � � � � � � � � � � � � � �290 electrical fundamentals � � � � � � � � � � � � � � � � 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� � � � � � � � � � �312 Contents vii Measuring Parasitic Draw � � � � � � � � � � � � � � � � � � � �312 removing, inspecting, and replacing identify and test Low-Voltage Disconnect (LVD) an Alternator � � � � � � � � � � � � � � � � � � � � � � � � � � � �390 systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �313 overhauling an Alternator � � � � � � � � � � � � � � � � � � � �390 recycling � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �313 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �392 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �314 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �392 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �316 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �393 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �317 Ase technician A/technician B style Questions � � �393 Ase technician A/technician B style Questions � � �317 CHAPTER 16 Electrical Sensors, CHAPTER 13 Electric Motors � � � � � � � � � � � �319 Sending Units, and Alarm Systems � � � � � � �395 introduction to electric Motors � � � � � � � � � � � � � � �320 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �396 Advantages of electric Motors � � � � � � � � � � � � � � � �321 types of sensors � � � � � � � � � � � � � � � � � � � � � � � � � � �396 Classification of electric Motors � � � � � � � � � � � � � � �323 sensors and Position Calculations � � � � � � � � � � � � � �410 AC Current types � � � � � � � � � � � � � � � � � � � � � � � � � �325 sensor fault Detection Principles � � � � � � � � � � � � � �412 AC Motor Construction and Classification � � � � � �331 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �423 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �340 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �424 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �340 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �425 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �341 Ase technician A/technician B style Questions � � �425 Ase technician A/technician B style Questions � � �341 CHAPTER 17 Electrical Instrumentation and Alarm Systems � � � � � � � � � � � � � � � � � � � �427 CHAPTER 14 Starting Systems � � � � � � � � � � �343 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �428 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �344 Warning Lights and Gauges � � � � � � � � � � � � � � � � � � �428 fundamentals of starting systems and Circuits � � � �344 operator information screens � � � � � � � � � � � � � � � �435 types of DC Motors � � � � � � � � � � � � � � � � � � � � � � � �348 troubleshooting instrument Gauge Problems � � � �437 Components of starters � � � � � � � � � � � � � � � � � � � � �351 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �440 starter Control Circuits � � � � � � � � � � � � � � � � � � � � �355 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �440 starting system testing � � � � � � � � � � � � � � � � � � � � � �358 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �440 starter Current Draw testing � � � � � � � � � � � � � � � � �362 Ase technician A/technician B Questions � � � � � � � �441 testing starter Circuit Voltage Drop � � � � � � � � � � � �363 inspecting and testing the starter Control Circuit � � � �363 CHAPTER 18 Principles of Machine inspecting and testing relays and solenoids � � � � � �364 Electronic Control Systems and Signal removing and replacing a starter and inspecting Processing � � � � � � � � � � � � � � � � � � � � � � � � � � �443 the ring Gear or flexplate � � � � � � � � � � � � � � � � � �365 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �444 overhauling a starter Motor � � � � � � � � � � � � � � � � � �366 Benefits of electronic Control � � � � � � � � � � � � � � � � �444 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �367 elements of electronic signal-Processing Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �368 systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �447 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �368 types of electrical signals� � � � � � � � � � � � � � � � � � � � �448 Ase technician A/technician B style Questions � � �369 Processing function � � � � � � � � � � � � � � � � � � � � � � � � �455 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �458 CHAPTER 15 Charging Systems � � � � � � � � � �371 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �459 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �372 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �459 Alternator functions � � � � � � � � � � � � � � � � � � � � � � � �372 Ase technician A/technician B style Questions � � �460 Alternator Construction � � � � � � � � � � � � � � � � � � � � �375 Charging system Diagnosis � � � � � � � � � � � � � � � � � � �386 CHAPTER 19 Onboard Networks Charging system output test � � � � � � � � � � � � � � � � �388 Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � �462 testing Charging system Circuit Voltage Drop � � � �389 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �463 inspecting, repairing, or replacing Connectors Machine onboard networks � � � � � � � � � � � � � � � � �463 and Wires of Charging Circuits � � � � � � � � � � � � � �390 network Construction and Classification � � � � � � �464 viii Contents time Division Multiplexing � � � � � � � � � � � � � � � � � � �465 Pascal’s Law and Hydraulic systems � � � � � � � � � � � � �534 Controlled Area networks � � � � � � � � � � � � � � � � � � �469 Bernoulli’s Principle � � � � � � � � � � � � � � � � � � � � � � � � �535 Diagnosing network Communication Measurement Units for Hydraulic systems � � � � � � �535 Problems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �475 Hydraulic Pressure and flow � � � � � � � � � � � � � � � � � �536 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �477 Positive and negative Pressure � � � � � � � � � � � � � � � �537 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �478 organizational Bodies Governing industrial review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �478 standards � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �538 Ase technician A/technician B style Questions � � �479 Calculating force, Pressure, and Area � � � � � � � � � � �538 safety Concerns related to Hydraulic systems � � �542 CHAPTER 20 Onboard Diagnostic De-energizing a Hydraulic system � � � � � � � � � � � � � �544 Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � �481 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �544 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �482 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �545 fundamentals of onboard Diagnostics � � � � � � � � � �482 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �545 self-Diagnostic Capabilities and Approaches � � � � � �483 Ase technician A/technician B style Questions � � �546 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �491 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �492 CHAPTER 23 Hydraulic Components— review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �492 Principles of Operations � � � � � � � � � � � � � � � �548 Ase technician A/technician B style Questions � � �493 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �549 types and Applications of Hydraulic systems CHAPTER 21 Automated Machines, Used for Mobile off-road equipment � � � � � � � � �549 Telematics, and Autonomous Machine Components of Basic Hydraulic systems � � � � � � � �551 Operation � � � � � � � � � � � � � � � � � � � � � � � � � � �495 operating Principles of Hydraulic system Applications of Autonomous and self-steering Components � � � � � � � � � � � � � � � � � � � � � � � � � � � �552 Machines � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �496 operation of a Basic Hydraulic system � � � � � � � � � �562 An overview of Automated Machine Calculating Cycle times and Hydraulic operation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �497 Horsepower � � � � � � � � � � � � � � � � � � � � � � � � � � � � �563 Classifications of Autonomous systems � � � � � � � � �499 Basic Hydraulic schematic symbols � � � � � � � � � � � � �565 enabling technologies for Machine Automation � � �504 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �569 Global Positioning systems � � � � � � � � � � � � � � � � � � �508 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �570 telematics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �517 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �571 remote Control � � � � � � � � � � � � � � � � � � � � � � � � � � �518 Ase technician A/technician B style Questions � � �572 Automated steering � � � � � � � � � � � � � � � � � � � � � � � � �519 Machine safety with radio and other Wireless CHAPTER 24 Hydraulic Reservoirs � � � � � � �573 technology � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �522 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �574 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �523 Purpose and fundamentals of Hydraulic Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �524 reservoirs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �574 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �525 types and Construction features of Hydraulic Ase technician A/technician B style Questions � � �526 reservoirs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �574 Principles of operation of Hydraulic SECTION III Fluid Power reservoirs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �580 identify the types and Construction features CHAPTER 22 Fundamentals of Hydraulic reservoirs � � � � � � � � � � � � � � � � � � � �581 of Hydraulics � � � � � � � � � � � � � � � � � � � � � � � � �530 inspect Hydraulic reservoirs following introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �531 Manufacturers’ recommended Procedures � � � �581 fundamentals of Hydraulics � � � � � � � � � � � � � � � � � � �531 Perform a reservoir Drain and Cleanout Hydraulic system terminology � � � � � � � � � � � � � � � �532 Procedure following Manufacturers’ Advantages and Disadvantages of Hydraulic recommendations for Hydraulic reservoirs� � � �582 systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �533 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �583 Contents ix Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �584 Hydraulic Actuator Construction � � � � � � � � � � � � � �648 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �584 seals on Hydraulic Actuators � � � � � � � � � � � � � � � � � �653 Ase technician A/technician B style Questions � � �585 Common Causes of Actuator failure � � � � � � � � � � �655 Calculating the force or Pressure of a Hydraulic CHAPTER 25 Hydraulic Pumps � � � � � � � � � � �586 Cylinder � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �655 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �587 Calculating Hydraulic Cylinder speed � � � � � � � � � � �657 the Purpose and fundamentals of Hydraulic Understanding torque � � � � � � � � � � � � � � � � � � � � � � �657 Pumps � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �587 Hydraulic Motor Calculations � � � � � � � � � � � � � � � � �658 types and Construction features of Hydraulic testing, Diagnosing, and trouble-shooting Pumps � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �588 Actuator Problems � � � � � � � � � � � � � � � � � � � � � � � �658 operation of Hydraulic Pumps � � � � � � � � � � � � � � � �595 inspection and repair Procedures � � � � � � � � � � � � � �660 Hydraulic Pump Performance Calculations � � � � � � �601 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �662 Diagnosing Hydraulic Pump Problems� � � � � � � � � � �604 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �662 Hydraulic Pump reconditioning and repairs � � � � �605 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �662 Common Causes of Pump failure � � � � � � � � � � � � � �606 Ase technician A/technician B style Questions � � �663 reconditioning Hydraulic Pumps � � � � � � � � � � � � � � �607 remove and install a Hydraulic Pump, following CHAPTER 28 Hydraulic Fluids Manufacturer’s service information � � � � � � � � � � �607 and Conditioners � � � � � � � � � � � � � � � � � � � � � �664 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �608 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �665 Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �609 Purpose and fundamentals of Hydraulic review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �610 fluids � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �665 Ase technician A/technician B style Questions � � �610 Composition and Properties of Hydraulic fluids � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �667 CHAPTER 26 Hydraulic Valves � � � � � � � � � � �612 Purpose and fundamentals of Hydraulic introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �613 fluid Conditioning � � � � � � � � � � � � � � � � � � � � � � � �672 Purpose and fundamentals of Hydraulic Valves � � � �613 function and Construction features of types and Construction features of Hydraulic fluid filters � � � � � � � � � � � � � � � � � � � � �677 Hydraulic Valves � � � � � � � � � � � � � � � � � � � � � � � � � �613 functions and Construction features of Principles of operation of Pressure Control Hydraulic fluid Heaters and Coolers � � � � � � � � �683 Valves � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �614 Perform a Post-failure external filtration operating Principles of Hydraulic flow Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �684 Control Valves � � � � � � � � � � � � � � � � � � � � � � � � � � �623 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �685 Principles of operation of Hydraulic Directional Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �686 Control Valves � � � � � � � � � � � � � � � � � � � � � � � � � � �626 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �687 Common Causes of Valve failures � � � � � � � � � � � � �637 Ase technician A/technician B style inspect, Diagnose, and Adjust Hydraulic Valves � � � �638 Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �687 recommend reconditioning or repairs of Hydraulic Valves � � � � � � � � � � � � � � � � � � � � � � � �639 ready for review � � � � � � � � � � � � � � � � � � � � � � � � � � �640 CHAPTER 29 Hydraulic Conductors Key terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �641 and Connectors � � � � � � � � � � � � � � � � � � � � � � �689 review Questions � � � � � � � � � � � � � � � � � � � � � � � � � �642 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �690 Ase technician A/technician B style Questions � � �643 Hydraulic Pressure in a Closed system � � � � � � � � � �691 safety requirements for Hydraulic system CHAPTER 27 Hydraulic Actuators � � � � � � � �644 Conductors and Connectors � � � � � � � � � � � � � � � �691 introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �645 Construction features of Hydraulic Lines � � � � � � �692 Purpose and fundamentals of Hydraulic Construction features of Hydraulic Hoses � � � � � � �695 Actuators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �645 Working Pressure and Burst Pressure ratings functions and Applications of Hydraulic for Conductors � � � � � � � � � � � � � � � � � � � � � � � � � �698 Actuators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �647 Conductor sizing � � � � � � � � � � � � � � � � � � � � � � � � � � �698

Description:
Fundamentals of Mobile Heavy Equipment provides students with a thorough introduction to the diagnosis, repair, and maintenance of off-road mobile heavy equipment. With comprehensive, up-to-date coverage of the latest technology in the field, it addresses the equipment used in construction, agricult
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