Modern diesel technology : electricity & electronics

546 Pages·2014·24.47 MB·English

by  Joseph Bell

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M D T :
ODERN IESEL ECHNOLOGY
E & E
LECTRICITY LECTRONICS
2 E
ND DITION
Joseph A. Bell
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
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Table of Contents
Preface for Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
CHAPTER 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Proper Attire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Personal Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHAPTER 2 The Fundamentals of Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Basic Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ohm’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Introduction to Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Circuit Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Metric Prefixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHAPTER 3 Physics for Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electric Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electric Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
iii
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CHAPTER 4 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Circuit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Troubleshooting Wiring Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
CHAPTER 5 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Lead Acid Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Lead Acid Battery Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Chemical Action in Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
External Battery Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Connecting Multiple Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Battery Internal Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Batteries and Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Battery Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Battery Recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Jump-Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Battery System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Recombinant Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Hybrid Electric Vehicle (HEV) Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
CHAPTER 6 Basic Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Semiconductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
CHAPTER 7 Charging Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Alternator Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Alternator Terminals and Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Brushless Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
iv
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Dual-Voltage Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Charging System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Key-Off Parasitic Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Alternator Disassembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Alternator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
CHAPTER 8 DC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Brushed DC Motor Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Starter Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Gear-Reduction Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Diagnosis of the Cranking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Starter Motor Disassembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Starter Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Rapid Check of Truck Charging and Cranking System . . . . . . . . . . . . . . . . . . . . . . 263
Other Brushed DC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
CHAPTER 9 Lighting Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Incandescent Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Exterior Lighting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Trailer Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
LED Lighting Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Interior Truck Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
CHAPTER 10 Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Windshield Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Motorized and Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Engine Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Hydraulic Brake System Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Extra for Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
v
Copyright 2013 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.
CHAPTER 11 Sensors, Digital Electronics, and Multiplexing . . . . . . . . . . . . . . . . . . . . . . . . 339
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Digital Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Multiplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
CHAPTER 12 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Conventional Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Multiplexed Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
CHAPTER 13 Body Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
International Multiplexed Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
International Diamond Logic Electrical System Details . . . . . . . . . . . . . . . . . . . . . 421
Freightliner Multiplexed Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Troubleshooting the Multiplexed Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
CHAPTER 14 Diesel Engine Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
The Electronically Controlled Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Diesel Exhaust Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Diesel Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
CHAPTER 15 Modern Truck Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Antilock Braking Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
Emerging Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Troubleshooting a Modern Truck Electrical System . . . . . . . . . . . . . . . . . . . . . . . . 504
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Suggested Internet Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
vi
Copyright 2013 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.
Preface for Series
The Modern Diesel Technology (MDT) series of tolackfocus.Itisalsoatestamenttothejobpotential
textbooks debuted in 2007 as a means of addressing of careers in the commercial vehicle technology field
the learning requirements of schools and colleges in a general employment climate that has stagnated
whose syllabi used a modular approach to curricula. for several years. Some forward-thinking high schools
The initial intent was to provide comprehensive cov- have developed transitional programs partnering with
erage of the subject matter of each title using ASE/ both colleges and industry to introduce motive power
NATEF learning outcomes and thus provide educators technology as early as Grade 10, an age at which
in programs that directly target a single certification many students make crucial career decisions. When a
field with a little more flexibility. In some cases, an high school student graduates with credits in Diesel
MDT textbook exceeds the certification competency Technology or Preventive Maintenance Practice it
standards. An example of this is Joseph Bell’s MDT: can accelerate progression through college programs
Electricity & Electronics, in which the approach as well as make those responsible for hiring future
challenges the student to attain the level of under- technicians for commercial fleets and dealerships
standingneededbyatechnicianspecializinginthekey take notice.
areas of chassis electrical and electronics systems—in As the MDT series has evolved, textbooks have
other words, higher than that required by the general been added that target specific ASE certifications,
service technician. providing an invaluable study guide for certified
The MDT series now boasts nine textbooks, some technicians who are adding to their qualifications
of which are going into their second edition. As the along with College programs that use a modular
series has evolved, it has expanded in scope with the learningapproach.ElectronicDieselEngineDiagnosis
introduction of books addressing a much broader (ASE L2), Truck Brakes, Suspension, and Steering
spectrum of commercial vehicles. Titles now include Systems (ASE T4 and T5) and Light Duty Diesel En-
Heavy Equipment Systems, Mobile Equipment Hy- gines (ASE A9) detail the learning outcomes required
draulics,andHeating,Ventilation,AirConditioning& for each ASE certification test.
Refrigeration. The latter includes a detailed examina- Because each textbook in the MDT series focuses
tion of trailer reefer technology, subject matter that exclusively on the competencies identified by its title,
falls outside the learning objectives of a general text- the books can be used as a review and study guide for
book. While technicians specializing in all three areas technicians prepping for specific certification exami-
areindemandinmostareasofthecountry,thereareas nations.CommontoallofthetitlesintheMDTseries,
yet no national certification standards in place. the objective is to develop hands-on competency
Inaddition,theseriesnowincludestwobooksthat withoutomittinganyoftheconceptualbuildingblocks
are ideal for students beginning their study of com- that enable an expert understanding of the subject
mercial vehicle technology. Thes two titles (Preven- matter from the technician’s perspective. The second
tive Maintenance and Inspection and Diesel Engines) editionsofthesetitlesnotonlyintegratethechangesin
are written so that they can be used in high school technology that have taken place over the past five
programs. Each uses simple language and a no- years, but also blend in a wide range of instructor
nonsenseapproachsuitedforeitherclassroomorself- feedback based on actual classroom proofing. Both
directed study. That some high schools now option should combine to make these second editions more
programs specializing in commercial vehicle tech- pedagogically effective.
nology is an enormous progression from the more
general secondary school ‘‘shop class’’ which tended Sean Bennett 2012
vii
Copyright 2013 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.
Preface
The primary purpose of this textbook is to provide the anxiety that electrical problems can present. The
an understanding of electricity and electronics to the goal of this book is to help alleviate the anxiety as-
extent required by an entry-level truck technician. The sociatedwithtroubleshootingamoderntruckelectrical
focus throughout this textbook is the fundamental systemproblembyexplainingsomeofthemysteriesof
principles of electricity and the application of these electricity and electronics.
principles to the diagnosis of modern truck electrical
systems.
DETAILS OF THE TEXT
The material in this textbook is presented using
AUTHOR’S BACKGROUND
easy-to-understand analogies whenever possible.
My career in the automotive industry began at a Theseanalogiesarecomparisonsofelectricalconcepts
service station with a garage when I was still in high withconceptsthataremucheasierformoststudentsto
school. After graduation, I joined the military where I understand, such as hydraulics and pneumatics. Math
became a truck technician. Following my military and non-relevant theory is kept at a minimum, but
service, I worked as an automobile and truck dealer- Extra for Experts sections appear at the end of most
ship technician throughout the automotive electronics chapters where more challenging topics are addressed.
revolutionofthe1980s.Likemostothertechniciansof The text also addresses the disassembly and testing of
that era, my electrical skills were lacking, so I decided crankingmotors(starters)andalternators.Repairingor
totakesomecollegecoursestoincreasemyknowledge rebuilding of cranking motors and alternators was
of electricity and electronics. After several years of common in truck repair facilities of the past. These
part-time study while still working full-time as a days, inoperative cranking motors and alternators are
technician, I was able to complete a bachelor’s degree usually just replaced with new or remanufactured
in Electrical Engineering Technology from Purdue units. Material covering the inner workings of
University. I then began working for International cranking motors and alternators was included in the
Truck and Engine Corporation (Navistar) and became text because many experienced technicians have in-
theleadelectricaltestengineer.Someofmyprojectsat dicated that it is still important for modern truck
International include the High Performance Truck se- technicianstounderstandhowtheseelectricaldevices
ries, 2007 emissions, and ProStar models. I am cur- function. This is true even though the cranking motor
rently a senior diagnostic engineer for a manufacturer oralternatorisprobablygoingtobereplacedanyway.
of diesel engines. An understanding of the inner workings of cranking
motors and alternators should help technicians to
troubleshoot problems associated with the cranking
REASONS FOR WRITING
and charging systems. This same philosophy is car-
THIS BOOK
ried over to the coverage of electronic modules found
Trucks of the past had very simple electrical sys- in modern trucks. Like cranking motors and alter-
tems. Anyone who has looked at the electrical system nators, electronic modules are almost never repaired
on a modern truck knows that this is no longer true. bytrucktechnicians.Evenso,thetextdescribessome
One of my main reasons for writing this book is to of the components that are contained within typical
provide a text designed specifically for truck techni- truck electronic modules and the manner in which
cians-in-training that stresses the importance of a these components interact with other devices in the
strong knowledge of the fundamentals of electricity. electrical system. A basic understanding of what is
As a former technician, I have experienced first-hand occurring insidethese electronic modules should help
viii
Copyright 2013 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.