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Modern diesel technology : electricity & electronics PDF

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This is an electronic version of the print textbook. Due to electronic rights restrictions, some third party content may be suppressed. Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. The publisher reserves the right to remove content from this title at any time if subsequent rights restrictions require it. For valuable information on pricing, previous editions, changes to current editions, and alternate formats, please visit www.cengage.com/highered to search by ISBN#, author, title, or keyword for materials in your areas of interest. 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. 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 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. ModernDieselTechnology:Electricity (cid:3)c 2014,2007Delmar,CengageLearning &Electronics,2ndEdition ALLRIGHTSRESERVED.Nopartofthisworkcoveredbythecopyright JosephA.Bell hereinmaybereproduced,transmitted,stored,orusedinanyformorby anymeansgraphic,electronic,ormechanical,includingbutnotlimitedto VicePresident,Careers&Computing: photocopying,recording,scanning,digitizing,taping,Webdistribution, DaveGarza informationnetworks,orinformationstorageandretrievalsystems,except DirectorofLearningSolutions:SandyClark aspermittedunderSection107or108ofthe1976UnitedStatesCopyright ExecutiveEditor:DaveBoelio Act,withoutthepriorwrittenpermissionofthepublisher. 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Printed in the United States of America 1 2 3 4 5 6 7 16 15 14 13 12 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. 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 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 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 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. 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.

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Todays diesel vehicles integrate electrical and electronic controls within all major systems, making a thorough understanding of current technology essential for success as a diesel technician. Bells MODERN DIESEL TECHNOLOGY: ELECTRICITY AND ELECTRONICS, Second Edition, provides this understanding t
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